1996 ACURA RL KA9 Service Repair Manual

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Page 1057 of 1954

ACURA RL KA9 1996 Service Repair Manual
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 bracke

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

Page 1058 of 1954

ACURA RL KA9 1996 Service Repair Manual 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 . R

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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Page 1059 of 1954

ACURA RL KA9 1996 Service Repair Manual
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 disc

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

Page 1060 of 1954

ACURA RL KA9 1996 Service Repair Manual 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

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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Page 1061 of 1954

ACURA RL KA9 1996 Service Repair Manual
Master Cylinder Inspection

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.

• Before re

Page 1062 of 1954

ACURA RL KA9 1996 Service Repair Manual CENTERSHAFT
SECONDAR Y PISTO N
PUSHRO D
ADJUSTMEN T GAUG E
07JAG-SD4010 0
CLEARANCE
ADJUSTING NU T
Pushro d Clearanc e Adjustmen t
NOTE: Maste r cylinde r pushrod-to-pisto n clearanc e mus t
b e chec

Page 1063 of 1954

ACURA RL KA9 1996 Service Repair Manual Master Cylinder/Brak e Booste r
Pushrod Clearanc e Adjustmen t
(cont'd)
NOTE: I f th e clearanc e betwee n th e gaug e bod y an d
adjustin g nu t i s 0. 2 m m (0.00 8 in) , th e pushrod-to-pisto

Page 1064 of 1954

ACURA RL KA9 1996 Service Repair Manual Master Cylinder/Brak e Booste r
Brake Booste r Inspectio n
Functiona l Tes t
1 . Wit h th e engin e stopped , pres s th e brak e peda l sev -
eral time s t o deplet e th e vacuu m reservoir , the n
pr

Master Cylinder/Brak e Booste r
Brake Booste r Inspectio n
Functiona l Tes t
1 . Wit h th e engin e stopped , pres s th e brak e peda l sev -
eral time s t o deplet e th e vacuu m reservoir , the n
pres s th e peda l har d an d hol d i t fo r 1 5 seconds . I f
th e peda l sinks , eithe r th e maste r cylinde r i s
bypassin g internally , o r th e brak e syste m (maste r
cylinder , lines , modulator , o r caliper ) i s leaking .
2 . Star t th e engin e wit h th e peda l pressed . I f th e peda l
sinks slightly , th e vacuu m booste r i s operatin g nor -
mally . I f th e peda l heigh t doe s no t vary , th e booste r
o r chec k valv e is faulty .
3. Wit h th e engin e running , pres s th e brak e peda l light -
ly. Appl y jus t enoug h pressur e t o hol d bac k auto -
mati c transmissio n creep . I f th e brak e peda l sink s
mor e tha n 2 5 m m (1. 0 in. ) i n 3 minutes , th e maste r
cylinde r i s faulty . A sligh t chang e i n peda l heigh t
whe n th e A/ C compresso r cycle s o n an d of f i s nor -
mal . (Th e A/ C compresso r loa d change s th e vacuu m
availabl e to th e booster. )
Leak Tes t
1 . Pres s th e brak e peda l wit h th e engin e running , the n
sto p th e engine . I f th e peda l heigh t doe s no t var y
whil e presse d fo r 3 0 seconds , th e vacuu m booste r i s
OK . I f th e peda l rises , th e booste r i s faulty .
2 . Wit h th e engin e stopped , pres s th e brak e peda l sev -
era l time s usin g norma l pressure . Whe n th e peda l i s
firs t pressed , i t shoul d b e low . O n consecutiv e appli -
cations , th e peda l heigh t shoul d graduall y rise . I f th e
peda l positio n doe s no t vary , chec k th e booste r
chec k valve .
Booste r Chec k Valv e Tes t
1 . Disconnec t th e brak e booste r vacuu m hos e a t th e
booster .
2 . Star t th e engine , an d le t i t idle . Ther e shoul d b e vac -
uum . I f n o vacuu m is available , th e chec k valv e i s
no t workin g properly . Replac e th e brak e booste r
vacuu m hos e an d chec k valve , an d retest .
NOTE : '9 6 - 9 7 model s shown .
BRAKE BOOSTE RVACUUM HOS E
(Chec k valv e is
built-in )
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