pedal HONDA CR-V 2000 RD1-RD3 / 1.G Service Manual

Road Test
NOTE: Warm up the engine to normal operating temperature (the radiator tan comes on).
1. Before testing, check the transmission fluid level, see page 14-160.
2. Apply the parking brake and block the wheels. start the engine, then shift to E {'97 - 98) or E {'gg - 00) position
while pressing the brake pedal. Press the accelerator pedal and release it suddenly. The engine should not stall.
3. Repeat same test in E position ('97 - 98 models).
4. Test-drive the vehicle on a flat road in the E or E position. Check that the shift points occur at approximate speeds
shown on a flat road. Also check for abnormal noise and clutch slippage.
Throttle position sensor voltage represents the throttle opening. Monitor it with the Honda PGM Tester or as follows:
a. Unbolt the PCM for road testing; reJer to page 14-58.
b. Set the digital multimeter to check throttle position sensor voltage between these terminals on the PCM:
. '97 Model: Between terminals D'! (+) and A9 (-) or A22 {-}
. '98 - OO Models; Between terminals C27 (+) and 820 (-) or 822 {-)
BACKPROBE ADAPTER
BACKPROBE SETorsAz - 001moA(two roquircdl
STACKING PATCH
CORD
DIGiTAL MULTIMETER
{Comm€rcirllY .vailablc}KS-AHM-32-003,or equival.nt
'97 Model:PCM CONNECTORS
'98 - 0O Models:
A l32Pt
Wire side of female terminals
PCM CONNECTORS
B {25Pt c l31P}
(cont'd)
LGl (BRN/BLK)
'. //B 1 l'o ti , jl. to a 2r / / 11111t1.t nait la t1 t213tr / t6t, tl / / / / 1 3 / 10n v
t-'a:IM-&E -Llfiffi-fl)\"".'E
Wire side ot female termanals14-157
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Stall Speed
Test
CAUTION:
. To prevent transmission damage, do not te3t stall speed for mors than 10 s€€onds at a time'
. Do not shift the lever while raising th€ engine spsed.
. Be sure to remove tho pressuro gauge bofore testing stall speed,
1. Before testing, check the transmission fluid level, s€e page 14-160.
2. Engage the parking brake and block all four wheels
3. Connect the tachometer, and start the engane.
4. Make sure the Ay'C switch is OFF
5. After the engine haswarmed upto normal operating temperature (the radiator fan comes on),shiftinto@ position.
6. Fully press the brake pedal and accelerator for 6 to 8 seconds, and note engine speed '
j. A|ow 2 minutes for cooling, then repeat the test in E, E ('97 - 98). E {'99 - 00}, and E positions. Stall speed should
be the same in E, E, E, tr. and E positions
Stall Speed rpm:
Specitication: 2,550 rpm
S€rvice Limit: ?,400 - 2.700 rpm
TROUBLEPROBAELE CAUSE
Stall rpm high in El, E, E, E and E
positions
ATF pump output is low
Clogged ATF strainer
Pressure regulator valve stuck closed
Slipping clutch
Stall rpm high in E positionSlippage of 1st clutch, 1st-hold clutch, or 1st gear one-way clutch
Stall rpm high in E positionSlippage of 2nd clutch
stall rpm high in E! or E positionSlippage of 1st clutch or 1st gear one-way clutch
Stall rpm high in E positionSlippage of 4th clutch
Stall rpm low in [dd, E. E, E, ana E
positions
. Engine output low
. Torque converter one-way clutch slipping
14-159
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Brakes
Special Tools ............. 19-2
Component Locations
lndex ................ ...... 19-3
Inspection and Adlustment
Brake System Rubber Parts
and Brake Booster ..........,,,.......... 19-4
Brake Pedal ............ 19-5
Parking Brake ........ 19-6
Bleeding ................. 19'7
Brake System Indicator ................... 19-8
Front Brake Pads
Inspection and Replacement .......... 19-9
Front Brake Disc
Disc Runout Inspection ................... 19-11
Disc Thickness and
Parallelism Inspection ........,........ 19-1 1
Front Brake Caliper
Disassembly/Reassembly ............... 19-12
Master Cylinder/Brake Booster
Removal/lnstallation ....................... 19-13
Master Cylinder
Inspection/Disassembly .............. 19-14
Pushrod Clearance Adiustment ...... 19-14
Brake Booster Inspection ...,.,,,,....... 1 9-1 5
Rear Drum Brakes
Inspection .............. 19-15
Brake Shoes
Replacement ..... 19-r 8
Wheel Cylinder Replacement ......... 19-20
Brake Hoses/Lines
Inspection/Torque Specifications ... 19-21
Hose Replacement ....,...,............. ..,,, 19-22
Parking Brake Cable
Inspection and Replacement .......... 19-23
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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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Brake Pedal
Pedal Hoight
1. Disconnect the brake switch connector, loosen the
brake switch locknut, and back off the brake switch
until it is no longer touching the brake pedal.
2. Lift up the carpet, At the insulator cutout, measure
the pedal height from the middle of the right side of
the oedal pad.
BRAKE SWITCH
ERAKE SWITCH
Standard Pedal Height (with floor m8i removed):
A/T: 161 mm (5 5/16 in)
M/T: 155 mm {6 U8 in}
Loosen the pushrod locknut, and screw the pushrod
in or out with pliers until the standard pedal height
from the floor is reached. Do not adjust the pedal
height with the pushrod pressed. After adiustment,
tighten the locknut firmly.
PUSHROD LOCKNUT
15 N.m11.5 kgj m, 11 lbf ftl
4. Screw in the brake switch until its plunger is fully
pressed (threaded end touching the pad on the
pedal arm), Then back otf the switch 1/4 turn to
make 0.3 mm (0.01 in) of clearance between the
threaded end and pad. Tighten the locknut firmly.
Connect the brake switch connecto.. Make sure that
the brake lights 90 off when the pedal is released
5. Checkthe brake pedalfree play as described below
Pedal Free Play
1. With the engine off. inspect the free play on the
pedal pad by pushing the pedal by hand-
Free Play: 1 - 5 mm (1/16 - 3/16 in)
2. lf the pedal free play is out of specification, adiust
the brake switch. lf the pedal free play is insuffi-
cient, it may result in brake drag.
swtTcH
PEOAL PAD
PEDAL FREE PLAY
19-5
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Bleeding
CAUNON:
. Do not spill brake tluid on the vehicle. it may damage
the paint; if brake fluid does contaqt th€ paint, wash
it otf immodiately with water.
. Maks sure no dirt oy other forsign matter is allowsd
to contaminate the brake fluid.
NOTE:
. Do not reuse the drained fluid.
. Always use Genuine Honda DOT 3 Brake Fluid. Using
a non-Honda brake fluid can cause corrosion and
decrease the life of the svstem.
. The reservoir on the master cylinder must be at the
MAX (upper) level mark at the start of bleeding pro-
cedure and checked after bleeding each brake caliper
and wheel cylinder. Add fluid as required.
1, Make sure the brake fluid level in the reservoir is at
the MAX (uDDer) level line.
MAX {UPPER) LEVELLINE
RESERVOIR
MASTER CYLINDER
2.
3.
Have someone slowly pump the brake pedal several
times, then apply steady pressu.e.
Loosen the brake bleed screw to allow air to escape
from the system. Then tighten the bleed screw
securely.
Repeat the procedure for each wheel in the sequence
shown below until air bubbles no longer appear in
the tluid.
Refill the reservoir on the master cvlinder to the
MAX (upper) level line.
ALEEDING SEOUENCE:
O Front RightGt Rear Right
O Front LeflO Rear Left
NOTE: Bleed the front calipers first in the bleeding
procedure.
4.
FRONT:
BLEEO SCREW7 N.m (0.? kgf.m, 5 lbf.ftl
19-7
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Front Brake Pads
Inspection and Replacement (cont'dl
9. Apply Molykote M77 grease or Daikalub 528Dgrease to both sides of the pad shims and the back
of the pads. Wipe excess grease off the shims.
Apply Molykote M77
to both sides of shims.
INOICATOR
Apply Molykote M77or 0aikalub 528Dto both sides of shim.
10.
INNER PAD
OUTER PAD
lnstall the brake pads and pad shims correctly.
Install the pad with the wear indicator on the inside.
. When reusing the pads, always reinstall thebrake pads in their original positions to prevent
loss of braking efficiency.. Contaminated brake discs or pads reduce stop-ping ability. Keep grease off the discs and pads.
19-10
'11. Push in the piston so that the caliper willfit over thepads. Make sure the piston boot is in position toprevent damaging it when pivoting the caliper
down.
CALIPER BOLT49 N.m (5.0 kgf.m, 36 lbf.ftl
13.
Pivot the caliper down into position, being careful
not to damage the pin boot. Install the caliper bolt
and tighten it,
Press the brake pedal several times to make sure
the brakes work, then test-drive.
NOTE: Engagement of the brake may require agreater pedal stroke immediately after the brakepads have been replaced as a set. Several applica-
tions of the brake pedal will restore the normalpedal stroke.
After installation, check for leaks at hose and linejoints and connections, and retighten if necessary.
14.
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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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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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Rear Drum Brakes
Brake Shoes Replacement (cont'd)
16. Install the brake shoes onto the backing plate. Be
careful not to damage the wheel cylinder dust cov-
ers.
17. Install the tension pins and the retainer springs.
18. Hook the upper return spring with the tool.
@ wsar eye proieclion whon using tho
brtko spring wronch.
lnstallthe brake drum.
lf the wheel cylinder has been removed, bleed the
brake system (see page 19-7).
Press the brake pedal several times to set the self-
adjusting brake.
Adjust the parking brako (see page 19-6).
19.
20.
21.
UPPER RETURN SPRING
TENSION PINS
19-20
7.
SEALANT
Wheel Cylinder Replacement
CAUTION:
. Do not spill brake fluid on th6 vehicle; it may damage
the paint; if brako fluid doos contact tho paint, wash
it off immedialely whh water.
. To pr6v6ni 3pills, cov6r th6 hose ioinls with rags ol
shop lowels,
. Use only a genuine Honda whoel cylinder spocial
bolt.
Remove the brake shoes {see page '19-18).
Disconnect the brake line,
BACKING PLATE
1.
15 N,m 11.5 kgt m,11 tbf.ftl
WHEEL CYLINDER
9 N.m 10,9 kgf'm.6.5 rbtft)
Remove the bolt and the wheel cylinder from the
backing plate.
Apply sealant between the wheel cylinder and back-
ing plate, and install the wheel cylinder.
Install the removed parts in the reverse order of
removal.
Fill the brake reservoir up. and bleed the brake sys-
tem {see page 19-7).
After installation. check for a leak at the line joint.
and retighten if necessary.
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