hose HONDA CIVIC 1996 6.G Workshop Manual

Master Cylinder/Brake Booster
IRemovaUlnstallation
CAUTION:
. Be care{ul nol to bend or damage the brake lines when
rsmoving the mastsr cYlinder.
. Do not soill brakefluid on the vehicle; it may damage
the paint; if brake fluid does contact the paint, wssh
it off immediatelY with water'
. To prevent spill3, cover the hose ioints with rags or
shop towels.
9. Remove the four booster mountlng nuts
10. Pull the brake booster forward until the clevis is
clear of the bulkhead.
11. Remove the brake booster from the engine com-
panmenr.'12. Install the brake booster and master cylinder in the
reverse order of removal.
CAUTION:
. When connecting the brake lines. make sure
that there is no inte erence between the brake
lines and oth6r Parts.
r Be careful not to bend or damage the brake lines
when installing the master cylinder.
NOTE: lf replacing the master cylinder or brake
booster, check and adiust the pushrod clearance
be{ore installing the master cylinder (see page 19-221'
Fill the master cylinder reservoir, and bleed the
brake svstem (see Page 19-7).
After installation. check the brake pedal height and
brake pedal tree play (see page l9-5) and adjust if
necessary.
BRAKE BOOSTER(With ABS: 7" + 8" tandem brake booster)
BRAKE FLUIO LEVELSWITCH CONNECTORS
MASTER CYLINDER
VACUUM HOSE
1.
2.
3,
5.
Disconnect the brake fluid level switch connectors'
Remove the reservoir cap from the master cylinder'
The brake fluid may be sucked out through the top
of the master cylinder reservoir with a syrlnge.
Disconnect the brake lines from the master cylinder'
Remove the master cylinder mounting nuts and
washers.
\l/
6. Remove the master cylinder from the brake booster'
7. Disconnect the vacuum hose trom the brake booster'
8. Remove the cotter pin and clevis pin from the clevis'
CAUTION: Do not disconnect the clevb by remov-
ing it from the operating rod of the brako booster' lf
the clevis is loosened, adiust the pushrod length
before installing th€ brake booster (see page 19-221'
COTTER PINReplace.
To Rear Wheel Cylinders
14.
-6.4CLEVIS PIN
To Front Caliper(Without ABS)$
t'N't'ttrnt'-''
To Front CaliperlWithout ABSi
PBOPORTIONING CONTROL VALVE
15 N.m {1.5 kgl m,11 tbtft)
15 N.m {1.5 kgif.m, 11 lbtft}(With ABS: To modulator unit)lr
19-21

Brake Booster InsPection
FunctionalTest
1. With the engine stopped, depress the brake pedal
several times to deplete the vacuum reservoir, then
depress 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 control
valve, or caliPer) is ieaking.
2. Start the engine with the pedal depressed lf the
pedal sinks slightly, the vacuum booster is operating
normally. lf the pedal height does not vary, the
booster or check valve is faultY.
3. With the engine running. depress the brake pedal
lightly. Apply just enough pressure to hold back
automatic transmission creep. lf the brake pedal
sinks more than 25 mm (1.0 in.) in three minutes,
the master cvlinder is faulty. A slight change in
pedal height when the A'lC compressor cycles on
and off if normal. (The A/C compressor load
changes the vacuum available to the booster')
Leak Test
1. Depress the brake pedal with the engine running.
then stop the engine. lf the pedal height does not
vary while depressed for 30 seconds, the vacuum
booster is OK. lf the pedal rises. the booster is
faulty.
2, With the engine stopped, depress the brake pedal
several times using normal pressure When the
Dedal is first depressed, it should be low On con-
secutive applications, the pedal height should grad-
uallv rise. lf the pedal position does not vary, checK
the booster check valve.
l./
19-23
Booster Check Valve Test
1. Disconnect the brake booster vacuum hose at the
booster.
2. Stan 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.
BRAKE BOOSTERVACUUM HOSE(Check valve
built-in)

Rear Brake Pads
Inspection and Replacement
Never use an air hose or dry brush to clean brakeassemblies.
Use an OsHA-apptoved vacuum cl€aner to avoidbreathing brake dust,
Block the front wheels, loosen the rear wneet nutsslightly, support the rear of the vehicle on safetystands, then remove the rear wheels.
Release the parking brake, and remove the calioersh ield.
CALIPER SHIELD
Remove the brake hose clamp bolt from the trailingarm first, then remove the two caliper mountingbolts and the caliper from the bracket.
CAUTION:
. Thoroughly clean the outside of the caliDer toprevent dust and dirt trom entering inside.. Support the calipor with a pieco of wire so thatit does not hang fuom the brake hose.
NOTEr Check the hoses and pin boots for damageor deterioration.
PARKING BRAKE CABLE ^.. ._-_ ---.
'L
19-24
4. Remove the outer pad shim, pads, and pad retainers.
PAO RETAINERS
OUTER PAOSHIMCheck for
REAR BRAKE PADSCheck for wear.
Using vernier calipers, measure the thickness ofeach brake pad lining. The measurement does notanclude the pad backing plate thickness.
Brake Pad Thickness:
Standard: 7.0 - 8.0 mm {0.28 - 0.31 in}Service Limit: 1.5 mm {0.06 in}
lf the pad thickness is less than the service limit,replace the pads and shims together as a set.
BACKING PI-ATE

I
7.
11.
Clean the caliper thoroughly; remove any rust, and
check for grooves and cracks.
Check the brake disc for damage and cracks.
lvlake sure that the pad retainers are installed in
their correct positions.
PAD RETAINERS
Apply grease to the points indicated by the arrow in
the following drawing:
NOTE: Use the pad grease included in the pad set
or lMolykote M77 grease, and apply a thin coat of
grease evenly to the designated points.
. Piston end and inner pad contact surface
. Pad and caliper bracket contact surface
. Outer pad shim and outer pad contact surface
. Outer pad shim and caliper body contact surface
lnstall the brake pads and outer pad shim on the
caliper bracket. Install the inner pad with its wear
indicator facing downward.
@iwhen reusing the pads, always reinstall the
brake pads in iheil original posiiions lo prevont
loss ol braking efficiency
. Contaminaled brake discs or pads reduce stop-
ping ability. Keep grease off the discs and pads.
t./
19-25
12. Rotate the caliper piston clockwise into the cylinder'
then align the cutout in the piston with the tab on
the inner pad by turning the piston back
CAUTION: Lubricate ths boot with rubber grease
to avoid twisting the piston boot. lf the piston boot
is twisted, back it out so it sits properly.
CALIP€R MOUNTINGBOLTS23 N,m {2.3 kg{.m, 17 lbt'ft)
13.
14.
15.
CUTOUT
BRAKE CALIPER
Install the brake hose clamp on the trailing arm.
Install and tighten the caliper mounting bolts.
Install the caliper shield.
After installation. check for leaks at hose and line
joints and connections, and retighten if necessary.
Depress the brake pedal several times to make sure
the brakes work, then test-drive
NOTE: Engagement of the brake may requrre greater
pedal travel immediately after the brake pads have
been replaced as a set. Several light applications of
the brake pedal will restore the normal pedal travel.
Greater than normal pedal travel may damage the
master cylinder.
16.
17.

Rear Brake Caliper
Disassembly
@f l',lever use an air hose or dry brush to clean
assemblies.
. Use an OsHA-approved vacuum cleaner to
brake
avoid
breathing brake dust.
. Contaminated brake discs or pads reduce stopping
ability.
CAUTION:
. Do not spill brake tluid on the cal; h may damage the
paint; if brake fluid does contact the paint, wash ii
ofl immediatelY with water.
. To prevent spills, cover the hose ioints whh rags or
shop tow€ls.
. Clean all parts in brake fluid and air dry; blow out all
passagss with complessed air.
1. Remove the caliper shield (see page 19-24).
2. Remove the lock pin and clevis pin. Remove the
cable clip, and disconnect the cable from the arm
CABLE CLIP
Remove the banjo bolt and two sealing washers
Remove the two caliper mounting bolts and caliper
body from the bracket.
CALIPER MOUNTNG AOLTS
CALIPER BRACKETCheck for cracksSEALINGWASHERSReplace.BANJOBOLT
5, Remove the pins and pin boots from the caliper
bracket.
6. Remove the pad spring from the caliper body
PIN A
(cont'd)
19-27

Rear Brake Caliper
Reassembly (cont'dl
'16. Installthe pad spring onto the caliper.
Apply the recommended pin groase in the caliper
seal set to the sliding surface of the pins and inside
of the new pin boots.
Install the pin boots into the grooves in the caliper
bracket properly.
PIN BOOTSReplsce.
(Bl.ck Colorl
PINRepl6ce.
19. Insert pin A and pin B into the caliper bracket.
20. Install the pin boots into the grooves in thepropefly.
PAD SPRING
11.
PIN GREASE
19-34
pr ns
22.
21. Install the brake pad retainers and brake pads (see
page 19-25).
Align the cutout in the piston with the tab on the
inner pad (see page 19-25).
Install the caliper onto the caliper bracket. and tight-
en the caliper mounting bolts.
CALIPER MOUNTING BOLTS23 N.m {2.3 kg{.m. 17 lbf.ft)
WASHERSReplace.
BANJO BOLT34 N.m13.5 kg{.m.25 rbtft)
24.Connect the brake hose to the caliper with new seal,
ing washers, and tighten the banjo bolt,
Insert ths cable through the arm, and connect the
cabls to the lever with the clevis pin and lock pin.
Install the cable clip securely.
CLEVIS PIN
-t
//t
LOCK PINRoplace.
26. Install the caliDer shield.
27. Fill the brake reservoir, and bleed the brake svstem(see page 19-71.
28. Operate the brake pedal several times, then adjust
the parking brake (see page 19-6).
29. After installation, perform the following checks:. Check for leaks at hose and line joints and con-nections, and retighten if necessary.. Check the parking brake lever for operation, and
adjust it if necessary.
. Check for brake hose for interference or twistinq.

Rear Drum Brake
Index/lnspection
'1.
a
a
Never use an air hose or dly brush to clean brake assemblies,
Use an OSHA approved vacuum cleanar to avoid breathing brake dust,
Contaminated brake linings or drums reduce stopping ability.
Block the tront wheels before iacking up ths r€ar of lhe vehicle.
Block the front wheels, loosen the rear wheel nuts slightly, support the rear of the vehicle on safety stands, then
remove the rear wheels.
2. Release the parking brake, and remove the rear brake drum.
I N m 10.9 kgtm, 6.5 lbf.ftl
TENSION PIN
10 mm BOLT6,1N m 15.5 kgf m,47 tbf.ft)
WHEEL CYLINDERInspect for leakage.lf necessary, replace as an assembly.
u-cLrPReplace.
WAVEWASHER
PARKING BRAKE LEVERMarked left and right.
Check for weaknessano oamage,
UPPER RETURN SPRING
I
@JPIVOT PIN
BACKING PLATEMarked lelt and right-
/
€f-l.^
I I
*'t")
ctEv'sB
/ (t
/ ,.ro,".r r.*,"n
/ , Install securely on
| / tension pin.
d"/
IU
ADJUSTER BOI-TCheck ratchet teethfor wear and damage.LOWER RETURNSPRINGCheck for weaknessand oamage.BRAKE SHOEInspection, see page 19-36lf brake shoes are to bereused, mark and reassemblein same position.
SELF.ADJUSTERLEVEB
SELF-ADJUSTERSPRINGCheck for weaknessano oamage.
BRAKE DRUMInspection, see page '19 36
t
19-35

Brake Hoses/Lines
LJ
Inspection/Torque Specifications
t. Inspect the brake hoses for damage, deterioration, leaks, interference, and twisting.
2. Check the brake lines for damage, rusting. and leakage. Also check for bent brake lines.
3. Check for ieaks at hose and line ioints and connections, and retighten if necessary'
4. Check the master cylinder and ABS modulator unit for damage and leakage
CAUTION: Replace tho brake hose clip whenev€r the brake hose is serviced.
ABS MODULATOR UNIT-Io-BRAKE l-lNE19 N.m (1.9 kgf.m, 14lbl.ftl
PROPOBTIONING CONTROL VALVE.io-BRAKE LINEl5 N.m (1.511 tbf.ftl
MASTER CYLINDER-Io-BMKE LINE
15 N.m (1.5 ksrf.m, 11 lbf'ft)
REAR DISG BRAKE:BRAKE HOSE-to4ALlPER
{BANJO BOLT}34 N.m (3.5 kgtm,25 lbf ftlBLEEO SCREW9 N'm (0.9 kgf.m, 6.5 lM.ftlBRAKE LINE-to-WHEEL CYLINDER15 N.m (1.5 kgl.m, 11 lbf.ftlBLEED SCREW7 N.m {0.7 kst m, 5 lbf,ttl
JBRAKE LINE-io-aRAKE HOSE15 N.m {1.511 tbtft)
BRAKE LINE-Io-BRAKE HOSE15 N.m (1.5 kgt.m, 11 lbf'ft)
(BANJO BOLT}3,1 N.m 13.5 kgf.m, 25 lbf.ft)
J
19-39

Brake Hoses/Lines
Hose Replacement
CAUTION:
. Bgfore reagsembling, chgck that all parts are free of
dust and othor foroign particles.
. Repl8ce parts with new ones whenever specified to
do so,
. Do not spill brake fluid on th6 vehicle; it may damage
tho paint; if brake fluid does contact the paint, wash
it off immediately with water.
1.Replace the brake hose if the hose is twisted, cracked,
or if it leaks.
Disconnect the brake hose from the brake line using
a 10 mm flare nut wrench.
FLARE NUTWRENCHlCommerciallyava ilable)
BRAKE LINE
BRAKE HOSE
Remove and discard the brake hose cliD from the
brake hose.
Remove the banjo bolt, and disconnect the brake
hose from the caliper.
Remove the brake hose bracket from the knuckle.
19-40
10.
6. Install the brake hose bracket and brake hose onto
the knuckle first. then connect the brake hose to the
caliper with the banjo bolt and new sealing washers.
BRAKE HOSE
6 mm HOSE BRACKETBOLTS9.8 N.m{1.0 kgf m, 7 lbtfr}
BANJO BOI.T34 N.m{3.5 kgf.m,25 lbt.ftl
7. Install the brake hose onto the uooer brake hose
bracket with a new brake hose clip
15 N.m(1.s ks{.m, 11 lbl.ftl
Connect the brake line to the brake hose.
After installing the brake hose, bleed the brake sys-
tem (see page 19-7).
Perform the following checks:
. Check the brake hose and line joint for leaks, and
tighten if necessary.
. Check the brake hoses for interference and twist-
I ng.
8.

Le
\.t
CONDITION FOR DETECTION
MANAGEI\,4ENT
FEFERTOPAGEDUNINGABS CONTFOLEXCEPTABS CONTAOL
19-60
19-62
The ABS indicator lighl cones on when vehicle is stopp€d and wheel sensor a given vohaqe does nol
19 64
The ABS indicaror comes on under th€lollowing conditions.When morethan one otwheels are a standstiland thelelocirv otthe fastest wheel reaches a
' fohen th. velocity of the faslesl wheel reaches or exceds a given sped, and it there ar€ somewh@lswhose velocity is slowe.lhan a cenain percenlage oi lh€ fast6t wheelsped for 3 given period. when rhere are lemporary open or short ctcuits ol rhe wheel sonsor' chipp€d pulser gear, orsrgnalorslJrbaaLe
19 64
The main relay repeats ON/OFF switching atalltimes.WhenthemainrelayisON,ashortt$tpulseissentloeachvalve lfthere s some dis'repa ncv, lheABS indicalor lightcomes on.. When rhe main relay is OFF, a shonl€sl pulse is s€nlto each valve lfth6 solenoid drive voltage rsout ol a qiven range, the ABS ndicalor lighl comes on19-66
'The pump nolot s activaled orc€ o' Mrce sfier every gn't'on sw'lch ON (ll) operarion whrle lte -^vchicle acLelerales lrenthemolorotivevo'taSersrhecled When lhevolla96 rs abnormar,lre Absindicaror llghl comes on.. Afte. ABS ;onl rol com pletion, the moror isswitched ofi 6nd the main CPU checks the molor dnvevoltase. when rhe vortase is abnormsl, the ABS indicato49!!!99!:l!:_-
19-68
D!rino an active motor lesl or AAS control,lhe main CPU checks ihe supplv voltage to the motor'whe;lhe vohage s abnofmal, the ABS indicator lightcomes on19,68
lirhe moror drvevoltage indicates molot operalion when the main cPU does notswilch the motoroN, rhe ABs indicaro. comes on19-64
. Wh"" " ".1"".1d ""1r. f"llure is detecred, the CPU checksth€ voltage ofthe main rel6v output lllhevohaqe is lowerthan 6 given vohage, theABS indicator light comes on. The ;ain r€lay repeats ON/OFF switching ar a!ltimss when the main rel.v is ofi, a shorl l6st pulse
is sent ro €ach valve. The CPU mon tors the reJer€nce vohage ll the vohage is out ot a g iven range'
the ABS indic.tor lightcomes on
19 71
wt'",, rt'e lgnitlon rottag" is ower or higherthan a given voltage,lhe CPU inhibils ABSlonlrolandswirches oli the ma in relaY, 6nd the ABS indicaror lig ht com€s on When the ig n ilion vohage recove'sto normal f6ng6, ABS inhibition is canceled.19.73
rimln CpU anO suU CeU ch€ck each other undercertain condnions. Whon rhe CPUS dstectthe fol'lowing discrepanaies, rhe ABS indicator light comss on. whe; rh€re is discGpancv n lhacarculated wheelspeed velocirv thar continuosJor more than a given
.i^/hen rhere is discrcoancv in the ehase informalion lhat continuesfor morerhan a given period' When rhere is discrepancY in thecalculared conlfol pa.amerer'. When thewatch dog conrrolp!lsetailslof a given penod. When th6 checkotth€ ROM tai1s.. when there is disrepancy inrhe data roading.nd wriung prcledurc ot RAM
19 7'l
tr
19-59