1999 HONDA CR-V 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
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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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Master Cylinder
I nspection/Disassembly
CAUTION: Do not spill brake fluid onthe vehicle; it may
damsge the paint; il brake fluid does contact th6 paint.
wash it off immodiately with water.
NOTE:
. Before reassembling, check that all parts are free of
dust and other foreign particles.
. Do not try to disassemble the master cylinder assem-
bly. Replace the master cylinder assembly with a new
pan it necessary,
. Make sure no dirt or other foreign matter is allowed
to contaminate the brake fluid.
RESERVOIR SEALCheck for damaoe anddeterioration,
RESERVOIRCheck for damage.
ROD SEALCheck for damageand deterioration.
-€-1SILICONE GREASE
MASTER CYLINOERCheck bore for wear, rust and damage.
19-14
Pushrod Clearance Adjustment
NOTE: Master cylinder pushrod-to-piston clearance must
be checked and adjustments made, if necessary. before
installing the master cylinder.
1. Set the special tool on the master cylinder body;
push in the center shaft until the top ot it contacts
the end of the secondary piston by turning the ad-justing nut.
PUSHROD ADJUSTMENT GAUGE07JAG - SD{o100
SECONDARY
MASTER CYLINDER
ADJUSTING NUT
Without disturbing the center shaft's position, in-
stallthe special tool upside down on the booster.
Install the master cylinder nuts, and tighten them to
the sDecified toroue.
Connect the booster iniine with a vacuum gauge 0 -
101 kPa (0 - 760 mmHg, 30 in Hg) to the booster's
engine vacuum supply, and maintain an engine
speed that will deliver 66 kPa (500 mmH9, 20 in Hg)
vacuum.
With a feeler gauge, measure the clearance between
the gauge body and the adiusting nut as shown.
Clearanco: 0 - 0.4 mm (0 - 0.02 inl
VACUUM GAUGElCommo.cidly 6vailablcl0 - 101 kPtl0 - 760 mm Hg, 30 in Hgl
MASTER CYLINDER NUT15 N.m 11.5 kgt m, 11 lbt.ftl
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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
Never use an air hose or dry brush to clgan brake assemblies,
Use an OSHA approved vacuum cleaner to avoid breathing brake dust.
Contaminated brake linings or drums reduce stopping ability.
Block the front wheels betore iacking up lhe rear ot the vehicle,
Block the front wheels, loosen the rear wheel nuts slightly, then raise the
poned. Remove the rear wheels.
2. Release the parking brake, and remove the rear brake drum.
I N.m {0.9rbr.ft)kgl.m,5.5
\\
\
196
@
Inspection
a
a
rl
a
1.vehicle, and make sure it is securely sup-
BACKING PLATEMarked left and right.
PARKING EBAKE I-EVERMarked left and right.
ADJUSTER BOLTCheck ratchet teethfor wear and damage.UPPER RETURN SPRINGCheck for weaknessand damage.
CLEVIS BCLEVIS A
64 N.m 16.5 kgl.m,47 lbt.ftl
\L;
SPRINGCheck for weaknessano oamage.
'l-'-' u-cllP
I Replace.
t/
6d/
BRAKE SHOEInspection, see page 19 17lf brake shoes are to bereused, mark and reassemblein same position.
WHEELInspect for leakage.Replacement, seepage 19-20
LOWER RETURNSPRINGCheck for weaknessano oamage.
RETAINER SPRINGInstall securely onlensron prn.
19-16
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Check the wheel cylinder for leakage.
Check the brake linings for cracking, glazing, wear,
and contamination.
Measure the brake lining thickness. Measurement
does not include brako shoe thickness.
Brake Lining Thicknoss:
Standard: 3.9 -,1.5 mm {0.15 - 0.18 inl
Sorvice Limil: 2.0 mm {0.08 in}
lf the brake lining thickness is less than the service
limit, replace the brake shoes as a set.
Check the bearings in the hub unit for smooth oper-
ation; if the bearing require servicing. refer to sec-
tion 18.
7.
WHEEL CYLINOER
LININGS
8. Measure the inside diameter of the brake drum
with inside vernier calioers,
Drum Insido Diamoter:
Standard: 219.9 - 220.0 mm (8.657 - 8.661 in)
Service Limit: 221.0 mm {8.700 inl
lf the inside diameter of the brake drum is more
than the service limit, replaca the brake drum.
Check the brake drum for scoring, grooves, and
cracKs.
10.
BRAKE DRUM
19-17
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Rear Drum Brakes
Brake Shoes Replacement
1. Remove the upper return spring with the tool.
l@ w€ar eye protestion when using the
brske spring wrench.
RETAINER SPRINGBRAKE SPRING WBENCH{Commerciallv available)
Remove the tension pins by pushing the retainer
spring and turning them.
Lower the brake shoe assembly, and remove the
lower return spring, Make sure not to damage the
dust cover on the wheel cylinder,
Disconnect the parking brake cable from the parking
brake lever.
Remove the brake shoe assembly,
Remove the upper return spring, self-adjuster lever,
and self-adjuster spring, and separate the brake
shoes.
TENSION PIN
5.
o.
SELF.ADJUSTER LEVER UPPER RETURN SPRING
19-18
7. Remove the wave washer, parking brake lever. and
pivot pin from the brake shoe by removing the U-
cliD.
BRAKE SHOE
Apply brake cylinder grease (P/N: 08733 - 80202) or
equivalent rubber grease to the sliding surface of
the pivot pin, 8nd insert the pin into the brake shoe.
Install the parking brake lever and wave washer on
the pivot pin, and secure them with a new U-clip.
. lnstall the wave washer with its convex side fac-
Ing our.
. Pinch the U-clip securely to prevent the pivot pin
from coming out of the brake shoe.
U.CLIPReplace.
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U-CLIPReplace.WAVE WASHERReplace.
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10.
11,
Connect the parking brake cable to the parking
brake lever,
Clean the threaded portions of clevises A and B.
Coat the threads of the clevises with grease. To
shorten the clevises, turn the adiuster bolt.
Hook the self-adjuster spring to the self-adjuster
lever first, then to the brake shoe,
Install the clevises and upper return spring noting
the installation direction. Be careful not to damage
the wheel cylinder dust covers.
Installthe lower return spring.
12.
14.
UPPER RETURN SPRING
Apply rubber greaseto sliding surface.
15. Apply grease on each sliding surface. Keep grease
or oil off the brake linings. Wipe any excess grease
off the parts.
. Apply brake cylinder grease (P/N: 08733 - 8020E)
or equivalent rubber grease to the sliding sur-
faces as shown.
..4 Slrdrng surface
Apply Molykote 44MA to the brake shoe ends
and opposite edges of the shoes as shown.
.. a Opposite edge of the shoe.: a) Brake shoe ends(Shoe side ends and backingplate contact surface)
(cont'd)
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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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