1996 ACURA RL KA9 engine

Differential Assembl y
Installation
NOTE: I f th e differentia l cas e i s replaced , th e 2 6 m m
shi m mus t b e adjuste d (se e ste p 1) . I f th e differentia l
cas e wa s no t replaced , g o to ste p 4 .
1 . Instal l th e differentia l assembly .
2 . Measur e th e clearanc e betwee n th e differentia l cas e
an d th e torqu e converte r housing .
26 m m SHI M
3. Selec t th e 2 6 m m shi m fro m th e followin g table .
2 6 m m SHI M
A
B
C
D
E
F
G
H
I
J
K
L
Part Numbe r
41432 -PY4 - 00 0
41433-PY4-00 0
41434-PY4-00 0
41435-PY4-000
41436-PY4-00 0
41437-PY4-00 0
41438-PY4-00 0
41439-PY4-00 0
41440-PY4-00 0
41441-PY4-00 0
41442-PY4-00 0
41443-PY4-00 0Thicknes
s
1.9 m m (0.0 7 48 in )
2.0 m m (0.078 7 in )
2.1 m m (0.082 7 in )
2.2 m m (0.086 6 in )
2.3 m m (0.090 6 in )
2.4 m m (0.094 5 in )
2.5 m m (0.098 4 in )
2.6 m m (0.102 4 in )
2.7 m m (0.106 3 in )
2.8 m m (0. 1 102 in )
2.9 m m (0. 1 142 in )
3.0 m m (0. 1 181 in )
Measuremen t
Value
1.99- 1.9 m m
2.0 9 - 2.0 m m
2.19-2. 1 m m
2.2 9 -2. 2 mm
2.39-2. 3 m m
2.4 9 -2. 4 mm
2.59-2. 5 m m
2.69-2. 6 m m
2.7 9 -2. 7 mm
2.89 - 2.8 m m
2.9 9 - 2.9 m m
3.09-3. 0 m m
4. Instal l th e tw o dowe l pin s o n th e differentia l assem -
bly.
DOWE L PIN S
5. Attac h th e differentia l assembl y t o th e engine , the n
tighte n th e fou r mountin g bolt s t o th e specifie d
torque .
O-RING .Replace .
12 x 1.2 5 mm64 N- m (6. 5 kgf-m ,
4 7 Ibf-ft )
26 m m SHI M
6. Instal l th e 2 6 m m shim , the n tighte n th e mountin g
bolt s t o th e specifie d torque .
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Inspection an d Adjustmen t
Steering Operatio n
Place th e fron t wheel s i n th e straigh t ahea d position ,
an d measur e th e distanc e th e steerin g whee l ca n b e
turne d withou t movin g th e fron t wheels .
ROTATIONA L PLAY : 0 - 1 0 m m (0 - 0.3 9 in )
If th e pla y exceed s th e servic e limit, perfor m rack guid e
adjustmen t (se e pag e 17-16 ).
I f th e pla y i s stil l excessiv e afte r rac k guid e adjustment ,
inspec t th e steerin g linkag e an d gearbo x (se e pag e
17-14 ).
Powe r Assis t Chec k wit h Vehicl e
Parked
1. Chec k th e powe r steerin g flui d leve l (se e pag e 17-16 )
an d pum p bel t tensio n (se e pag e 17-15 ).
2 . Star t th e engine , allo w it t o idle , an d tur n th e steer -
in g whee l fro m lock-to-loc k severa l time s t o war m
up th e fluid .
3. Attac h a sprin g scal e to th e steerin g wheel . Wit h th e
engin e idlin g an d th e vehicl e o n a clean , dr y floor ,
pul l th e scal e a s shown . Rotat e th e steerin g whee l
mor e tha n 9 0 degre e angl e b y pullin g th e sprin g
scale . Rea d th e figur e o n th e sprin g scal e whil e th e
steerin g whee l i s in motion .
4 . Th e scal e shoul d rea d n o mor e the n 2 5 N (2. 6 kgf ,
5. 7 Ibf) . I f i t read s more , g o o n to ste p 5 .
5 . Sto p th e engine . Disconnec t th e senso r inle t hos e
fro m th e powe r steerin g spee d sensor , an d plu g th e
hos e an d th e senso r fittin g a s shown .
6 . Star t th e engine , an d le t i t idle .
• I f th e readin g i s stil l mor e tha n 2 5 N (2. 6 kgf , 5. 7
Ibf ) th e powe r steerin g spee d senso r i s OK .
Proble m is i n th e pum p o r valv e bod y uni t (se e
Genera l Troubleshooting) .
• I f th e readin g is no w 2 5 N (2. 6 kgf , 5. 7 Ibf ) o r less ,
powe r steerin g spee d senso r leak s internally .
Replac e th e senso r (se e pag e 17-13 ).
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Assist Chec k a t Roa d Spee d
Assist (excessivel y ligh t steering ) a t hig h speed :
1 . Chec k th e powe r steerin g flui d leve l (se e pag e 17-16 ),
an d pum p bel t tensio n (se e pag e 17-15 ).
2 . Star t th e engine , allo w it t o idle , an d tur n th e steerin g
whee l fro m lock-to-loc k severa l time s t o war m u p th e
fluid .
3. Sto p th e engine . T o simulat e speed s abov e 6 2 mp h
(10 0 km/h) , disconnec t th e hose s fro m th e powe r
steerin g spee d sensor , an d connec t the m to th e
bypas s tub e joint . Plu g th e en d o f th e bypas s tub e
joint .
Powe r Steerin g Spee d Senso r
Replacemen t
1. Disconnec t th e VS S connecto r fro m th e powe r steer -
in g spee d sensor .
2 . Remov e th e senso r mountin g bolt , the n remov e th e
powe r steerin g spee d senso r fro m th e differentia l
housing .
3 . Disconnec t th e senso r inle t an d outle t hoses , an d
plu g th e hos e fittings .
4 . Installatio n is th e revers e o f th e remova l procedure .
5 . Afte r installin g a ne w sensor , tur n th e steerin g
whee l lock-to-loc k wit h th e engine idling t o blee d ai r
fro m th e system .
6 . Chec k th e reservoir , an d ad d flui d if necessary .
BYPASS TUB E JOIN T07406-001010 1(Included wit h07406-0010001 )
4. Attac h a sprin g scal e to th e steerin g wheel .
Star t th e engine ; wit h th e engin e idlin g an d th e vehi -
cl e o n a clean , dr y floor , pul l th e scal e a s shown .
Rotat e th e steerin g whee l mor e tha n 9 0 degree s b y
pullin g th e sprin g scale . Rea d th e figur e o n th e
sprin g scal e whil e th e steerin g whee l i s i n motion .
• I f th e scal e read s mor e tha n 2 5 N (2. 6 kgf , 5. 7
Ibf) , th e valv e bod y uni t i s OK .
Th e powe r steerin g spee d senso r abnormal .
Replac e th e sensor , an d chec k b y roadtesting .
• I f th e readin g is no w 2 5 N (2. 6 kgf , 5. 7 Ibf ) o r less ,
proble m is i n th e valv e bod y uni t o r pum p (se e
Genera l Troubleshooting) .
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2. Tighte n th e rac k guid e scre w to 2 5 N- m (2. 5 kgf-m ,
18lbf-ft) , the n loose n it .
3 . Retighte n th e rac k guid e scre w to 5. 9 N- m (0. 6 kgfm ,
4 Ibf-ft) , the n bac k it of f t o specifie d angle .
Specifie d Retur n Angle : 1 5 ± 5°
4 . Tighte n th e locknu t whil e holdin g th e rac k guid e
screw .
5 . Chec k fo r tigh t o r loos e steerin g throug h th e com -
plet e turnin g travel .
6 . Perfor m th e followin g inspection s (se e pag e 17-12 ).
• Steerin g operation .
• Powe r assis t wit h vehicl e parked . 2
. Connec t a hos e o f correc t diamete r t o th e discon -
necte d retur n hose , an d pu t th e hos e en d i n a suit -
abl e container .
CAUTION : Tak e car e no t t o spil l th e flui d o n th e
bod y an d parts . Wip e of f an y spille d flui d a t once .
3 . Star t th e engine , le t i t ru n a t idle , an d tur n th e steer -
in g whee l fro m lock-to-loc k severa l times . Whe n
flui d stop s runnin g ou t of the hose , shu t of f th e
engine . Discar d th e fluid .
4 . Reinstal l th e retur n hos e o n th e reservoir .
5 . Fil l th e reservoi r t o th e uppe r leve l line .
6 . Star t th e engin e an d ru n i t a t fas t idle , the n tur n th e
steerin g fro m lock-to-loc k severa l time s t o blee d ai r
fro m th e system .
7 . Rechec k th e flui d leve l an d ad d mor e if necessary .
CAUTION : D o no t fil l th e reservoi r beyon d th e
uppe r leve l line .
Inspectio n an d Adjustmen t
Rack Guid e Adjustmen t
NOTE: Perfor m rac k guid e adjustmen t wit h th e wheel s
i n th e straigh t ahea d position .
1 . Loose n th e rac k guid e scre w locknu t wit h th e spe -
cial tool .
'96 - 9 8 models :
Loose n th e rac k guid e screw .
'9 9 - 0 1 models :
Remov e th e rac k guid e screw . Remov e th e ol d
sealan t fro m th e rac k guid e scre w threade d section ,
an d appl y ne w sealan t t o th e al l aroun d threads .
Loosel y instal l th e rac k guid e scre w o n th e steerin g
gearbox .
Fluid Replacemen t
Check th e reservoi r a t regula r intervals , an d ad d th e rec -
ommende d flui d a s necessary .
CAUTION : Alway s us e Genuin e Hond a Powe r Steerin g
Fluid- V o r S . Usin g an y othe r typ e o f powe r steerin g
flui d o r automati c transmissio n flui d ca n caus e
increase d wea r an d poo r steerin g in col d weather .
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12. Instal l th e fron t wheels .
13 . Fil l th e syste m wit h th e recommende d powe r steer -
in g fluid , an d blee d ai r fro m th e syste m (se e pag e
17-16 ).
14 . Afte r installation , perfor m th e followin g checks .
• Star t th e engine , allo w it t o idle , an d tur n th e steer -
in g whee l fro m lock-to-loc k severa l time s t o war m
u p th e fluid . Chec k th e gearbo x fo r leak s (se e pag e
17-23 ).
• Adjus t th e fron t to e (se e sectio n 18 ).
• Chec k th e steerin g whee l spok e angle . Adjus t b y
turnin g th e righ t an d lef t tie-rods , i f necessary .
NOTE : Tur n th e righ t an d lef t tie-rod s equally .
11
. Reconnec t th e tie-ro d end s t o th e steerin g knuckles ,
tighte n th e castl e nu t ('9 6 - 9 8 models ) o r he x nu t
('9 9 - 0 1 models ) t o th e specifie d torque , an d instal l
ne w cotte r pins .
NOTE : Befor e connectin g th e tie-ro d ends , wip e of f
an y greas e contaminatio n fro m th e bal l join t tapere d
sectio n an d threads .
CAUTION : Torqu e th e castl e nu t t o th e lowe r torqu e
specification , the n tighte n it onl y fa r enoug h to alig n
th e slo t wit h th e pi n hole . D o no t alig n th e nu t b y
loosening .
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Front Suspensio n
Knuckle/Hub Replacemen t
NOTE:
• Us e onl y genuin e Hond a whee l weight s fo r aluminu m wheels . Non-genuin e whee l weight s ma y corrod e an d damag e
aluminu m wheels .
• Befor e installin g th e wheel , clea n th e matin g surfac e o f th e brak e dis c an d insid e o f th e wheel .
KNUCKL E
WHEEL BEARIN G
Replace .
Replacement , pag e 18- 9
SPLASH GUAR D
BALL JOIN T BOO T
CASTL E NU T14 x 2. 0 m m
FRON T HU B
Chec k fo r damag e an d
cracks .
BRAKE DIS C
Chec k fo r wea r an d
rust .Removal , pag e 18-1 0Inspection , sectio n 1 9
6 m m SCRE W5 N- m(0.5 kgf-m , 4 Ibf-ft )
WHEE L NU T
12 x 1. 5 m m108 N- m (1 1 kgf-m , 8 0 Ibf-ft )
CENTE R CA P
SPINDL E NU T
24 x 1. 5 m m245 N- m (2 5 kgf-m , 18 1 Ibf-ft )
Replace .
NOTE :
• Befor e installin g th e spindl e nut , appl y
engine oi l t o th eseatin g surfac e o f th e nut .• Afte r tightening , us e a drif t t o stak e th espindl e nu tshoulde r agains t th e spindle .
FLAT-HEA
D SCRE W
9.8 N- m(1.0 kgf-m , 7. 2 Ibf-ft )
COTTE
R PI N
Replace .
SNAP RIN G
CASTL
E NU T
10 x 1.2 5 mm
SE T RIN G
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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

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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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