Disc: Other Honda Pilot I

BLEEDING PROCEDURES

Note. Do not reuse drained fluid. Always use Honda Genuine DOT 3 Brake Fluid from an unopened can. Ensure no dirt or other materials enter brake fluid. Do not spill brake fluid on vehicle, it may damage paint; if some does spill, wash off immediately with water. The reservoir on master cylinder must be at the MAX (upper) level mark at start of bleeding procedure and checked after bleeding each brake caliper. Add fluid as required.

Raise and support vehicle. Fill master cylinder to maximum using only genuine Honda DOT 3 brake fluid. Have someone slowly pump brake pedal several times, then apply steady pressure. Loosen left-front brake bleed screw to allow air to escape from system, then tighten bleed screw securely. Repeat procedure for each wheel in sequence. Sequence is FL, FR, RR and RL. Fill master cylinder to maximum level line.

Pedal Height

1. Disconnect brake pedal position switch connector. Loosen brake pedal position switch lock nut and back off switch until it no longer touches brake pedal. Lift up carpet and measure pedal height at insulator cutout, middle of left side center of pedal pad. (Scheme 15) See «BRAKE PEDAL HEIGHT SPECIFICATIONS»(ref-164864-S36369683302004081700000) table for standard pedal height.
2. Loosen pushrod lock nut, and screw pushrod in or out with pliers until correct pedal height is obtained. Tighten lock nut firmly. Do not adjust the pedal height with pushrod pressed. Manufacturer does not provide adjustment procedure.
3. Screw in brake pedal position switch until its plunger is fully pressed (threaded end touching pad on pedal arm). (Scheme 16) Back off switch to make.01" (.3 mm) of clearance between threaded end and pad. Tighten lock nut firmly. Connect brake pedal position switch connector. Make sure brake lights go off when pedal is released. Check brake pedal free play. See «FREE PLAY»(ref-164864-S12383348072004081700000). NOTE: When brake pedal is released, the brake pedal position switch is normally open and the idle stop switch is normally closed.

BRAKE PEDAL HEIGHT SPECIFICATIONS

Scheme 15

Scheme 16

Free Play

With engine off, check brake pedal free play by pushing pedal by hand. If pedal free play is out of specification, adjust brake switch. (Scheme 17) See PEDAL FREE PLAY table. If pedal free play is insufficient, it may result in brake drag. Make sure brake lights go off when pedal is released.

PEDAL FREE PLAY

Scheme 17

PARKING BRAKE SWITCH

Brake warning light indicates ABS/TCS problem, parking brake is engaged and/or brake fluid level is low. To check parking brake light switch, turn ignition on. Disconnect harness connector and check for continuity between switch terminal and ground. When parking brake pedal is pressed, there should be continuity. When parking brake pedal is released, there should not be continuity.

Check

Press parking brake pedal with 66 lbs. (294 N) of force. Parking brake pedal should 4-6 clicks. Check rear brake shoe self-adjuster, and make sure brake shoes are properly adjusted.

THROTTLE CABLE

Check cable free play at the throttle linkage. Cable free play should be .4-.5" (10-12 mm). If free play is not within specification, loosen lock nut and adjust nut until the free play is as specified, then retighten the locknut. With the cable properly adjusted, check the throttle valve to be sure it opens fully when accelerator pedal is pushed to the floor. Also check the throttle valve to be sure it returns to the idle position whenever accelerator pedal is fully released.

BRAKE HOSE AND LINE

Note. Replace the brake hose clip whenever the brake hose is serviced. Always use NEW sealing washers on banjo bolts.

Inspect the brake hoses, for damage, deterioration, leaks, interference, and twisting. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines. Check for leaks at hose and line joints or connections, and retighten if necessary. Check the master cylinder and ABS modulator unit (if equipped), for damage and leakage.

Runout

Raise and support vehicle. Remove front wheels. Remove brake pads. See FRONT DISC BRAKE PADS under REMOVAL & INSTALLATION. Inspect disc surface for damage and cracks. Clean disc thoroughly, and remove all rust. Use wheel nuts and suitable flat washers to hold disc securely against hub, then mount a dial indicator to brake and measure runout at .4" (10 mm) from outer edge of disc.

1. Brake Disc Runout Service Limit - .004" (.10 mm)

If disc is beyond service limit, refinish brake disc with an on-car brake lathe. See DISC BRAKE SPECIFICATIONS .

Note. A new disc should be refinished if its runout is greater than service limit.

Thickness & Parallelism

Raise and support vehicle. Remove wheels. Remove brake pads. See FRONT DISC BRAKE PADS under REMOVAL & INSTALLATION. Using a micrometer, measure disc thickness at 8 points approximately 45 degrees apart and .4" (10 mm) in from outer edge of disc. Replace brake disc if smallest measurement is less than the MAX. refinishing limit. See DISC BRAKE SPECIFICATIONS .

Note. This is the maximum allowable difference between the thickness measurements.

If the disc is beyond the service limit for parallelism, refinish brake disc with an on-car brake lathe. See DISC BRAKE SPECIFICATIONS . If it is beyond service limit for refinishing, replace the brake disc. See BRAKE DISC (FRONT & REAR) under REMOVAL & INSTALLATION.

Disconnect parking brake switch connector from switch. Check for continuity between positive terminal and body ground. With pedal pressed there should be continuity. With pedal released, there should be no continuity. If both ABS or TCS indicator and brake system indicator come on at the same time, diagnose anti-lock/traction control system. See appropriate ANTI-LOCK/TRACTION CONTROL article.

Raise and support vehicle. Remove wheels. Remove brake pads. See REAR DISC BRAKE PADS under REMOVAL & INSTALLATION. Inspect disc surface for damage and cracks. Clean disc thoroughly, and remove all rust. Use wheel nuts and suitable flat washers to hold disc securely against hub, then mount a dial indicator to brake and measure runout at .4" (10 mm) from outer edge of disc.

1. Brake Disc Runout Service Limit - .004" (.10 mm)

If disc is beyond service limit, refinish brake disc. See DISC BRAKE SPECIFICATIONS .

Note. A new disc should be refinished if its runout is greater than .004" (.10 mm)

Raise, support, and remove wheels. Remove brake pads. See REAR DISC BRAKE PADS under REMOVAL & INSTALLATION. Using a micrometer, measure disc thickness at 8 points approximately 45° apart and .4" (10 mm) in from outer edge of disc. Replace brake disc if smallest measurement is less than the MAX. Refinishing limit. See DISC BRAKE SPECIFICATIONS .

Note. This is the maximum allowable difference between thickness measurements.

If the disc is beyond the service limit for parallelism, refinish brake disc.

1. Brake Disc Parallelism Standard - .0006" (.015 mm)

If it is beyond service limit for refinishing, replace. See BRAKE DISC (FRONT & REAR) under REMOVAL & INSTALLATION.

PARKING BRAKE SHOE LINING BREAK-IN

Park vehicle on firm, level surface. Perform major parking brake adjustment, then minor parking brake adjustment. See PARKING BRAKE under ADJUSTMENTS. Push parking brake pedal 2-4 clicks. Drive vehicle at no more than 31 mph (50 km/h) for 1/4 mile (400 m). Stop vehicle, and release parking brake lever for 5-10 minutes to allow drums to cool. Repeat driving procedure 3 more times. Perform major parking brake adjustment again.