rev light HONDA CIVIC 1996 6.G User Guide

25. Install the 32 mm sealing bolt
NOTE: Apply liquid gasket (P/N 08718 - 0001 or
08718 - 0003) to the threads.
26. Tighten the reverse idler gear shaft bolt'
REVERSE IDLER G€AR
SHAFT BOLT10 x 1.25 mm5a N.rn t5.5 kgl m, {0 lbtftl
32 mm SEALING BOLT
25 N.m {2.5 kgl'm,
lnstall the steel balls, the springs, and the set
screws.
Install the back-up light switch and the transmission
hanger B.
BACK.UP LIGHT SWITCH
25 N.m 12.5 kgt m, 18 lblttl
TRANSMISSIONHANGER B
8x2117
1.25 mmN.m (2.4 kgf m,lbf.ftt
II
I
I
EALL
\\
\
\
SET SCREW'12 x 1.0 mm
22 N.m (2.2 kgf'm,16 tbt.trl
13-95

Troubleshooting Flowchart - PH-PL Control Linear Solenoid
NOTE: Record all freeze data before you troubleshoot.
Possibls c.use
. Oisconn6dod solenoid harness
conn6ctol. Short or ooen in PH-PL controllinear solenoid wire. F.ulty PH-PL cont.ol linear sole-noid. ODen in VB SOL wire. Op€n in PGl and PG2 wires orpoor ground lG101l
PCM CONNECTORS
Wire side of female terminals
LGT IBRN/BLKILG2 IBRN/BLK)
(cont'd)
B (25P1 D {16P}
. OBD ll Scan Tool indicates
Codo P1873.. sslt-disgnosis E indicltor lightindicates Code 31.
Mo.surevB SOL Vohagg:1. Turn the ignition switch OFF.
2. Disconnect the 8 (25P) and D(16P) connectors from the
PCM,3. Turn tho ignition switch ON (ll),
4. Measure the voltage between
the D5 and 820 or 822 termi-nals,
Ropair open or shod in the wiJe
bstwaon tho D5 terminal and the
under-dalh tuso/relay box.
Check the Ground Circuh:1. Turn the ignition switch OFF2. Check tor continuity betweenthe terminals 82 and 822 andbetween terminals 810 and820.
Fepair open in tho wiro b€tw€entho torminds 82, 810, 820, and
822 and G101. Repair Poorground (G1011.
(BRN/BLX)
Fo page 14-274
PCM CONNECTOR B (25P|
14-273

Pressure Testing
. While testing, be careful of the rot8ling front wheels.
. M8k6 suro lifts, iacks, and satety stands are placed properly lsee section 11.
CAUTION:
. Before testing, be sur. the transmb3ion fluid is fillod to the propor lcvel.. Warm up the engin€ to nolmal operating tsmperature bofore testing. While t€sting, be 3ure not to allow dust and other loreign particles to onler into the transmi$ion.
1. Raise the front of the vehicle, and support it with safety stands (see section 1).
2. Set the parking brake. and block both rear wheels securely.
3. Allow the front wheels to rotate freely.
4. Warm up the engine (the radiator fan comes on), then stop arid connect a tachometer.
5. Connect the special tool to each inspection hole.
TOROUE: 18 N.m (1.8 kgt'm, 13 tbtfr)
GAUTION:
. Connect the oil pressuro gauge !!€curoly, bs sur6 not to allow dust and other foroign particlG3 to ontar the inspsc-tion hole.
. Whon troubleshooting by tho E indicltor light indic.t6 a problam. you mu3t u3e an oil p.essure gluge that moa,sures 4,9(X) kPa (a.90 MPa,50.0 kS cr*,771psi) or more when molsuring driv. pulley pressure and driven pullcypre33ure.
NOTE:
. D.ive pulley pressure may be above 3,430 kPa (3.i8 MPa,35.0 kgf/cmr, 498 psi) wh€n there is a transmission prob-
lem that causes the TCM or PCM to go into the fail-safe mode,. Use a commercially available oil pressure gauge that measures 4,900 kPa {4.90 MPa, 5O.O kgf/cmr, 711 psi) ormore, and the Ay'T Oil Pressure Hose, 2210 mm (07MAJ - PY4011A).
FORWARD CLUTCH PRESSUREINSPECTION
lMarked with "F")
REVERSE BRAKE PRESSUREINSPECTION I.IOLE
A/T OIL PRESSUREGAUGESET W/PANEL0ta{r6 - oO2Oi|(Xt
A/T LOW PRESSUREGAUGE W/PANEL0706 - qt7o:t{ro
DRIVE PULLEY PRESSUREINSPECTION HOI.E(Marked with "DR")
A/T PRESSURE HOSEADAPTER07MAJ - PYar'120lil R.qulr.d)
A/T PRESSUBE HOSE2210 mm07MAJ - PYitollAla R.quir.d)
(
INSPECNON HOLE(Marked with "SC")
CLUICH PRESSURE
INSPECTION HOLE(Marked with "LUB")
DRIVEN PULLEY PRESSUREINSPECTION HOLElMarked with "DN")
14-300
ATF DIPSTICK

Driveshafts
Reassembly (cont'dl
8. Fit the inboard joint onto the driveshaft, and note
these items:
. Reinstall the inboard joint onto the driveshaft by
aligning the marks on the inboard joint with the
marks on the rollers.
. Hold the driveshaft so that the inboard joint
points up to prevent it from falling off.
Adjust the length of the driveshafts to the figure
below, then adjust the boots to halfway between
full comDression and full extension. The ends of the
boots seat in the groove of the driveshaft and joint.
Right driveshaft, 1600 OOHC VTEC model:475 - 480 mm (18.7 - 18.9 in)Left driveshaft, all othei models:774-779 mm (30.5 - 30.7 in)Right driveshaft, all other models:501 - 506 mm 119.7 -'19.9 inl
Left driveshaft. 1600 DOHC WEC model:475 - 480 mm 118.7 - 18,9 inl
16-12
OYNAMIC DAMPEROUTBOARD JOINT
10. lf necessary position the dynamic damper as shown
Detow.
. Install a new dynamic damper band. and bend
down both sets of locking tabs.
. Lightly tap on the doubled-over ponjon of the
band to reduce its height.
Loft:
1600 DOHC VTEC model: 26 i 2 mm (1.0 t 0.1 inl
All other models: 9,1t 2 mm (3.7 10.1 inl
With "SR1" mark: 7512 mm 12.9 ! 0.1 inl
Right:
16dl DOHC VTEC models: 2612 mm 11.0 t 0.1 inl
All other modelii
DYNAMIC DAMPER
-SR1" MARK
U.S. and Canada-Produced ITPE BOOTI
Left 53612 mm {21.1 10.1 in}
Right: 2txt 12 mm {10.it 1 0.1 in}
5512 mm (2.2 t 0.1 inl
INBOARO JOINT
DYNAMIC DAMPER BAND

It
12.
13.
lnstall the new lock washer in the groove in the
steering rack.
Installthe steering rack end into the rack
LOCK WASHER RACK END 54 N m ts.s kgf'm, 40 lbtft)
Replace.
TAB
(l*v
14.
15.
RACK END
Hold the steering rack with a wrench and tighten
the rack end with another.
CAUTION: Be careful not to damage the tack sur-
fac€ with the wrench.
After tightening the rack ends, stake the four sec-
tions of the lock washer with a roll pin drift and a
mallet.
. Place the wood block on the press table. then set
the lock washer section of the rack end on the
wood block securelY.
. Be sure the tool is aligned with the flat sections
of the steering rack end before pressing
. Stake the lock washer in the center of the flat
section of the steering rack end.
ROLL PIN DnlFTl(Commorci.lly .Yril.blolSnap-On No. PPRS or oquival.nt
NOTE: This drift has a flat
tip, to prevent puncturing
of metal washer.
srEEatruG nlCr/rl,WOODEN BLOCK
TIE.ROO CLIP
16. Apply grease around the outside ot the rack end
housing.
Apply a light coat of silicone grease to the boot
grooves on the rack ends.
lnstall the boots in the rack end with the tie-rod
clips.
NOTE: Install the boot band with the rack in the
straight ahead position (right and left tie-rods are
equal in length).
=-..r=-q!q!!.n
SILICONE GREASE
17.
(cont'd)
17-11
NOTE| WiPe grease off
the thread sectlon

Steering Wheel
l,/
Removal
SRS components are located in this area Review the
SRS component locations, precautions, and procedures
in the SRS section (24) before performing repairs or ser-
vice.
NOTE: Before removing the steering wheel. align the
front wheels straight ahead.
1. Remove the driver's airbag assembly from the
steering wheel (see section 24)
2. Disconnect the horn connector and cruise control
switches connector.
CRUISESWITCHES CONNECTOR
3. Remove the steering wheel nut
STEERING WHEEL NUT
Replace.
Remove the steering wheel by rocking it slightly from
side-to-side as you pull steadily with both hands.
ag N.m {5.0 kgt rn, 36lbfft)
1.,
17-35
lnstallation
CAUTION: Do not tap on the steering wheel or steering
column shaft when installing the stsering wheel.
NOTE: Before installing the steering wheel, align the
front wheels straight ahead.
1. Before installing the steering wheel, center the
cable reel, Do this by first rotating the cable reel
clockwise until it stops. Then rotate it counterclock-
wise approximately two turns The arrow mark on
the cable reel label should points straight up.
Install the steering wheel with the steering wheel
nut.
NOTE: Be sure the steering wheel shaft engages
the cable reel and canceling sleeve.
Attach the cruise control switches connector io the
steering wheel cliP,
Connect the horn connector.
Install the driver's airbag assembly, and confirm
proper system operation (see section 24).
Check the horn and cruise control switches for
proper operatrons.
CAELE REEL

)
1.Loosen the wheel nuts slightlY.
Raise the front of the vehicle, and support it with safe-
ty stands in the proper locations (see section 1).
Remove the wheel nuts and wheel.3.
l)
WHEEL NUT'108 N.m
18'l N.m 118.5 kgf m, 134lblfti
Replace.NOTEI Before installing the spandle nut, apply
engine oil to the seating surface of the nut After
tightening, use a drift to stake the spindle nut
shoulder againsl the driveshaft
Raise the locking tab on the spindle nut, then remove
the nut.
Remove the brake hose mounting bolts.
BRAKE HOSE MOUNTING BOLT
I x 1.25 mm12 N.m (1,2 kgtm,8,7 lbf'ftl
6. Remove the caliper mounting bolts and hang the
caliper assembiy to one side
CAUTTON: To prevent accidental damage to the
caliper assembly or brake hoso' use a short piece of
wire to hang the caliPer tlom lhe undelcarriage.
{11 kgf m, 80 lbl.ft)
CALIPER MOUNTING BOLTS12 x 1.25 mm108 N.m {'11.0 kgtm, 80 lbt.ft)
7. Remove the 6 mm brake disc retaining screws.
8.
I x 1.25 mm BOLTS
Screw two 8 x 1.25 mm bolts into the disc to push it
away from the hub,
NOTE: Turn each bolt two turns at a tame to prevent
cocking the disc excessivelY.
Remove the brake disc from the knuckle.
Check the front hub for damage and cracks.
Remove the wheel sensor from the knuckle (for
vehicles with ABS).
NOTE: Do not disconnect the wheel sensor connec-
tor.
N.m
6 mm BRAKE OISCRETAINING SCREWS9.8 N.m t1.0 kgf.m, 7 lbf'ft)
{'1.0 kgf m,
7 tbf.ft)
10.
11.
MOUNTING
WHEEL
BOLTS9.8 N.m11.0 kgf,m, 7 lbf'ft)(cont'd)

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.

\il
Modulator Unit
RemovaUlnstallation
CAUTION:
. Do not spill brake tluid on the car; it may damage the paint; it brako lluid does contact the paint, wash it off immedi-
ately with wator.
a Take care not to damage or delorm the brake lin€s during removal and installation.
. To prevent the brake tluid from tlowing, plug and cover the hose €nds and ioints with a shop tow6l or equivalent
mat€rial.
NOTE| Tightentheflare nutsto 15 N.m (1.5 kgnm. l1 lbf.ft).
Removal
'1. Disconnect the modulator unit 10P and Dump motor 2P connectors.
2. Disconnect the brake lines, then remove the modulator unit.
Installaiion
1. Install the modulator unit. then connect the brake lines.
2. Connect the modulator unit 10P and oumD motor 2P connectors.
3. Bleed the brake system.
4. Start the engine, and check that the ABS indicator light goes off.
Fomright-1461
PUMP MOTOR2P CONNECTOR
J
-R
/2e'
t'
TOR UNIT
tt
19-75