Lamp HONDA CIVIC 1996 6.G Repair Manual

Steering Gearbox
Installation (cont'dl
5. Install the stiffener plate with the two gearbox
mounting bolts and stiffener plate aftaching bolts.
CAUTION: Be sure the air tube is not caught orpinched by stiffener plate,
NOTE: Install the bolts loosely first, then tighten
them securely.
7.
8.
6.Install the return hose joint by tightening the l6 mm
flare nut.
Connect the relurn hose securely, and tighten the
adjustable hose clamp from the engine compart-ment.
Connect the feed line and tighten the 14 mm flare
nut.
NOTE: Make sure that there is no interference
between the fluid lines, the rear beam or any otherparts.
ADJUSTABLE HOSECLAMP(see page 17-39)
16 mm FLARE NUT28 N.m {2.9 ksl.m. 20 lbf.ft)
RETURN
1a mm FLARE NUT37 N.m (3.8 kg{.m, 27 lbt.ftl
ATTACHING AOLTS38 N.m 13.9 kgf.m, 28 lbf.ftl
MOUNTING BOLTS(} N.m (4.a kgt m, 32 lbf.ftl
17-66
9.Center the steering rack within its stroke.
Slip the lower end of the steering joint onto the pin-
ion shaft (line up the bolt hole with the groove
around the shaft), and tighten the upper and lower
steering joint bolt.
NOTE:
. Connect the steering shaft and pinion with the
cable reel and steering rack centered.. Be sure that the lower steering joint bolt is securely
in the groove in the steering gearbox pinion.
. lf the steering wheel and rack are not centered,
reposition the serrations at lower end of the
steering joint.
10.
STEERING JOINTUPPER BOLT22 N.m (2.2 kgf.m,16 tbt.ftl
PINION SHAFT
Groove,
STEERING JOINTLOWER BOLT22 N.m (2.2 kgt.m, 16lbtttl
11.Center the cable reel by first rotating it clockwise
until it stops. Then rotate it counterclockwise(approximately two turns) until the arrow mark onthe label points straight up. Reinstall the steeringwheel (see page 17 35).

)
1?
12, Install the steering joint cover with the clamps and a
clrp.
Reconnect the tie-rod ends to the steering knuckles,
tighten the castle nut ('96 -'97 models) or nut ('98 -
'OO models) to the specified torque, and install new
cotter plns.
NOTE: Before connecting the tie-rod ends, wipe off
any grease contamination from the ball joint tapered
section and threads.
CAUTION: Torquo the castle nut to the lower torque
sp€cification, then tighten it only tar enough to align
the slot with the pin hole. Do not align the nut by
loosening {,96 -'97 models only).
COTTER PINSReplace.On reassembly, bend
the cotter Pin 6s shown.'96 -'97 models:'98 -'00 mod€ls:
tr
CASTLE NUT40 - a8 N'm(4.0 - 4.8 kgf'm,29 - 35 lbf.ftl
NUT&l N.m{a.5 kgf'm, 33 lbl'ftl
NE-ROD END
(l-,
17-67
14.
15.
16.
17.
18.
Install the exhaust pipe A or TWC (see section 9).
Connect the shift linkage (see section 13 or section
14).
lnstall the front wheels
Fill the system with power steering fluid, and bleed
air from the system (see page 17-331
After installation, perform the following checks
. Start the engine, allow it to idle, and turn the
steering wheel from lock-tolock several times to
warm up the fluid. Check the gearbox for leaks
(see page 17-39).
. Adjust the front toe (see section 18).
. Check the steering wheel spoke angle. Adjust by
turning the right and left tie-rods, if necessary.
NOTE: Turn the right and left tie-rods equallv

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.

Diagnostic Trouble Code (DTCI
Diagnostic Trouble Code {DTC) Indication
NOTE: This operation can also be carried out with the Honda pGM Tesrer.
l connect the scs service connector to the service check connector inside the passenger,s side kick panel.
2. Turn the ignition switch ON (||). but do not start the engine.NOTE: Do not depress the brake pedal when turning the ignition switch.
3 Record the brinking frequency of the ABS indicator right. The brinking frequency indicates the DTc.
4, Turn the ignition switch OFF, and remove the SCS service connector.NorE: The Mslfunction Indicator Lamp (MlL) will stay on after the engine is started if the scs service connector isconnected.
5. Erase the DTC.
Condhions for DTC indication. The vehicle is stoDDed.. The SCS service connector is connected before the ignition switch is turned ON fll).. The brake pedal is released.. Th€ SCS service connector remains connected during this procedure
The DTG indication stops 8nd the ABs conltol unit executes the softwaro tunqtion if at least one of the following condi-tions b satisfied:
o The vehicle is not stoDoed.' The ABS control unit receives the normat signal (which is for the ABS controt unit) from a Honda pGM Tester.. The SCS service connector is disconnected during this procedu.e,
u.s.A.
@
CANADA
@
SERVICE CHECKCONNECTOR {2PISCS SERVICE CONNECTOR07PAZ - 0010100
ABS INDICATOR LIGHT
DTC : 3 3
A8S INDICAIOR LIGHT
Snilion swirch
' when the ignition switch is turned oN (ll), the ABs indicator light comes on to check the bulb. Do not count it as a DTc.o The ABS control unit can memorize any number of DTCs.. The new DTC is not memorized when the ABS control unit has already memorized the same DTC,.lftheDTCisnotmemorized,theABSindicatorlightstaysONafteritgoesofffor3.6seconds.
19-56

Heater Unit
Replacement
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-
L Disconnect the negative cable from the battery.
2. Frcm under the hood, open the clamp, then discon-
nect the heater valve cable from the heater valve
arm. Turn the heater valve arm to the fully opened
position as shown.
When the engine is cool. drain the engine coolant
from the radiator (see section 10).
!@ Do not remove the radiator cap when
the engine is hot; the ongine coolant is under pres'
surg and could severely scald you.
CLAMP
HEATER VALVC CABLE
4. Disconnect the heater hoses from the heater unit.
CAUTION: Engine coolant will damage p8int.
Ouickly rinse any spilled engins coolant from painted
su aces,
NOTE: Engine coolant will run out when the hoses
are disconnected; drain it into a clean drip pan.
5. Remove the mounting nut from the heater unit.
NOTE: When removing the mounting nut, take care
not to damage or bend the fuel lines, the brake
lines, etc.
I x 1 .25 mm22 N.m {2.2 kgl.m, 16lblftl
21-39

Heater Unit
Replacement (cont'dl
6.
7.
8.
9.
Remove the dashboard (see section 20).
Remove the heater duct (see page 21-37) or evapo-
rator (see page 22-28).
Disconnect the connectors from the mode control
motor and air mix control motor ('99 - 00 models),
then remove the wire harness clips and wire har-
ness from the heater unit. Remove the clip from the
heater duct, then remove the two mounting nuts
and the heater unit.
6x1.0mm9.8 N.m 11.0 kgl.m,7.2 lbf.ftl
HEATER UNIT
lnstall in the reverse order of removal. Make note of
the following items.
Apply sealant to the grommets.
Do not interchange the inlet and outlet heater
hoses. Make sure that the clamps are secure.
Refill the cooling system with engine coolant
(see section 10).
Connect all cables, and make sure they are prop-
erly adjusted (see page 21-44 (96 - 98 models)
or page 21-45 ('99 - 00 models)).
Make sure that there is no air leakage.
21-40

Overhaul
'1. Remove the two self-tapping screws and the heater
core cover.
2. Pull out the grommet from the heater core pipes.
3. Remove the self-tapping screw and the clamp.
GROMMET
Pull out the heater core from the heater unit.
NOTE: Be careful not to bend the inlet and outlet
pipes during heater core removal.
Assemble in the reverse order of disassembly.
HEATER CORE COVER
21-41

Temperature Control
Adjustment -'96 - 98 Models
1. From under the hood, disconnect the heater valve
cable from the heater valve.
TERVALVECABLEHEATER VALVE ARM
2.From under the dash, disconnect the air mix control
cable housing from the cable clamp,
AIR MIXCONTROLARM
3.Set the temperature control lever to MAX. COOL.
With the air mix control cable attached to the air
mix control arm, gently pull on the outer cable
housing to fully close the door and to remove any
slack in the cable. Don't pullto hard, or the temper-
ature control lever will move.
Hold the air mix control arm against the stop. then
snap the air mix control cable housing into the
cable clamp.
21-44
6. From under the hood. move the heater valve arm to
the fully closed position. then attach the heater
valve cable to the heater valve arm.
7. Hold the heater valve arm in the closed position,
and gently pull on the heater cable outer housing to
take up any slack. then install the heater valve cable
housing into the cable clamp.
HEATER VALVE ARM

Adjustment -'99 - 00 Models
1. From under the hood, open the cable clamp, then
disconnect the heater valve cable from the heater
valve arm.
From under the dash. disconnect the heater valve
cable housing from the cable clamp, and disconnect
the heater valve cable from the air mix control arm.
HEATER VALVE CABLE
Set the temperature control dial on MAX COOL with
the ignition switch ON {ll).
Attach the heater valve cable to the air mix control
arm as shown above. Hold the end of the heater
valve cable housing against the stop, then snap the
heater valve cable housing into the cable clamp.
HEATER VALVE ARM
5. From under the hood. turn the heater valve arm to
the fullv closed oosition as shown, and hold it,
Attach the heater valve cable to the heater valve
arm, and gently pull on the heater valve cable hous-
ing to take up any slack, then install the heater valve
cable housing into the cable clamp.
HEATER VALVE ARM
21-45