Connector a HONDA CIVIC 1996 6.G Workshop Manual

)
Brake Pedal
Pedal Height
1. Disconnect the brake switch connector, loosen the
brake switch locknut, and back off the brake switch
until it is no longer touching the brake pedal,
2. At the carpet cutout, measure the pedal height from
the right side center of the pedal pad.
PUSHRODLOCKNUT
Standard Pedal Height (with carpet removed):
M/T: 156.5 mm 16.16 inl
A/T, CVT: 161 mm (5 5/16 in)
3. Loosen the pushrod locknut, and screw the pushrod
in or out with pliers until the standard pedal height
from the floor is reached. After adjustment, tighten
the locknut firmly.
NOTE: Do not adiust the pedal height with the
Dushrod depressed.
It
PUSHROO LOCKNUT15 N.m(1.5 kgf.m. 11 lbI.ft)
POINT ICUTOUTI
4. Screw in the brake switch until its plunger is fully
depressed (threaded end touching the pad on the
pedal arm). Then back off the switch 1/4 turn to
make 0.3 mm (0.01 in) of clearance between the
threaded end and pad. Tighten the locknut firmly.
Connect the brake switch connector.
CAUTION: Make sure that the brake lights go off
when the pedal is released.
LOCKNUT
5. Check the brake pedal free play as described below.
Pedal Free Plsy
1. With the engine off, inspect the play on the pedal
pad by pushing the pedal by hand.
Free Play: 1 - 5 mm (1/16 - 3/16 inl
2. lf the pedal free play is out of specitication, adjust
the brake switch.
CAUTION: lf the pedal free play is insufficient, it
may result in brake drag.
BRAKE PEDAL PAO
)
19-5
*0.3 mm(0.01 in)

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

Special Tools
Ret. No. I Tool Number I Description I O,V I page Reference
(!) I 07PM- 0010100 I SCS Service Connector t I 19_s6
19-44

Component Locations
ta
SERVICE CHECK CONNECTOR {2PIBIGHT.REAR WHEELSENSOR CONNECTORMOOULATOR UNITABS CONTROL UNIT
RIGHT-REAR WHEEL SENSOR
LEFT.R€AR WHEELSENSOR CONNECTOR
J
UNDER.DASH FUSE/RELAY 8OX
LEFT.FRONT WHEEL SENSOR
ABS +B (20 A) FUSE
UNDER.HOOD FUSE/RELAY BOX
lcl lilo Al FUSE
ABS INDICATOR LIGHT
UNOEF.DASI{ FUSE/RELAY BOX
HORN/STOP I15 A) FUSE
UNDER.HOOO ABS FUSE/RELAY BOX
PUMP MOTOR {'O A} FUSE
PUMP MOTOR BELAY
E
o
METEB I7.5 AI FUSE
0
0
0
00000 n
00000 u
BR DEF RLY 17,5 A) FUSE
t
MTR CHECK (7.5 AI FUSE
19-45

t-Operation
t
ABS Control Unit
Main Control
The ABS control unit detects the wheel speed based on the wheel sensor signal it received, then it calculates the vehicle
speed based on the detected wheel speed. The control unit detects the vehicle speed during deceleration based on the
rate of deceleration.
The ABS control unit calculates the slip rate of each wheel. and it transmits the control signal to the modulator unit
solenoid valve when the slip rate is high.
The pressure reduction control is a three-mode system, that is pressure reduction, pressure retaining and pressure intensi-
fying modes.
Self -diagnosis Funqtion
The ABS control unit is equipped with a main CPU and a sub CPU, and the CPUS check each other'
The CPUs check the circuit of the svstem.
When the CPUS detect failure, they shift to the "system down mode" or the "control inhibition mode"
The self-diagnosis can be classifield into these four categories:
O: Initial diagnosis
@: Except ABS control
@: During ABS control
@: During warning
On-board Diagnosis Funstion
The ABS control unit is connected to the data link connector {16P).
The ABS system can be diagnosed with the Honda PGM Tester.
(cont'd)
MODEABS INDICATOR LIGHTMAIN
RELAY
SOLENOID
VALVECPURestart conditionDTC
SYSTE IV
DOWNONNo
operation
Drive
inhibitionOperation*rlgnition
switchOFF + ONMemory
CONTROL
INHIBITIONONNo
operalron
Drive
inhibitionOperationAutomaticMemory
*1: Except CPU failure
/
19-47

Gircuit Diagram
MOOULATOR UNIT IOP CONNECTOR
zrJrF!_lll 2 3ll
14TiEltl
c@4
PIMP MOTOR 2P CONNECTOR(Ll number)fFlGTN
UNDER.HOOO A8S FUSE,/FELAY BOX3P CONNECTOR (O number)
| 2 3l
UNDER.HOOD AAS FUSE/RELAY BOX2P CONNECTOR (! number)
| -l
GAUGE ASSEMELY 5P CONNECTOR
---t--t1 t/ 13 )/l5l
Wire side ot temale terminals
- E8l{'Ytr
AA DEF BLY I7.5AI
_@f_u,
n4@f-n,
LEFT.FSONT SOLENOIO
UNDER-OASH FUSSRELAY 8OXZoP CONNECTOR (O numbe,
235678It0tlt3/ i15 /t820
UNDER.OASH FUSE,/RELAY BOX18P CONNECTOR (E numb€r)
23569ll213)t4 /1617
19-50

tABS CONIROL UN]TECM / PCMISCS'
V
,,, +-{l-, ?,,] B6li! [,b.,,,,,-F-
SENSOR
+B
YWHTNED
8U(
J-
G,Ol, Ga02
l
\EWIK
LEFT.
RIGHT,
LEFT
;___.|-1
**1. ,I
coierou
SERVICE CHECKCONNECTOR (2P}
lrl2f
OATA LINKCONNECTOR O 6P)
WHEEL SENSOR2P CONNECTOB
FRONT
/.[Ttl\
REAR
tc-T-lI zlr[B'1213
ABS CONTROL UNIT 26P CONNECTOR1O numb€r)
12346/8Il0./ tt12r3
14 t516 1719 ,/2123
-o&"^1'
cot, croz
Terminalside ofmale terminals
ABS CONTROL UNIT 22P CONNECTOR1! numb€r)
/Wire side of female terminals
19-51

ABS Control Unit Terminal Arrangement
ABS CONTROL UNIT 26P CONNECTOR
Wire side of temale terminals
Terminalnumo0rWirecolorTerminal signTerminalnamoDgscriptionVoltage
Conditions(lgnition Switch ON flt))Output voltagoteminals
PCOM(Primary
common)
Power source for the solenoidvalve and pump motor.1-GNDON
=ONOV
AC: 3-6 V
BLK/WHTscoM(Secondary
common)
Power source for the solenoid
2.GNDOFF
lConnect the SCS service\
conneclor lApprox. 3 V
ELVBLUtG2(lgnition 2)Detects ignition switch 2
!9nal. (system activate signal)3-GNDBatt€ry voltage
BLU/YELRRO(Rear-right 0)Detects right-rear wheelsensor signal.4-17
When the wheel isturned at 1 turn/second.
53 mV or above ondigitaltester (ACra nge) {Fefera nce)150 mvp-p or aboveon oscilloscope
6GRYRLO(Rear-left 0)Detects left-rear wheel sensorsrgnal.6-19
8GRNFRO(Front-right 0)D€tects right-front wheelsgnsor srgnal,a-21StopsApprox.2.5VSTOP(Stop)hects brake switch signal.(Prevents unnecess€ry ABS operation)9-GNDBrake pedal depressed.Battery voltage
Brake pedal released.OV
10BRN^/vHTFLO(Front-left 0)
Detects left-front wheel sensorsignal.
10-23
When the wheel isturned at 1 turn/secono.
53 mV or above ondigitaltester (ACrange) (Referance)
150 mVFporaboveon oscilloscope
9!opsApprox. 2.5 V
12YELRLOUT(Rearjeft outlet)
Drives left-rear outlet solenoid
12.GNDON-9ONOV
OFFAC: 3^6 V
REDMHTRR]N(Rear-right
inlet)
Drives right-rear inlet solenoidvalve.13-GNDOFF
lconnect the SCS service]i connector IApprox. 3 V
14B1(Battery 1)Power source for the solenoidvatve and pump motor.14.GND
Battery voltage15WHT/G R N82(Baftery 2)Power source for the solenoidvarve ano pump motor.15.GND
r6BLKGND2{Ground 2)Ground for the ABS controlunit.16-GNDBelow 0.3 V
17GRN/'/ELRR1(Rear-right 1)Detects right-rear wheelsensor signal.17-4
When the wheel is turnedat 1 turn/second.
53 mV or aboveon digitaltester(AC range)(Referance) 150mVp-p or aboveon oscilloscope
19LT BLURLl(Rea.-left 1)Detects left-rear wheel sensorsagnal.19-6
GRN/BLKFRl(Front-right 1)Detects right-front wheelsensor signal.21-8
FL1(Front-left 1)Detects left-front wheel sensorsignal.23-10StopsApprox. 2.5 V
REDRL-IN(Rear-lett inletl
Drives left-r€ar inlet solenoid
25.GND
ut
ON
'6
-9ONOV
OFFAC: 3-6 V
OFF
lconnect the SCS service] connector lApprox. 3 V
BLKGND3(Ground 3)Ground for the ABS cgntrolunit.26.GNDBelow 0.3 V
19-52

e\
t
ABS CONTROL UNIT 22P CONNECTOR
Wire side of female terminals
TerminalnumbelWirocororTerminalsignDe3cription
Volt.ge
ConditionE(lgnition Switch ON (ll)lOutput voltagolTqrminal namslterminils
RED/BLUFR-IN{Front-rightinlet)
Drives right-front inletsolenoid valve.
I-GNDriJ
ON-9ONOV
OFFAC: 3-6 V
OFF
/Connect the SCS servicq
connector IApprox. 3 V
BRNscs(Service checksignal)
Detects service check signal
{Diagnostic trouble codeindication)4-GND
SCS service connectorconnected.OV
SCS service connectordisconneded.Appro)(. 5 V
7BLU/RED(Warning
ramp)
Drives ABS indicator light (The
indicator light go€s off when
ABS control unit outputs bat-
tery volta9e),
7-GND
Indicator light ONApprox, 2 V
Indicator light OFFBattery voltage
8BLU/YELNot used.
10YEUBLKFL.OUT{Front-leftoutlet)
Drives left-front outletsolenoid valve.10-GNOON
ONOV
OFFAC:3-6 V
11RED/BLKFLIN{Front-l€ft inlet)
Drives left-front inlet solenoid11-GNDOFF
lconnect the SCS servicq
connector IApprox. 3 V
YEUBLU
FR.OUT(Front-right
outlet)
Drives right-front outlet
solenoid valve.12-GNO
l4LT BLUDLC(Data linkconnector)
Communicates withPGM Tester.Honda14.GNDApprox. 5 V
17BRNA/ELMCK
lMotor check)
Detects pump motor drivesrgnal.17.GNDPumpmotorreray
ONBattery voltage
OFFOV
19YELREDPMR(Pump motorreray,
Drives pump motor relay.
19-GND
ONONOV
OFFAC: 3-6 V
OFFponnect the SCS sewicq
connedor lApprox. 3 V
BLURR-OUT(Rear-right
outletl
Drives right-rear outlel
solenoid valve.
21-GNDuJ
ON
Pumpmotorrelay
ONOV
OFFAC: 3-6 V
OFF
lconnect the SCS servicq
connedor )Approx. 3 V
22BLKGND2(Ground 2)Ground for the ABS controluntt.22-GNDBelow 0.3 v
19-53

tJ
t\
Kickback
1. The motor operates when the ABS is functioning, and the fluid in the reservoir is forced out to the master cylinder
causing kickback at the brake pedal.
2. TheABScontrol unit operates the solenoid valve when the brake pedal is released afterthe initial diagnosis Youmay
hear the faint solenoid valve operation sound at this time. but it is normal.
Pump Motor
1. The pump motor operates when the ABS is functioning
2. The ABS control unit checks the pump motor operation during acceleration. You may hear the faint operation sound
at this time. but it is normal.
Brake Fluid Replacament/Air Blsading
1. Brake fluid replacement and air bleeding procedures are the same as for conventional brakes
Troubleshooting
1. The troubleshooting flowcharts explain the procedures on the assumption that the cause of the problem is still pre-
sent and the ABS indicator light is still on.
Note that troubleshooting following the flowchart when the ABS indicator light does not come on can result in incor-
rect judgment.
2. Ouestion the customer about the conditions when the problem occurred, and try to reproduce the same conditions
for troubleshooting.
self,diagnosis is made at various times such as the initial diagnosis, except ABS control. during ABS control, during
acceleraiion, during the specified vehicle speed, etc. Therefore, the symptom cannot be checked unless the check
conditions match with the problem conditions
3. When the ABS indicator light does not come on during the test drive, but the troubleshooting is performed based on
the DTC, check for the loose connectors. poor contact of the terminals, etc, before troubleshooting.
4. After troubleshooting, erase the DTC and test-drive the car. Be sure that the ABS indicator light does not come on.
5. The connector illustrations show the female connectors with a single outline and the male connectors with a double
ouflrne.
6. The connector terminal cavities containing female terminals are always numbered by looking at the connector from
the wire side. and the cavities containing male terminals are always numbered by looking at the connector from the
terminal side.
r'
19-55