Acura RSX Honda Integra. Manual — part 354

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Runout

Thickness and Parallelism

Brake disc runout:

Service limit: 0.10 mm (0.004 in.)

Max. refinish limit:

K20A2, K20Z1 engine models:

23.0 mm (0.91 in.)

K20A3 engine model:

19.0 mm (0.75 in.)

Brake disc thickness:

Standard:

K20A2, K20Z1 engine models:

24.9

25.1 mm (0.98

0.99 in.)

K20A3 engine model:

20.9

21.1 mm (0.82

0.83 in.)

Max. refinishing limit:

K20A2, K20Z1 engine models:23.0 mm (0.91 in.)
K20A3 engine model:

19.0 mm (0.75 in.)

Brake disc parallelism: 0.015 mm (0.0006 in.) max.

19-13

Front Brake Disc Inspection

B
108 N·m
(11.0 kgf·m, 79.6 lbf·ft)

A

10 mm (3/8 in.)

10 mm (3/8 in.)

1. Raise the front of the vehicle, and support it with

safety stands in the proper locations (see page
1-12).

2. Remove the front wheels.

3. Remove the brake pads (see page 19-11).

4. Inspect the brake disc surface for damage and

cracks. Clean the brake disc thoroughly, and
remove all rust.

5. Install suitable flat washers (A) and the wheel nuts

(B), and tighten the wheel nuts to the specified
torque to hold the brake disc securely against the
hub.

6. Set up the dial gauge against the brake disc as

shown, and measure the runout at 10 mm (3/8 in.)
from the outer edge of the brake disc.

7. If the brake disc is beyond the service limit, refinish

the brake disc with an on-car brake lathe. The
Kwik-Lathe produced by Kwik-way Manufacturing
Co. and the ‘‘Front Brake Disc Lathe’’ offered by
Snap-on Tools Co. are approved for this operation.

NOTE:

• If the brake disc is beyond the service limit for

refinishing, replace it (see page 18-11).

• A new brake disc should be refinished if its

runout is greater than 0.10 mm (0.004 in.).

1. Raise the front of the vehicle, and support it with

safety stands in the proper locations (see page
1-12).

2. Remove the front wheels.

3. Remove the brake pads (see page 19-11).

4. Using a micrometer, measure brake disc thickness

at eight points, about 45 ° apart and 10 mm (3/8 in.)
in from the outer edge of the brake disc. Replace
the brake disc if the smallest measurement is less
than the max. refinishing limit.

NOTE: Parallelism is the maximum allowable
difference between the thickness measurements.

5. If the brake disc is beyond the service limit for

parallelism, refinish the brake disc with an on-car
brake lathe. The Kwik-Lathe produced by Kwik-way
Manufacturing Co. and the ‘‘Front Brake Disc
Lathe’’ offered by Snap-on Tools Co. are approved
for this operation.

NOTE: If the brake disc is beyond the service limit
for refinishing, replace it (see page 18-11).

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19-14

Conventional Brake Components

Front Brake Caliper Overhaul

WEAR INDICATOR

CALIPER
BRACKET

BRAKE PADS

PISTON

8 x 1.0 mm
14 inch model:
22 N·m
(2.2 kgf·m, 16 lbf·ft)

16 inch model:
32 N·m
(3.3 kgf·m, 24 lbf·ft)

SEALING
WASHERS

BANJO BOLT
34 N·m
(3.5 kgf·m,
25 lbf·ft)

CALIPER BODY

OUTER PAD SHIM

12 x 1.25 mm
108 N·m (11.0 kgf·m,
79.6 lbf·ft)

PISTON SEAL

PISTON BOOT

BOOT

CALIPER PIN A

BLEED SCREW
9 N·m
(0.9 kgf·m, 7 lbf·ft)

PISTON BOOT

CALIPER PIN B

PAD RETAINER

INNER PAD SHIMS

: Honda silicone grease (P/N 08C30-B0234M)

Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.

• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

Remove, disassemble, inspect, reassemble, and install the caliper, and note these items:

NOTE: Make sure that the caliper pins are installed correctly. The upper and lower caliper pins are different. If the
caliper pins are installed in the wrong location, it will cause uneven tire wear, vibration, and or uneven or rapid pad
wear.

• Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off

immediately with water.

• To prevent dripping, cover disconnected 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 as specified in the illustration.
• Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
• Make sure no grease or oil gets on the brake discs or pads.
• When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency.
• Do not reuse drained brake fluid. Use only clean ACURA DOT 3 Brake Fluid from an unopened container. Using a

non-Acura 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.
• Replace all rubber parts with new ones whenever disassembled.
• After installing the caliper, check the brake hose and line for leaks, interference, and twisting.

Install inner pad with
its wear indicator downward.

Replace.

Replace.

Replace.

Replace.

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19-15

Master Cylinder Replacement

F

G

E

A

B

C

D

15 N·m
(1.5 kgf·m,
11 lbf·ft)

15 N·m
(1.5 kgf·m,
11 lbf·ft)

NOTE: 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.

1. Remove the air cleaner.

2. Remove the reservoir cap and brake fluid from the

master cylinder reservoir.

3. Remove the brake fluid level sensor connector (A).

4. Disconnect the brake lines (B) from the master

cylinder (C). To prevent spills, cover the hose joints
with rags or shop towels.

5. Remove the master cylinder mounting nuts (D) and

washers.

6. Remove the master cylinder from the brake booster

(E). Be careful not to bend or damage the brake
lines when removing the master cylinder.

7. Remove the rod seal (F) from the master cylinder.

8. 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
(see page 19-16).

• 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 page 19-6).

• Bleed the brake system (see page 19-8).

9. Spin the wheels to check for brake drag.

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Special Tools Required

19-16

19-16

Conventional Brake Components

Master Cylinder Inspection

Brake Booster Pushrod Clearance
Adjustment

RESERVOIR CAP

RESERVOIR SEAL

RESERVOIR

STRAINER

MASTER CYLINDER

A
07JAG-SD40100

E

C

B

D

C
0

101 kPa

(0

760 mmHg, 0

30 in.Hg)

A
07JAG-SD40100

B
15 N·m (1.5 kgf·m,
11 lbf·ft)

NOTE:

• 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.

• Bleed the brake system (see page 19-8).

Pushrod adjustment gauge 07JAG-SD40100

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 adjusting nut (E).

2. Without disturbing the center shaft’s position,

install the special tool (A) backwards on the booster.

3. Install the master cylinder nuts (B), and tighten

them to the specified torque.

4. Connect the booster in-line with a vacuum gauge

(C) 0

101 kPa (0

760 mmHg, 0

30 in.Hg) to the

booster’s engine vacuum supply, and maintain an
engine speed that will deliver 66 kPa (500 mmHg,
20 in.Hg) vacuum.

Check for blockage
of vent holes.

Check for damage
and deterioration.

Check for damage.

Remove accumulated
sediment.

Check for leaks,
rust, and damage.

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