Indicator HONDA CIVIC 2003 7.G Repair Manual

EPS Components
(Motor RemovaUlnstallation (cont'dl
lnsiallation
7. Clean the mating surface of the motor (A) and
gearbox.
Apply a thin coat of silicone grease (P/N 08733-
8070E)to the new O-ring (B), and carefully fit it on
the motor.
Apply grease {Nippon Grease WR-S or equivalent
steering gear grease) into the motor shaft (C).
qE
8 x '1.25 mm20 N.m12.0 kgt.m,7 .2lbl ftl
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9.
17-50
r0.Install the motor on the gearbox by engaging the
motor shaft and worm shaft (D). Note the motor
installation position {direction of motor wires).
Before tightening the bolts, turn the motor two or
three times right and left about 45 degrees. lvlake
sure the motor is evenly seated on the steering
gearbox and that the O-ring is not pinched betlveen
the mating surfaces.
Installthe removed Darts in the reverse order of
removal. and note these items:
lvlake sure the motor 2P connector is properly
connected.
lvlake sure the motor and EPS wires are not
caught or pinched by any parts.
Reconnect the negative cable to the battery.
Do the engine control module (ECM) idle learn
procedure (see page 11-139).
Enter the anti-theft code for the radio station
Dresets. Reset the clock,
Do the oower window control unit reset
procedure (see page 22-1241.
After installation, start the engine, and let it idle.
Turn the steering wheel from lock-to-lock several
times. Check that the EPS indicator does not come
on.
11.
12.
13.

EPS Control Unit Removal/
Installation
1. Remove the passenger's under panel.
2. Turn up the floor carpel, remove lhe EPS control
untr.
Disconnect the EPS control unit connectors.
lnstallthe EPS control unit in the reverse order of
removal.
After installation, start the engine, and let it idle.
Turn the steering wheelfrom lock-to-lock several
times. Check that the EPS indicator does not come
on.
3.
E
Tie-rod Ball Joint Boot Replacement
Special Tool Required
Attachment, 42 mm 07OAD-P0A0100
l. Remove the boot from the tie-rod end, and wipe the
old grease off the ball pin.
2. Pack the lower area of the ball pin(A)wilhfresh
mulr purpose grease.
3. Pack the interior of the new boot (B) and lip (C) with
fresh multipurpose grease.
Note these items when installing new grease;
. Keep grease offthe boot installation section (D)
and the tapered section (E) of the ball pin.
. Do not allow dust, dirt, or other foreign materials
to enter the boot.
4. Installthe new boot (A) using the specialtool. The
boot must not have a gap at the boot installation
sections (B). After installing the boot. check the ball
pin tapered section for grease contamination, and
wipe it if necessary.
07(lAD-P0A0100
*-4
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17-67

Brakes
Conventional Brake Components
Special Tools ... ..... ... l9-2
Component Location Index ......................................... 19-3
Brake System Inspection and
Tests ............... .......... 19-4
Brake Pedal and Brake Pedal Position Switch
Adjustment .............. 19-6
Parking Brake Check and
Adjustment .............. 19-7
Brake System Bleeding ...................... 19-8
Brake System Indicator Circuit
Diagram ................... 19-9
Parking Brake Switch Test ................. 19-10
Brake Fluid Level Switch Test ...................................... 19-10
Front Brake Pads lnsoection and
Replacement ........... 19-11
Front Brake Disc Inspection ............... 19-13
Front Brake Calioer Overhaul ...................................... 19-14
Master Cylinder Replacement ........... 19-15
Master Cylinder Inspection ................ 19-16
Brake Booster
Pushrod Clearance Adjustment ................................ 19-16
Brake BoosterTest ................... .......... 19-18
Brake Booster Reolacement .............. 19-19
Rear Brake Pads Inspection and
Reolacement ........... 19-20
Rear Brake Disc Inspection ................ 19-22
Rear Brake Caliper Overhaul ....................................... 19-23
Brake Hoses and Lines Insoection .... 19-24
Brake Hose Reolacement ................... 19-25
Parking Brake Cable Replacement .............................. 19-26
ABS (Anti-lock Brake System)
Gomponents ... 19-29

Component Location Index
FRONT BRAKESFront Brake Pads, Inspection andReplacement, page 19-1 1Front Brake DiscInspection, page 19'13Front Brake CaliperOverhaul, page 19-14
INDICATORBrake System Indicator CircuitDiagram, page 19-9Parking Brake SwitchTest, page 19 10Brake Fluid Level SwitchTest, page 19-10
BRAKE CABLE
BRAKE BOOSTERBrake BoosterTest, page 19-18Brake EoosterReplacement, page 19 19
Parking Brake CableReplacement, page 19 26
REAR DISC BRAKERear Brake Pads Inspection andReplacement, page l9-20Rear Brake DiscInspection, page 19'22Rear Brake Caliper Overhaul,page 19'23
PARKING BRAKE LEVERParkino BrakeCheck and Adjustment, page 19-7
BRAKE PEDALBrake Pedal and Erake Pedal Position SwitchAdjustment, page l9-6
BRAKE HOSES and LINESBrake Hoses and LinesInspection, page 19 24Brake HosesReplacement, page 19 25
MASTER CYLINDERMaster CylinderFl6^1.^6m6nr ^2^o 1O-18Master Cylinder Inspection, page 19-16Brake Booster Pushrod ClearanceAdjustment, page'19-16Brake System Bleeding, page 19-8
19-3

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Brake System Indicator Circuit Diagram
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EBAK€FLUIDIEVELSwlICH
19-9

Conventional Brake Gomponents
Front Brake Pads Inspection and Replacement (cont'dl
3. Remove the pad retainers (A), and check the caliperpins for free movement.
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4. Clean the caliper thoroughly; remove any rust, andcheck for grooves and cracks.
5. Checkthe brake disc for damage and cracks.
6. Apply Dow Corning Molykote M77 grease to theretainers on their mating surfaces against thecaliper bracket.
7. Installthe pad retainers. Wipe excess grease offtheretainers. Contaminated brake discs and pads
reduce stopping ability. Keep grease off the discsand pads.
8. Apply Molykote l\477 grease to both sides of thepad shim {A), the back ofthe pads (B), and the other
areas indicated by the arrows.
Wipe excess grease off the shim. Contaminated
brake discs and pads reduce stopping ability. Keepgrease off the discs and pads.
Installthe brake pads and pad shim correctly.Install the pads with the wear indicators (C) on theinside.
lf you are reusing the pads, always reinstall thebrake pads in their original positions to prevent amomentary loss of braking efficiency.
, a .).
19-12
10. Push in the piston (A) so the caliper will fitoverthepads. Check the brake fluid level. The brake fluid
may overflow if the reservoir is too full. lvlake surethe piston boot is in position to prevent damaging itwhen pivoting the caliper down
8x1.0mm34 N.m3.5 kgt m.25 tbf.ft)
11. Pivot the caliper down into position. Being carefulnot to damage the pin boots, install the bolt (B), and
tighten it to the specified torque.
12. Press the brake pedal several timestomakesure
the brake works, then test drive.
NOTE: Engagement of the brake may require agreater pedal stroke immediately after the brakepads have been replaced as a set. Several
applications of lhe brake pedal will restore thenormal pedal stroke.
13. After installation, check for leaks at hose and linejoants or connections, and retighten if necessary.
\

4. Remove the pad retainers (A). and check the caliper
pins for free movement.
:.i _ _l
7.
8.
5. Clean the caliper thoroughly; remove any rust. and
check for grooves and cracks.
6, Check the brake disc for damage and cracks.
Apply Dow Corning Molykote M77 grease to the
retainers on their mating surfaces against the
caliper bracket,
Installthe pad retainers. Wipe excess grease offthe
retainers. Contaminated brake discs and pads
reduce stopping ability. Keep grease off the discs
and pads.
Apply Dow Corning Molykote lvl77 grease to both
sides of the pad shims {A), the back of the pads (B),
and the other areas indicated by the arrows. Wipe
excess grease off the shim. Contaminated brake
discs and pads reduce stopping ability. Keep
grease off the discs and pads.
9.
..-.
10. Installthe brake pads and pad shims correctly.
Installthe pads wirh the wear indicators {C) on the
inside.
lf you are reusing the pads, always reinstall the
brake pads in their original positions to prevent a
momentary loss of braking efficiency.
11. Rotate the caliper piston clockwise into the cylinder,
then align the cutout (A) in the piston with the tab
{B) on the inner pad by turning the piston back so
the caliper can be installed on the pad. Lubricate
the boot with rubber grease to avoid twisting the
Diston boot. lf the piston boot is twisted, back it out
so it is positioned properly.
8 x 1.25 mm22 N.ml2.2 kgt m,16 rbl.ttl
.ar
D8 x 1.25 mm23Nm{2.3 kgf.m,17 rbf.ft)
13.
14.
Installthe brake caliper (C) and caliper bolts (D).
and tighten the bolts to the specified torque.
Installthe brake hose (E).
Press the brake pedal several times to make sure
the brake works, then test-drive.
NOTE: Engagement of the brake may require a
greeter pedal stroke immediately after the brake
pads have been replaced as a set. Several
applications of the brake pedal will restore the
normal pedal stroke,
15. Check the parking brake adjustment {see page 19-7).
16. After installation, check for leaks at hose and line
joints or connections, and retighten if necessarY.
19-21

Brakes
Conventional Brake Components ................ 1 9-1
ABS (Anti-lock Brake System) Components
Comoonent Location lndex .............,........................... 19-30
General Troubleshooting Information ....................... 19-31
DTC Troubleshooting Index .............. 19-34
Symptom Troubleshooting Index ...,........................... 19-35
System Description ................. ........... 19-36
Circuit Diagram ......... 19-42
DTC Troubleshooting ............... .......... 19-45
ABS Indicator CircuitTroubleshooting ...................... 19-52
Brake System Indicator Circuit
Troubleshooting ...................... ....... 19-55
ABS Modulator-Control Unit Removal and
lnstallation ............. 19-57
Wheel Sensor Insoection ................... 19-59
Wheel Sensor Reolacement .............. 19-59

General Troubleshooting Information
ABS Indicator
. lf the system is OK,theABS indicator goes off 2
seconds after turning the ignition switch ON (ll)
without starting the engine, and then comes on again
and goes off 2 seconds later after starting the engine.
This occurs because the ABS control unitisturned
on by the lG2 power source.. The ABS indicator comes on when the ABS control
unit detects a problem in the system. However, even
though the system is operating properly, the indicator
will come on under these conditions:- Only the drive wheels rotate- One drive wheel is stuck- The vehicle goes into a spin- The ABS continues to operate for a long time.- The vehicle is subjected to an electrical signal
disturbance
To determine the actual cause of the problem, question
the customer about the problem. taking the above
condilions into consideration.
. When a Droblem is detected and lhe ABS indicator
comes on, there are cases when the indicator stays
on until the ignition switch is turned OFF, and cases
when the indicator goes off automatically when the
sYstem returns to normal.- DTC 61: The ABS indicator goes off automatically
when the system returns to normal.- DTC 11, 13,15,17 ,31,32,33, 34, 35, 36, 37, 38, 54,
or 81: The ABS indicator stays on until the ignition
switch is turned OFF whether or not the system
returns to normal.- DfC 12, 14, 16, 1a,21,51,52, or 53; The ABS
indicator goes off when the vehicle is driven again
and the system is OK after the ignition switch is
turned from OFF to ON {ll}.
Diagnostic Trouble Code {DTCI
. The memory can hold three DTCS. However, when
the same DTC is detected more than once, the more
recent DTC is written over the earlier one.
Therefore, when the same problem is detected
repeatedly, it is memorized as a single DTC.. The DTCs are in the order they occurred, beginning
with the most recent.. The DTCS are memorized in the EEPROM (non-
volatile memory). Therefore. the memorized DTCs
are not cleared when the battery is disconnected, the
ignition switch is turned off, or the system returns to
normal. Do the specified procedures to clear the
DTCs.
Self-diagnosis
. Self-diagnosis can be classified into two categories:- Initial diagnosis:
Done right after the engine starts and until the ABS
indicator goes off- Regular diagnosis:
Done rightafterthe initial diagnosis until the
ignition switch is turned OFF. When a problem is detected by self-diagnosis, the
system does the following:- Turns the ABS indicator on- Memorizes the DTC- Stops ABS control
Kickback
The pump 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.
Pump Motor
. The pump motor operates when the ABS is
functioning.. The ABS control unit checks the pump motor
operation when the vehicle is started the first time
after the ignition switch is turned ON (ll). You may
hear the motor operate at this time, but it is normal.
(cont'd)
19-31

ABS Components
General Troubleshooting Information (cont'd)
How to Troubleshoot ABS DTCs
The troubleshooting flowchart procedures assume that
the cause of the oroblem is still Dresent and the ABS
indicator is still on. Following the flowchart when the
ABS indicator does not come on can result in incorrect
diagnosis.
The connector illustrations show the female terminal
connectors with a single outline and the male terminal
connectors with a double outline.
1. Ouestion the customer about the conditions when
the problem occured, and try to reproduce the
same conditions for troubleshooting. Find out
when the ABS indicator came on, such as during
ABS control, after ABS control, when the vehicle
was at a certain speed, etc.
2. When the ABS indicator does not come on during
the test-drive, but troubleshooting is done based on
the DTC, check for loose connectors. poor terminal
contact, etc., before you start troubleshooting.
3. After troubleshooting, clear the DTC,disconnect the
Honda PGM Tester. and test-drive the vehicle.
Make sure the ABS indicator does not come on.
How to Retrieve ABS DTCs
Honda PGM Tester Method:
1, Wjth the ignition switch OFF, connect the Honda
PGM Tester (A) to the 16P data link connector (DLC)
(B) under the driver's side of the dashboard.
19-32
2. Turn the ignition switch ON (ll), and follow the
prompts on the PGM Tester to display the DTC{S)
on the screen. After determining the DTC, refer to
the DTC Troubleshooting Index.
NOTE: See the Honda PGM Tester user's manual
for specific instructions.
Service Check Signal (SCS) Circuit Method:
1. With the ignition switch OFF, connect the Honda
PGM Tester (A) to the 16P data link connector (DLC)
(BI under the driver's side of the dashboard.
2. Short the SCS circuit to body ground using the
Honda PGM Tester.
3. Turn the ignition switch ON (ll).