tension HONDA CIVIC 1996 6.G Owner's Guide

t-
Brake Shoe Disassembly
1. Remove the tension pins by pushing the retainer
springs and turning them.
TENSION PINS
RETAINER SPRINGS
Lower the brake shoe assembly, and remove the
lower return spring.
NOTEi Be careful not to damage the dust cover on
the wheel cylinder.
Remove the brake shoe assembly.
Disconnect the parking brake cable from the parking
brake lever.
Remove the upper return spring, self-adjuster lever,
and self-adjuster spring, and separate the brake
snoe5.
t
3.
4.
ADJUSTEB BOLTCheck ratchet teeth forwear ano oamage.
UPPER RETURN SPRINGCheck for weaknessano oamage.
ll
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//
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6. Remove the wave washer, parking brake lever, and
pivot pin from the brake shoe by removing the U-
clrp.
PARKING ERAKEI-EVER
WAVE WASHER
/
@@
I
IU-CLIPReplace.
Brake Shoe Reassembly
1.Apply brake cylinder grease (P/Nr 08733 - B020E) or
equivalent rubber grease to the sliding surface of
the pivot pin, and insert the pin into the brake shoe.
Install the parking brake lever and wave washer on
the pivot pin and secure them with the U-clip,
NOTE: Pinch the U-clip securely to prevent the pivot
pin from coming out of the brake shoe.
,6;::"'
(cont'd)
19-37
LEVER

Rear Drum Brake
Brake Shoe Reassembly {cont'dl
Connect the parking brake cable to the parking
brake lever.
Apply grease on each sliding surface.
!@ contaminated brake linings reduce
stopping ability. Keep grease or oil off the blake lin-
ings. 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.
+a Sliding surlace
Apply Molykote 44MA to the brake shoe ends and
opposite edges ofthe shoes as shown.
_' o Opposite edge of the shoe+O Brake shoe ends
19-38
13.
5. Clean the threaded portions of clevises A and B.
Coat the threads of the clevises with grease. To
shoften the clevises, tun the adjuster bolt.
6. Hook the self-adjuster spring to the self-adjuster
lever first, then to the brake shoe
7. Install the clevises and upper return spring. noting
the installation direction.
NOTE: Be careful not to damage the wheel cylinder
dust covers,
8. Install the lower return spring.
9. Install the tension pins and retaining springs.
uppER RETURT{ SpRtNG CLEVIS B
CLEVIS A
Installthe brake drum.
lf the wheel cylinder has been removed, bleed the
brake system (see page 19-7), and check for leaks at
brake line connections, and retighten if necessary.
Depress the brake pedal several times to set the
self-adjusting brake.
Adjust the parking brake (see page 19-6).
't0.
11.
12.
LOWER RETURN SPRING

Opening Drag Check
{Motor Removed)
Before installing the motor, measure lhe effort required
to open the glass using a spring scale as shown.
CAUTION: When using a spring scale, pfotest the lead-
ing edge ol the glass with a shop towel.
lf load is over 40 N (4 kgf,9 lbf), check the side clearance
and glass height (see page 20-51).
SHOP TOWEL
l,e
20-57
Closing Force Check
(Motor Installedl
'1. After installing all removed parts, have a helper
hold the switch to close the glass while you mea-
sure the force required to stop it. Attach a spring
scale as shown. Read the force as soon as the glass
stops moving, then immediately release the switch
and spring scale.
CAUTION: When using a spring scale, protect the
lerding edge ol the glass with a shop towel.
Closing Force: 200 - 290 N(20 - 30 kst, 44 - 66 lbfl
lf the torce in not within specification, install a new
lock washer, adjust the tension by turnang the motor
clutch adjusting nut, and bend the lock washer
against the motor clutch adjusting nut.
LOCKWASHERReplace.
COUNTER.cLocKwrsETo decrease
SCALE

Special Tools
Bef. No. Tool NumberDescriptionQty I Page Reference
o
@
*07JGG - 00l0l0A
07sAz - 0010004
07947 - 6340300
07965 - 6920500
Belt Tension Gauge
Backprobe Set
Driver Attachment
Hub Assembly Gulde Attachment
1
'1
1
22-43
22-14,16
22-34
22-35' Included in the Belt Tension cauge Set, 07TGG-0010004.
a6r
L
3r
22-2

A/G GomPressor Belt
Adjustment
Detlection Method
'1. Apply a force of 98 N (10 kgf, 22 lbf), and measure
the deflection between the A,/C compressor and the
crankshaft PulleY
A/C ComPressor Belt
Used Belt: 816A2 engine
6.0 - 9.5 mm 10 2'l - 0.37 inl
Except 816A2 engine
7.5 - 9.5 mm (0.30 - 0.37 in)
New Belt: 816A2 engine
4.5- 6 5 mm (0.18-0.26 in)
Except 815A2 engine
5.0-5 5 mm (0.20-0.26 inl
Note these items when adjusting belt tens'on:
. lf there are cracks or any damage evident on the
belt, replace it with a new one.
. "Used belt" means a belt which has been used
for five minutes or more.
. "New belt" means a belt which has been used
tor less than five minutes.
2. Loosen, the center nut ofthe idler pulley (SANDEN), or
the pivot bolt of the idler pulley bracket and the lock
nut ofthe adjusting bolt (DENSO).
3. Turn the adjusting bolt to get proper belt tension'
4. Retighten the center nut of the idler pulley (SANDEN),
or the pivot bolt of the idler pulley bracket and the lock
nut of the adjusting bolt (DENSO).
5. Recheck the deflection of the A,/C compressor belt'
Tension Gauge Method
1. Attach the special tool to the IVC compressor belt as
shown below, and measure the tension of the belt
A/C Compressor Belt
Used Belt: 816A2 engine
390 - 540 N (40 - 55 kgf, 88 - 120 lbll
Except 816A2 engine
340 - 490 N (35 - 50 ksf, 77 - 110 lbfl
New Belt: B16A2 engine
?40 - 880 N {75 - 90 ksf' 170 - 200 lbf)
Except Bl642 engine
690 - 830 N (70 - 85 ksf, 150 - 190 lbf)
Note these items when adjusting belt tension:
. Follow the manufacturer's instructions for the
belt tension gauge.
. lf there are cracks or any damage evident on the
belt, rePlace it with a new one.
. "Used belt" means a belt which has been used
for five minutes or more.
. "New belt" means a belt which has been used
for less than five minutes
2 Loosen the center nut of the idler pulley (SANDEN)' or
the pivot bolt of the idler pulley bracket and the lock
nut of the adjusting bolt (DENSO).
3. Turn the adjusting bolt to get proper belt tension
4. Retighten the center nut of the idler pulley (SANDEN),
or the pivot bolt of the idler pulley bracket and the lock
nut of the adjusting bolt (DENSO)
5. Recheck the tension of the A/C compressor belt'
22-43

Special Tools
Ref. No. Tool NumberDescriptionOty Page Reference
O)
@-
o
@
o
tol
A973X_041 _XXXXX
07JGG 00l0l0A
OTLAJ - PT3O2OA
07NAC - SR20100
07PM - 0010r 00
07MAJ - SP00300
Vacuum Pump Gauge, 0 - 30 in.Hg.
Belt Tension Gauge
Test Harness
Fuel Sender Wrench
SCS Service Connector
Keyless Entry Checker
1
1'I
1
1
1
23-245
23-140,141
23-142
23-105
23-264
': Included in Belt Tension Gauge Set 07T66 - 0010004
or/4,
(!
23-2

Troubleshooting
ll.
Tips and Precautions
Bef ore Troubleshooting
. Check applicable fuses in the appropriate fuse/relay
box.
. Check the battery for damage, state of charge, and
clean and tight connections.
. Check the alternator belt tension.
CAUTION:
. Do not quick-charge a battery unless the battery
ground cable has been disconneqted, otherwise you
will damage the alternator diodes.
. Do not attempt to crank the engine with the battery
ground cable loosely connecled or you will severely
damage the wiling,
Handling Connectois
. Make sure the connectors are clean and have no loose
wire terminals.
. Make sure multiple cavity connectors are packed with
grease (except watertight connectors)
. All connectors have push-down release type locks.
Some connectors have a clip on their side used to
attach them to a mount bracket on the body or on
another component. This clip has a pulltype lock.
Some mounted connectors cannot be disconnected
unless you first release the lock and remove the con-
nector from its mount bracket.
LOCKINGPAWL ONOTHERHALF OFCONNECTOR
Pull todrsengage
LOCKING TAB
BRACKET
Never try to disconnect connectors by pulling on
their wires; pull on the connector halves instead
Alwavs reinstall plastic covers.
Before connectang connectors,
nals are in place and not bent.
make sure the terml-
. Check for loose retainer and rubber seals.
RETAINER
The backs of some connectors are packed with
grease. Add grease if necessary. lf the grease is con-
taminated, replace it.
(cont'd)
23-3

JBrush Holder Test
1. Check that there is no continuity between the O and
o brush holders.
lf there is continuity, replace the brush holder
assemoly.
O BRUSH HOLDER
@ BRUSH HOLDER€) BRUSH HOLDER
2. Insert the brush into the brush holder, and b.ing the
brush into contact with the commutator, then attach
a spring scale to the spring. Measure the spring ten-
sion at the moment the spring lifts off the brush.
SPRING SCALE
Spring Tension
15.7 - 17.7 N (1.60 - 1.80 kgf. 3.5 - 4.0 lbf)
ERUSH
Brush Inspection
Measure the brush length. lf not within the service limit,
replace the brush (or brush holder assembly).
Brush Length
NOTE: To seat new brushes after installing them in their
holders, slip a strip ot #500 or #600 sandpaper. with the
grit side up, over the commutator and smoothly rotate
the armature. The contact surface of the brushes will be
sanded to the same contour as the commutator.
Overrunning Clutch lnspection
Slide the overrunning clutch along the shaft. Does it
move freely? lf not, replace it.
Rotate the overrunning clutch both ways. Does it
lock in one direction and rotate smoothly in
reverse? lf it does not lock in either direction or it
locks in both directions, replace it.
2.
L
Standard (NEW)Service Limit
15.8 - 16.2 mm
(0.62 - 0.64 in)
1 1.0 mm
{0.43 in)
CLUTCH GEAR
DRIVE GEAR

Charging System
Alternator Replacement
NOTE: Remove the alternator from below the vehicle.
'1. Make sure you have the anti-theft code for theradio, then write down the frequencies for theradio's preset buttons ('99 - 00 models).
2. Remove the battery negative cable, then disconnectthe positive cable.
3. Disconnect the 4P (or 3P) connector from the alter-naIor.
TERMINAL NUT7.85 N.m (0.8 kgf.m, 5.79lbf.ftl
{ }: Cansd.
4. Remove the terminal
the B terminal.
nut and the WHT wire from
23-120
5. Remove the adjusting bolt and through bolt nut,then remove the alternator belt from the Dullev.
UPPER MOUNTBRACKET BOLT44 N.m 14.5 kgt.m, 33 lbl.ftlALTERNATORAD.'USTING BOLT24 N.rh l2.a kgf.m, 17 lbtft)
ALTERNATORBOLT
a4 N.m 14.5 kstm.33lbf'ftl
LOWER MOUNTBRACKET BOLTSa4 N.m l{.5 kgf.m,33lbfft)
Pull out the alternator through bolt, then removethe alternator.
lf necessary, remove the mount bracket bolts. andthe upper and lower mount brackets
Adjust the alternator belt tension after installation(see page 23-125).
Enter the anti-theft code for the radio, then enter thecustomer's radio station presets ('99 - 00 models).
7.

It -Alternator Belt Inspection and Adiustment
Deflection Method:
Apply a force of 98 N (10 kgl,22lbll, and measure the
deflection between the alternator and the crankshaft pul-
ley.
Detlection | 8.0 - 10.5 mm (0.31 - 0.41 in)
NOTE: On a brand-new belt {one that has been run for less
than five minutes). the deflection should be 6.0 - 8.5 mm
(0.26 - 0.33 in) when first measured. If the belt is worn or
damaged, replace it.
CRANKSHAFTPULLEY
lf adiustm€nt is necossary:
1. Loosen the lower mounting nut and the upper mount-
ing bolt.
2, Move the alternator to obtain the proper belt tension,
then retighten the upper mounting bolt and the lower
mounting nut to the specified torques.
3. Recheckthe deflection ofthe belt.
24 N.m (2.4 kgl m,
Belt T€nsion Gauge Method:
Following the gauge manufacturer's instructions. attach
the soecial tool to the belt, and measure the tension.
Tension 340 - 490 N (35 - 50 kgf,77 - 110lbf)
NOTE: On a brand-new belt {one that has been run for less
than five minutes), the tension should be 540 -740 N
(55 - 75 kgf, 121 - 165 lbf) when first measured. lf the belt
is worn or damaged, replace it.
PULLEY BELT TENSION GAUGE
07JGG - 0010104
It adiustment is necossary:
1, Loosen the lower mounting nut and the upper mount-
ing bolt.
2. Move the alternator to obtain the proper belt tension.
then retighten the upper mounting bolt and the lower
mounting nut to the specified torques
3. Recheck the tension of the belt
23-125