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1996-2004 Acura 3.5RL Service Manual & Body Repair Manual.pdf

October 27, 2008 · Filed Under Acura  · Tags: , , ,

The Acura 3.5RL (RL stands for Refine Luxury) was an executive car built in Saitama Japan and also called as Honda Legend. It internally known and KA9 and is powered by 3.5L V6/C35A1 SOHC Sequential Multiport Fuel Injected engine and uses M5DA 4 speed automatic transmission. The Acura RL was intended to replace its predecessor, the Acura Legend.

This zipped material consists 2 manual, a Acura 3.5RL Service Manual and Acura 3.5RL Collision/Body Repair Manual, specially for Model Year 1996-2004 (first generation of Acura 3.5RL).

Service Manual Table of Contents:

  • General Information [ Chassis and Paint Codes for '96 Models; '97 Models; '98 Models; '99 Models; '00 Models; '01 Models; '02 Models; '03 Models & '04 Models ~ Revised Component Terms ~ Parts Marking ('03-'04 Models) ~ Identification Number Locations ~ Warning/Caution Label Locations ~ Under-hood Emissions Control Label ~ Lift and Support Points ~ Towing ~ Service Precautions ]
  • Specifications [ Standards and Service Limits ~ Engine Electrical ~ Cylinder Head/Valve Train ~ Engine Block ~ Engine Lubrication ~ Cooling ~ Fuel and Emissions ~ Automatic Transmission ~ Differential ~ Steering ~ Suspension ~ Brakes ~ Air Conditioning ~ Design Specifications ~ Body Specifications ]
  • Maintenance [ Lubrication Points ~ Maintenance Schedule ~ Normal Conditions ~ Severe Conditions ]
  • Engine Electrical [ Special Tools ~ Starting System ~ Starter Test ~ Starter ~ Starter Solenoid Test ~ Field Winding Test ~ Armature Inspection and Test ~ Starter Brush Holder Test ~ Starter Brush Inspection ~ Planetary Gear Inspection ~ Overrunning Clutch Inspection ~ Overrunning Clutch Removal ~ Starter Reassembly ~ Performance Test ~ Ignition System ~ Ignition Timing Inspection ~ Idle Speed Check ~ Noise Condenser Capacity Test ~ Ignition Control Module Input Test ~ Ignition Coil ~ Spark Plug Inspection ~ Charging System ~ Alternator ~ Cruise Control ~ Control Unit Input Test ~ Set/Resume/Cancel Switch Test/ ~ Main Switch Test ~ Brake Pedal Position Switch Test ~ Actuator Solenoid Test ~ Actuator Test ~ Actuator Cable ]
  • Engine [ Engine Removal/Installation ~ Cylinder Head/Valve Train ~ Engine Block ~ Engine Lubrication ~ Intake Manifold/Exhaust System ~ Cooling ]
  • Cooling [ Radiator ~ Replacement ~ Engine Coolant Refilling and Bleeding ~ Cap Testing ~ Testing ~ Thermostat ~ Replacement ~ Testing ~ Water Pump ~ Fan Control ~ Fan Control Module Terminals ~ Fan Motor Testing ~ Radiator Fan Control Sensor Testing ~ Engine Coolant Temperature (ECT) Gauge ('96-'02 models) ~ Gauge Testing ~ Sending Unit Testing ]
  • Fuel and Emissions [ Special Tools ~ System Description ~ Vacuum Connections ~ Electrical Connections ~ System Connectors ~ Engine Compartment ~ Dash and Floor ~ Procedures ~ Symptom Chart ~ Probable Cause Chart ~ PCM Terminal Arrangement ~ DTC Chart ~ How to Read Flow Charts ~ PGM-FI System ~ System Description ~ How to Set Readiness Codes ~ MIL Circuit ~ Idle Control System ~ System Description ~ Air Conditioning Signal ~ Alternator FR Signal ~ Starter Switch Signal ~ PSP Switch Signal ~ Brake Pedal Position Switch ~ Signal ~ Idle Air Control Thermal ~ Valve ~ Idle Speed Setting ~ PCM Memory Setting ~ Fuel Supply System ~ Fuel Lines ~ Fuel Tube/Quick-Connect ~ Fittings ~ System Description ~ Fuel Pressure ~ Fuel Injectors ~ Fuel Pressure Regulator ~ Fuel Pump Relay ~ Fuel Pump Resistor ~ Fuel Filter ~ Fuel Pump ~ Fuel Gauge ~ Fuel Gauge Sending Unit ~ Low Fuel Indicator System ~ PGM-FI Main Relay ~ Fuel Tank ~ Intake Air System ~ System Description ~ Air Cleaner ~ Throttle Cable ~ Throttle Body ~ Intake Manifold Runner Control (IMRC) System ~ Intake Air Bypass (IAB) Control ~ System ~ Emission Control System ~ System Description ~ Tailpipe Emission ~ Three Way Catalytic ~ Converter ~ EGR System ~ PCV System ~ Evaporative Emission Controls ~ Description ~ EVAP Canister and Canister ~ Vent Shut Valve ~ Replacement ~ EVAP Two Way Valve and Bypass ~ Solenoid Valve ~ Replacement ~ Fuel Tank Vapor Control Valve ('00-'04 Models) ~ Test ~ Replacement ~ Evaporative Emission EVAP Two Way ~ Valve Testing ]
  • Transmission [ Automatic Transmission ~ Differential ~ Driveshafts ]
  • Steering [ Special Tools ~ General Troubleshooting ~ Noise and Vibration ~ Fluid Leaks ~ Steering Operation ~ Power Assist Check Parked ~ Power Assist Check at Road ~ Speed ~ Power Steering Speed Sensor ~ Replacement ~ Linkage and Gearbox ~ Pump Belt ~ Rack Guide Adjustment ~ Fluid Replacement ~ Pump Pressure Check ~ Steering Wheel ~ Steering Column ~ Steering Lock Replacement ~ Power Steering Hoses, Lines ~ Fluid Leakage Inspection ~ Power Steering Pump ~ Power Steering Gearbox ~ Removal ~ Ball Joint Boot Replacement ]
  • Suspension [ Special Tools ~ Wheel Alignment ~ Caster ~ Camber ~ Front Toe Inspection ~ Rear Toe Inspection/Adjustment ~ Turning Angle Inspection ~ Wheel/Hub Inspection ~ Bearing End Play ~ Wheel Runout ~ Front Suspension ~ Knuckle/Hub Replacement ~ Ball Joint Boot Replacement ~ Suspension Arms ~ Front Damper ~ Rear Suspension ~ Hub Bearing Unit ~ Replacement ~ Suspension Arms ~ Ball Joint Boot Replacement ~ Rear Damper ]
  • Brakes [ Conventional Brake ~ Special Tools ~ Rubber Parts/Brake ~ Booster ~ Brake Pedal ~ Parking Brake Pedal ~ Bleeding ~ Brake System Indicator ~ Front Brake Pads ~ Front Brake Disc ~ Disc Runout Inspection ~ Disc Thickness and Parallelism Inspection ~ Front Brake Caliper ~ Disassembly/Reassembly ~ Master Cylinder/Brake Booster ~ Removal/Installation ~ Master Cylinder ~ Pushrod Clearance ~ Adjustment ~ Brake Booster Inspection ~ Rear Brake Pads ~ Rear Brake Disc ~ Disc Runout Inspection ~ Disc Thickness and Parallelism ~ Rear Brake Caliper ~ Disassembly/Reassembly ~ Parking Brake ~ Parking Brake Shoes ~ Replacement ~ Lining Surface Break-in ~ Brake Hoses/Lines ~ Inspection/Torque Specifications ~ Hose Replacement ~ Parking Brake Cable Inspection and Replacement ~ ABS (Anti-lock Brake System) ('96-97 models) ~ Special Tools ~ ABS Control Unit Terminal Arrangement ~ Diagnostic Trouble Code (DTC) ~ DTC Indication ~ Symptom-to-System Chart ~ ABS Function Test ~ Modulator Unit ~ Relieving System ~ Pressure ~ High Pressure Brake Fluid ~ Replacement/Bleeding ~ Modulator Function Check ~ Wire Harness Replacement ~ Pump Motor Replacement ~ Reservoir Replacement ~ Accumulator Replacement and Disposal ~ ABS Control Unit ~ Pulsers/Wheel Sensors ~ ABS (Anti-lock Brake System) ('98-99 models) ]
  • Anti-lock Brake System [ Features/Construction ~ ABS Control Unit Terminal ~ Diagnostic Trouble Code (DTC) ~ DTC Indication ~ DTC Erasure ~ Modulator Unit ~ ABS Control Unit ~ Pulsers/Wheel Sensors Inspection ~ Wheel Sensor Replacement ~ TCS (Traction Control System) ('96-99 models) ~ System Description Outline ~ Construction and Function ~ TCS Control Unit Terminal Arrangement ~ Diagnostic Trouble Code (DTC) Indication ~ DTC Erasure ~ Troubleshooting Index ~ Steering Angle Sensor Replacement ~ System Check ~ TCS Control Valve Assembly Replacement ~ TCS Switch Test ~ TCS Control Unit Replacement ~ VSA (Vehicle Stability Assist System) ('00-'04 Models) ~ Special Tools ~ VSA Control Unit Terminal Arrangement ~ VSA Converter Unit Terminal Arrangement ~ Diagnostic Trouble Code (DTC) Indication ~ DTC Clearing ~ DTC Chart ~ Steering Angle Sensor ~ Neutral Position Check and Memorizing ~ VSA Modulator-Control Unit Removal/Installation ~ Precharge Pump Motor Removal/Installation ~ Precharge Brake Line Bleeding ~ TCS Control Valve Assembly Replacement ~ VSA Off Switch Test ~ VSA Converter Unit Removal/Installation ~ Yaw Rate/Lateral Acceleration Sensor Removal/Installation ~ Pulsers/Wheel Sensors ~ Wheel Sensor ]
  • Body [ Doors (Front) ~ Door Panel Removal ~ Outer Handle/Latch Removal ~ Glass/Regulator Removal ~ Sash Trim Removal ~ Inner Sash Trim Removal ~ Glass Adjustment ~ Position Adjustment ~ Striker Adjustment ~ Doors (Rear) ~ Door Panel Removal ~ Outer Handle/Latch Removal ~ Glass/Regulator Removal ~ Sash Trim Removal ~ Inner Sash Trim Removal ~ Glass Adjustment ~ Position Adjustment ~ Striker Adjustment ~ Mirrors ~ Power Mirror Removal ~ Mirror Holder Removal ~ Rearview Mirror Removal ~ Windshield/Rear Window ~ Windshield ~ Rear Window ~ Moonroof ~ Troubleshooting ~ Glass Height Adjustment ~ Glass, Glass Bracket, and Sunshade ~ Removal ~ Motor, Drain Tube and Frame ~ Removal ~ Guide Rails, Cable Assembly ~ Replacement ~ Switch Plate Adjustment ~ (Fully Closed Position/Auto Stop Position) ~ Opening Drag Check ~ (Motor Removed) ~ Closing Force Check ~ (Motor Installed) ~ Interior ~ Interior Trim Removal ~ Trunk Trim Removal ~ Headliner Removal ~ Carpet ~ Console Panel/Rear Console ~ Removal ~ Dashboard ~ Seats ~ Front Seat ~ Disassembly ~ Driver's ~ Passenger's ~ Seat Cover Replacement ~ Seat Linkage Disassembly ~ Wire Harness Installation ~ Power Lumbar Support ('04 Model) ~ Replacement ~ Rear Seat ~ Removal ~ Trunk Pass-through Cover Key ~ Cylinder Replacement ~ Seat Cover Replacement ~ Exterior ~ Front Bumper Removal ~ Rear Bumper Removal ~ Hood Adjustment ~ Trunk Lid Adjustment ~ Front Grille Removal ~ Trunk Lid Torsion Bars ~ Trunk Lid Weatherstrip ~ Trunk Lid Hinge Cover ~ License Plate Trim Removal ~ Side Window Moldings ~ Roof Molding Removal ~ Door and Side Moldings Removal ~ Side Sill Panel Removal ~ Inner Fender, Fenderwell Trim, ~ Rear Fender Cover and Rear Air ~ Outlet Removal ~ Opener Cable/Opener and Latch/ ~ Wiper and Washer ~ Opener Cables Removal ~ Opener and Latch Removal ~ Windshield Wiper Arms and Linkage Removal ~ Washer Reservoir Removal ~ Washer Tube Replacement ~ Wiper Arms/Washer Nozzle ~ Emblems Installation ~ Frame ~ Sub-frame ~ Frame Repair Chart ]
  • HVAC (Heating, Ventilation and Air Conditioning) [ Special Tools ~ Wiring/Connector ~ Fan Control Unit ~ A/C Pressure Switch ~ Evaporator Pressure Regulator (EPR) ~ Climate Control Unit Input/Output Signals ~ Climate Control Unit ~ Face Panel/Button ~ Air Mix Control Motor ~ Mode Control Motor ~ Recirculation Control Motor ~ In-car Temperature Sensor ~ Outside Air Temperature Sensor ~ Sunlight Sensor ~ Evaporator Temperature Sensor ~ Power Transistor Test ~ Relays Test ~ Evaporator/Blower Unit ~ Dust and Pollen Filters ~ Temperature Control ~ A/C Service Tips and Precautions ~ A/C System Torque Specifications ~ A/C System Service Refrigerant Recovery ~ Evacuation ~ Leak Test ~ Compressor Replacement ~ Clutch Inspection ~ Clutch Overhaul ~ Relief Valve ~ A/C Compressor Belt Adjustment ~ Condenser ]
  • Body Electrical [ Relay and Control Unit Locations ~ Engine Compartment Dashboard ~ Door, Floor, Roof and Rear ~ Bulkhead ~ Under-dash Fuse/Relay Box ~ Removal/Installation ~ Power Relays Test ~ Electrical Switch ~ Battery Test ~ Gauge Assembly ~ Gauge/Terminal Location Index ~ Bulb Locations ~ Maintenance Reminder ~ Light ~ Select/Reset Switch Test ~ Outside Air Temperature Indicator ~ Troubleshooting ~ Calibration ~ Replacement ~ Vehicle Speed Sensor (VSS) ~ Safety Indicator ~ Indicator Input Test ~ Brake Light Failure Sensor ~ Test ~ Lighting System ~ Automatic Lighting Control Unit ~ Input Test (USA) ~ Daytime Running Lights Control ~ Unit Input Test ~ (Canada) ~ Combination Light Switch ~ Test ~ Replacement ~ HID Lamp System Troubleshooting ~ Headlights ~ HID Bulb Removal ~ Taillights ~ Fog lights ~ Switch Test . License Plate Light ~ High Mount Brake Light ~ Turn Signal/Hazard Flasher System ~ Turn Signal/Hazard Relay ~ Input Test ~ Hazard Warning Switch ~ Test ~ Interior Lights ~ Trunk Light Test ~ Glove Box Light Test ~ Vanity Mirrror Light Test ~ Clock ~ Stereo Sound System ~ Stereo Amplifier Terminals ~ (with Bose Sound System) ~ Audio Unit Terminals ~ CD Changer Removal ~ Stereo Amplifier Removal ~ Speaker Replacement ~ Radio Remote Switch Test ~ Window Antenna Wire ~ Test/Repair ~ XM Radio ('04 Model) ~ Receiver Terminals ~ Antenna Terminals ~ Accessory Power Socket ~ Cigarette Lighter ~ Horns ~ Horn Test ~ Switch Test ~ Seat Belt Tension Reducer ~ Moonroof ~ Control Unit Input Test ~ Motor Test ~ Switch Test ~ Seat Heaters ~ System Description ~ Switch Test/Replacement ~ Heater Test ~ Automatic Inside Dimming Mirror ~ Front Passenger's Power Seat ~ Switch Test/Replacement ~ Motor Test ~ Immobilizer System ~ Control Unit Input Test ~ Immobilizer Receiver and ~ Transponder Test ~ Immobilizer Receiver ~ Driving Position Memory System (DPMS) ~ DTC Chart ~ Troubleshooting Guide ~ Pre-troubleshooting Tests ~ Driving Position Memory ~ Steering Column ~ Tilt/Extend-retract ~ Motor Test ~ Tilt/Extend-retract Position ~ Sensor Test ~ Driver's Power Seat Switch ~ Driver's Power Seat Motor ~ Driver's Power Seat Position ~ Steering Column Control Unit ~ Power Seat Control Unit ~ Power Mirror Control Unit ~ Multiplex Control System ~ System Description ~ System Functions ~ Multiplex Communication ~ System ~ Troubleshooting Guide ~ Power and Ground Test ~ Self Diagnosis Function ~ (Mode 1) ~ Wake-up Function Test ~ Confirming the Function ~ Faulty Wake-up Line ~ Symptoms ~ Check the Wake-up ~ Function ~ Self Diagnosis Function (Mode 2) ~ Integrated Control ~ Ignition Key Light ]
  • Restraints [ Seat Belts ~ Front Seat Belt Removal/Installation ~ Rear Seat Belt Removal/Installation ~ Seat Belt Inspection ~ Child Seat Tether Anchor Installation ~ Child Seat Tether Anchor Removal/Supplemental Restraint System (SRS) ~ Special Tools ~ Component/Wiring Location Index ~ Description ~ SRS Airbag System ~ Precautions/Procedures ~ General Precautions ~ Airbag Handling and ~ Storage ~ Seat Belt Tensioner Handling ~ and Storage ~ SRS Unit ('96-04 models) and Side Impact Sensor ('99-04 models) ~ Inspection After Deployment ~ Disconnecting the SRS Connector at the Fuse Box ('96-98 models) ~ Wiring Precautions ~ Spring-loaded Lock Connectors ~ Spring-loaded Lock Connectors with Built-in Short Contact ~ Seats with Side Airbags ~ Backprobing Spring-loaded ~ Lock Connectors ~ Disconnecting the Airbag ~ Connectors and Seat Belt ~ Tensioner Connectors ('96-98 models) ~ Disconnecting the Airbag ~ Connectors, Side Airbag ~ Connectors, and Seat Belt ~ Tensioner Connectors ~ Steering-related ~ Troubleshooting ~ Self-diagnostic Procedures ~ Reading the DTC ~ Erasing the DTC Memory ~ Troubleshooting Intermittent ~ Failures ~ Initializing the OPDS (Occupant Position Detection System) Unit ~ SRS Indicator Light Wire Connections ~ Fuse Box and Connector Locations ~ Airbag Replacement ~ Side Airbag Replacement ~ Seat Belt Tensioner ~ Replacement ~ Airbag and Seat Belt Tensioner ~ Disposal ~ Cable Reel Replacement ~ SRS Unit Replacement ~ Side Impact Sensor ]

Body Repair Manual Table of Contents:

  • Preparation of Work [ Description ~ Checkpoints ~ Correction of the Damaged Area ~ Measurement (Excluding small damage) ~ Positioning Jigs ]
  • Welding Methods / Repair Tools [ Spot Welding ~ Gas Welding ~ Carbon Dioxide Arc Welder (MIG Arc Weld) ~ Examples of Repair Tools ]
  • General Information [ Zinc-plated Steel Plate Repair ~ Door and Bumper Reinforcement ]
  • Replacement [ Construction ~ Exterior Body Parts ~ Front Bulkhead ~ Mass Production Body ~ Front Wheelhouse/Damper Housing ~ Mass Production Body ~ Front Side Frame ~ Front Side Extension ~ Front Pillar (Outer Panel) ~ Welding Diagram ~ Side Sill (Outer Panel) ~ Roof Panel ~ Rear Side Outer Panel ~ Rear Panel ~ Rear Floor/Rear Floor Cross-member ~ Honeycomb Floors ]
  • Cross Section of Body and Sealants [ Engine Compartment/Front Wheelhouse ~ Front Pillar Iner Panel and Dashboard Lower ~ Front Floor and Rear Floor ~ Roof Panel and Outer Panel/Outer Panel and Rear Panel ~ Under Floor/Frame ~ Hood, Door, Trunk Lid ]
  • Body Dimensional Drawings [ Upper Body Measuring Dimensions ~ Under Body Measuring Dimensions ~ Opening Repair Chart ~ Frame Repair Chart ]
  • Rust-preventive Treatments [ General ~ Diagram ~ Area to be Covered by Anti-rust Agents ~ Undercoating Diagram ]
  • Body Paint Repair [ Color Chart Painting Specifications ~ Paint ~ Intermediate Coat Colors ~ Paint Refinishing ~ Defects and Refinishing Processes ~ Refinishing Processes ~ Refinishing Procedures ~ NH-585P (Cayman White Pearl) Paint ~ Color Matching ~ Soft Chipping Guard Primer Coat ~ General ~ Coating Diagram ~ Types of Soft Chipping Guard Primer (Reference) ~ Repair Material and Tools ~ Coating Procedures ]
  • Resin Parts Paint Repair (Exterior) [ Types and Materials of Exterior Resin Parts ~ Polypropylene (PP) Resin Parts ~ ABS/PC Resin Parts ]

Download Free 1996-2004 Acura 3.5RL Service Manual & Body Repair Manual.pdf (multiple pdf files, 44 MB in *.zip).

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Comments

One Response to “1996-2004 Acura 3.5RL Service Manual & Body Repair Manual.pdf”

  1. Henoke Tekle on October 29th, 2008 6:26 pm

    i am a mecanical enginer and i have an interest to work my msc in automotive engineering and i will be glad if you send me ebooks of any type which can upgrade my knowldge of ic engines and as a whole automobiles. hope i will get what i ask.
    thanks

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