rod HONDA CR-V 1998 RD1-RD3 / 1.G Manual PDF

6.
7.
8.
lf the clearance between the gauge body and
adjusting nut is 0.4 mm (0.02 in), the pushrod-to-
piston clearance is 0 mm. However. if the clearance
between the gauge body and adjusting nut is 0 mm,
the pushrod-to-piston clearance is 0.4 mm (0.02 in)
or more. Therefore it must be adjusted and
recheck€d.
lf clearance is incorrect, loosen the star locknut, and
turn the adjuster in or out to adjust.
. Adjust the clearance while the specified vacuum
is applied to the booster.
. Hold the clevis while adjusting.
Tighten the star locknut securely.
Remove the special tool.
0 - 0.4 mm (0 - 0.02 inl
Adjust the pushrod length as shown if the
is removed,
booster
11610.5 mm{4.6 t 0.02 inl
PUSHRODLOCKNUT1.5N.m 11.5 kgf.m. '11 lbtfl)
Install the master cylinder (see page 19-13).
9.
STAR LOCKNUT22 N.m12.2 kgt m. 16 lbtftl
10.
(Check valve is built-in)
Brake Booster Inspection
FunctionalTest
1. With the engine stopped, press the brake pedal sev-
eral times to deplete the vacuum reservoir. thenpress the pedal hard, and hold it for 15 seconds. lf
the pedal sinks, either the master cylinder is
bypassing internally, or the brake system (master
cylinder, lines, modulator, proportioning valve. or
caliper) is leaking.
2. Start the engine with the pedal pressed. lf the pedal
sinks slightly. the vacuum booster is operating nor-
mally. lf the pedal height does not vary, the booster
or check valve is faultv.
3. With the engine running, press the brake pedal light-
ly. Apply just enough pressure to hold back auto-
matic transmission creep. lf the brake pedal sinks
more than 10 mm (3/8 in.) in three minutes, the mas-
ter cylinder is faulty. A slight change in pedal height
when the Ay'C compressor cycles on and off is nor-
mal. (The Ay'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. lf the pedal height does not vary
while pressed for 30 seconds, the vacuum booster is
OK. lf the pedal rises, the booster is faulty.
With the engine stopped, press the brake pedal sev-
eral times using normal pressure. When the pedal is
first pressed. it should be low, On consecutive appli-
cations, the pedal height should gradually rise. lf thepedal position does not vary. check the booster
check valve.
Boostor Chock Valve Test
1. Disconnect the brake booster vacuum hose at the
booster.
2. Start the engine, and let it idle. There should be vac-
uum. lf no vacuum is available, the check valve is
not working properly. Replace the brake booster
vacuum hose and check valve. and retest.
ERAKE BOOSTERVACUUM HOSE
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Kickback'1. The motor operates when the ABS is functioning. and the fluid in the reservoir is forced out to the master cylinder,
causing kickback at the brake pedal.
2. The ABS control unit operates the solenoid valve when the brake pedal is released after the initial diagnosis You may
hear the solenoid valve operate at this time, but it is normal
Pumo Motol
1. The pump motor operates when the ABS is functioning
2. The ABS control unit checks the pump motor operation during acceleration. You may hear the motor operate at this
time, but it is normal.
Brake Fluid Replacement/Ail Bleeding
L Brake fluid replacement and air bleeding procedures are the same as for vehicles without ABS To ease bleeding, start
with the front wheels.
Troubleshooting
1. The troubleshooting flowchart procedures assume that the cause of the problem is still present and the ABS indicator
is still on. Following the flowchart when the ABS indicator does not come on can result in incorrect diagnosis.
2. Ouestion the customer about the conditions when the problem occurred, and try to reproduce the same conditions
for troubleshooting.
Self-diagnosis is made at various times such as the initial diagnosis, except ABS control, during ABS control, during
acceleration, during the specified vehicle speed, etc. Therefore, the symptom canngt be checked unless the check
conditions match with the problem conditjons
3. When the ABS jndicator does not come on during the test-drive. but troubleshooting is performed based on the DTC,
check lor loose connectors, poor contact of the terminals, etc., before you start troubleshooting.
4. After troubleshooting, erase the DTC and test-drive the vehicle. Be sure the ABS indicator does not come on.
5. The connector illustratjons show the female terminals with a single outline and the male terminals with a double out-
l ne.
ABS Function Test
To simulate ABS operation and activate the solenoid valves and pump, use the Honda PGM Tester.
Connect the PGM Tester to the 16P Data Link Connector (DLC). When the System Select menu is displayed, select the ABS
Test Mode menu, and follow the tester's prompts.
19-37
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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
I
W*
INN€R HANDLE
/ eowea wrruoow
I sYtfcH
s /* /
M-q/-\ flsg
LOCK RODPROTECTORCItr'6,1-
iI
\LOCKCRANK
LATCHPROTECTOB
(cont'd)
20-5
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Doors
Front Door Outer Handle Replacement
CAUTION: Put on gloves to protect your hands.
NOTE; Raise the glass fully.
2.
1.Removel
. Door panel (see page 20-7). Plastic cover {see page 2O-2)
Disconnect the cylinder rod. Remove the retainer
clip, then remove the lock cylinder.
5.
6 x'1.0 mmI N.m {0.9 kgt.m,7 rbf.ftl
LOCK CYLINDER
Remove the bolts securing the
remove the cylinder protector.
>: Eolt locations,2
RETAINEBCLIP
outer handle, then
HANDLE
20-8
4. Pull out the outer handle, Pry the outer handle rod
out of its joint using diagonal cutters.
NOTE:
. To ease reassembly, note location @ ofthe outerhandle rod on the joint before disconnecting it.. Take care not to bend the outer handle rod.. Use a shop towel to protect the opening in the
door.
OUTEBHANDLE
5. Installation is the reverse of the removal procedure.
NOTE:
. Make sure each rod is connected securely.. Make sure the door locks and opens properly.
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Front Door Latch Replacement
CAUTION: Put on gloves to protect your hands,
NOTEr Raise the glass fully.
'1. Remove:
. Door panel (see page 20-7)
. Plastic cover (see page 20-21
. Outer handle
2. Remove the bolt, then move the rear lower channel
forward.
>: Bolt location, 1
6xl.0mm8 N.m (0.8 kgf m,6 tbf ft)
3. Disconnect the connector, and detach the harness
clip from the door. Remove the screws, and remove
the latch through the hole in the door.
NOTE: Take care not to bend any of the rods.
>: Screw locations,3
6x1.0mm6 N.m 10.6 kgt m,4 tbf.ft)
CYLINDERROD
OUTERHANDLEROD
LOCK RODPROTECTOR
CONNECTOR
HARNESS
Installation is the reverse of the removal procedure.
NOTE:
. Make sure the connector is plugged in properly,
and each rod is connected securely.
a Make sure the door locks and opens properly.
CLIP
20-9
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Doors
Rear Door Outer Handle Replacement
CAUTION: Put on gloves to protect your hands.
NOTE: Raise the glass fully.
1. Remove:
. Door panel (see page 20-11). Plastic cover (see page 20-4)
2. Remove the lock crank. then remove the screws
securing the latch.
>: Screw locationsA>.3
6x1.0mm6 N.m 10.6 kgf.m.4 tbf.ft)
B>,'l
^lPC tlTn-i I
LOCK RODPROTECTOR
and remove the bolts secur-Move the latch down,
ing the outer handle,
>: Bolt locations. 2
20-12
.
6x1.0mm9.8 N.m {1.0 kgf.m,7.2 rbf.ft)
4, Pull out the outer handle. Pry the outer handle rod
out of its joint using diagonal cutters.
NOTE;
o To ease reassembly, note location @ of the outerhandle rod on the joint before disconnecting it.. Take care not to bend the outer handle rod.. Use a shop towel to protect the opening in the
door.
5. Installation is the reverse ofthe removal procedure.
NOTE:
a Make sure the door locks and opens properly.. Make sure the oute. handle rod is connectedproperly.
OUTER HANDLEROD
SHOP TOWEL
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Rear Door Latch Replacement
CAUTION: Put on gloves to protect your hands,
NOTE: Raise the glass fully.
1. Removel
. Door panel (see page 20-11)
. Plastic cover (see page 20-4)
. Outer handle (see page 20-121
2. Disconnect the connector and harness clip, then
remove the latch through the hole in the door.
NOTE: Take care not to bend any of the rods.
3. Installation is the reverse of the removal procedure.
NOTE:
. Make sure the outer handle rod and inner handle
rod are connected properly.
. Make sure the door locks and opens properly.
Rear Door Glass, Ouarter Glass and
Regulator Replacement
CAUTION: Put on gloves to protect your hands.
1. Remove:
o Door panel (see page 20-1 1)
. Plastic cover (see page 20-4)
2. Carefully move the glass until you can see the bolts,
then loosen them. Slide the guide to the rear, then
remove the glass from the guide.
NOTE: Take care not to drop the glass inside the door.
>: Boll locations, 2
6x1.0mm9.8 N.m (1.0 kgtm,7.2 tb{ft)
GLASS
(cont'd)
20-13
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Doors
License Plate Trim Removal and
Installation
CAUTION: Put on gloves to prolest your hands.
NOTE: Take care not to scratch the license plate trim
and tailgate door.
'1. Remove the license olate.
2. Remove the tailgate door panel (see page 20-15).
3. Remove the nuts, detach the clip, then remove the
license olate trim.
NOTE: Take care not to drop the nuts inside the
tailgate door.
a: Nut loc.lions.4
5x0.8mm1.8Nm(0.18kgt.m.1.3 rbf.ft)
4. Installation is the reverse of the removal procedure.
NOTE: lf the clip is damaged, replace it.
20-16
TAILGATE DOOR
Tailgate Door Handle Replacement
CAUTION; Put on gloves to protecl your hands,
NOTE: Take care not to scratch the tailgate door.
1. Remove:
. Tailgate door panel (see page 20,15)
. License plate
. License plate trim
2. Disconnect the handle rod. Remove the nuts secur-
ing the tailgate door handle, then remove the tail-gate door handle by pulling it out.
NOTE: Take care not to bend the handle rod.
6x1.0mm9.8 N.m {1.0 kgtm,7.2 rbtft)
TAILGATE DOORHANDLE
Installation is the reverse of the removal procedure.
NOTE:
. Make sure the handle rod is connected properly.
. Make sure the tailgate door opens propedy.
a: Nut locations,2
,Is
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Tailgate Door Latch and Latch Stop Replacement
CAUTION: Put on gloves to protect your hands.
NOTE: Take care notto scratch the tailgate door.
'1. Remove the tailgate door panel (see page 20-15).
2. Disconnect the handle rod. Remove the bolts secur-
ing the latch stop and screws securing the latch.
>: Bolt, screw locationsA>,3 B>,3
6x1.0mm
3. Move the latch stop and latch down, then pry the
latch stop rod out of its joint using diagonal cutters.
Remove the latch stop and latch through the hole in
the tailgate door.
NOTE:
. To ease reassembly, note location @ of the latch
stop rod on the joint before disconnecting it.. Take care not to bend the latch stop rod.
''-t.-Ngta
-\S/r
tBUSHING
(cont'd)
20-17
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Doors
Tailgate Door Latch and Latch Stop
Replacement (cont'd)
4. lnstallation is the reverse of the removal orocedure.
NOTE:
. Make sure the handle rod and latch stop rod are
connected properly.
a Make sure the tailgate door locks and opens prop-
env.
. After installing the latch stop and tailgate door
latch, make sure that there is about 1 mm {0.039
in.l between the link A and link B of the latch stop.
Adjust the joint position of the latch stop rod as
needed, then check the latch stop operation. (Pull
the tailgate door handle while you push on the
latch stop knob; the tailgate door should not
oDen.)
LATCH STOPKNOE
20-18
Rear Hatch Glass Latch
Replacement
NOTE: Take care not to scratch the tailgate door.
'1. Remove the tailgate door panel (seepage20-15).
2. Disconnect the connector. Remove the bolts secur-
ing the latch, then remove the latch.
>: Boh locations, 3
6x1.0mm9.8 N.m {1.0 kgI.m,7.2 tbl.Itl
REAR HATCHGLASS LATCH
3. Installation is the reverse of the removal procedure.
NOTE: Make sure the rear hatch glass locks and
opens properly.
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