Disc Brakes Acura RSX I

DESCRIPTION

The Acura RSX is equipped with disc brakes at all four wheels. A power assist helps reduce the effort needed on the brake pedal. All four brakes have audible brake wear indicators. When the brake pads need replacing, you will hear a distinctive metallic "screeching" sound when you apply the brakes. The hydraulic system that operates the brakes has two separate circuits. Each circuit works diagonally across the vehicle (the left-front brake is connected with the right-rear brake, etc.). If one circuit should develop a problem, you will still have braking at the opposite two wheels.

BLEEDING BRAKE SYSTEM

1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A). (Scheme 1)
2. Slide a piece of clear plastic hose over the first bleed screw, and submerge the other end in a container of new brake fluid. Have someone slowly pump the brake pedal several times, then apply steady pressure.
3. Loosen the left front 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. (Scheme 2)
5. Refill the master cylinder reservoir to the MAX (upper) level line.

Scheme 1

Scheme 2

BRAKE BOOSTER PUSHROD CLEARANCE

Note. Brake booster pushrod-to-piston clearance must be checked and adjustments made, if necessary, before installing the master cylinder.

1. Set the special tool (A) on the master cylinder body (B), push in the center shaft (C) until the top of it contacts the end of the secondary piston (D) by turning the adjustment nut (E). (Scheme 3)
2. Without disturbing the center shaft's position, install the special tool (A) backwards on the booster. (Scheme 4)
3. Install the master cylinder nuts (B) and tighten them to the specified torque. See «TORQUE SPECIFICATIONS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__torque-specifications). (Scheme 4)
4. Connect the booster in-line with a 0-30 in. Hg vacuum gauge (C) to the booster's engine vacuum supply, and maintain an engine speed that will deliver 20 in. Hg of vacuum. (Scheme 4)
5. With a feeler gauge (A), measure the clearance between the gauge body and the adjusting nut (B). (Scheme 5) If the clearance between the gauge body and the adjusting nut is 0.02" (0.4 mm), the pushrod-to-piston clearance is 0 mm. However, if the clearance between the gauge body and the adjusting nut is 0 mm, the pushrod-to-piston clearance is 0.02" (0.4 mm) or more. Therefore it must be adjusted and rechecked.
6. If the clearance is incorrect, loosen the star lock nut (A), and turn the adjuster (B) in or out to adjust. Adjust the clearance while the specified vacuum is applied to the booster. Hold the clevis (C) while adjusting. (Scheme 6)
7. Tighten the star lock nut securely. Remove the special tool (D). (Scheme 6)
8. Check the pushrod length (A) as shown if the booster is removed. If the length is incorrect, loosen the pushrod lock nut (B), and turn the clevis (C) in or out to adjust. (Scheme 7)

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Pedal Height

1. Disconnect the brake pedal position switch connector, turn the brake pedal position switch (A) counterclockwise, and pull it back until it is no longer touching the brake pedal. Lift up the carpet. At the insulator cutout, measure the pedal height (B) from the middle of the right side of the pedal pad (C). (Scheme 8) Standard Pedal Height (with carpet removed) M/T: 7 1/16" (180 mm) A/T: 7 3/16" (183 mm)
2. Loosen the push rod lock nut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the lock-nut firmly. Do not adjust the pedal height with the pushrod pressed. (Scheme 9)
3. Push in the brake pedal position switch until its plunger is fully pressed (threaded end (A) touching the pad (B) on the pedal arm). Then, turn the switch 45° clockwise to lock it. The gap between the brake pedal position switch and the pad is automatically adjusted to 0.016-0.118" (0.4 to 3.0 mm) by locking the switch. Make sure the brake lights go off when the pedal is released. (Scheme 10)

Scheme 8

Scheme 9

Scheme 10

Pedal Free Play

1. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the pedal by hand. (Scheme 11) Free Play 1/16-3/16" (1-5 mm)
2. If the pedal free play is out of specification, adjust the brake pedal position switch (C). If the pedal free play is insufficient, it may result in brake drag. (Scheme 11)

Scheme 11

PARKING BRAKE

1. Pull the parking brake lever with 44 lbs. (20 kg) of force to fully apply the parking brake. The parking brake lever should be locked within the specified number of clicks. Adjust the parking brake if the lever clicks are not within specification. Lever Locked Clicks 7-9 clicks
2. Release the parking brake lever fully. Loosen the parking brake adjusting nut, start the engine, and press the brake pedal several times to set the self adjusting brake before adjusting the parking brake.
3. Block the front wheels, then raise the rear of the vehicle, and make sure it is securely supported. Make sure the parking brake arm (A) on the rear brake caliper contacts the brake caliper pin (B). (Scheme 12) NOTE: The parking brake arm will only contact the brake caliper pin when the parking brake adjusting nut is loosened.
4. Remove the console cover. Pull the parking brake lever up one click.
5. Tighten the adjusting nut (A) until the parking brakes drag slightly when the rear wheels are turned. Release the parking brake lever fully, and check that the parking brakes do not drag when the rear wheels are turned. Readjust if necessary. Make sure the parking brakes are fully applied when the parking brake lever is pulled up fully. Reinstall the console cover. (Scheme 13)

Scheme 12

Scheme 13

TROUBLE SHOOTING

Note. For brake system trouble shooting (Scheme 14)

Scheme 14

Functional Test

1. With the engine stopped, press the brake pedal several times to deplete the vacuum reservoir, then press 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 control valve, or calipers) is leaking.
2. Start the engine with the pedal pressed. If the pedal sinks slightly, the vacuum booster is operating normally. If the pedal height does not vary, the booster or check valve is faulty.
3. With the engine running, press the brake pedal lightly. If the brake pedal sinks more than 3/8" (10 mm), in 3 minutes, the master cylinder is faulty. A slight change in pedal height when the A/C compressor cycles on and off is normal. (The A/C compressor load changes the vacuum available to the booster.)

Leak Test

1. Press the brake pedal with the engine running, then stop the engine. If the pedal height does not vary while pressed for 30 seconds, the vacuum booster is OK. If the pedal rises, the booster is faulty.
2. With the engine stopped, press the brake pedal several times using normal pressure. When the pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. If the pedal position does not vary, check the booster check valve.

Booster Check Valve Test

1. Disconnect the brake booster vacuum hose (check valve built-in) (A) at the booster (B) side. (Scheme 15)
2. Start the engine, and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not working properly. Replace the brake booster vacuum hose and check valve, and retest.

Scheme 15

PARKING BRAKE SWITCH

1. Remove the console, and disconnect the connector (A) from the switch (B). (Scheme 16)
2. Check for continuity between the positive terminal and body ground: With the brake lever up, there should be continuity. With the brake lever down, there should be no continuity.

Scheme 16

BRAKE FLUID LEVEL SWITCH

1. Check for continuity between the terminals (A) with the float in the down position and the up position. (Scheme 17) Remove the brake fluid completely from the reservoir. With the float down, there should be continuity. Fill the reservoir with brake fluid to MAX (upper) level (B). With the float up, there should be no continuity.

Scheme 17

Removal

1. Remove the master cylinder. See «MASTER CYLINDER»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes). Disconnect the vacuum hose (A) from the brake booster. (Scheme 18)
2. Remove the clip (A) and the joint pin (B), and disconnect the yoke from the brake pedal. (Scheme 19) Remove the brake booster mounting flange nuts (C).
3. Remove the brake booster (A) from the engine compartment. (Scheme 20)

Scheme 18

Scheme 19

Scheme 20

Installation

1. Adjust the pushrod clearance before installing the brake booster. See «BRAKE BOOSTER PUSHROD CLEARANCE»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__brake-booster-pushrod-clearance) (under ADJUSTMENTS). Use a new clip whenever installing.
2. After installing the brake booster and master cylinder, fill the reservoir with new brake fluid, bleed the brake system. See «BLEEDING BRAKE SYSTEM»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__bleeding-brake-system) . Adjust the brake pedal height and free play. See «ADJUSTMENTS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes) .
3. Install the brake booster in the reverse order of removal, and note these items. Adjust the pushrod clearance before installing the brake booster. Use a new clip whenever installing. After installing the brake booster and master cylinder, fill the reservoir with new brake fluid, bleed the brake system, and adjust the brake pedal height and free play. See «ADJUSTMENTS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes) .

BRAKE HOSE

1. Replace the brake hose (A) if the hose is twisted, cracked, or leaks. Disconnect the brake hose from the brake line (B) using a 10 mm flare nut wrench. (Scheme 21)
2. Remove the flange bolt (A), and remove the brake hose brackets from the damper. Remove and discard the hose clip (B). Remove the banjo bolt (C), and remove the brake hose from the caliper. (Scheme 22)

Scheme 21

Scheme 22

1. Install the brake hose bracket (A) on the damper with the flange bolt (B) first, then connect the brake hose to the caliper with the banjo bolt (C) and new sealing washers (D). (Scheme 23)
2. Install the hose onto the hose bracket on the body with a new hose clip (A). Connect the brake line to the brake hose. After installing the brake hose, bleed the brake system. See «BLEEDING BRAKE SYSTEM»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__bleeding-brake-system).
3. Check the brake hose and line joint for leaks, and tighten if necessary. Check the brake hoses for interference and twisting.

Scheme 23

FRONT BRAKE PADS

Removal & Installation

1. Remove the bolt, and pivot the caliper up and out of the way. Check the hose and pin boots for damage and deterioration. Remove the pad shims (A) and (B). (Scheme 24) Remove pad retainers (A). (Scheme 25)
2. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. Check the brake disc for damage and cracks.

Scheme 24

Scheme 25

Brake Pad Inspection

1. Check the thickness of the inner pad (A) and outer pad (B). Do not include the thickness of the backing plate. If the brake thickness is less than the service limit, replace all the pads as a set. See «DISC BRAKE SPECIFICATIONS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__disc-brake-specifications) .

Disc Runout Inspection

1. Inspect the disc surface for damage and cracks. Clean disc thoroughly, and remove all rust. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc securely against the hub. See «DISC BRAKE SPECIFICATIONS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__disc-brake-specifications). (Scheme 26)(Scheme 27).
2. Set up the dial gauge against the brake disc and measure the runout at 0.4" (10 mm) from the outer edge of the disc. (Scheme 26)and (Scheme 27). (Runout limit applies to Rear Disc Brake Pads also.) See «DISC BRAKE SPECIFICATIONS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__disc-brake-specifications).
3. If the disc runout is beyond the service limit, refinish the brake disc. NOTE: If the brake disc is beyond the service limit for refinishing, replace it. A new disc should be refinished if its runout is greater than 0.004" (0.10 mm).

Scheme 26

Scheme 27

Disc Thickness & Parallelism Inspection

1. Using a micrometer, measure disc thickness at 8 points, approximately 45 degrees apart and 0.4" (10 mm) in from the outer edge of the disc. (Scheme 28) Replace the brake disc if the smallest measurement is less than the Minimum Thickness. See «DISC BRAKE SPECIFICATIONS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__disc-brake-specifications). NOTE: Parallelism is the difference between the thickness measurements.
2. If the disc is beyond the service limit for parallelism, refinish the brake disc with an on-car brake lathe. If the brake disc is beyond the service limit for refinishing, replace it. See «DISC BRAKE SPECIFICATIONS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__disc-brake-specifications).

Scheme 28

1. Apply Dow Corning Molykote M77 grease to the retainers on their matting surfaces against the caliper bracket. Install the pad retainers. Wipe excess grease off the retainers. Contaminated brake discs and pads reduce stopping ability. Keep grease off the discs and pads.
2. Apply Dow Corning Molykote M77 or Daikalub 528D grease to both sides of the pad shims, the back of the pad. Wipe excess grease off the retainers. Contaminated brake discs and pads reduce stopping ability.
3. Install the brake pads and pad shims correctly. Install the pads with the wear indicators on the inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.
4. Push in the piston (A) 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. (Scheme 29)
5. Pivot caliper down into position. Being careful not to damage the pin boots, install the bolt (B) and tighten it to the specified torque. See «TORQUE SPECIFICATIONS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__torque-specifications). (Scheme 29) Press the brake pedal several times to make sure the brake works, 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 applications of the brake pedal will restore the normal pedal stroke.
6. After installation, check for leaks at the hose and line joints or connections, and retighten if necessary.

Scheme 29

1. Remove the air cleaner. Remove the reservoir cap and brake fluid from the master cylinder reservoir. Remove the brake fluid level sensor connector (A). (Scheme 30)
2. Disconnect the brake lines (B) from the master cylinder (C). To prevent spills, cover the hose joints with rags or shop towels. (Scheme 30) Remove the master cylinder mounting nuts (D) and washers.
3. Remove the master cylinder from the brake booster (E). Be careful not to bend or damage the brake lines when removing the master cylinder. Remove the rod seal (F) from the master cylinder.

Scheme 30

Inspection

Before reassembling, check that all parts are free of dust and other foreign particles. Do not try to disassemble the master cylinder assembly. Replace the master cylinder assembly with a new part if necessary. Do not allow dirt or foreign matter to contaminate the brake fluid.

1. Install the master cylinder in the reverse order of removal, and note these items. Replace all the rubber parts with new ones whenever the master cylinder is removed. Check the pushrod clearance before installing the master cylinder, and adjust it if necessary. Use a new rod seal on reassembly. Coat the inner bore lip and outer circumference of the new rod seal with the recommended seal grease in the master cylinder set. Install the rod seal onto the master cylinder with its grooved side (G) toward the master cylinder. Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary. See «ADJUSTMENTS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes) .

PARKING BRAKE CABLE

Note. (Scheme 31)for exploded view of Parking Brake Cable.

Note. The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature failure. (Scheme 31)as needed during this procedure.

1. Release the parking brake lever fully. Remove the console cover. Loosen the parking brake cable adjusting nut (A). (Scheme 13)
2. Remove the parking brake cable clip (A) from the brake cable (B). Disconnect the parking brake cable from the lever (C). (Scheme 32)
3. Remove the parking brake cable mounting hardware, then remove the cable.
4. Install the new cable in reverse order of removal, and note these items. Be careful not to bend or distort the cable. Make sure the parking brake cable clip is fully seated on the cable housing. Do the parking brake cable adjustment. See «PARKING BRAKE»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__parking-brake) under ADJUSTMENTS.

Scheme 31

Scheme 32

1. Remove the bolt (A) and brake hose (B) from the mounting bracket. Remove the caliper bolts (C), and remove the caliper (D) from the caliper bracket. (Scheme 33)
2. Remove the pad shims and pads. Remove the pad retainers. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. Check the brake disc for damage and cracks.

Scheme 33

Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. Check the thickness of the inner and outer pads (A). Do not include the thickness of the backing plate. See DISC BRAKE SPECIFICATIONS. If the brake pad thickness is less than the service limit, replace all the pads as a set. (Scheme 34)

Note. (Scheme 27)and (Scheme 28) for Inspection Of Rear Brake Runout, Thickness & Parallelism.

Scheme 34

Brake Disc Runout Inspection

1. Inspect the disc surface for damage and cracks. Clean disc thoroughly, and remove all rust. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc securely against the hub. See «DISC BRAKE SPECIFICATIONS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__disc-brake-specifications). (Scheme 26)and (Scheme 27).
2. Set up the dial gauge against the brake disc and measure the runout at 0.4" (10 mm) from the outer edge of the disc. (Scheme 26)and (Scheme 27). (Runout limit applies to Rear Disc Brake Pads also.) See «DISC BRAKE SPECIFICATIONS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__disc-brake-specifications).
3. If the disc runout is beyond the service limit, refinish the brake disc. NOTE: If the brake disc is beyond the service limit for refinishing, replace it. A new disc should be refinished if its runout is greater than 0.004" (0.10 mm).

Brake Disc Thickness & Parallelism Inspection

1. Using a micrometer, measure disc thickness at 8 points, approximately 45 degrees apart and 0.4" (10 mm) in from the outer edge of the disc. (Scheme 28) Replace the brake disc if the smallest measurement is less than the Minimum Thickness. See «DISC BRAKE SPECIFICATIONS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__disc-brake-specifications). NOTE: Parallelism is the difference between the thickness measurements.
2. If the disc is beyond the service limit for parallelism, refinish the brake disc with an on-car brake lathe. If the brake disc is beyond the service limit for refinishing, replace it. See «DISC BRAKE SPECIFICATIONS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__disc-brake-specifications).

1. Apply Dow Corning Molykote M77 grease to the retainers on their mating surfaces against the caliper bracket. Install the pad retainers. Wipe excess grease off the retainers. Contaminated brake discs and pads reduce stopping ability. Keep grease off the discs and pads.
2. Apply Dow Corning Molykote M77 or Daikalub 528D grease to both sides of the pad shims (A), the back of the pads (B), and the other areas indicated by the arrows. (Scheme 35) Wipe excess grease off the shim. Contaminated brake discs and pads reduce stopping ability.
3. Install the brake pads and pad shims correctly. Install the pads with the wear indicators (C) on the inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. (Scheme 35)
4. Rotate the caliper piston clockwise into the cylinder, then align the cutout (A) in the piston with the tab (B) on the inner pad by turning the piston back so the caliper can be installed on the pad. Lubricate the boot with rubber grease to avoid twisting the piston boot. If the piston boot is twisted, back it out so it is positioned properly. (Scheme 36)
5. Install the brake caliper (C) and caliper bolts (D), and tighten the bolts to the specified torque. See «TORQUE SPECIFICATIONS»(/acura/rsx/i-2001-2004/remont/mechanical-hydraulic/#disc-brakes__torque-specifications). (Scheme 36) Install the brake hose (E). Press the brake pedal several times to make sure the brake works, 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 applications of the brake pedal will restore the normal pedal stroke.

Scheme 35

Scheme 36

Disassembly & Reassembly

Note. (Scheme 37)and (Scheme 38) for exploded view of Front & Rear Brake Caliper.

Note. Before reassembling caliper, check that all parts are free of dust and other foreign particles. Replace parts with new ones as specified in the illustration. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.

Note. When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. Do not reuse drained brake fluid. Always use Genuine Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. Do not mix different brands of brake fluid as they may not be compatible. Coat the piston, piston seal groove, and caliper bore with clean brake fluid.

Brake Hose & Lines Inspection (Rear Brakes)

Inspect the brake hoses, for damage, deterioration, leaks, interference, and twisting. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines. Check for leaks at hose and line joints or connections, and retighten if necessary. Check the master cylinder and ABS modulator unit (if equipped) for damage and leakage. (Scheme 39)

Note. Replace the brake hose clip whenever the brake hose is serviced.

Scheme 37

Scheme 38

Scheme 39

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS
• MASTER CYLINDER
• BRAKE BOOSTER PUSHROD CLEARANCE
• BLEEDING BRAKE SYSTEM
• DISC BRAKE SPECIFICATIONS
• PARKING BRAKE