adjustment HONDA CR-V 1999 RD1-RD3 / 1.G Service Manual

Gomponent Locations
lndex
ERAKE SYSTEM INOICATORCircuit Diagram, page't9-8
PARKING BRAKEAdjustment, page 19-6Parking Brake Switch Test, page '19-8
PARKING BRAKE CABI..EInspection and Replacement,page 19-23
BRAKE BOOSTERBrake Booster Inspection, page 19-15
Removal/lnstallation, page 19 13
MASTER CYLINDER
Inspection, pago 19-16Brake Shoes Replacement,page 19-18Wheel CylinderReplacement, page 19-20
REAR DRUM BRAKE
Removal/lnstallation, page 19-13lnspection/Disassembly.page 19-14Pushrod Clearance Adjustment,page 19 ldBrake Fluid LevelSwitch Test,page 19-8
Inspection/Torque Specification, pag€'19-21
Hose Replacement, Page 19-22
Front Brake Pads, page 19-9Front Brake Disc. page 19-11Front Brake Caliper, page 19-12
)i't ' -"''
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t ^fl)
19-3
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Inspection and Adjustment
Brake System Rubber Parts and Brake Booster
@-Brake Booster
Check brake operation by applying the brakes.
lf the brakes do not work properly, check the brake
booster. Replace the brake booster as an assembly ifit does not work properly or if there are signs of leak-
age.
@-Piston Cup and Pressure Cup Inspection. Check brake operation by applying the brakes.
Visually check for damage or signs of tluid leakage.Replace the master cylinder as an assembly if thepedal does not work properly or if there is damage orsigns of fluid leakage.
. Check for a difference in brake pedal stroke betweenquick and slow brake applications. Replace the mas-.
ter cylinder if there is a difference in pedal stroke.
(9-Brake Hoses
Visually check for damage or signs of fluid leakage.
Replace the brake hose with a new one if it is dam-
aged or leaking.
O-Caliper Piston S€al and Piston Boots
Check brake operation by applying the brakes.
Visually check for damage or signs of fluid leakage. lf
the pedal does not operate properly, the brakes drag,
or there is damage or signs of fluid leakage, disas-
semble and inspect the brake caliper. Replace the
boots and seals with new ones whenever the brake
caliper is disassembled.
@-Wheel Cylinder Piston Cup and Dust Cover
Check brake operation by applying the brakes.
Visually check for damage or signs of fluid leakage. lf
the pedal does not operate properly, the brakes drag,
or there is damage or signs of fluid leakage, replace
the wheel cvlinder.
19-4
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Inspection and Adjustment
Parking Brake
Inspeqtion
1. Pull the parking brake lever with
lbfl force to fully apply the parking
The parking brake lever should be
specified number of clicks.
L.var Lockod Clicks: 2 - 6
196 N (20 kqf, 44
brake.
locked within the
2. Adjust the parking brake if the lever clicks are out ofspecification.
Adiustment
1. Raise the rear wheels off the ground. and support
the vehicle on safety stands.
@@ Bbck tho front who€ts betore iackingup the rear ot tho vohicle.
2. Remove the parking brake cover
PARKING BRAKE COVER
19-6
3. Release the parking brake lever.
Adjust the parking brake by turning the adjusting
nut.
Check that the parking brakes do not drag when therear wheels are turned. Readjust if necessary.
Make sure the parking brakes are fully applied when
the parking brake lever is pulled up fully.
Installthe parking brake cover.7.
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Inspection and Adjustment
Brake System Indicator
Circuit Diagram lNuLR.HorJDGNrT 0llSt!ITCHUNDEB.DASHFUSE]NEtAY BOIrllA Nl] 42 4!A
PAFK NC BRA(E S\I'ICH
GBNiBEO
Io\lt j I ERAKE tuU 0 rEVEr 9!1 I(N
| oPt^r'f,'1 .r
BIKI-o-:G401
Parking Brake Switch Test
1. Remove the parking brake cover,
2. Disconnect the connector from the parking brakeswitch.
3. Check for continuity between the terminal and bodyground in each position according to the table.
Terminal
Lever Position \
Positive
TerminalBody Ground
Lever Up--o
Lever Down
NOTE (Canada): lf the parking brake switch is OK, butthe brake system indicator does not function, perform
the input test for the daytime running lights control unit(see section 23).
Brake Fluid Level Switch Test
1. Remove the reservoir cap. Check that the float
moves up and down freely; if it doesn't, replace the
reservoir cap assembly.
2. Check for continuity between the terminals in each
switch position according to the table.
- r9''r
Position12
FLOAT UP
FLOAT DOWNo
RESERVOIR CAP
GROUND
Switch contacts open atproper fluid level.
19-8
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Master Cylinder
I nspection/Disassembly
CAUTION: Do not spill brake fluid onthe vehicle; it may
damsge the paint; il brake fluid does contact th6 paint.
wash it off immodiately with water.
NOTE:
. Before reassembling, check that all parts are free of
dust and other foreign particles.
. Do not try to disassemble the master cylinder assem-
bly. Replace the master cylinder assembly with a new
pan it necessary,
. Make sure no dirt or other foreign matter is allowed
to contaminate the brake fluid.
RESERVOIR SEALCheck for damaoe anddeterioration,
RESERVOIRCheck for damage.
ROD SEALCheck for damageand deterioration.
-€-1SILICONE GREASE
MASTER CYLINOERCheck bore for wear, rust and damage.
19-14
Pushrod Clearance Adjustment
NOTE: Master cylinder pushrod-to-piston clearance must
be checked and adjustments made, if necessary. before
installing the master cylinder.
1. Set the special tool on the master cylinder body;
push in the center shaft until the top ot it contacts
the end of the secondary piston by turning the ad-justing nut.
PUSHROD ADJUSTMENT GAUGE07JAG - SD{o100
SECONDARY
MASTER CYLINDER
ADJUSTING NUT
Without disturbing the center shaft's position, in-
stallthe special tool upside down on the booster.
Install the master cylinder nuts, and tighten them to
the sDecified toroue.
Connect the booster iniine with a vacuum gauge 0 -
101 kPa (0 - 760 mmHg, 30 in Hg) to the booster's
engine vacuum supply, and maintain an engine
speed that will deliver 66 kPa (500 mmH9, 20 in Hg)
vacuum.
With a feeler gauge, measure the clearance between
the gauge body and the adiusting nut as shown.
Clearanco: 0 - 0.4 mm (0 - 0.02 inl
VACUUM GAUGElCommo.cidly 6vailablcl0 - 101 kPtl0 - 760 mm Hg, 30 in Hgl
MASTER CYLINDER NUT15 N.m 11.5 kgt m, 11 lbt.ftl
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Body
Bumpers
Front Bumper Removal and
fnstaflation .........20-72
Rear Bumper Removal and
fnstaflation .........20-74
'Dashboard
lnstrument Panel Removal and
lnstallation .........20-47
Driver's Dashboard Lower Cover and
Knee Bolster Removal and
Installation .........20-48
Glove Box Removal and
lnstallation .........20-49
Center Pocket Removal and
lnstallation .........20-49
Center Dashboard Lower Cover
Removal and lnstallation ............ 20-50
Center Panel Removal and
lnstallation .........20-50
Power Window Switch Removal and
lnstallation .........20-51
Center Air Vent Removal and
lnstallation .........20-51
Side Air Vent Removal and
fnstallation .........20-52
Side Defogger Trim Removal and
fnstallation .........20-52
Dashboard Removal and
lnstallation .........20-53
Dashboard Frame Replacement ..... 20-55
Doors
Component Location Index
Front Door ,,...,,,,20-2
Rear Door ...........20-4
Tailgate Door ................................ 20-6
Fenderwell
Front Wheelwell Protector
Replacement .....20-89
Inner Fender Replacement .,.....,.,.... 20-89
Rear Wheelwell Protectol
Replacement .....20-90
Fuel Pipe Protector Replacement ... 20-90
Rear Air Outlet Replacement .......... 20-91
*Frame Repair Chart .............................. 20-106
Front Grille
Repf acement .........20-77
Glass
Component Location Index ............ 20-29
Hood
Replacement ......,,,20-75
Adjustment ............20-76
*lnterior Trim
Component Location Index ............ 20-40
Mirrors
Component Location Index .........,,, 20-26
Moldings
Roof Molding Replacement ............ 20-84
Door Moldings Replacement .......... 20-85
Openers
Component Location Index ............ 20-92
Rear Hatch Glass
Replacement .........20-74
Disassembly and Reassembly ........ 20-79
Adiustment ............20-81
Rear Weatherstrip Replacement .... 20-83
Seats
Component Location Index ............ 20-56
Side Sill Panel
Repfacement .........20-87
Spare Tire Cover
Emblem Installation ........................ 20-88
Sub-frame ..................20-104
Wiper/Washer
Component Location lndex ,,,,,....... 20-97
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Doors
Component Location Index
Front Door:
NOTE: Refertothe 1997 Series Honda CR-V Body Repair Manual (P/N 61S1030) forfrontdoor removat.
ffi
*Y
lPOWER DOOR LOCKCONTROL UNIT
t\q
efl-Nr2
/ *-8
ARMREST
OOOR CHANNEL TAPE
INNERW€ATHERSTRIP
v
MIRROR MOUNTCOVER
----s-re
"\-,-.*
€fl
FRONT DOORPosition Adjustment,page 20-22
FRONT DOOR PANELRemoval and lnstallation, page 20,7
OUTER MOLDING
PLASTICCOVER
,.r=R
\//
::r
HINGE
20-2
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OUARTERSEAL
OUARTERGLASSReplacement,page 20-13
-flHiili^'i--_Fffi
POWER WINDOWMOTOR
REAR CHANNEL-\UPPERCOLLAR -.-----_----_-""
trw
page 20 2L
LATCHReplacement,page 20'13
POWEB DOORLOCK ACTUATOB
,6S
REGULATORReplacement, page 20'13
GLASS RUNCHANNEL
FRONT LOWERCHANNEL
STRIKERAdjustment,
l
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W*
INN€R HANDLE
/ eowea wrruoow
I sYtfcH
s /* /
M-q/-\<SU
flsg
LOCK RODPROTECTORCItr'6,1-
iI
\LOCKCRANK
LATCHPROTECTOB
(cont'd)
20-5
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Doors
Component
Tailgate Door:
NOTE: Refer to the
Location Index (cont'dl
1997 Series Honda CR-V Body Repair Manual {P/N 61S1030) for tailgate door removal.
LICENSE PLATETRIMReplacement, page 20-16TAILGATE OOORPosition Adjustment, page 20-23
TAILGATE DOORWEATHERSTRIP
HINGECOVER \
V
illt
REAR HATCH GLASS LATCHReplacement, page 20 18
HINGE
\
I
SUPPORT STRUT
€\A
LATCH STOPReplacement, page 20-17
Replacement,page 20'19
TAILGATE DOOR PANELRemoval and Installation, page 20-15
TAILGATE DOOR LATCHReplacement, page 20-17
TAILGATE DOORHANDLEReplacement, page 20-16
TAILGATE DOORSTRIKERAdjustment, page 20-25
k@/
%
-6
\
TAILGATE DOOR WEDGEAdiustment, page 20-25
N
REAR HATCH GLASSACTUATORReplacement, page 20-19
REAR HATCH GLASS
lVr
d+-BA^cKEr
d
d\
FLEXIBLE CARGOHOOK
20-6
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Doors
Front Door Glass and Regulator Replacement
CAUTION: Put on gloves to protect your hands,
1. Remove;
. Door panel (see page 20-7)
. Plastic cover (see page 20-21
2. Carefully move the glass until you can see the bolts,
then loosen them. Slide the guide to the front, then
remove the glass from the guide. Carefully pull the
glass out through the window slot.
NOTE: Take care not to drop the glass inside the door.
>: Bolt locations,2
6xl.0mm9.8Nm(1.0kgt.m.7.2 tbt.ftl
GLASS
REGULATOR
20-10
3. Disconnect the connector, and detach the harness
clip, then remove the regulator through the hole in
the door.
NOTE:
. Scribe a line around the rear roller guide bolt to
show the original adjustment.
. When installing the regulator, align the hole of
the roller guide toward th€ rear.
>: Bolt locations,6
6x1.0mm8 N.m {0.8 kgt.m,6 rbtft)
Roaru/ard
Loosen,
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