Brakes. VSA (Vehicle Stability Assist) System Components

Transcription

1 rakes Conventional rake Components Special Tools Component Location Index rake System Inspection and Test Symptom Troubleshooting rake Pedal and rake Pedal Position Switch djustment Parking rake Inspection and djustment rake System leeding rake System Indicator Circuit Diagram Parking rake Switch Test rake Fluid Level Switch Test Front rake Pad Inspection and Replacement Front rake Disc Inspection Front rake Disc Replacement Front rake Caliper Overhaul Master Cylinder Replacement Master Cylinder Inspection rake ooster Test rake ooster Replacement Rear rake Pad Inspection and Replacement Rear rake Disc Inspection Rear rake Disc Replacement Rear rake Caliper Overhaul Parking rake Inspection Parking rake Shoe Replacement Parking rake Shoe Lining reak-in rake Pedal Replacement rake Hose and Line Inspection rake Hose Replacement Parking rake Cable Replacement VS (Vehicle Stability ssist) System Components

2 Conventional rake Components Special Tools Ref. No. Tool Number Description Qty 07E-SEP101 rake Caliper Piston Compressor

3 Component Location Index RKE SYSTEM INDICTOR rake System Indicator Circuit Diagram, page Parking rake Switch Test, page rake Fluid Level Switch Test, page RKEHOSEandLINE Inspection, page rake Hose Replacement, page RER DISC RKE Pad Inspection and Replacement, page Disc Inspection, page Disc Replacement, page Caliper Overhaul, page PRKING DRUM RKE Inspection, page Shoe Replacement, page Shoe Lining reak-in, page RKE OOSTER Test, page Replacement, page RKE PEDL rake Pedal and rake Pedal Position Switch djustment, page 19-6 Replacement, page PRKING RKE CLE Replacement, page PRKING RKE PEDL Inspection and djustment, page 19-7 FRONT RKE Pad Inspection and Replacement, page Disc Inspection, page Disc Replacement, page Caliper Overhaul, page MSTER CYLINDER rake System leeding, page 19-9 Replacement, page Inspection, page

4 Conventional rake Components rake System Inspection and Test Inspect the brake system components listed. Repair or replace any parts that are leaking or damaged. Component Inspections: Component Procedure lso check for: Master Cylinder Look for damage or signs of fluid leakage at: ulging seat at reservoir cap. This is a Reservoir or reservoir grommets sign of fluid contamination. Line joints etween master cylinder and booster rake Hoses Look for damage or signs of fluid leakage at: ulging, twisted, or bent lines. Line joints and banjo bolt connections Hoses and lines, also inspect for twisting or damage Caliper Look for damage or signs of fluid leakage at: Seized or sticking caliper pins. Piston seal anjo bolt connections leed screw VS Modulator Look for damage or signs of fluid leakage at: Line joints Modulator rake System Test rake pedal sinks/fades when braking 1. Start the engine, and let it warm up to operating temperature. 2. ttach a 50 mm (2 in.) piece of masking tape along the bottom of the steering wheel, and draw a horizontal reference mark across it. 3. With the transmission in the P or N position, press and hold the brake pedal lightly (about the same pressure needed to keep an /T-equipped vehicle from creeping), then release the parking brake. 4. While still holding the brake pedal, hook the end of the tape measure behind it. Then pull the tape up to the steering wheel, noting where the tape measure lines up with the reference mark you made on the masking tape. 5. pply steady pressure to the brake pedal for 3 minutes. 6. Watch the tape measure. If it moves less than 10 mm (3/8 in.), the master cylinder is OK. If it moves more than 10 mm (3/8 in.) replace the master cylinder. NOTE: If the brake pedal sinks more than 10 mm (3/8 in.) in 3 minutes, the master cylinder is faulty. slight change in pedal height when the /C compressor cycles on and off is normal. (The /C compressor load changes the vacuum available to the brake booster.) 19-4

5 Symptom Troubleshooting Rapid brake pad wear, vehicle vibration (after a long drive), or high, hard brake pedal NOTE: Make sure that the caliper pins are installed correctly. The upper and lower caliper pins are different. If the top and bottom caliper pins are installed in the wrong location, it will cause uneven tire wear, vibration, and or uneven or rapid pad wear. For proper caliper pin location (see page 19-16). 1. Drive the vehicle until the brakes drag or until the pedal is high and hard. This can take 20 or more brake pedal applications during an extended test drive. 2. With the engine running, raise the vehicle on a lift, and spin all four wheels by hand. Is there brake drag at any of the wheels? YES Go to step Loosen the hydraulic lines at the master cylinder, then spin the wheels to check for brake drag. Is there brake drag at any of the wheels? YES Go to step 6. NO Replace the master cylinder (see page 19-18). 6. Loosen the bleed screws at each caliper, then spin the wheels to check for brake drag. Is there brake drag at any of the wheels? YES Disassemble and repair the caliper on the wheel(s) with brake drag. NO Look for and replace any damaged brake lines. If all brake lines are OK, replace the VS modulator-control unit (see page 19-94). NO Look for other causes of the pad wear, high pedal, or vehicle vibration. 3. Turn the engine off, pump the brake pedal to deplete the vacuum in the brake booster, and then spin the wheels again to check for brake drag. Is there brake drag at any of the wheels? YES Go to step 4. NO Replace the brake booster (see page 19-20). 4. Without removing the brake lines, unbolt and separate the master cylinder from the booster, then spin the wheels to check for brake drag. Is there brake drag at any of the wheels? YES Go to step 5. NO Check the brake pedal position switch adjustment and pedal free play (see page 19-6). 19-5

6 Conventional rake Components rake Pedal and rake Pedal Position Switch djustment Pedal Height 1. Turn the brake pedal position switch () counterclockwise, and pull it back until it is no longer touching the brake pedal. rake Pedal Position Switch Clearance 3. Lift up on the brake pedal by hand. Push in the brake pedal position switch until its plunger is fully pressed (the threaded end () touches the pad () on the pedal arm). Then back off the switch 3/4 turn to make 0.7 mm (0.03 in.) of clearance between the threaded end and pad. Tighten the locknut securely. Connect the brake pedal position switch connector. Make sure the brake lights go off when the pedal is released. 0.7 mm (0.03 in.) C 2. Pull back the carpet and find the cutout in the insulator. Lift up the insulator cutout and measure the pedal height () at the middle of the left side center of the pedal pad (C) to the floor. Standard pedal height (with carpet removed): 155 mm (6 1/8 in.) 19-6

7 Pedal Free Play 1. With the engine off, inspect the pedal free play () on the pedal pad () by pushing the pedal by hand. Free play: 1 5 mm (1/16 3/16 in.) C Parking rake Inspection and djustment Inspection 1. Press the parking brake pedal () with 294 N (30 kgf, 66 lbf) of force. The parking brake pedal should travel within the specified number of clicks (). Pedal locked clicks: 10 to 12 If the number of pedal clicks is excessive, adjust the parking brake. Pressed with 294 N m (30kgf,66lbf) 2. If the pedal free play is out of specification, adjust the brake pedal position switch (C). If the brake pedal free play is insufficient, it may result in excessive brake drag. Minor djustment 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 2. Tighten the adjusting nut () until the parking brakes drag slightly when the rear wheels are turned. 3. ack off the adjusting nut in half-turn increments, and check for proper adjustment (10 to 12 clicks) at a pedal force of 294 N (30 kgf, 66 lbf). (cont d) 19-7

8 Conventional rake Components Parking rake Inspection and djustment (cont d) Major djustment (to be done when replacing parking brake shoes) 4. Remove the access plug (). 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 2. Remove the rear wheels. 3. Release the parking brake, and back off the adjusting nut (). C 5. Use a flat tip screwdriver () to rotate the adjuster assembly (C) until the shoes lock against the drum. Then back off ten clicks, and install the access plug. 6. Clean the mating surface of the brake disc/drum and the inside of the wheel, then install the rear wheels. 7. Do the minor adjustment procedure. 8. Do the parking brake shoe lining break-in procedure (see page 19-31). 19-8

9 rake System leeding NOTE: Do not reuse the drained fluid. Use only clean Honda DOT 3 rake Fluid from an unopened container. Using a non-honda brake fluid can cause corrosion and shorten the life of the system. Do not mix different brands of brake fluid; they may not be compatible. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. The reservoir on the master cylinder must be at the MX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. dd fluid as required. 1. Make sure the brake fluid level in the reservoir is at the MX (upper) level line (). 4. Repeat the procedure for each caliper until no air bubbles are in the fluid. leed the calipers in the sequence shown. Front LEEDING SEQUENCE: Front Right Front Left Rear Right Rear Left 9.0 N m (0.9 kgf m, 7.0 lbf ft) 2. Have someone slowly pump the brake pedal several times, then apply steady pressure. Rear 3. Starting at the left-front, loosen the brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. 9.0 N m (0.9 kgf m, 7.0 lbf ft) 5. Refill the master cylinder reservoir to the MX (upper) level line. 19-9

10 Conventional rake Components rake System Indicator Circuit Diagram TTERY LK/YEL UNDER HOOD FUSE/RELY OX No.22 (T) (120 ) No.15 (40 ) D6 YEL IGNITION SWITCH 4 UNDER DSH FUSE/RELY OX No.7 (7.5 ) No.23 (IG) (50 ) G1 WHT T IG1 LK/YEL 6 No.21 (7.5 ) IG1 HOT in ON (II) and STRT (III) N44 X35 YEL WHT/RED GUGE CONTROL MODULE RKE SYSTEM INDICTOR (LED) RKE SYSTEM INDICTOR DRIVE CIRCUIT 14 RED/WHT 2 9 GRN/RED GRN/ORN 2 RKE FLUID LEVEL SWITCH (Closed : Float down) (Open : Float up) VS OFF SWITCH LK PRKING RKE SWITCH (Closed : Pedal pressed) (Open : Pedal released) LK 3 G301 G

11 Parking rake Switch Test NOTE: If both the S/VS indicator and the brake system indicator come on at the same time, check the VS system first (see page 19-39). 1. Disconnect the parking brake switch connector () from the parking brake switch (). rake 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. C D C 2. Check for continuity between the terminals with the float in the down position (C) and the up position (D): 2. Check for continuity between the positive terminal (C) and body ground: With the float up, there should be no continuity. With the float down, there should be continuity. With the parking brake pedal pressed, there should be continuity. With the parking brake pedal released, there should be no continuity. NOTE: If both the S/VS indicator and the brake system indicator come on at the same time, check the VS first. If the parking brake switch/fluid level switch is OK, but the brake system indicator does not function, check the VS (For Canada models: do the input test for the daytime running lights control unit first)

12 Conventional rake Components Front rake Pad Inspection and Replacement Special Tools Required rake caliper piston compressor 07E-SEP101 Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. void breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSH-approved vacuum cleaner. Inspection Replacement 1. Remove some brake fluid from the master cylinder. 2. Raise the front of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 3. Remove the front wheels. 4. While holding the caliper pin () with a wrench, remove the flange bolt (). e careful not to damage the pin boot. Then pivot the caliper (C) up out of the way. Check the hose and the pin boots for damage and deterioration. 1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 2. Remove the front wheels. 3. Check the thickness of the inner pad () and the outer pad (). Do not include the thickness of the backing plate. rake pad thickness: Standard: mm ( in.) Service limit: 1.0 mm (0.04 in.) C 5. Remove the pad shims () and the brake pads (). 4. If the brake pad thickness is less than the service limit, replace the front brake pads as a set. 5. Clean the mating surface of the brake disc and the inside of the wheel, then install the front wheels

13 6. Remove the pad retainers (). 10. pply Molykote M-77 assembly paste (P/N ) to the pad side of inner shim, outer pad shim, and outer pad shim C, the back of the brake pads (D), and the other areas indicated by the arrows.wipeexcessassemblypasteofftheshims and brake pads. Contaminated brake discs or brake pads reduce stopping ability. Keep grease and assembly paste off the brake discs and brake pads. 7. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. E 8. Check the brake disc for damage and cracks. 9. Clean and install the pad retainers. D D C 11. Install the brake pads and the pad shims as shown. Install the brake pad with the wear indicator (E) on the upper inside. If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. (cont d) 19-13

14 Conventional rake Components Front rake Pad Inspection and Replacement (cont d) 12. Mount the brake caliper piston compressor () on the caliper (). 07E-SEP Press in the piston with the brake caliper piston compressor so the caliper will fit over the brake pads. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down. 16. Clean the mating surface of the brake disc and the inside of the wheel, then install the front wheels. 17. Press the brake pedal several times to make sure the brakes work. NOTE: Engagement of the brakes may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 18. dd brake fluid as needed. 19. fter installation, check for leaks at hose and line joints or connections, and retighten if necessary. Test-drive the vehicle, then check for leaks. NOTE: e careful when pressing in the pistons because brake fluid might overflow from the master cylinder s reservoir. 14. Remove the brake caliper piston compressor. 15. Pivot the caliper down into position. Install the flange bolt (), and tighten it to the specified torque while holding the caliper pin (), with a wrench, being careful not to damage the pin boot. 10x1.25mm 72 N m (7.3 kgf m, 53 lbf ft) 19-14

15 Front rake Disc Inspection Runout 1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 2. Remove the front wheels. 3. Remove the brake pads (see page 19-12). 4. Inspect the brake disc surface for damage and cracks. Clean the brake disc thoroughly, and remove all rust. 5. Install suitable flat washers () and wheel nuts (), and tighten the nuts to the specified torque to hold the brake disc securely against the hub. rake disc runout: Service limit: 0.04 mm ( in.) Thickness and Parallelism 1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 2. Remove the front wheels. 3. Remove the brake pads (see page 19-12). 4. Using a micrometer, measure brake disc thickness at eight points, about 45 apart and 10 mm (3/8 in.) in from the outer edge of the brake disc. Replace the brake disc if the smallest measurement is less than the max. refinishing limit. rake disc thickness: Standard: mm ( in.) Max. refinishing limit: 26.0 mm (1.02 in.) rake disc parallelism: mm ( in.) max. NOTE: This is the maximum allowable difference between the thickness measurements. 10 mm (3/8 in.) 10 mm (3/8 in.) 69 N m (7.0 kgf m, 51 lbf ft) 6. Set up the dial gauge against the brake disc as shown, and measure the runout at 10 mm (3/8 in.) from the outer edge of the brake disc. 7. If the brake disc is beyond the service limit, refinish the brake disc with a commercially available on-car brake lathe. 5. If the brake disc is beyond the service limit for parallelism, refinish the brake disc with a commercially available on-car brake lathe. NOTE: If the brake disc is beyond the service limit for refinishing, replace it (see page 19-16). Max. refinish limit: 26.0 mm (1.02 in.) NOTE: If the brake disc is beyond the service limit for refinishing, replace it (see page 19-16). new brake disc should be refinished if its runout is greater than 0.04 mm ( in.)

16 Conventional rake Components Front rake Disc Replacement 1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 5. Remove the 6 mm brake disc retaining screws (). 2. Remove the front wheels. 3. Remove the brake hose mounting bolt (). 8x1.25mm 22 N m (2.2 kgf m, 16 lbf ft) 8x1.25mm 14 x 1.5 mm 137 N m (14.0 kgf m, 101 lbf ft) 4. Remove the brake caliper bracket mounting bolts (), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. C 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) 6. Screw two 8 x 1.25 mm bolts () into the brake disc to push it away from the hub. Turn each bolt 90 degrees to prevent the brake disc from binding. 7. Remove the brake disc from the hub. 8. Install the brake disc in the reverse order of removal, and note these items: efore installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. efore installing the wheels, clean the mating surface of the brake disc and the inside of the wheel

17 Front rake Caliper Overhaul Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. void breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSH-approved vacuum cleaner. Remove, disassemble, inspect, reassemble, and install the caliper, and note these items: NOTE: Make sure that the caliper pins are installed correctly. The upper and lower caliper pins are different. If the caliper pins are installed in the wrong location, it will cause uneven tire wear, vibration, and or uneven or rapid pad wear. Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. To prevent dripping brake fluid, cover disconnected hose joints with rags or shop towels. Clean all parts in brake fluid and air dry; blow out all passages with compressed air. efore reassembling, check that all parts are free of dirt and other foreign particles. Replace parts with new ones as specified in the illustration. Make sure no dirt or other foreign matter gets in the brake fluid. Make sure no grease or oil gets on the brake discs or pads. When reusing brake pads, always reinstall them in their original positions to prevent loss of braking efficiency. Do not reuse drained brake fluid. Use only clean Honda DOT 3 rake Fluid from an unopened container. Using a non-honda brake fluid can cause corrosion and shorten the life of the system. Do not mix different brands of brake fluid as they may not be compatible. Coat the pistons, piston seal grooves, and caliper bores with clean brake fluid. Replace all rubber parts with new ones whenever disassembled. fter installing the caliper, check the brake hose and line for leaks, interference, and twisting. : Honda silicone grease (P/N 08C M) WER INDICTOR Install inner brake pad with its wear indicator upward. UPPER CLIPER PIN CLIPER PIN PIN OOT Replace. INNER PD SHIM RKE HOSE NJO OLT 34 N m (3.5 kgf m, 25 lbf ft) RKE PDS LEED SCREW 10 x 1.0 mm 8 N m (0.8 kgf m, 6 lbf ft) SELING WSHERS Replace. OUTER PD SHIM C LOWER CLIPER PIN PIN OOT 14 x 1.5 mm 137 N m (14.0 kgf m, 101 lbf ft) CLIPER ODY PD RETINERS CLIPER RCKET 10x1.25mm 72 N m (7.3 kgf m, 53 lbf ft) PISTON SEL Replace. PISTON PISTON OOT Replace

18 Conventional rake Components Master Cylinder Replacement Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. e careful no to damage or deform the brake lines during removal and inspection. To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent. 1. Remove the intake manifold cover. 2. Remove the intake air duct (see step 9 on page 5-2). Master Cylinder Inspection NOTE: efore reassembling, check that all parts are free of dirt and other foreign particles. Do not try to disassemble the master cylinder assembly. Replace the master cylinder assembly with a new part if necessary. Do not allow dirt or foreign matter to contaminate the brake fluid. leed the brake system (see page 19-9). RESERVOIR CP Check for blockage of vent holes. 3. Disconnect the brake fluid level switch connectors (), and remove the reservoir cap (). RESERVOIR SEL Check for damage and deterioration. STRINER Remove accumulated sediment. RESERVOIR Check for damage. C D 14x1.25mm 35 N m (3.6 kgf m, 26 lbf ft) SCREW GROMMETS Check for damage and deterioration. G F E 8x1.25mm 25 N m (2.5 kgf m, 18 lbf ft) SEL Check for damage and deterioration. MSTER CYLINDER Check for leaks, rust, and damage. 4. Remove the brake fluid from the master cylinder reservoir (C) with a syringe. 5. Disconnect the brake lines (D) from the master cylinder. To prevent spills, cover the hose joints with rags or shop towels. 6. Remove the master cylinder mounting nuts (E). 7. Remove the master cylinder (F) from the brake booster (G). e careful not to bend or damage the brake lines when removing the master cylinder. 8. Install the master cylinder in the reverse order of removal, and note this item: Spin the wheels to check for brake drag. 9. leed the brake system (see page 19-9)

19 rake ooster Test Functional Test 1. With the engine stopped, press the brake pedal several times to deplete the vacuum reservoir, then press the brake pedal hard, and hold it for 15 seconds. If the brake pedal sinks, either the master cylinder is bypassing brake fluid internally, or the brake system (master cylinder, lines, modulator, or caliper) is leaking. 2. Start the engine with the brake pedal pressed. If the brake pedal sinks slightly, the vacuum booster is operating normally. If the brake pedal height does not vary, perform the leak test. 3. With the engine running, press the brake pedal lightly, and shift the transmission to the D position. pply just enough pressure to hold back automatic transmission creep. If the brake pedal sinks more than 10 mm (3/8 in.) in 3 minutes, the master cylinder is faulty. slight change in pedal height when the /C compressor cycles on and off is normal. (The /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. If the brake pedal height does not vary while pressed for 30 seconds, the vacuum booster is OK. If the pedal height rises go to step 6. If it does not rise go to step Start the engine and let it idle for 30 seconds. Turn the engine off, and wait 30 seconds. Press the brake pedal several times using normal pressure. When the pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. Does the pedal rise on each consecutive application? If it rises the booster is OK. If it does not go to step Disconnect the brake booster vacuum hose () at the booster. The check valve () is built into the hose. 4. Start the engine, and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not working properly. Replace the brake booster vacuum hose and check valve, and retest. If vacuum is found, go to step Reconnect the vacuum hose to the brake booster. 6. Start the engine, and then pinch the brake booster vacuum hose between the check valve and the booster. 7. Turn the engine off and wait 30 seconds. Press the brake pedal several times using normal pressure. When the pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. If the pedal position does not vary inspect the seal between the master cylinder and booster. If the seal is OK, replace the brake booster. If the pedal position varies, replace the brake booster vacuum hose/check valve assembly

20 Conventional rake Components rake ooster Replacement 1. Remove the master cylinder (see page 19-18). 2. Disconnect the brake booster vacuum hose () from the brake booster (). 5. Pull the brake booster () forward, and remove it from the engine compartment. e careful not to damage the booster surfaces and threads of the booster stud bolts. e careful not to bend or damage the brake lines. 3. Remove the lock pin () and joint pin (). 6. Install the brake booster in the reverse order of removal, and note these items: C 8x1.25mm 25N m(2.5kgf m,18lbf ft) 4. Remove the brake booster mounting nuts (C). Use a new lock pin whenever installing. fter installing the brake booster and master cylinder, fill the reservoir with new brake fluid, bleed the brake system (see page 19-9), and adjust the brake pedal height and free play (see page 19-6)

21 Rear rake Pad Inspection and Replacement Special Tools Required rake caliper piston compressor 07E-SEP101 Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. void breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSH-approved vacuum cleaner. Inspection Replacement 1. Remove some brake fluid from the master cylinder. 2. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 3. Remove the rear wheels. 4. Remove the flange bolt () while holding the caliper pin with a wrench being careful not to damage the pin boot, and pivot the caliper (C) up out of the way. Check the hose and pin boots for damage and deterioration. 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 2. Remove the rear wheels. 3. Check the thickness of the inner pad () and the outer pad (). Do not include the thickness of the backing plate. rake pad thickness: Standard: mm ( in.) Service limit: 1.0 mm (0.04 in.) C 5. Remove the pad shims () and brake pads (). 4. If the brake pad thickness is less than the service limit, replace all the rear brake pads as a set. 5. Clean the mating surface of the brake disc and the inside of the wheel, then install the front wheels. (cont d) 19-21

22 Conventional rake Components Rear rake Pad Inspection and Replacement (cont d) 6. Remove the pad retainers (). 12. Install the brake pads and the pad shims as shown. Install the brake pad with the wear indicator (C) on the bottom inside. If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. 13. Mount the brake caliper piston compressor () on the caliper (). 07E-SEP101 C 7. Clean the caliper bracket () thoroughly; remove any rust, and check for grooves and cracks. 8. Check the brake disc/drum for damage and cracks. 9. pply a thin coat of M-77 assembly paste (P/N ) to the retainers on their mating surfaces (indicated by the arrow) against the caliper bracket. 10. Install the pad retainers. Wipe excess assembly paste off the retainers. Keep any assembly paste off the discs and pads. 11. pply a thin coat of M-77 assembly paste (P/N ) to the pad side of the shims (), the back of the brake pads (), and the other areas indicated by the arrows. Wipe excess assembly paste off the pad shims and brake pads. Contaminated brake discs or pads reduce stopping ability. Keep assembly paste off the brake discs and pads. 14. Push in the piston with a brake caliper piston compressor so the caliper will fit over the brake pads. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down. NOTE: e careful when pushing in the caliper piston, brake fluid might overfllow from the master cylinder s reservoir. 15. Pivot the caliper down into position. Install the flange bolt (C), and tighten it to the specified torque while holding the caliper pin with a wrench. e careful not to damage the pin boot. 16. Clean the mating surface of the brake disc and the inside of the wheel, then install the front wheels. 17. Press the brake pedal several times to make sure the brakes work. NOTE: rake engagement may require a greater pedal stroke immediately after the brake pads have been replaced. Several applications of the brake pedal will restore the normal pedal stroke. C 18. dd brake fluid as needed. 19. fter installation, check for leaks at hose and line joints or connections, and retighten if necessary

23 Rear rake Disc Inspection Runout 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 2. Remove the rear wheels. 3. Remove the brake pads (see page 19-21). 4. Inspect the brake disc/drum surface for damage and cracks. Clean the brake disc/drum thoroughly, and remove all rust. 5. Install suitable flat washers () and wheel nuts (), and tighten the wheel nuts to the specified torque to hold the brake disc/drum securely against the hub. 10 mm (3/8 in.) Thickness and Parallelism 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 2. Remove the rear wheels. 3. Remove the brake pads (see page 19-21). 4. Using a micrometer, measure brake disc thickness at eight points, about 45 apart and 10 mm (3/8 in.) in from the outer edge of the brake disc/drum. Replace the brake disc/drum if the smallest measurement is less than the max. refinishing limit. rake disc/drum thickness: Standard: mm ( in.) Max. refinishing limit: 9.0 mm (0.35 in.) rake disc/drum parallelism: mm ( in.) max. NOTE: This is the maximum allowable difference between the thickness measurements. 10 mm (3/8 in.) 69 N m (7.0 kgf m, 51 lbf ft) 6. Set up the dial gauge against the brake disc/drum as shown, and measure the runout at 10 mm (3/8 in.) from the outer edge of the brake disc. rake disc/drum runout: Service limit: 0.04 mm ( in.) 7. If the brake disc/drum is beyond the service limit, refinish the brake disc/drum with a commercially available on-car brake lathe. Max. refinish limit: 9.0 mm (0.35 in.) 5. If the brake disc/drum is beyond the service limit for parallelism, refinish the brake disc/drum with a commercially available on-car brake lathe. NOTE: If the brake disc/drum is beyond the service limit for refinishing, replace it (see page 19-24). NOTE: If the brake disc/drum is beyond the service limit for refinishing, replace it (see page 19-24). new brake disc/drum should be refinished if its runout is greater than 0.04 mm ( in.)

24 Conventional rake Components Rear rake Disc Replacement 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 6. Remove the 6 mm brake disc/drum retaining screw (). 2. Remove the rear wheels. 3. Remove and discard the brake hose clip () from thebrakehose(). 8x1.25mm NOTE: During installation, install the new brake hose clip. 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) 7. Screw two 8 x 1.25 mm bolts () into the brake disc/ drum to push it away from the hub. Turn each bolt 90 degrees at a time to prevent the brake disc from binding. 8. Remove the brake disc/drum from the hub. 4. Remove the brake hose bracket mounting bolt () from the knuckle. 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) 9. Install the brake disc/drum in the reverse order of removal, and note these items: efore installing the wheel, clean the mating surface of the brake disc/drum and the inside of the wheel. efore installing the wheels, clean the mating surface of the brake disc and the inside of the wheel. C 12x1.25mm 108 N m (11.0 kgf m, 79.6 lbf ft) 5. Remove the brake caliper bracket mounting bolts (), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force

25 Rear rake Caliper Overhaul Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. void breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSH-approved vacuum cleaner. Remove, disassemble, inspect, reassemble, and install the caliper, and note these items: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. To prevent dripping brake fluid, cover disconnected hose joints with rags or shop towels. Clean all parts in brake fluid and air dry; blow out all passages with compressed air. efore reassembling, check that all parts are free of dirt and other foreign particles. Replace parts with new ones as specified in the illustration. Make sure no dirt or other foreign matter gets into the brake fluid. Make sure no grease or oil gets on the brake discs or pads. When reusing brake pads, always reinstall them in their original positions to prevent loss of braking efficiency. Do not reuse drained brake fluid. Use only clean Honda DOT 3 rake Fluid from an unopened container. Using a non-honda brake fluid can cause corrosion and shorten the life of the system. Do not mix different brands of brake fluid as they may not be compatible. Coat the piston, piston seal groove, and caliper bore with clean brake fluid. Replace all rubber parts with new ones whenever disassembled. fter installing the caliper, check the brake hose and line for leaks, interference, and twisting. : Honda silicone grease (P/N 08C M) 8 x 1.25 mm 22 N m (2.2 kgf m, 16 lbf ft) PIN CLIPER RCKET RKE HOSE NJO OLT 34 N m (3.5 kgf m, 25 lbf ft) SELING WSHERS Replace. LEED SCREW 9.0 N m (0.9. kgf m, 7lbf ft) PISTON SEL Replace. PISTON PIN OOT Replace. INNER PD SHIM RKE PDS CLIPER ODY OUTER PD SHIM PISTON OOT Replace. CLIPER PIN INNER PD SHIM WER INDICTOR Install inner pad with its wear indicator downward. CLIPER PIN 12x1.25mm 108 N m (11kgf m,80lbf ft) PD RETINERS 19-25

26 Conventional rake Components Parking rake Inspection Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. void breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSH-approved vacuum cleaner. 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 2. Remove the rear wheels. 3. Release the parking brake, and remove the rear caliper and brake disc/drum (see page 18-28). TENSION PIN RKE SHOE OSSES Check for deep grooves and rust. SHOE GUIDE PLTE U-CLIP Replace. WVE WSHER PRKING RKE LEVER Marked left and right. FLNGE NUT 12x1.25mm 74 N m (7.5 kgf m, 54 lbf ft) ROD SPRING Check for weakness and damage. RETINER SPRING RKE SHOE OSSES Check for deep grooves and rust. CKING PLTE Marked left and right. CONNECTING ROD RETINER Install securely on tension pin. RKE SHOE If brake shoes are to be reused, mark and reassemble in their original position. LOWER RETURN SPRING Check for weakness and damage. DJUSTER SSEMLY Check ratchet teeth for wear and damage. UPPER RETURN SPRING Check for weakness and damage

27 4. Check the parking brake linings () for cracking, glazing, wear, and contamination. 8. Measure the inside diameter of the parking brake disc/drum with inside vernier calipers. Parking brake drum inside diameter: Standard: mm ( in.) Service limit: mm (8.307 in.) 5. Measure the parking brake lining thickness (). Measurement does not include brake shoe thickness. Parking brake lining thickness: Standard: mm ( in.) Service limit: 1.0 mm (0.04 in.) 6. If the parking brake lining thickness is less than the service limit, replace all the parking brake shoes as a set (see page 19-28). 7. Check the bearings in the hub unit for smooth operation. 9. If the inside diameter of the parking brake disc/ drum is more than the service limit, replace the brake disc/drum. 10. Check the parking brake disc/drum for scoring, grooves, and cracks. 11. Clean the mating surface of the brake disc/drum and the inside of the wheel, then install the rear wheels

28 Conventional rake Components Parking rake Shoe Replacement Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. void breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSH-approved vacuum cleaner. 6. Remove the connecting rod (). Disassembly 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see page 1-10). 2. Remove the rear wheels. 3. Release the parking brake, and remove the rear brake caliper and brake disc/drum (see page 18-28). 7. Lower the parking brake shoe assembly. 8. Remove the forward brake shoe by removing the lower return spring () and adjuster assembly (). 4. Disconnect and remove the upper return springs (). 5. Remove the tension pins () by pushing and turning the retainers ()

29 9. Remove the rearward brake shoe by disconnecting the parking brake cable () from the parking brake lever (). Reassembly 1. pply Molykote 44 M grease to the sliding surface of the pivot pin () of the rearward brake shoe (). C 10. Remove the U-clip (), wave washer (), and parking brake lever (C) from the brake shoe. E 2. Install the parking brake lever (C) and wave washer (D) on the pivot pin, and secure with a new U-clip (E). D Install the wave washer with its convex side facing out. Pinch the U-clip securely to prevent the parking brake lever from coming out from the brake shoe. C 3. Connect the parking brake cable () to the parking brake lever (). (cont d) 19-29

30 Conventional rake Components Parking rake Shoe Replacement (cont d) 4. pply a thin coat of 44 M grease to the shoe ends and connecting rod ends (), sliding surfaces (), and opposite edges of the parking brake shoe (C) as shown. Wipe off any excess. Keep grease off the brake linings. 6. Clean the threaded portions of the clevis, and coat the threads with multipurpose grease. Clean the sliding surface of the clevis, and coat the sliding surface with multipurpose grease. Install the clevis and on the adjuster (C), and shorten the clevis by turning the adjuster. C C D C C C Greasing symbols: rake shoe ends and connecting rod ends Opposite edge of the shoe Sliding surface 5. Install the tension pin (), retainer spring (), and retainer (C) of the rearward brake shoe (D). Make sure the tension pin does not contact the parking brake lever. C C 7. Reinstall the brake shoe adjuster assembly (D), and hook the lower return spring (E) on the parking brake shoes. 8. Install the rod spring () to the connecting rod () first. Then install the connecting rod on the parking brake shoes. E C D 19-30

31 Parking rake Shoe Lining reak-in 9. Install the tension pin (), the retainer spring (), and the retainer (C) on the forward brake shoe (D). NOTE: Do the brake linings surface break-in when installing new parking brake shoes and/or new rear drum in brake disc. D Do this operation in a safe area. C 1. Park the vehicle on a firm, level surface. 2. Do the major parking brake adjustment (see page 19-8). 3. Do the minor parking brake adjustment (see page 19-7). 10. Install the upper return springs (). 4. Press the parking brake pedal 2 to 4 clicks. 11. Install the rear brake disc/drum and the rear brake caliper. 12. Do the major parking brake adjustment (see page 19-8). 5. Drive the vehicle for 1/4 mile (400 m) at no more than 31 mph (50 km/h). 6. Stop the vehicle and release the parking brake for 5 10 minutes or drive the vehicle for 5 10 minutes to allow the brake disc/drum to cool. 7. Repeat steps 4 through 6 three more times. 8. Check the parking brake pedal adjustment (see page 19-7)

32 Conventional rake Components rake Pedal Replacement 1. Disconnect the brake pedal position switch connector (). F D 8x1.25mm 22 N m (2.2 kgf m, 161 lbf ft) C E 8x1.25mm 25 N m (2.6 kgf m, 19 lbf ft) 2. Remove the lock pin () and joint pin (C). NOTE: Use a new lock pin when reinstalling. 3. Remove the brake pedal bracket mounting bolt (D) and nuts (E). 4. Remove the brake pedal with bracket (F). 5. Install in the reverse order of removal. 6. Do the brake pedal and brake pedal position switch adjustment (see page 19-6)

33 rake Hose and Line Inspection 1. Inspect the brake hoses for damage, deterioration, leaks, interference, and twisting. 2. Check the brake lines for damage, rusting, and leaks. lso check for bent brake lines. 3. Check for leaks at hose and line joints and connections, and retighten if necessary. 4. Check the master cylinder and VS modulator-control unit for damage and leaks. NOTE: Replace the brake hose clip whenever the brake hose is serviced. Connection Point Component Connected to Specified Torque Value Note Front brake caliper rake hose 34 N m (3.5 kgf m, 25 lbf ft) anjo bolt leed screw 9.0 N m (0.9 kgf m, 7.0 lbf ft) Rear brake caliper rake hose 34 N m (3.5 kgf m, 25 lbf ft) anjo bolt leed screw 9.0 N m (0.9 kgf m, 6.5 lbf ft) C rake hose rake line 15 N m (1.5 kgf m, 11 lbf ft) Flare nut D Master cylinder rake line 35 N m (3.6 kgf m, 26 lbf ft) Flare nut E VS modulatorcontrol rake line 30 N m (3.1 kgf m, 22 lbf ft) Flare nut unit (14 mm nut) rake line 15 N m (1.5 kgf m, 11 lbf ft) Flare nut (10 mm nut) D E C C C E 19-33

34 Conventional rake Components rake Hose Replacement NOTE: efore reassembling, check that all parts are free of dirt and other foreign particles. Replace parts with new ones whenever specified to do so. Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material. 1. Replace the brake hose () if the hose is twisted, cracked, or leaking. 5. Remove the brake hose from the damper bracket. 6. Install the brake hose () on the damper bracket with flange bolt () first, then connect the brake hose to the caliper with the banjo bolt (C) and new sealing washers (D). C 10x1.0mm 34 N m (3.5 kgf m, 25 lbf ft) 8x1.25mm 22 N m (2.2 kgf m, 16 lbf ft) C D 7. Install the brake hose () on the upper brake hose bracket () with a new brake hose clip (C). 2. Disconnect the brake hose from the brake line () using a 10 mm flare-nut wrench (C). C D 10x1.0mm 15 N m (1.5 kgf m, 11 lbf ft) 3. Remove and discard the brake hose clip () from thebrakehose(). 8. Connect the brake line (D) to the brake hose. 9. fter installing the brake hose, bleed the brake system (see page 19-9). C 4. Remove the banjo bolt (C), and disconnect the brake hose from the caliper. 10. Do the following check: Check the brake hose and line joint for leaks, and tighten if necessary. Check the brake hoses for interference and twisting

35 Parking rake Cable Replacement Exploded View 8x1.25mm 22 N m (2.2 kgf m, 16 lbf ft) PRKING RKE CLE Check for faulty movement. LEFT PRKING RKE CLE Check for faulty movement. PRKING RKE SWITCH EQULIZER 8x1.25mm 22 N m (2.2 kgf m, 16 lbf ft) RIGHT PRKING RKE CLE Check for faulty movement. PRKING RKE RELESE LEVER PRKING RKE PEDL Check for smooth operation. Multipurpose (Sliding surface) PRKING RKE PEDL SSEMLY FLNGE NUT 8x1.25mm 22 N m (2.2 kgf m, 16 lbf ft) (cont d) 19-35

36 Conventional rake Components Parking rake Cable Replacement (cont d) NOTE: The parking brake cable must not be bent or distorted. This will lead to stiff operation and premature cable failure. Refer to the Exploded View as needed during this procedure. 1. Remove the parking brake shoes, and disconnect the parking brake cable from the brake shoe (see page 19-28). 2. Remove the parking brake cable () from the backing plate () using a 12 mm offset wrench (C). C 3. Install the parking brake cable in the reverse order of removal, and adjust the parking brake (see page 19-7). pply the parking brake firmly ten times, then adjust it again

37 rakes Conventional rake Components VS (Vehicle Stability ssist) System Components Component Location Index General Troubleshooting Information DTC Troubleshooting Index Symptom Troubleshooting Index System Description Circuit Diagram DTC Troubleshooting Symptom Troubleshooting Steering ngle Sensor Replacement Steering ngle Sensor Center Point Writing Yaw Rate-Lateral cceleration Sensor Replacement VS OFF Switch Test VS Modulator-Control Unit Removal and Installation Wheel Sensor Inspection Wheel Sensor Replacement

38 VS System Components Component Location Index STEERING NGLE SENSOR Replacement, page UNDER-HOOD FUSE/RELY OX UXILIRY FUSE OX DT LINK CONNECTOR (DLC) YW RTE-LTERL CCELERTION SENSOR Replacement, page RIGHT-RER WHEEL SENSOR Inspection, page Replacement, page WHEEL ERING (MGNETIC ENCODER) Replacement, page VS MODULOR-CONTROL UNIT Removal and Installation, page RIGHT-FRONT WHEEL SENSOR Inspection, page Replacement, page WHEEL ERING (MGNETIC ENCODER) Replacement, page UNDER-DSH FUSE/RELY OX LEFT-FRONT WHEEL SENSOR Inspection, page Replacement, page WHEEL ERING (MGNETIC ENCODER) Replacement, page LEFT-RER WHEEL SENSOR Inspection, page Replacement, page WHEEL ERING (MGNETIC ENCODER) Replacement, page

39 General Troubleshooting Information System Indicator This system has four indicators: S indicator () rake system indicator () VS indicator (C) VS activation indicator (D) When the system detects a problem, it turns the appropriate indicators on. Depending on the failure, the VS modulator-control unit determines which indicators to turn on. When the system is OK, each indicator comes on for about 2 seconds after turning the ignition switch ON (II), then goes off. S and VS indicators go off Each indicator goes off after a problem goes away, but the timing which the VS modulator-control unit turns off the indicators varies between DTCs. DTC 61 or 62: The indicators go off automatically when the system returns to normal. DTC 11, 13, 15, 17, 21, 25, 26, 27, 31, 32, 33, 34, 35, 36, 37, 38, 45, 46, 47, 48, 54, 65, 66, 67, 68, 72, 73, 74, 75, 76, 81, 84, 91, 92, or 97 : The indicators stay on until the ignition switch is turned OFF whether or not the system returns to normal. : There are some cases that the indicators stay on until the vehicle is driven after the system returns to normal. : There are some cases that the indicators go off automatically when the system returns to normal. DTC 12, 14, 16, 18, 51, 52, or 53: The indicators stay on until the vehicle is driven after the system returns to normal. C D S indicator The S indicator comes on when the S function is lost. The brakes still work like a conventional system. rake system indicator The brake system indicator comes on when the ED function is lost, the parking brake is applied, and/or the brake fluid level is low. VS indicator The VS indicator comes on when the VS function is lost. VS activation indicator The VS activation indicator blinks when the VS function is activating. The VS activation indicator comes on when VS is off or VS function is lost. (cont d) 19-39

40 VS System Components General Troubleshooting Information (cont d) Diagnostic Trouble Code (DTC) The memory can hold 10 DTCs. However, when the same DTC is detected more than once, the more recent DTC is written over the earlier one. Therefore, when the same problem is detected repeatedly, it is memorized as a single DTC. The DTCs are indicated in the order they occur. The DTCs are memorized in the EEPROM. Therefore, the memorized DTCs cannot be canceled by disconnecting the battery. Do the specified procedures to clear the DTCs. Self-diagnosis Self-diagnosis can be classified into two categories: Initial diagnosis: Done right after the ignition switch is turned ON (II) and until the S and VS indicators go off. Regular diagnosis: Done right after the initial diagnosis until the ignition switch is turned OFF. When the system detects a problem, the VS modulator-control unit shifts to fail-safe mode. Kickback The pump motor operates when the VS modulatorcontrol unit is functioning, and the fluid in the reservoir is forced out to the master cylinder, causing kickback at the brake pedal. Pump Motor The pump motor operates when the VS modulatorcontrol unit is functioning. The VS modulator-control unit checks the pump motor operation one time after completing initial diagnosis during regular diagnosis when the vehicle is driven over 10 mph (15 km/h). You may hear the motor operate at this time, but it is normal. rake Fluid Replacement/ir leeding rake fluid replacement and air bleeding procedures are identical to the procedures used on vehicles not equipped with the VS system (see page 19-9). How to Troubleshoot DTCs The troubleshooting procedures assume that the cause of the problem is still present and the S and/or VS indicator is still on. Following the flowchart when the S and/or VS indicator does not come on can result in incorrect diagnosis. The connector illustrations show the female terminal connectors with a single outline and the male terminal connectors with a double outline. 1. sk the customer about the conditions when the problem occured, and try to reproduce the same conditions for troubleshooting. Find out when the S and/or VS indicator came on, such as during control, after control, when the vehicle was travelling at a certain speed, etc. 2. When the S or VS indicator does not come on during the test-drive, but troubleshooting is done based on the DTC, check for loose connectors, poor contact of the terminals, etc. before you start troubleshooting. 3. fter troubleshooting, or repairs are done, clear the DTCs, and test-drive the vehicle under the same conditions as originally set with the DTCs. Make sure the S and VS indicators do not come on. 4. Check for other systems DTCs which connected via F-CN, if there are DTCs that are related to F-CN, the most likely cause was that the ignition switch was turned ON (II) with the VS modulator-control unit connector disconnected. Clear the DTCs. Check for PGM-FI and S codes, and troubleshoot those first. Intermittent Failures The term intermittent failure means a system may have had a failure, but it checks OK now. If the indicator(s) of the system does not come on, check for loose connectors or poor contacts in the terminals related to the circuit that you are troubleshooting. If the indicators were on, but then went out, the original problem may have been intermittent