pedal HONDA CIVIC 1997 6.G Repair Manual

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.

Rear Brake Caliper
Reassembly (cont'dl
'16. Installthe pad spring onto the caliper.
Apply the recommended pin groase in the caliper
seal set to the sliding surface of the pins and inside
of the new pin boots.
Install the pin boots into the grooves in the caliper
bracket properly.
PIN BOOTSReplsce.
(Bl.ck Colorl
PINRepl6ce.
19. Insert pin A and pin B into the caliper bracket.
20. Install the pin boots into the grooves in thepropefly.
PAD SPRING
11.
PIN GREASE
19-34
pr ns
22.
21. Install the brake pad retainers and brake pads (see
page 19-25).
Align the cutout in the piston with the tab on the
inner pad (see page 19-25).
Install the caliper onto the caliper bracket. and tight-
en the caliper mounting bolts.
CALIPER MOUNTING BOLTS23 N.m {2.3 kg{.m. 17 lbf.ft)
WASHERSReplace.
BANJO BOLT34 N.m13.5 kg{.m.25 rbtft)
24.Connect the brake hose to the caliper with new seal,
ing washers, and tighten the banjo bolt,
Insert ths cable through the arm, and connect the
cabls to the lever with the clevis pin and lock pin.
Install the cable clip securely.
CLEVIS PIN
-t
//t
LOCK PINRoplace.
26. Install the caliDer shield.
27. Fill the brake reservoir, and bleed the brake svstem(see page 19-71.
28. Operate the brake pedal several times, then adjust
the parking brake (see page 19-6).
29. After installation, perform the following checks:. Check for leaks at hose and line joints and con-nections, and retighten if necessary.. Check the parking brake lever for operation, and
adjust it if necessary.
. Check for brake hose for interference or twistinq.

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

Anti-lock Brake System (ABSI
Featu res/Construction
When the brake pedal is depressed during driving, the wheels can lock before the vehicle comes to a stop, In such a case,the maneuverability of the vehicle is reduced if the front wheels are locked, and the stability of the vehicle is reduced if therear wheels are locked, creating an extremely unstable condition. The ABS precisely controls the slip rate of the wheels toensure the grip force of the tires. and it thereby ensures the maneuverbility and stability of the vehicle.Judging the vehicle speed. the ABS calculates the slip rate of the wheels based on the vehicle speed and the wheel speed,then it controls the brake fluid pressure to attain the target slip rate.
Grip Force of Tire and Road Surlace
COEFFICIENT OFFRICTION
TARGET SLIP RATE
Slip Rate
BRAKINGSTART POINT
ROTATIONALDIRECTION
RADIALDIRECTIONOF THEROTATIONALOIRECTION
A: Distance without slio8: Slippsd distanceC: Actuel distance
sr-rrmre=f=SLIP RATEVEIIICLE SPEED - WHEEL SPEEOVEHICLE SPEED
19-46

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

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

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

LJDTG Erasure
1.
2.
Connect the SCS service connector to the service check connector inside the passenger's side kick panel.
Depress the brake pedal.
Turn the ignition switch oN (ll) while holding the brake pedal, but do not start the engine. The ABS indicator light
goes off after two seconds.
After the indicator light goes off, release the brake pedal The indicator lightcomeson after four seconds
After the indicator light comes on, depress the brake pedal again. The indicator light goes off again after four sec-
onds. The brake pedal is still depressed.
4.
5.
\t
6. After the jndicator light goes off, release the brake pedal again'
7. After four seconds, the indicator light blinks twice for 0 3 second and the DTC is erased
8. Confirm the DTC indication, and check that the DTC was erased
NOTE: Always maintain these steps. lf you disconnect the scs service connector and/or fail to operate the brake pedal
according to the indicator light indication, the DTC will not be erased
Conditions for DTC erasure
o The vehicle is stopped.
. The SCS service connector is connected before the ignition switch is turned ON {ll)
. The brake pedal is depressed before the ignition switch is turned ON (ll)'
. The SCS service connector remains connected during this procedure
The DTC erasure stops and ABS control unit executes the software lunction it at least one ot the following conditions is
satisfied:
o The vehicle is not stopped.
. The SCS service connector is disconnected during this servace'
.TheABscontro|unitreceivesthenormaIsigna|(whichisfortheAEscontro|unit)fromaHondaPGMTester'
. The brake pedal is not operated according to the indicator light indication
. The DTC erasure is finished
ABS INDICATOR LIGHT
OFF
DEPRESS
BRAKE PEDAL
RELEASE
0.3sec
lqnition switchoN (I)
J
19-57

-Starter Test
NOTE; The air temoerature must be between 59 and
100'F (15 and 38"C) before testing.
Recommended Procedure:
. Use a staner system tester.
. Connect and operate the equipment in accordance
with the manufacturer's instructions.
. Test and troubleshoot as described,
Alternate Procedurg:
. Use the following equipment:- Ammeter, 0 - 400 A
- Voltmeter, 0 - 20 V (accurate within 0.1 volt)
- Tachometer, 0 - 1,200 rpm
. Hook up a voltmeter and ammeter as shown.
NEGATIVETERMINAL
NOTE: After this test, or any subsequent repair. reset
the ECM/PCM to clear any codes (see section l1)
Check the Start€r Engagemont:
1. Remove the No. 44 (15 A) fuse from the under-hood
fuse/relay box,
2. Turn the ignition switch to START (llll with the shift
lever in E or E position (rVT) or with the clutch pedal
depressed {M/T). The starter should crank the engine.
. lf the starter does not crank the engine, go to
step 3.
. lf itcranksthe engineerraticallyortooslowly, go
to "Check for Wear and Damage" on the next
page.
Check the battery. battery positive cable, ground,
starter cut relay, and the wire connections for loose-
ness and corrosion, Test again.
lf the starter still does not crank the engine, go to
step 4,
Unplug the connector (BLK,/WHT wire and solenoid
terminal) from the starter,
Connect a jumper wire from the battery positive (+)
terminal to the solenoid terminal.
The starter should crank the engine.
. lf the starter still does not crank the engine,
remove it, and diagnose its internal problem
. lf the startercranksthe engine, goto step 6.
Check the ignition switch (see page 23-891.
Check the starter cut relay and clutch interlock switch
(see page 23-86,87).
Check the A/f gear position switch (see page 23-154).
Check for an open in the wire between the ignition
switch and starter.
7.
(cont'd)
23-95
9.

Starting System
Starter Test lcont'dl
Ch€ck tor Wear and Damage
The starter should crank the engine smoothly and
steadily, lf the starter engages. but cranks the engine
erratically, remove it, and inspect the starter drive gear
and torque converter or flywheel ring gear for damage.
. Check the drive gear overrunning clutch for binding
or slipping when the armature is rotated with the
drive gear held,- lf damaged. replace the gears.
Check Cranking Voltsge and Curr€nt Draw
Cranking voltage should be no less than 8.5 volts.
Current draw should be no more than 350 amperes.
lf cranking voltage is too low, or current draw too high,
check for;
. dead or low batterv.
. open circuit in starter armature commutator seg-
ments,
. starter armature dragging.
. shorted armature winding.
o excessive drag in engine.
Check Cranking rpm
Engine speed during cranking should be above 100 rpm,
lf speed is too low, check for:
. loose battery or stanerterminals.
. excessively worn starter brushes,
. open circuit in commutator segments.
o dirty or damaged helical spline or drive gear.
. defective drive gear overrunning clutch.
Check Siarter Disengag€ment
With the shift lever in El or @ position (A/T) or with the
clutch pedal depressed (M/T), turn the ignition switch to
START (lll), and release to ON (ll).
The starter drive gear should disengage from the torque
converter or flywheel ring gear when you release the
Key.
lf the drive gear hangs up on the torque converter or fly-
wheel ring gear, check for:
. solenoid plunger and switch malfunction,
. dirty drive gear assembly or damaged overrunning
clutch.
Starter Solenoid Test
1. Check the hold-in coil for continuitv between the S
terminal and the armature housing (ground). The
coil is OK if there is continuitv,
ARMATUREHOUSING(GROUND)
S TERMINAL
M TERMINAL
B TERMINAL
STARTERCAELE B TERMINALMOUNTING NUTI N.m {0.9 kgf.m,7 tbf.ft)
Check the pull-in coil for continuity between the S
and M terminals. The coil is OK if there is continuity.