brake HONDA PASSPORT 2002 2.G Service Manual

208 Care and Maintenance
Promptly take any safety
problems to your Honda dealer
for service advice.
Parking
brake — Park on a fairly
steep hill and hold the vehicle
with the parking brake only. This
checks its holding ability.
Starter safety switch (automatic
transmission) —
Check the safety
switch by trying to start the
engine in each gear. The starter
should work only with the shift
lever in the “P” (Park) or “N”
(Neutral) position.
Starter safety switch (manual
transmission) —
To check the
safety switch, place the shift lever
in “Neutral,” push the clutch
pedal halfway and try to start the
engine. The starter should not
work. The starter should work only when the clutch pedal is fully
depressed.
Transmission shift indicator
(automatic transmission)
—
Check that the indicator points to
the gear chosen.
Steering — Be alert for any
changes in steering action. An
inspection or service is needed
when the steering wheel is harder
to turn or has too much free play,
or if there are unusual sounds
when turning or parking.
Wheel alignment, balance and
tires —
Uneven or abnormal tire
wear, or pulling to the right or left
on a straight and level road may
show the need for a wheel
alignment. A vibration of the
steering wheel or seat at normal
highway speeds means wheel balancing is needed. Check tire
pressures (including the spare) at
least monthly and whenever the
vehicle is serviced (see page 163).
Brakes — Watch for the
“
BRAKE” light coming on. Other
signs of possible brake trouble are
such things as repeated pulling to
one side when braking, unusual
sounds when braking or between
brake applications, or increased
brake pedal travel. If you note one
of these conditions, have the
system checked at once and
repaired if needed.
Owner Safety Checks

209Care and Maintenance
Sit in the driver
’s seat and
perform these checks:
1. With the engine stopped,
depress the brake pedal several
times; the travel distance and
effective pedal stroke should
remain unchanged.
2. Start the engine with the brake pedal fully depressed.
The brake pedal should go down
a little as the engine starts.
3. Depress the brake pedal, stop the engine and hold the pedal
depressed for about 30
seconds; the brake pedal
should remain in position
without rising or going down.
4. Restart the engine and run it for about a minute, then turn it
off and depress the brake
pedal firmly several times; the
brake pedal travel should decrease each time the brake
pedal is depressed.
If the brakes do not operate
normally, have them checked and
corrected by your Honda dealer.
Exhaust system — Be alert to any
changes in the sound of the exhaust
system or any smell of fumes.
These are signs the system may be
leaking or overheating. Have the
system checked and/or repaired at
once if these conditions exist. (Also
see “Carbon Monoxide Hazard” in
the “Driver and Passenger Safety ”
section and “ Three-Way Catalytic
Converter ” in the “Driving Tips ”
section.)
Windshield wipers and
washers —
Check the operation
and condition of the wiper blades.
Check the flow and aim of the
washer spray.
Defrosters — Check performance
by moving the controls to the
defrost setting and noting the
amount of air directed against the
windshield.
Rear view mirrors and sun
visors —
Check that the friction
joints hold the mirrors and sun
visors firmly in place.
Horn — Blow the horn now and
then to be sure it works.
Lap and shoulder belts — Check
the belt system, including
webbing, buckles, latch plates,
retractors, guide loops and
anchors for proper operation and
damage.
Seat adjusters — When adjusting
a seat, be sure the seat adjusters
latch securely by pushing the seat
forward and backward.

210Care and Maintenance
Seat-back latches — Seat-back
latches are designed to prevent
forward motion of the seat-back
when the vehicle stops suddenly.
Check to see that the seat-back
latches are holding by pulling
forward on the top of the folding
seat-back.
Also check to see that the
reclining seats are operating
properly.
Lights and beepers — Check
panel lighting, warning lights, and
the seat belt reminder light and
beeper. Also check the key beeper
and interior lights. On the outside,
check the license plate light, side
marker lights, headlights, parking
lights, taillights, brake lights, turn
signals, backup lights and hazard
warning flashers. Have the
headlight aim checked promptly if the beams seem to be aimed
improperly.
Glass — Check for broken,
scratched or damaged glass that
could reduce visibility or cause
injury.
Door latches — Check that the
doors close, latch and lock
securely.
Hood latch — Check that the
hood closes firmly. Check for
broken, damaged, or missing parts
that might prevent secure
latching. Make sure the secondary
latch keeps the hood from
opening all the way when first
released.
Fluid leaks — Check for fuel,
water, oil or other fluid leaks by
looking at the surface beneath the
vehicle after it has been parked
for awhile. Water dripping from
the air conditioning system after
use is normal. If you notice
gasoline fumes or fluid at any
time, locate the source and have it
corrected at once.
Spare tire and jack — Check that
the spare tire and all jack gear are
securely stowed at all times.
Tailgate latch — Check that the
tailgate closes, latches and locks
securely.

219Care and Maintenance
(–36

C) to ensure protection
against corrosion and loss of
engine coolant from boiling.
This should be done even if
freezing temperatures are not
expected.
•Add ethylene glycol-based
antifreeze when antifreeze has
to be added because of engine
coolant loss or if more
protection against freezing at
temperatures lower than –33
F
(–36
C) is needed. Do not use
an alcohol-based or
methanol-based antifreeze, or
plain water. They boil at a
lower point, and do not provide
corrosion protection.
Thermostat
The engine coolant temperature is
controlled by a thermostat, which
stops engine coolant flow through
the radiator until a preset
temperature is reached. This
thermostat is installed in the
engine coolant inlet on the front
of the engine block. The same
thermostat is used in both winter
and summer.Brake Master Cylinder
Check the master cylinder fluid
level in the reservoir every time
you check the engine oil level.
The level should be between the
MAX and ADD level line. If the
level is lower than the
ADD level
line, fill to the
MAX level line
with
DOT-3 or DOT-4 fluid.
Other Required
Maintenance

220 Care and Maintenance
If the diaphragm inside the
reservoir cap is deformed, return
it to the original (collapsed)
condition, then tighten the cap.
It is normal for the brake fluid
level to go down slightly as the
front brake pads wear. So be sure
to keep the reservoir fluid at the
proper level.
If the reservoir needs frequent
refilling, it may indicate a serious
mechanical problem.
Brake fluid absorbs water from
the air. Never use brake fluid that
has been open to the air for an
extended period. Throw it away
and use new brake fluid from a
sealed container.

Brake fluid can damage your
vehicle’s paint. Thoroughly clean
up any brake fluid spills.
Shift-on-the-Fly System
The fluid level in the system should
be checked at the intervals shown
in the Maintenance Schedule.
FILLER
PLUG
Remove the filler plug and make
sure the fluid level is up to the
edge of the hole. If it is not, add
GL-5 gear oil to bring to that
level. Use the same
GL-5 gear oil
specified for the front axle (see
page 216).
Front Wheel Bearings
Clean and repack the front wheel
bearings whenever the front brake
pads are replaced. Due to the
weight of the tire and wheel
assembly it is recommended that
they be removed from the hub
before lubricating the bearings to
prevent damage to the oil seal.
“Long Fiber” grease should not be
used to lubricate the wheel bearings.
It can cause damage. Clean the old
grease out of the bearings and hubs
before repacking.

223Care and Maintenance
Spark Plugs
Replace the spark plugs with the
type specified in the “Technical
Data” section.
Clutch
Check the clutch play at the pedal.
Lubricate the clutch pedal bushing
and clevis pin, at the intervals
shown in the Maintenance
Schedule, with water-resistant
chassis lubricant. If you hear a
squeaking noise coming from the
area of the bushing or clevis pin at
the clutch pedal arm when the
clutch pedal is depressed,
lubricate it with water-resistant
EP
chassis grease.
Check the fluid level in the clutch
reservoir at the interval shown in
the Maintenance Schedule. If the
fluid is low in the reservoir, it should be filled to the maximum
level line with
DOT-3 or DOT-4
fluid.
Fluid or Lubricant Levels
Check the fluid or lubricant level
in the brake master cylinder,
clutch master cylinder, power
steering reservoir, rear axle,
engine and transmission,
windshield washer reservoir and
engine coolant at specified
intervals.
Power Steering
Check the fluid level in the power
steering fluid reservoir as
recommended in the Maintenance
Schedule. The fluid level should
be between the “
MIN” and
“
MAX” marks on the reservoir.
Use only automatic transmission
fluid labeled
DEXRON III.

233Technical Data
equipment on the vehicle when it
was shipped from the factory. Be
sure to provide this information to
your authorized Honda dealer
when it is necessary to order
parts.
Vehicle Loading Information
The components of your vehicle
are designed to provide
satisfactory service only if the
vehicle is not loaded in excess of
either the Gross Vehicle Weight
Rating (
GVWR) or the maximum
front and rear Gross Axle Weight
Ratings (
GAWRs). These ratings
are listed on the Vehicle
Certification Label located on the
left door lock pillar.
Your Honda dealer can advise you
of the proper loading conditions
for your vehicle. The use of
selected heavier suspension
components for added durability
purposes does not increase any of
the weight ratings printed on the
Vehicle Certification Label.
Maximum Front and Rear
Axle Weight
The weight of the cargo load must
be properly distributed over both
the front and rear axles. The
Certification Label shows the
maximum weight that the front
axle (front
GAWR) can carry. It
also shows the maximum weight
that the rear axle (rear
GAWR) can
carry. The
GVWR represents the
maximum permissible loaded
weight of the vehicle and takes
into account the engine,
transmission, frame, springs,
brake, axle, and tire capabilities.
Actual loads on the front and rear
axles can only be determined by
weighing the vehicle. This can be
done at highway weight stations
or other such commercial weigh
stations. Consult your Honda
dealer for assistance. The cargo
Vehicle Loading

238Technical Data
Front Suspension
Independent wishbone arms, torsion bar springs with
stabilizer bar.
Front Wheel Alignment
Toe-in2

2 mm (0.08 in.)–
Camber0°
30No more than 30 
side-to-side variation
Caster2
30 
45No more than 30 
side-to-side variation
Rear Suspension
5-link, coil spring type with stabilizer bar and direct
double-acting shock absorbers.
Rear Wheel Alignment
Toe-in0
5 mm (0.2 in.)
Camber0°
1°
Toe-Axis
1

Steering
Rack and pinion.
Service Brake
Hydraulic Front: Disc brake.
Rear: Self-adjusting drum brake, leading-trailing (2
WD model).
Disc brake (4
WD model).
Parking Brake
Mechanical, operating on rear wheels (2
WD model).
Mechanical, drum in disc, duo-servo, manual-adjusting,
operating on rear wheels (4
WD model).
Battery
Voltage (V)12
Cold-cranking performance (Amp)600
Reserve capacity (Min.)125
BCI group no.24

Technical Data241
Fuse Box: Instrument Panel
AmperageApplicability
120AAccessory power sockets
2––––
315ACigarette lighter
415ADash/parking lights
510AInterior lights
615ABrake lights, cruise control
720APower door locks
810AMirror defoggers
915ARear window defogger
1015ARear window defogger
1115AGauges, indicators
1215ACharging system, fuel injection
1315AIgnition system
1415ATurn signals, backup lights
1515AABS, 4WD, cruise control
1620AWindshield wiper/washer
1710ARear wiper/washer
1810ASecurity & keyless entry
1915AAudio system
2020AStarter
2130APower windows, moonroof
2210ASRS
23––––

255
A
ABS.
See Anti-Lock Brake
System
Accessories, Installation
173. . . .
ACCESSORY
(Ignition Key Position)101. . . . .

\b 
\b\f

 117
\b\b\b\b\b
Adults\b 

 10
\b\b\b\b\b\b\b\b\b\b\b
Airbags (SRS)7. . . . . . . . . . . . .
\f\b\b
\b 19
\b\b\b\b
Air Cleaner Filter170, 214. . . . . .
Air Conditioning Maintenance
221. . . . . . . . . . .
Usage
120. . . . . . . . . . . . . . . . .
Air Filter. See Air Cleaner Filter
Air Outlets (Vents)
124. . . . . . . . .
Air Pressure, Tires
239. . . . . . . . . Alcohol and Driving
4. . . . . . . .
Alcohol in Gasoline
200. . . . . . . .
Alternator Belt. See Drive Belts
Antifreeze
217. . . . . . . . . . . . . . . .
Anti-Lock Brake System Indicator
67. . . . . . . . . . . . . . .
Operation
159. . . . . . . . . . . . . .
Anti-Theft Steering Column Lock
102. . . .
System
152. . . . . . . . . . . . . . . .
Appearance Care. See Cleaning
Ashtray
116. . . . . . . . . . . . . . . . . .
Assist Grip
115. . . . . . . . . . . . . . .
Audio System
125. . . . . . . . . . . . .
Automatic Transmission
76. . . .
Capacity, Fluid
237. . . . . . . . . .
Driving Pattern Selector
81. .
Fluid Temperature Indicator
70
Oil Temperature Indicator70.
Shift Lever Position Indicator
76. . . . . . .
Shift Lock
78. . . . . . . . . . . . .
Transfer Control, 4
WD80. . .
B
Battery198. . . . . . . . . . . . . . . . . .
Charging System Indicator
62
Jump Starting184. . . . . . . . . . .
Maintenance
198. . . . . . . . . . .
Specifications
238. . . . . . . . . .
Before Driving
156. . . . . . . . . . . .
Belts, Seat
6. . . . . . . . . . . . . . . .
Additional Information
41. . .
Beverage Holder
113. . . . . . . . . .
Body Repair
225. . . . . . . . . . . . . .
Brakes Anti-Lock Brake System
159. .
Brake System Indicator
61. . .
Index