connector a HONDA CR-V 1999 RD1-RD3 / 1.G Workshop Manual

Master Cylinder/Brake Booster
Removal/lnstallation
1, Disconnect the brake fluid level switch connectors.
2. Remove the reservoir cap from the master cylinder.
3. Remove the brake fluid from the master cvlinder
reservoir with a syringe.
4. Disconnect the brake lines from the master cylinder.
To prevent spills, cover the line joints with rags or
shop towels.
5. Remove the master cylinder mounting nuts and
wasners.
6. Remove the master cylinder from the brake booster.
CAUTION: Be careful not to bend or damage the
brake lines when removing the master cylinder.
Do not spill brake fluid on the vehicle; it may dam.
age the paint; it brake fluid does cont.ct the paint,
wash it oft immediately with water.
7. Disconnect the vacuum hose from the brake booster.
8. Remove the cotter pin and clevis pin from the clevis.
Do not disconnect the clevis by removing it from
the operating rod of the brake booster. lf the clevis
is loosened, adjust the pushrod length before
installing the brake booster (see page 19-15).
To Front Caliper (Without ABS)
\\
15 N.m {1.5 kgtm, vAcuuM HosE
r r rbf.ft) |
/ | BRAKE FLUTD LEvEL
/l /
swrrcHcoNNEcroRs
/ I I I COTTER PIN
I I / neotace
l,/-- ro Rear wheet cylinders / | I
h ./-''' /. I I IYli //*s (.S
I /r:
9. Remove the four booster mounting nuts.'10. Pull the brake booster forward until the clevis is
clear of the bulkhead.
11. Remove the brake booster from the enqine com-
panment.
12. Install the brake booster and master cylinder in the
reverse order of removal, and note these items:
. When connecting the brake lines, make sure that
there is no interference between the brake lines
and other parts.
. Be careful not to bend or damage the brake lines
when installing the master cylinder.
. lf replacing the master cylinder or brake booster,
check and adjust the pushrod clearance before
installing the master cylinder (see page 19-14).
Fill the master cylinder reservoir, and bleed the
brake system (see page 19-7).
After installation, check the brake pedal height and
brake pedal free play (see page 19-5), and adjust if
necessary.
13 N.m 11.3 kg{.m,I rbf.ft)
13.
14.
To Master Cylinder(Without ABS)To Modulator Unit(with ABs)@-\
\
^ To Front Caliper
9i\.
-#qCLEVIS PIN
):-,/
PROPORTIONING CONTROL VALVE
MASTER CYLINDER
15 N.m (1.5 kgf.m, 11 lbl.ftl
BRAXE BOOSTER
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Parking Brake Cable
Inspection and Replacement
Inspection
The parking brake cables must not be bent or distorted, This will lead to stiff operation and premature cable failure.
Replacoment
l. Disconnect the parking brake switch connector.
2. Release the parking brake lever. and disconnect the
parking brake cable.
3, Bemove the parking brake lever assembly.
4. Remove the parking brake shoes {see page '19-18).
5. Remove the parking brake cable from the backing
plate using a '12 mm offset wrench as shown.
6. Installthe cable in the reverse order of removal.
BRACKET
PABKING ARAKE CABLE
Check toror corroston,
PARKING BRAKE LEVERCheck for smoothoperation,
d
,"u/n*UM
-6l(Sliding surface)
PARKING BRAKE CABI-E
19-23
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SpecialTools
Rel. No. I Tool NumberDescriptionOty Page Relerence
o07PAZ - 0010100SCS Service Connector119-38
19-26
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Component Locations
NOTE: The illustrations show the '97 - 98 models. The '99 - 00 models are similar.
ABS CONTROL UNITRIGHT-REAR WHEEL SENSOR
UNDER.HOOD ABSFUSE/RELAY BOX
RIGHT.FRONT WHEELSENSOR CONNECTOR
RIGHT-FRONTWHEEL SENSORRIGHT-REAB WHEELSENSOR CONNECTOR
MODULATOR UNIT
LEFT.FRONT WHEEL SENSOB
UNDER.DASH FUSE,/RELAY 8OX
UNDER.HOOO FUSE/RELAY AOX
IGl I(, AI FUSE
ABS +B 120 Al FUSEPUMP MOTOR ('II AI FUSE
HOBN/STOP I15 AI FUSE
UNDER.HOOD ABS FUSE/RELAY BOX
LEFT.FRONT WHEELSENSOE CONNECTOR
GAUGE ASSEMBLY
ABS INDICATOR
UNDER-DASH FUSE/NELAY BOX
METER {7.5 AI FUSE
MOTOR RELAY
19-27
SERVICE CHECK CONNECTOR {2PI
D!
trtrtr
[r D!
ABS {7.5 AI FUSEMTR CHECK 17.5 AI FUSE
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Circuit Diagram
UNDFS I]OOD FISAFELAY 8OXCbsod: &rrc ped. deprelled
wHT/GrN -tjF GFrlrr'vril
GNITION
*oJG\'*"\€F*,-
UNDER-HOOD A8S FUSE/FELAY BOX3P CONNECTOR (O number)
t_--t l-|ll'"1
UNDER.HOOO A8S FUSE/RELAY BOX2P CONNECTOF (! numbor)
EFIAKE SWITCH CONNECTOR
l€-4| 1 txl2 |
f s a'lLr--'--.----1
UNDER,DASH FUSFJRELAY BOX20P CONNECTOR (O number)M-OD U LATOR UN IT CON N ECTOR
ll3 2ir I
{tT6TsF}
!]q:]j_1,
MP MOTOR CONNECTORnumber)
ATi)
PU
UNDER-DASH FUSE/RELAY BOX18P CONNECTOR (E number)
(tr
ASSEMBLY 5P CONNECTOR
----.4-l1)/l3l/l5l
356J89
10111213,/ 115 ,/19
123456
910'1213|i4 /718
19-32
Wire side ol female lerminals
Terminal side oJ lemale terminals
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ABS CONTROL I.]NII {NBK)
Gil
SEFVCE CHEC(STOP
-[rf$-n*'"[m;] t
ra
G2t
rlr*r"t_._*hr;c, ------ r"-!cc
-
Pf:-tL
t=
#
J*tt-
-
55
V-
,ln l'? g,l,BFN+BsN-,| Br(--o-.8:
Y G101cr02
WIT/BLIJ
,r-,,..J A ^ l0lTA L M|; i trr cor'hrEcroF 'r6P)
8LK
4c1013,402
tG2,
Lffi-
_-- -.^ PMR,
t!94
.,._ PCOM,
9
GRN/8I(x
,,-:gLTpliirn
Ilcrom.:C, IRE^R4iq!AGFNmL---l
BLr( -l
eli -.1
BtK-L,-ry
ABs coNTRoL uNrr 26p coNNEcroR 9E-FY!!(o;fib;;; -- coNNF
e -rlr z :ltl,/ a ,18 e tol/ 12li3l I'
| | 4 1 5 16)17 V I1s V l2' VIIU)4 p91ffi
ABS coNTRoL uNrr 22p coNNEcroR QAIA.Li-;;i,;;) -- coNNE
T
t,*---;T- =l------5o ril mtTlI r, / , | #l,'2 -14 i7 19 -)1 .221 | | ,z
Wire side of lemale terminals
)E CHECK:CTOR (2P)
,f
'97
FRO
TermmateINKcroR (16P)
?'--"r""""-./ 6 ,/ 8\
F{ c7
HEEL SENSOR CONNECTOR
model '98-99 models
NT/ REAR FRONTI RIG-HT-REAR
iTtl /J r lz !\
nal side ol Terminal side olterminals male terminals
LEFT.REAR/nf'\1./ 1F
r .4-;1V L:JTerminal side ollemale terminals
19-33
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ABS Control Unit Terminal Arrangement
ABS CONTROL UNIT 26P CONNECTOR
Wire side of female terminals
TeiminalnumbelWiiecolorTerminal3ignTeiminalnamglDescription
Voltrge
tdminalsCondhions(lgnition Switch ON llll)Output voltago
1GRNn/VHTPCOM(Primary
common)
Power source for the solenoidvalve and pump motor.1-GNDON6
ONOV
OFFAC:3-6V
2BLI(WHTSCOM(Secondary
common)
Power source for the solenoid2-GNDOFF
lConnect the SCS seNice] connector IApprox.3 V
BLVBLU(lgnition 2)Detects ignition switch 2signal. (System activate signal)3-GNDBattery Voltage
4BLUA/ELRRO(Rear-right 0)Detocts right-rear wheelsensor srgnat.When the wheel isturned at 1 turn/second.
53 mV or above ondigitaltester (ACrange) {Beference)150 mvtrp or aboveon oscilloscope
GRYRLO(Rear-left 0)Detects left-rear wheel sensorsrgnat.6-19
8GRNFRO(Fronr-right 0)Detects right-front wheelsensor signal.8-21StopsApprox.2.5 VSTOP
{Stop)Detects bfake switch signal.(Prevents unnecessary ABS operation)9-GNDBrake pedal pressed.Battery Voltage
Brake Dedal released.OV
10BRN^/VHTFLO(Front-left 0)
Detects left-front wheel sensorsrgnal.
10-23
When the wheel isturned at 1 turn/second.
53 mV or above ondigitaltester lACrange) (Reference)
150 mvpp or aboveon oscilloscope
StopsADprox. 2.5 V
YELRL-oUT(Rearleft outlet)
Drives left-rear outlet solenoid12.GNDONONOV
OFFAC:3-6V
13RED^/vHTRR.IN(Rear-right
inlet)
Drives right-rear inlet solenoid13.GNDOFF
lConnect the SCS service\ connector IApprox. 3 V
14WHT/GRNB1(Baftery 1)Power source for the solenoidvalve and pump motor.14.GND
Every timeBattery Voltage82(Battery 2)Power source for the solenoidvalve and pump motor.15-GND
16BLKGND2(Ground 2)Ground for the ABS controlunit.16-GNDBelow 0.3 V
't7GRN/YELRR1(Rear-right 1)Detects right-rear wheelsensor signal.'t7 -4
When the wheel is turnedat l turn/second,
53 mV or aboveon digitaltester(AC range)(Reference) 150mVp-p or aboveon oscilloscope
19LT BLURL1(Rearieft 1)Detects left-rear wheel sensorsignal.19-6
GRN/BLKFR1(Front-right 1)Detects right-front wheelsensor srgnat.21-8
23GBN/ORNFL1{Front-left 1}Detects left-front wheel sensorsagnal.23-10StopsApprox. 2.5 V
REDRLI N(Rear-left inlet)
Drives left-rear inlet solenoid
25,GND
ON
=
-9ONOV
AC:3-6V
OFF
/Connect the SCS service] conneclor IApprox. 3 V
26BLKGND3(Gtound 3)Ground tor the ABS controluntI.26-GNDBelow 0.3 V
19-34
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ABS CONTROL UNIT 22P CONNECIOR
Wire side ol lemale terminals
TerminalnumDerWirecolorTerminal 3i9nTerminal nameDescription
Voltage
Conditions(lgnition Switch ON (ll)lOutput voltagetominals
1RED/BLUFR-IN(Front-right
inlet)
Drives right-front inletsolenoid valve.
1-GND.9otur
ONIONOV
OFFAC:3-6V
OFF
lconnect the SCS servicel
connedor lApprox.3 V
BRN(Service checksignal)
Detects service check signal(Diagnostic trouble codeindication)4.GND
SCS service connectorconnected.OV
SCS service connectordisconnected.Approx. S V
7BLU/RED(Warning
ramp)
Drives ABS indicator {The indi-
cator goes off when ABS con-
trol unit outputs battery volt-age).
7.GND
lndicator ONApprox. 2 V
lndicator OFFBattery Voltage
10YEUBLKFL-OUT(Frontieft
outlet)
Drives left-front outletsolenoid valve.1O-GNDON
=
I
ONOV
OFFAC:3-6V
l'lRED/BLKFL-IN(Front-left inlet)
Drives left-front inlet solenoid11-GNDOFF
lconnect the SCS servicq connector lApprox.3 V
YEUBLUFR-OUT(Front-right
outlet)
Drives right-front outletsolenoid valve.12-GND
14LT BLU(Data linkconnectod
Communicates with HondaPGM Tester.14-GNDApprox. 5 V
17BRN/YELMCK(Motor check)
Detects PumP motor drivesignal.17-GNDPumpmotorrelay
ONBattery Vollage
OFFOV
19YEUREDPMR(Pump motorreray,
Drives pump motor relay.
19.GNDcl)
ON6IONOV
OFFAC:3-6V
OFFponnecl the SCS service]
connector IApprox.3 V
BLURR-OUT(Rear-right
outlet)
Drives right-rear outletsolenoid valve.
21.GND'a)
ONPumpmororrcray
ONOV
OFFAC:3 6V
OFF
lconnect the SCS service] connector lApprox.3 V
BLKGND2(Ground 2)Ground for the ABS controlunit.22.GNDBelow 0.3 V
19-35
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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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Diagnostic Trouble Code (DTC)
Diagnostic Trouble Gode IDTCI Indication
NOTE: This operation can also be done with the Honda pGM Tester.
1. Connect the SCS service connector to the service check connector (2P) located on the passenger's side of the centerconsote.
2. Turn the ignition switch ON (ll).
NOTE; Do not press the brake pedal whenturningthe ignition switch.
3 Record the blinking frequency of the ABS indicator. The brinking frequency indicates the DTc.
4. Turn the ignition switch OFF. and remove the SCS service connector.NOTE: The Malfunction Indicator Lamp (MlL) will stay on after the engine is startsd if the SCS seryica connecror rsconnected.
5. Erase the DTC.
Conditions for DTC indication. The vehicle is stopped.. The SCS service connector is connected before the ignition switch is turned ON flt).. The brake pedal is released.. The SCS service connector remains connected during this procedure.
The DTC indication stops and the ABS control unit axecutos tha softwaro lunction if at least one of tho following condi-tions i3 satisfiod:
. The vehicle is not stoooed.. The ABS control unit receives the normal signal (which is for the ABS control unit) from a Honda pGM Tesrer.. The SCS service connector is disconnectod during this procedure.
NQTE: The illustration of gauge assembly shows the '97 - 98 models. The '99 - oo models are similar.
SEFVICE CHECKCONNESTOR I2P}
GAUGE ASSEMBLY
A8S II{DEATOR
u.s.A.
@
CANADA
@
19-38
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