1995 ACURA TL Service Repair Manual

Front Brake Caliper

Disassembly

• Never use an air hose or dry brush to clean brake

assemblies.

• Use an OSHA-approved vacuum cleaner to avoid

breathing brake dust.

CAUTION:

• 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.

• 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.

1. Remove the banjo bolt, and disconnect the brake

hose from the caliper.

2. Remove the caliper bolts, then remove the caliper

from the bracket.

CALIPER BOLT

CALIPER

BANJO BOLT

SEALING WASHERS

Replace.

3. Remove the caliper pins and pin boots from the

caliper bracket.

CALIPER BRACKET

Check for cracks.

PIN BOOTS

Replace.

CALIPER PIN A
4. Remove the pad spring from the caliper.

. PAD SPRING

5.
If necessary, apply compressed air to the caliper

fluid inlet to get the piston out. Place a shop rag or

wooden block as shown to cushion the piston when

it is expelled. Use low pressure air in short spurts.

• Do not place your fingers in front of the piston.

• Do not use high air pressure; use an OSHA

approved 30 PSI nozzle.

WOODEN BLOCK

6. Remove the piston from the caliper, and check the

piston for scoring.

7. Remove the piston boot and piston seal.

CAUTION: Take care not to damage the cylinder

bore.

PISTON SEAL

Replace.

PISTON BOOT

Replace.
CALIPER BODY

Check for scoring

on cylinder wall.
CALIPER PIN BProCarManuals.com

Front Brake Caliper

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.

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.

NOTE:

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

Replace all rubber parts with new ones whenever disassembled.

: Use recommended rubber grease in the caliper seal set.

: Use recommended seal grease in the caliper seal set.

WEAR INDICATOR

Install inner pad with

its wear indicator upward.

BRAKE PADS

('97-98 models)
CALIPER PIN B PIN BOOTS

Replace.

INNER PAD SHIM B
CALIPER BRACKET MOUNTING BOLT

108 N-m (11.0 kgf-m, 80 Ibf-ft)

INNER PAD SHIM A

BLEED SCREW

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

CALIPER BODY

CALIPER BOLT

49 N-m (5.0 kgf-m,

36 Ibf-ft)
('95 - 96 models)

PAD SPRING
CALIPER BRACKET

PAD RETAINERS

PISTON

PISTON SEAL

Replace.
PISTON BOOT

Replace.
OUTER PAD SHIM

CALIPER PIN AProCarManuals.com

2.
3.
Clea n th e pisto n an d calipe r bor e wit h brak e fluid ,
an d inspec t fo r wea r an d damage .
Coa t a ne w pisto n sea l wit h th e
recommended sea l
greas e in th e calipe r sea l set , an d instal l th e sea l i n
th e cylinde r groove .
Apply th e recommende d rubbe r greas e i n th e
calipe r sea l se t t o th e sealin g lip s an d insid e o f a
ne w pisto n boot , an d instal l i t i n th e caliper .
CAUTION : B e carefu l no t t o damage the calipe r
cylinde r wall .
PISTO N SEA L
Replace .
RUBBE R GREAS E
4. Lubricat e th e calipe r an d pisto n wit h brak e fluid ,
the n instal l th e pisto n i n th e cylinde r wit h th e dishe d
end facin g in .
PISTO N
5. Instal l th e pa d sprin g o n th e caliper .
PAD SPRIN G
6. Appl y th e recommende d sea l greas e i n th e calipe r
sea l se t t o th e slidin g surfac e o f th e pin s an d th e
insid e o f th e ne w pi n boots .
7. Instal l th e pi n boot s int o th e groove s i n th e calipe r
bracke t properly .
CALIPER BRACKE T
PIN BOO T
Replace .
CALIPER PI N
CALIPE R PI N A
8. Inser t pi n A an d pi n B int o th e calipe r bracket .
9 . Instal l th e pi n boot s int o th e groove s i n th e pin s
properly .
10 . Instal l th e brak e pad s i n thei r origina l position s (se e
pag e 19-8 ).
11 . Pus h i n th e pisto n s o tha t th e calipe r wil l fi t ove r th e
pads , an d instal l th e caliper .
12. Tighte n th e calipe r bolts .
13. Connec t th e brak e hos e to th e calipe r wit h ne w seal -
in g washers , an d tighte n th e banj o bolt .
BANJ O BOL T
3 4 N- m (3. 5 kgf-m , 2 5 Ibf-ft ) CALIPE
R BOL T
4 9 N- m (5. 0 kgf-m ,
3 0 Ibf-ft )
SEALIN G WASHER S
Replace .
14. Fil l th e brak e reservoi r an d blee d th e brak e syste m
(see pag e 19-7 ).
15 . Afte r installation , chec k fo r leak s a t hos e an d lin e
joint s o r connections , an d retighte n if necessary .
PISTON BOO TReplace .
SEAL GREAS E CALIPE
R PI N B
PI N BOOT SReplace .
1.
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Master Cylinde r
Removal
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
th e paint ; i f brak e flui d doe s contac t th e paint , was h
i t 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 .
NOTE : '9 5 - 9 6 mode l i s shown .
1. Disconnec t th e brak e flui d leve l switc h connectors .THROTTLE CABL EBRAKE FLUI D LEVE LSWITC H CONNECTOR S
CHECK VALV E
MASTE R CYLINDE R4-WAY JOIN TBRACKE T
4-WAY JOIN T
4-WA Y JOIN TMOUNTIN G BOL TMASTE R CYLINDE RMOUNTING NUT S
2. Remov e th e reservoi r ca p fro m th e maste r cylinder .
3 . Th e brak e flui d ma y b e sucke d ou t throug h th e to p
o f th e maste r cylinde r reservoi r wit h a syringe .
4 . Remov e th e chec k valv e an d th e throttl e cabl e fro m
th e 4-wa y join t bracket .
5 . Remov e th e 4-wa y join t mountin g bolt .
6 . Disconnec t th e brak e line s fro m th e maste r cylinder .
7 . Remov e th e maste r cylinde r mountin g nuts , wash -
er s an d 4-wa y join t bracket .
8 . Remov e th e maste r cylinde r fro m th e brak e booster .
Inspection/Disassembl y
CAUTION:
• 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 .
• Befor e reassembling , chec k tha t al l part s ar e fre e o f
dus t an d othe r foreig n particles .
• D o no t tr y t o disassembl e th e maste r cylinde r assem -
bly . Replac e th e maste r cylinde r assembl y wit h a ne w
par t i f necessary .
• Mak e sur e n o dir t o r othe r foreig n matte r i s allowe d
t o contaminat e th e brak e fluid .
NOTE : '95-9 6 mode l i s shown .
RESERVOI R SEA LCheck fo r damag e an ddeterioration .
STRAINERRemove accumulate dsediment.
RESERVOI R CA PChec k fo r blockag eof ven t holes .
ROD SEA LCheck fo r damag eand deterioration .
SILICONE GREAS E
MASTER CYLINDE RCheck fo r leak s an d damage .
BRAKE LINE S
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Pushrod Clearanc e Adjustmen t
NOTE: Maste r cylinde r pushrod-t o pisto n clearanc e mus t
b e checke d an d adjustment s made , i f necessary , befor e
installin g maste r cylinder .
1.
2 .
3.
4 .
5 .
Se t th e specia l too l o n th e maste r cylinde r body ;
pus h in th e cente r shaf t unti l th e to p o f i t contact s th e
en d o f th e secondar y pisto n b y turnin g th e adjustin g
nut.
NOTE : '9 7 - 9 8 model s i s shown .
PUSHRO D ADJUSTMEN T GAUG E07JAG-SD4010 0
CENTERSHAFT
ADJUSTIN G NU T
Withou t disturbin g th e cente r shaft' s position , instal l
th e specia l too l upsid e dow n o n th e booster .
Instal l th e maste r cylinde r nut s an d tighte n t o th e
specifie d torque .
Connec t th e booste r in-lin e wit h a vacuu m gaug e 0 -
10 1 kP a ( 0 - 76 0 mmHg , 3 0 in Hg ) t o th e booster' s
engin e vacuu m supply , an d maintai n a n engin e
spee d tha t wil l delive r 6 6 kP a (50 0 mmHg , 2 0 in Hg )
vacuum .
With a feele r gauge , measur e th e clearanc e betwee n
th e gaug e bod y an d th e adjustin g nu t a s shown .
Clearance : 0 - 0. 4 m m (0 - 0.0 2 in )
FEELE R GAUG E
ADJUSTIN G NU T VACUU
M GAUG E
(Commerciall y available )0 -101 kPa(0-760mmHg,30in.Hg )
BRAKEBOOSTE R
MASTER CYLINDE R NU T
1 5 N- m (1. 5 kgf-m , 1 1 Ibf-ft )
NOTE : I f th e clearanc e betwee n th e gaug e bod y
an d adjustin g nu t i s 0. 4 m m (0.0 2 in) , th e pushrod -
to-pisto n clearanc e i s 0 mm . However , i f th e clear -
anc e betwee n th e gaug e bod y an d adjustin g nu t i s
0 mm , th e pushrod-to-pisto n clearanc e i s 0. 4 m m
(0.0 2 in ) o r more . Therefor e it mus t b e adjuste d an d
rechecked .
6. I f clearanc e i s incorrect , loose n th e sta r locknu t an d
tur n th e adjuste r i n o r ou t t o adjust .
NOTE:
Adjust th e clearanc e whil e th e specifie d vacuu m
i s applie d t o th e booster .
Hol d th e clevi s whil e adjusting .
7 . Tighte n th e sta r locknu t securely .
8 . Remov e th e specia l tool .
0-0. 4 m m (0-0.0 2 in )
STA R LOCKNU T22 N- m(2.2 kgf-m , 1 6 Ibf-ft )
PUSHRO D
LOCKNU T
1.5N- m (1. 5 kgf-m , 1 1 Ibf-ft )
10. Instal l th e maste r cylinde r (se e pag e 19-16 ).
MASTE R CYLINDE RSECONDAR
Y
PISTO N
CLEVIS
ADJUSTE R
PUSHRO D
ADJUSTMEN T GAUG E
07JA G - SD4010 0
122 ±0. 5 mm(4.8 ± 0.0 2 in)
CLEVI S
PUSHRO D
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Master Cylinde r
Installatio n
CAUTION:
• Whe n connectin g th e brak e lines , mak e sur e tha t
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 ).
1 . Instal l th e maste r cylinde r an d 4-wa y join t bracke t
wit h th e mountin g nut s an d washers .
NOTE : '9 5 - 9 6 mode l i s shown .
THROTTL E CABL E
CHECK VALV E
BRAKE FLUI D LEVE L
SWITC H CONNECTOR S
4-WA Y JOIN T
BRACKE T
BRAKEBOOSTE R
4-WAY JOIN T
9. 8 N- m (1. 0 kgf-m ,
7 Ibf-ft )
RESERVOI R
MASTER CYLINDE R
1 5 N- m (1. 5 kgf-m ,
1 1 Ibf-ft )
1 9 N- m (1. 9 kgf-m ,
1 4 Ibf-ft )
2. Connec t th e brak e line s t o th e maste r cylinder .
3 . Instal l th e 4-wa y joint , chec k valv e an d throttl e cabl e
t o th e 4-wa y join t bracket .
4 . Fil l th e maste r cylinde r reservoir , an d blee d th e
brak e syste m (se e pag e 19-7 ).
5 . Instal l th e reservoi r cap , an d connec t th e brak e flui d
leve l switc h connectors .
6 . 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 .
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Brake Booster

Inspection

Functional Test

1. With the engine stopped, depress the brake pedal

several times to deplete the vacuum reservoir, then

depress the pedal hard and hold it for 15 seconds. If

the pedal sinks, either the master cylinder is

bypassing internally, or the brake system (master

cylinder, lines, modulator, proportioning valve, or

caliper) is leaking.

2. Start the engine with the pedal depressed. If the

pedal sinks slightly, the vacuum booster is operat-

ing normally. If the pedal height does not vary, the

booster or check valve is faulty.

3. With the engine running, depress the brake pedal

lightly. Apply just enough pressure to hold back

automatic transmission creep. If the brake pedal

sinks more than 25 mm (1.0 in.) in three minutes, the

master cylinder is faulty. A slight change in pedal

height when the A/C compressor cycles on and off if

normal. (The A/C compressor load changes the vac-

uum available to the booster.)

Leak Test

1. Depress the brake pedal with the engine running,

then stop the engine. If the pedal height does not

vary while depressed for 30 seconds, the vacuum

booster is OK. If the pedal rises, the booster is faulty.

2. With the engine stopped, depress the brake pedal

several times using normal pressure. When the

pedal is first depressed, it should be low. On consec-

utive applications, the pedal height should gradually

rise. If the pedal position does not vary, check the

booster check valve.ProCarManuals.com

Booster Check Valve Test ('95, '96 models)

1.

2.
Disconnect the brake booster vacuum hose at the

booster or at the booster side of the valve.

Start the engine and let it idle. There should be vac-

uum. If no vacuum is available, the check valve is

not working properly. Replace the check valve and

retest.

CHECK VALVE

VACUUM HOSE

Booster Check Valve Test ('97 - 98 models)

1. Disconnect the brake booster vacuum hose at the

booster.

2. Start the engine and let it idle. There should be vac-

uum. If no vacuum is available, the check valve is

not working properly. Replace the brake booster

vacuum hose and check valve, and retest.

BRAKE BOOSTER

VACUUM HOSE

(Check valve

built-in)

VACUUM HOSEProCarManuals.com