Repair Procedure - 2004-06 TL
1. Remove the left rear and the left side engine compartment covers.
2. Remove the brake fluid from the clutch master cylinder reservoir with a syringe.
3. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the client's audio presets. Make sure the ignition switch is OFF.
4. Disconnect the negative cable from the battery first, then disconnect the positive cable.
5. Remove the battery.
6. Remove the air cleaner assembly.
7. Remove the battery base.
8. Remove the under-hood fuse/relay box.
9. Remove the driver's dashboard undercover:
^ Gently pull down the rear edges of the undercover to detach the clips.
^ Pull the cover away to release the pins from the holders.
^ Disconnect the foot light illumination connector (if equipped).
10. Pry out the lock pin, and pull the pedal clevis pin out of the yoke. Remove the master cylinder mounting nuts.
11. Remove the clutch fluid reservoir mounting bolt.
12. Disconnect the clutch line from the bracket.
13. Detach the clutch line from the clamp(s).
14. Remove the clutch master cylinder.
15. Disconnect the clutch fluid reservoir hose and the clutch line:
^ Remove the retaining clip.
^ Remove the clutch line from the clutch master cylinder.
^ Wrap the ends of the reservoir hose and the clutch line with shop towels to prevent brake fluid from coming out.
^ Remove the 0-ring and the clutch master cylinder seal from the clutch master cylinder.
16. Apply brake assembly lube to the clutch line, and install a new 0-ring and clutch master cylinder seal.
17. Attach the clutch line to the clamps, install a new retaining clip, and connect the reservoir hose.
18. To prevent the retaining clip from coming off, pry apart the the tip of the retaining clip with a screwdriver.
19. Install the clutch master cylinder.
20. Connect the clutch line to the bracket.
21. Install the reservoir mounting bolt.
22. Make sure the hose clamps are positioned on the master cylinder and reservoir as shown.
23. Torque the master cylinder mounting nuts to 13 N.m (9.4 lb-ft).
24. Apply grease to the pedal clevis pin, slide it into the yoke, then install a new lock pin.
25. Adjust the clutch pedal, the clutch pedal position switch, and the clutch interlock switch.
26. Bleed the clutch master hydraulic system.
^ Attach a hose to the bleeder screw, and suspend the hose in a container of brake fluid.
^ Use only Acura DOT 3 Brake Fluid, from an unopened container.
^ Make sure there is an adequate supply of brake fluid in the clutch reservoir, then slowly pump the clutch pedal until no more bubbles appear at the bleeder hose.
^ It may be necessary to limit the movement of the clutch release fork with a block of wood to remove all the air from the system.
^ Tighten the bleeder screw to 8 N.m (5.8 lb-ft) (do not overtighten).
^ Make sure the clutch works properly, and check for brake fluid leaks.
27. Install the driver's dashboard undercover:
^ Plug in the foot light illumination connector (if equipped).
^ Push in the undercover to connect the pins to the holders.
^ Gently push up the rear edges of the undercover to attach the clips.
28. Install the under-hood fuse/relay box, and torque the two bolts.
29. Install the battery base.
30. Install the air cleaner assembly.
31. Install the battery.
^ Clean the battery posts and cable terminals.
^ Connect the positive cable to the battery first, then connect the negative cable.
^ Apply multipurpose grease to the posts and cable terminals to prevent corrosion.
32. Enter the anti-theft codes for the audio system and navigation system (if equipped).
^ Enter the client's audio presets.
^ Set the clock.
33. Install the left rear and the left side engine compartment covers.
34. Refill the brake fluid in the clutch reservoir to the MAX (upper) level line.