Cam HONDA CIVIC 1996 6.G Repair Manual

I
8.
9.
Assemble pump rotor to the pump cover with the" " " marks on the rotor facing down.
Set the 10 vanes in the grooves in the rotor.
NOTE: Be sure that the round ends ot the vanes are
in contact with the sliding surface of the cam ring.
Coat the O-ring with power steering fluid, and
install it into the grooves in the side plate.
Install the side plate on the cam ring by aligning the
roller set holes in the side plate with the rollers.
mm O-RING
ROLIIR SET HOTT
SET HOI.^E
0E
gn
10.
11.
r
E15.2 x 2,1Replace.
PUMP ROTOR
SIDE PLATE
ROI.I.ERSl,
't2.Coat the O-ring with power steering fluid. and posi
tion it into the pump housing.
Install the pump cover assembly in the pump hous-
tng.
FI.ANGE EOLTS20 N.m (2.0 kgf.m,14 tbf.ft)
PUMP COVERASSEMBLY
51 x 2.4 mmReplace.
Coat the flow control valve with power steerlng
fluid.
15. lnstall the flow control valve and spring on the
pump housing.
Coat the O-ring with power steering fluid, and
install it on the Jlow control valve cap.
Install the flow control valve cap on the pump hous-
't 4.
16.
17.
ing, and tighten it.
{cont'd)
17-45
FLOW CONTROLVALVE CAP49 N.m (5.0 kgj m,
36 tbf.ft)

)
Suspension
Special Tools ............. 18-2
Component Locations
lndex ,,.............. ...... f8-3
Wheel Alignment
Caster .............. ....... 18-4
Camber .................. l8-4
Front Toe Inspection/
Adiustment ........ 18-5
Rear Toe lnspection/
Adiustment ........ 18-5
Turning Angle Inspection ................ 18-6
Wheel/Hub Inspection
Bearing End P|ay .............................. l8-7
Wheel Runout ....... 18-7
Front Suspension
Suspension Arms Replacement
('96 - 99 modelsl .......................... 18-8
Suspension Arms Replacement
('99 2D Si and Si-R models) ........ 18-9
Knuckle/Hub Replacement ............. 18-10
Lower Ball Joint Replacement ....... 18-16
Ball Joint Boot Replacement .......... 18-17
Front Damper
Removal ................. 18-17
Disassembly/1nspection .................. 18-18
Reassembly ........... 18-19
lnstallation ............. 18-19
Rear Suspension
Suspension Arms Replacement
('96 - 99 models) ....................,..... 18-21
Suspension Arms Replacement
('99 2D Si and Si-R models) ........ 1A-22
Hub Bearing Unit Replacement ...... 18-23
Upper Arm Eushing
Replacement .....18-25
Rear Damper
Removal ................. 18-26
Disassembly/|nspection ............. ..... 1A-27
Reassembly ........... 18-28
lnstallation ............. 18-29
lr

Wheel Alignment
,f,
Caster
NOTE: For proper inspection/adjustment of the wheel
alignment check and adjust the following before check-
ing the alignment.
. Check that the suspension is not modified.
. Check the tire size and tire pressure.
. Check the runout of the wheels and tires.
. Check the suspension ball ioints. {Hold a wheel with
your hands and move it up and down and right and
left to check for wobbling.)
Inspection
NOTE: Use commercia lly-available computerized four
wheel alignment equipment to measure wheel align-
ment {caster. camber, toe, and turning angle). Follow
the equiDment manufacturer's instructions.
Check the caster angle.
Caster angle: 1',10' I 1'
lf out of specification, check for bent or damaged
suspensron components.
2.
1.
18-4
Camber
lnspection
NOTE: Use commercially-available computerized four
wheel alignment equipment to measure wheel align-
ment (caster, camber, toe, and turning angle). Follow
the equipment manufacturer's instructions.
1. Check the camber angle.
Camber angle:
Front: 0'00' j 1"
Rear:-1"11"
2. lf out ol specification, check for bent or damaged
suspensron components.

?
Front Toe Inspection/Adiustment
NOTE: Use commercially-available computerized four
wheel alignment equipment to measure wheel align-
ment (caster, camber, toe, and turning angle). Follow
the equipment manufacturer's instructions.
1. Check the tire pressure.
Center steering wheel spokes.
Check the toe with the wheels pointed straight
a head.
Front toe: lN 1 1 2 mm llN l/16 r 1/16 inl
- lf adjustment is required, go on to step 4.
- lf no adjustment is required, remove alignment
equrpmenr.
Loosen the tie-rod locknuts, and turn both tie-rods
in the same direction until the front wheels are in
straight ahead position.
TIE.ROD LOCKNUT'14 x 1.5 mm
4.
tJ
6.
Turn both tie-rods equally until the toe readang on
the turning radius gauge is correct.
After adjusting, tighten the tie-rod locknuts.
NOTE: Reposition the tie-rod boot if it is twisted or
displaced.
4,1 N.m {4.5 kgf.m, 33 lb{.ft)
2.
Rear Toe Inspection/Adiustment
NOTE: Use commercially-available computerjzed Iour
wheel alignment equjpment to measure wheel align-
ment (caster, camber, toe, and turning angle). Follow
the equipment manufacturer's instructions.
1. Release parking brake.
NOTE:
a Measure difference in toe measurements wlth
the wheels pointed straight ahead.
. if the parking brake is engaged, you may get an
incorrect readang,
Rear toe-in: 2 11 mm ttltollllS int
- lf adjustment is required, go to step 2.
- lf no adjustment is required, remove alignment
equipment.
Before adjustment, note the locations of adiusting
bolts on the right and left compensator arms
Loosen the adjusting bolts, and slide the compen
sator arm in or out. as shown, to adjust the toe
ADJUSTING BOLT10 x 1.25 mm
In CoMPENSAToR ARM
4. Tighten the adiusting bolts
. Example:
After the rear toe inspection, the wheel is 2 mm
(0.08 in) out of the specification.- Move the arm so the adjusfing bolt moves 2 mm
(0.08 in) inward trom the position recorded before the
adjustment.- The distance the adjusting bolt is moved should be
equal to the amount out-of-specification.
64 N.m 16.5 ksf m, 47 lbtft)
18-5

Wheel Alignment
Turning Angle Inspection
NOTEr Use commercially-available computerized four
wheel alignment equipment to measure wheel align-
ment (caster, camber, toe, and turning angle). Follow
the equipment manufacturer's instructions.
'1. Turn the wheel right and left while applying the
brake, and measure the turning angle of both
wneets.
Turning angle:
lnward wheel: 39'50'
Outwald wheel (ref erencel: 33'10'
2.lf the turning angle
check for bent or
nents,
is not within the specifications,
da m aged suspension compo-
18-6

\
13.
Lower the locknuts fully, and tighten them securely.
NOTE: Keep the locknuts in this position until you
reinstallthe circlip.
Remove the circlip with snap ring pliers.
SNAP RINGPLIERS07914 - SA50001
't 4.Hold the plate with your fingers, and turn the shaft
counterclockwise. Remove the special tool from the
calioer.
LOCKNUTS
l./
15. Remove the adjusting bolt.
Remove the spring cover, adjusting spring B, spacer,
bearing A, and cup from the adjusting bolt.
Remove the sleeve piston, and remove the pin from
the cam in the caliper body.
'17 .
SLEEVE PISTONCheck lor wear anddamage,
i
I
I
6-50-awl \
IO-RIITGRepl6ce.
(cont'd)
19-29

Rear Brake Galiper
Disassembly (cont'dl
18. Remove the return spring.
PARKING LEVER/CAM ASSEMBLYCheck lor damage.
Remove the parking lever and cam as an assemblvfrom the caliper body.
CAUTION: Do not loosen the parking nut with thecam inslalled in the caliper body, lf the leyer andshaft must be separated, hold the lever in a vise,and loosen the parking nut,
Remove the cam boot.
RETURNSPRING
19.
19-30

Rear Brake Caliper
Reassembly (cont'dl
L
PARKING NUT28 N.m (2.8 kgt m,20 rbr.trt
Pack all cavities of the needle bearing with the rec,
ommended rubber grease in the caliper seal set,
Coat a new cam boot with recommended rubbergrease in the caliper seal set, and install it in thecaliper body.
SPRII{GWASHEN
z..-_e!!!9!.{RUBBERGREASE
Apply recommended rubber grease in the caliperseal set to the pin contacting area of the cam, andinstall the cam and lever assembly into the caliperbodv.
lnstall the return spring.
CAUTION:
. When the cam and lever wgre separatod. b€ surgto assemble them bofore installing the cam inthe caliper body, Install the lev€r and spring
washer. apply locking agent to the threads, andtighten the parking nut while holding the l.vorwhh a vise,
. Avoid damaging the cam boot since it must bsinstalled before thg cam.. When installing the cam, do nol allow the camboot lips lo turn outside in.
19-32
5. Installthe pin in the cam.
O.RINGReplace.
SLEEVE PISTON
Install a new O-ring on the sleeve pisron.
Install the sleeve piston so that the hole in the bot-tom of the piston is aligned with the pin in the cam,and the two pins on the piston are aligned with theholes in the calioer.
Coat a new cup with recommended rubber grease
in the caliper seal set, and install it with its groove
facing the bearing A side of the adjusting bolt.
7.
€8.--:BTif
@'-.-3nfi""'i"
@--seacrn
$ eeenrne a
fi,*,*^"
GF-
Fit the bearing A, spacer. adjusting spring B, andspring cover on the adjusting bolt, and install themin the caliDer cvlinder.
CUPReplace.
=^.#-g!!!!!Jl
RUBBER GREASE
o

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

'11.Thoroughly mix the adhesive and hardener together
on a glass or metal plate wilh a putty knife.
NOTE:
. Clean the plate with a sponge and alcohol before
mixing.
. Follow the instructions that came with the adhe-
sive.
Before filling a cartridge, cut the end of the nozzle
as shown.
10 mm {0.39 in.)
7 mm (0.27 in.l
Pack adhesive into the cartridge without air pockets
to ensure continous delivery. Put the canridge in a
caulking gun, and run a bead ol adhesive around
the edge of the rear window as shown.
NOTE| Apply the adhesive within 30 minutes after
applying the glass primer.
12.
13.
J
12 mm 10.,U in.)
[/ oo*r.,u.
8 mm (0.31 in.)
Make a slightly thickerbead at each corner.
GLASS
FASTENER
SPACER
MOLDING
MOLDING
)REAR WINDOW
FASTENER
20-35
14. Use suction cups to hold the rear window over the
opening, align it with the alignment marks made in
step 7, and set it down on the adhesive. Lightly
push on the rear window until its edges are {ully
seated on the adhesive all the way around.
NOTE: Do not open or close the doors until the adhe-
sive is dry.
SUCTION ALIGNMENTCUPS MARK
Scrape or wipe the excess adhesive off with a putty
knife or towel.
NOTE: To remove adhesive from a painted surface
or the rear window, use a soft shop towel damp-
ened with alcohol.
Let the adhesive dry for at least one hour, then
spray water over the rear window and check for
leaks. Mark the leaking areas, let the rear window
dry, then seal with sealant.
NOTE: Let the car stand for at least four hours after
rear window installation. lf the car has to be used
within the Iirst tour hours, it must be driven slowly
Reinstall all remaining removed parts
NOTE: Advise the customer not to do the following
things for two to three days:
. Slam the doors with all the windows rolled up.
. Twist the body excessively (such as when going
in and out of driveways at an angle or driving
over rough. uneven roads).
16.
1-7 .