ACURA RL KA9 1996 Service Repair Manual

Inspection and Adjustment

Brake Pedal

Pedal Height

1. Disconnect the brake pedal position switch connec-

tor, loosen the brake pedal position switch locknut,

and back off the brake pedal position switch

until it is no longer touching the brake pedal.

2.

Lift up the carpet. At the insulator cutout, measure

the pedal height from the middle of the right side of

the pedal pad.

PUSHROD

LOCKNUT
BRAKE PEDAL POSITION SWITCH

BRAKE PEDAL POSITION SWITCH

LOCKNUT

INSULATOR

(CUTOUT)

MEASURING POINT

Standard Pedal Height (with carpet removed):

182 mm (7
3/16
in)

3. Loosen the pushrod locknut, and screw the pushrod

in or out with pliers until the standard pedal height

from the floor is reached. After adjustment, tighten

the locknut firmly.

NOTE: Do not adjust the pedal height with the

pushrod pressed.

Lower the pedal

PUSHROD LOCKNUT

15 N-m

(1.5 kgf-m, 11 Ibf-ft)
4.
Screw in the brake pedal position switch until its

plunger is fully pressed (threaded end touching the

pad on the pedal arm). Then back off the switch 1/4

turn to make 0.3 mm (0.01 in) of clearance between

the threaded end and pad. Tighten the locknut firm-

ly. Connect the brake pedal position switch connec-

tor.

CAUTION: Make sure the brake lights go off when

the pedal is released.

PAD

5. Check the brake pedal free play as described below.

Pedal Free Play

1. With the engine off, check the play on the pedal pad

by pushing the pedal by hand.

Free Play: 0.5 - 2.0 mm (0.02 - 0.08 in)

2. If the pedal free play is out of specification, adjust

the brake pedal position switch.

CAUTION: If the pedal free play is insufficient, it

may result in brake drag.

BRAKE PEDAL POSITION SWITCH

BRAKE PEDAL PAD

PEDAL FREE PLAY
LOCKNUT
THREADED

END

0.3 mm

(0.01
in)
BRAKE PEDAL PAD

PEDAL HEIGHT

Raise

the pedalProCarManuals.com

Inspection an d Adjustmen t
Parking Brak e Peda l
Inspectio n
1 . Pres s th e parkin g brak e peda l wit h 29 4 N (3 0 kgf , 6 6
Ibf ) o f pressur e to full y appl y th e parkin g brake .
Th e parkin g brak e peda l shoul d b e locke d withi n th e
specifie d numbe r o f clicks .
PARKIN G BRAK E PEDA L
Pedal Locke d Clicks : 6- 8Presse d wit h 29 4 N (3 0 kgf , 6 6 Ibf )
If th e numbe r o f peda l click s i s excessive , inspec t th e
parkin g brak e lining s fo r wea r (se e pag e 19-23 ). I f th e
parkin g brak e lining s ar e no t wor n beyon d th e servic e
limit, mino r adjustment s (1- 2 clicks ) ca n b e mad e wit h
the adjustin g nu t i n th e equalizer . Fo r majo r adjustment ,
se e th e nex t page .
CAUTION : Afte r replacin g th e linings , mak e sur e yo u
driv e th e vehicl e fo r "break-in " purposes . Refe r t o pag e
19-27 fo r th e linin g break-i n procedure .
Minor adjustment :
1 . Rais e th e rea r wheel s of f th e ground , an d suppor t
th e vehicl e o n safet y stands .
Bloc k th e fron t wheel s befor e jackin g
u p th e rea r o f th e vehicle .
2 . Remov e th e rea r consol e en d cover .
3 . Pres s th e parkin g brak e peda l on e click .
PARKIN G BRAK E PEDA L
4.Tighte n th e adjustin g nu t unti l th e parkin g brake s
dra g slightl y whe n th e rea r wheel s ar e turned .
EQUALIZE R
5.
6.
ADJUSTIN GNUT
Releas e th e parkin g brak e peda l fully , an d chec k
tha t th e parkin g brake s d o no t dra g whe n th e rea r
wheel s ar e turned . Readjus t i f necessary .
Wit h th e equalize r properl y adjusted , th e parkin g
brak e shoul d b e full y applie d whe n th e parkin g
brak e peda l i s presse d 6- 8 clicks .
7 . Instal l th e rea r consol e en d cover .
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Major adjustment :
Adjust th e parkin g brak e sho e lining-to-dru m clearanc e
with th e adjuste r i n th e dru m o f eac h rea r wheel .
NOTE : Mak e sur e th e parkin g brak e lining s ar e no t wor n
beyon d th e servic e limi t (se e pag e 19-23 ).
If eithe r lining is wor n beyon d the limit , both brak e
shoe s mus t b e replaced .
CAUTION : Afte r replacin g th e linings , mak e sur e yo u
driv e th e vehicl e fo r "break-in " purposes . Refe r t o pag e
19-2 7 fo r th e linin g surfac e brake-i n procedure .
1 . Rais e th e rea r wheel s of f th e ground , an d suppor t
th e vehicl e o n safet y stands .
Bloc k th e fron t wheel s befor e jackin g
u p th e rea r o f th e vehicle .
2 . Remov e th e rea r wheels .
3 . Remov e th e rea r consol e en d cover .
4 . Releas e th e parkin g brak e pedal , an d bac k of f th e
adjustin g nu t i n th e equalizer .
EQUALIZE R
ADJUSTIN GNUT
5. Tur n th e brak e sho e adjuste r u p wit h a fla t blad e
screwdrive r unti l th e shoe s lock , the n bac k of f 8
stops .
FLATBLAD E
SCREW -
DRIVE R
BRAK E SHO E ADJUSTE R
ACCESS PLU G
6. Chec k th e numbe r o f click s b y pressin g th e parkin g
brak e peda l wit h 29 4 N (3 0 kgf , 6 6 Ibf ) force .
Peda l Locke d Clicks : 6- 8
7 . Adjus t th e parkin g brak e wit h th e adjustin g nu t i n
th e equalize r i f th e peda l click s ar e ou t o f specifica -
tion.
8. Instal l th e rea r consol e en d cover .
9. Instal l th e rea r wheels , an d lowe r th e vehicle .
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Inspection and Adjustment

Bleeding

CAUTION:

• Always use Genuine Honda DOT 3 Brake Fluid. Using

a non-Honda brake fluid can cause corrosion and

decrease the life of the system.

• Make sure no dirt or other foreign matter is allowed

to contaminate the brake fluid.

• Do not spill brake fluid on the vehicle, it may damage

the paint; if brake fluid does contact the paint, wash

it off immediately with water.

NOTE: The reservoir on the master cylinder must be at

the MAX (upper) level mark at the start of the bleeding

procedure and checked after bleeding each brake

caliper. Add fluid as required.

1. Make sure the brake fluid level in the reservoir is at

the MAX (upper) level line.

'96 - 97 models: '98 - 01 models:

MAX (UPPER) LEVEL

LINE

MASTER CYLINDER

2. Have someone slowly pump the brake pedal several

times, then apply steady pressure.

3. Loosen the brake bleed screw to allow air to escape

from the system. Then tighten the bleed screw

securely.

4. Repeat the procedure for each wheel in the sequence

shown below until air bubbles no longer appear in

the fluid.

5. Refill the reservoir on the master cylinder to the

MAX (upper) level line.

BLEEDING SEQUENCE:

NOTE: Bleed the front calipers first.
FRONT:

BLEED SCREW

9 N-m (0.9 kgf-m, 6.5 Ibf-ft)

REAR:

BLEED SCREW

9 N-m (0.9 kgf-m, 6.5 Ibf-ft)

Front Right

Rear Right

Rear Left

Front LeftProCarManuals.com

Brake Syste m Indicato r
Parking Brak e Switc h Tes t
1 . Remov e th e dashboar d lowe r cove r an d kne e bol -
ste r (se e sectio n 20 ).
2 . Disconnec t th e connecto r fro m th e parkin g brak e
switch .
3 . Chec k fo r continuit y betwee n th e termina l an d bod y
groun d i n eac h positio n accordin g t o th e table .
TERMINA LRELEASE D (Switch : OFF )
PARKIN G BRAK ESWITCH
PARKIN G BRAK EPEDAL
PRESSE D (Switch : ON )
NOT E (Canada) : I f th e parkin g brak e switc h i s OK ,
but th e brak e syste m indicato r doe s no t function , d o
th e inpu t tes t fo r th e daytim e runnin g light s contro l
uni t (se e sectio n 23 ). Brak
e Flui d Leve l Switc h Tes t
1 . Remov e th e reservoi r cap . Chec k tha t th e floa t
move s u p an d dow n freely ; i f i t doesn't , replac e th e
reservoi r ca p assembly .
2 . Chec k fo r continuit y betwee n th e terminal s i n eac h
switc h positio n accordin g t o th e table .
RESERVOI R CA PDOW N POSITIO N
FLOAT
Switch contact s close dwhen floa t drops .
sSwitch contact s ope n a tprope r flui d level .
19-9
UP POSITIO N
MAGNET
BODYGROUN D
Positive
Termina lBod
y Groun d
Termina
l
Peda l Positio n
Pressed
Release d
Termina l
Positio n
FLOA T U P
FLOA T DOW N
12
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Front Brak e Pad s
Inspectio n an d Replacemen t
• Neve r us e a n ai r hos e o r dr y brus h t o clea n brake
assemblies .
• Us e a n OSHA-approve d vacuu m cleane r t o avoi d
breathin g brak e dust .
1 . Loose n th e fron t whee l nut s slightly , the n rais e th e
vehicle , an d suppor t i t o n safet y stands . Remov e
th e fron t wheels .
2 . Remov e th e brak e hos e bracke t fro m th e knuckle .
BRAKE HOS E BRACKE T
CALIPE R BOL T
CALIPE R BOD Y
3. Hol d th e calipe r pi n wit h a wrench , bein g carefu l
not t o damag e th e pi n boot . Remov e th e calipe r bol t
wit h anothe r wrench , an d pivo t th e calipe r u p ou t o f
the way .
NOTE : Chec k th e hose s an d pi n boot s fo r damag e
an d deterioration .
4 . Remov e th e pa d shims , pa d retainers , an d pads .
NOTE : '96 , '97 , '99 , '0 0 an d 0 1 model s shown .
PAD RETAINER S
INNER PA D SHIM SCheck fo r weakness .
OUTE R PA D
Chec k fo r wear .
OUTE R PA D SHI M
Chec k fo r weakness .
NOTE: Replac e th e shim s togethe r wit h th e pad s a s a set . 5
. Usin g vernie r calipers , measur e th e thicknes s of
eac h brak e pa d lining .
Brake Pa d Thickness :
Standard: 10. 5 - 11. 5 m m (0.4 1 - 0.4 5 in )
Servic e Limit : 1. 6 m m (0.0 6 in )
'96 , '97 , '99 , '0 0 an d 0 1 models :
BACKIN G PLAT E
NOTE: Measuremen t doe s no t includ e pa d backin g
plat e thickness .
6 . I f th e brak e pa d thicknes s i s les s tha n th e servic e
limit , replac e th e fron t pad s a s a set .
7 . Clea n th e calipe r thoroughly ; remov e an y rust , an d
chec k fo r groove s an d cracks .
8 . Chec k th e brak e dis c fo r damag e an d cracks .
9 . Instal l th e pa d retainers .
PAD RETAINER S
BACKIN
G PLAT E
'9 8 mode l onl y
INNE R PA DChec k fo r wear .
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10. Apply grease to the points indicated by the arrows

in the following illustration:

Piston end and inner shim B contact surface

Inner shim A contact surface (both sides)

Pads and caliper bracket contact surface

Outer pad and caliper body contact surface

Outer pad shim and outer pad contact surface

Outer pad shim and caliper body contact surface

NOTE:

Use the pad grease included in the pad set or

Molykote M77 grease, and apply a thin coat of

grease evenly to the designated points.

'96, '97, '99, '00 and 01 models shown.

PISTON

INNER PAD

Apply Molykote M77

to both sides of shims.

INNER

SHIM B

(Stainless)

INNER

SHIM A

WEAR

INDICATOR

OUTER PAD

OUTER

PAD
SHIM

Apply Molykote M77

to both sides of shim.

11. Install the brake pads and pad shims correctly.

When reusing the pads, always reinstall the

brake pads in their original positions to prevent

loss of braking efficiency.

Contaminated brake discs or pads reduce stop-

ping ability. Keep grease off the discs and pads.

NOTE: Install the pad with the wear indicator on

the inside.
12. Push in the piston so the caliper will fit over the

pads. Make sure the piston boot is in position to

prevent damaging it when pivoting the caliper

down.

CALIPER BOLT

49 N-m (5.0 kgf-m, 36 Ibf-ft)

PISTON

13. Pivot the caliper down into position. Hold the caliper

pin with a wrench, being careful not to damage the

pin boot. Install the caliper bolt with another wrench,

and tighten it.

CAUTION: Be careful not damage the pin boot

when pivoting the caliper down.

14. Install the brake hose bracket on the knuckle.

NOTE: Inspect the brake hose for interference and

twisting.

15. Press the brake pedal several times to make sure

the brakes work, then test-drive.

NOTE: Engagement of the brake may require a

greater pedal stroke immediately after the brake

pads have been replaced as a set. Several applica-

tions of the brake pedal will restore the normal

pedal stroke.

16. After installation, check for leaks at hose and line

joints and connections, and retighten if necessary.ProCarManuals.com

Front Brak e Dis c
Disc Runou t Inspectio n
1. Loose n th e fron t whee l nut s slightly , the n rais e th e
vehicle , an d mak e sur e i t i s securel y supported .
Remov e th e fron t wheels .
2 . Remov e th e brak e pad s (se e pag e 19-10 ).
3 .
4 .
5 .
Inspec t th e dis c surfac e fo r damag e an d cracks .
Clean th e dis c thoroughly , an d remov e al l rust .
Us e whee l nut s an d suitabl e plai n washer s t o hol d
th e dis c securel y agains t th e hub , the n moun t a dia l
indicato r a s shown , an d measur e th e runou t a t
1 0 m m (0. 4 in ) fro m th e oute r edg e o f th e disc .
Brak e Dis c Runout :
Service Limit : 0.1 0 m m (0.00 4 in )
10 m m(0.4 in )
WHEE L NU T AN DPLAI N WASHE R108 N- m(11 kgf-m , 8 0 Ibf-ft )
If th e dis c i s beyon d th e servic e limit , refinis h th e
brak e dis c wit h a n on-ca r brak e lathe . Th e Kwik -
Lathe produce d b y Kwik-wa y Manufacturin g Co .
and th e "Fron t Brak e Dis c Lathe " offere d b y Snap -
on Tool s Co . ar e approve d fo r thi s operation .
Max. Refinis h Limit :
'9 6 - 9 8 models :
21.0 mm (0.8 3 in)
'99 - 0 1 models :
26.0 mm (1.0 2 in)
NOTE : A ne w dis c shoul d b e refinishe d i f it s runou t
i s greate r tha n 0.1 0 m m (0.00 4 in )
Dis c Thicknes s an d Parallelis m
Inspectio n
1. Loose n th e fron t whee l nut s slightly , the n rais e th e
vehicle , an d mak e sur e i t i s securel y supported .
Remov e th e fron t wheels .
2 . Remov e th e brak e pad s (se e pag e 19-10 ).
3 .
4.
Usin g a micrometer , measur e dis c thicknes s a t
eigh t points , approximatel y 45 ° apar t an d 1 0 m m
(0.4 in ) i n fro m th e oute r edg e o f th e disc .
MICROMETE R
Brake Dis c Thickness :
'9 6 - 9 8 models :
Standard : 22. 9 - 23. 1 m m (0.9 0 - 0.9 1 in )
Max . Refinishin g Limit : 21. 0 m m (0.8 3 in )
'9 9 - 0 1 models :
Standard : 27. 9 - 28. 1 m m (1.1 0 - 1.1 1 in )
Max . Refinishin g Limit : 26. 0 m m (1.0 2 in )
NOTE : Replac e th e brak e dis c i f th e smalles t mea -
suremen t i s les s tha n th e max . refinishin g limit .
Brak e Dis c Parallelism : 0.01 5 m m (0.000 6 in ) max .
NOTE : Thi s i s th e maximu m allowabl e differenc e
between th e thicknes s measurements .
I f th e dis c i s beyon d th e servic e limi t fo r parallelism ,
refinis h th e brak e dis c wit h a n on-ca r brak e lathe .
Th e Kwik-Lath e produce d b y Kwik-Wa y Manufac -
turin g Co . an d th e "Fron t Brak e Dis c Lathe " offere d
b y Snap-o n Tool s Co . ar e approve d fo r thi s opera -
tion.
NOTE : Se e sectio n 1 8 fo r brak e dis c replacement .
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Front Brake Caliper

Disassembly/Reassembly

Never use an air hose or dry brush to clean brake assemblies.

Use an OSHA-approved vacuum cleaner to avoid breathing brake dust.

Contaminated brake discs or pads reduce stopping ability.

When reusing the pads, always reinstall the brake pads in their original positions to prevent loss of braking efficiency.

CAUTION:

Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off imme-

diately with water.

To prevent spills, cover the hose joints with rags or shop towels.

Clean all parts in brake fluid and air dry; blow out all passages with compressed air.

Before reassembling, check that all parts are free of dust and other foreign particles.

Replace parts with new ones whenever specified to do so.

Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.

Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the

life of the system.

INNER PAD SHIM A

INNER PAD SHIM B

(STAINLESS)
'96, '97, '99,
'00 and

01 models:

INNER PAD

WEAR INDICATOR

Install inner pad with its

wear indicator downward.
PISTON SEAL

Replace.

OUTER PAD

PIN BOOTS

Replace.

'98 model only

CALIPER PIN A

CALIPER PIN B

CALIPER BRACKET

CALIPER PIN

PIN BOOT

Replace.
PISTON BOOT

Replace.

PAD RETAINERS
OUTER PAD SHIM

CALIPER BRACKET

Check for cracks.

CALIPER BRACKET MOUNTING BOLT

108 N-m (11 kgf-m, 80 Ibf-ft)
Brake cylinder grease

or equivalent rubber grease.

Silicone grease (Use

recommended grease in the caliper set).
NOTE:

Coat the piston, piston seal, and caliper bore with clean brake fluid.

Replace all rubber parts with new ones whenever disassembled.

After installing the front brake caliper:

— Check for leaks at hose and line joints and connections, and retighten if necessary.

— Check the brake hoses for interference and twisting.

BANJO BOLT

34 N-m (3.5 kgf-m,

25 Ibf-ft)

CALIPER BOLT

49 N-m (5.0 kgf-m,

36 Ibf-ft)
SEALING WASHERS

Replace.

BLEED SCREW

9 N-m (0.9 kgf-m,

6.5 Ibf-ft)

CALIPER BODY

Check for scoring on

cylinder wall.

PAD SPRINGProCarManuals.com

Master Cylinder/Brak e Booste r
Removal/Installatio n
CAUTION:
B e carefu l no t t o ben d o r damag e th e brak e line s
whe n removin g th e maste r cylinder .
D o no t spil l brak e flui d o n th e vehicle ; i t ma y damag e
the paint ; i f brak e flui d doe s contac t th e paint , was h
it of f immediatel y wit h water .
T o preven t spills , cove r th e hos e joint s wit h rag s o r
sho p towels .
1 . Disconnec t th e brak e flui d leve l switc h connectors .
2 . Remov e th e reservoi r ca p fro m th e maste r cylinder .
3. Remov e th e brak e flui d fro m th e maste r cylinde r
reservoi r wit h a syringe .
4 . Disconnec t th e brak e line s fro m th e maste r cylinder .
5 . Remov e th e maste r cylinde r mountin g nuts .
6 . Remov e th e maste r cylinde r fro m th e brak e booster .
7 . Disconnec t th e vacuu m hos e fro m th e brak e booster .
8 . Remov e th e cotte r pi n an d clevi s pi n fro m th e clevis .
CAUTION : D o no t disconnec t th e clevi s b y remov -
in g it fro m th e operatin g ro d o f th e brak e booster . I f
th e clevi s i s loosened , adjus t th e pushro d lengt h
befor e installin g th e brak e booste r (se e pag e 19-16 ).
NOTE : '9 6 - 9 7 model s shown . 9
. Remov e th e fou r brak e booste r mountin g nuts .
10 . Pul l th e brak e booste r forwar d unti l th e clevi s i s
clea r o f th e bulkhead .
11 . Remov e th e brak e booste r fro m th e engin e com -
partment .
12 . Instal l th e brak e booste r an d maste r cylinde r i n th e
revers e orde r o f removal .
CAUTION :
Whe n connectin g th e brak e lines , mak e sur e
ther e i s n o interferenc e betwee n th e brak e line s
an d othe r parts .
B e carefu l no t t o ben d o r damag e th e brak e line s
whe n installin g th e maste r cylinder .
NOTE : I f replacin g th e maste r cylinde r o r brak e
booster , chec k an d adjus t th e pushro d clearanc e
befor e installin g th e maste r cylinde r (se e pag e 19-15 ).
13 . Fil l th e maste r cylinde r reservoir , an d blee d th e
brak e syste m (se e pag e 19-8 ).
14 . Afte r installation , chec k th e brak e peda l heigh t an d
brak e peda l fre e pla y (se e pag e 19-5 ), an d adjus t i f
necessary .
VACUUM HOS E
COTTE R PI NReplace .
12 N- m (1. 3 kgf-m , 9 Ibf-ft )
BRAK E BOOSTE RDo no t disassemble .
BRAKE FLUI D LEVE LSWITC H CONNECTOR S
MASTERCYLINDE RDo no t disassemble .
13 N- m (1. 3 kgf-m , 9 Ibf-ft )
To AB S modulato r uni t14 N- m 11. 5 kgf-m , 1 1 Ibf-ft )
CLEVI S
JOINT PI N
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