1996 HONDA CIVIC iat

Front Brake Galiper
Reassembly
5410 Type:
NOTE: For 2056 type reassembly procedures, see page 19-18.
o Never use an air hose or dry brush to clean brako assemblies.. Use an OSHA approved vacuum cleanerto avoid breathing brake dust.. Contaminated brake discs or pads reduce stopping abilhy.. when reusing the pads, always reinstall the brake pads in their original positions to pr€vent loss of braking €fficiency.
CAUTION:
. Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid do€s contaci the psint, wash it oft imme"diately with water.
. Clean all parts in brake fluid and air dry; blow out all passag€s whh comp.€ssed air.. Betore reassembling, check that all parts are free ol dust and othor toreign particlos.
. Replace parts wilh new ones whenever specified to do so.. Make sure no dirt or other toreign matt€r is allowed to contaminate the brake fluid.. Always use Genuine Honda DOT 3 Brake Fluid. Using a non.Honda brake tluid can cause corrosion and decresse thelife of th€ system.
NOTE:
. Coat the piston, piston seal, and caliper bore with clean brake fluid.. Replace all rubber parts with new ones whenever disassembled.
z_..=-.q8! .9!,H: Use recommended rubber grease in the caliper seal set.
-.61' use recommended seal grease in the catiper seal set.
BRAKE PADSPIN BOOTSReplace.
OUTER PAD SHIM
-o -'''---&@CAI-IPER PIN A -
BLEED SCREWS N.m (0.9 kgt.m, 6.5 tbf.ftl
"k..6
*/\*
car-rpen prr'r e-....,-q\,
-W@{
q
1
PAD RETAINERS
CALIPER BRACKET
WEAB INDICATOR
tilfliltn
tw tfi lJlWEAB rNDrcAroR \J I Ilnsrall inner pad with lAVirs weat indicatot !pwatd/,.
CALIPER BRACKEI MOUNTING BOLT108 N.m {11.0 kgt m,80lbf.ft)
PISTON BOOTReplace.
-6r
/ eoor cr-re
I neptace.
6/vo
PISTON SEALReplace.
19-16
CALIPER BODY

Front Brake Caliper
Reassembly (cont'd)
2056 Type:
. Never use an air hose or dry b.ush to clean brake assemblies.. Uso an OSHA approved vacuum cleansr to avoid breathing brake dust.. Contaminated brake discs or pads reduce stopping ability.t when reusing the pads, always r6instsll the brake pads in their original positioos to prevent loss ol braking efficiency.
CAUTION:
' Do not spill brake tluid or th€ vehicle; it m8y damage the paint; if brake fluid does contact the paint, wash it off imme-diately with water.
. Clean all parts in brake tluid and air dry; blow out all passages with compr63ed air.. Beforo reassembling, check that all parts are fr€e of dust and other foreign particles,. Replace parts with new ones whenevea specified to do so.. Make sure no dirt or other foreign matter is allowad to contaminato the brake fluid,' Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can caus€ corrosior and decrease thelife ol the system.
NOTE:
. Coat the piston, piston seal, and caliper bore with clean brake fluid.. Replaceall rubber parts with new ones whenever disassembled.
.'=5@: Use recommended rubber grease in the caliper seal set,
-6l ' Use recommended seal grease In the caliper seal set.
@6--i#i['i,?li"..;:l]l?Y]li"'"'
I
r""'"rr r"""ip"autr, -/ffr
e"6ft 'ADRETATNERSitswearndcatoru'ward
MffiA pr
GUIDE PIN BOOT ) {I I II ) I I
% caL,PER
\I\d/ tt ' id 6
u -es'---r..'.* ".-,."oo*'J.l, ru,oonW U
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WEAR,INDICAToR. ,ffi OUTERIPAD
BLEED SCREW9 N.m (0.9 kgf.m, 6.5 lbf.ft)
\o@
CALIPER BRACKET
PISTON EOOTReplace. -.&l
BOOT CLIPReplace.
SLEEVE A
SLEEVE 8
-"-41
r{.i'""Jg*'
a,t/ c'f3!@
q.-
t\
20 tbf.ftl
CALIPER BOLT B26Nm{2.7kgf.m,
CALIPER BODY
PIN BOOTReplace.
BRAKE PAOS
19-18

Master Cylinder/Brake Booster
IRemovaUlnstallation
CAUTION:
. Be care{ul nol to bend or damage the brake lines when
rsmoving the mastsr cYlinder.
. Do not soill brakefluid on the vehicle; it may damage
the paint; if brake fluid does contact the paint, wssh
it off immediatelY with water'
. To prevent spill3, cover the hose ioints with rags or
shop towels.
9. Remove the four booster mountlng nuts
10. Pull the brake booster forward until the clevis is
clear of the bulkhead.
11. Remove the brake booster from the engine com-
panmenr.'12. Install the brake booster and master cylinder in the
reverse order of removal.
CAUTION:
. When connecting the brake lines. make sure
that there is no inte erence between the brake
lines and oth6r Parts.
r Be careful not to bend or damage the brake lines
when installing the master cylinder.
NOTE: lf replacing the master cylinder or brake
booster, check and adiust the pushrod clearance
be{ore installing the master cylinder (see page 19-221'
Fill the master cylinder reservoir, and bleed the
brake svstem (see Page 19-7).
After installation. check the brake pedal height and
brake pedal tree play (see page l9-5) and adjust if
necessary.
BRAKE BOOSTER(With ABS: 7" + 8" tandem brake booster)
BRAKE FLUIO LEVELSWITCH CONNECTORS
MASTER CYLINDER
VACUUM HOSE
1.
2.
3,
5.
Disconnect the brake fluid level switch connectors'
Remove the reservoir cap from the master cylinder'
The brake fluid may be sucked out through the top
of the master cylinder reservoir with a syrlnge.
Disconnect the brake lines from the master cylinder'
Remove the master cylinder mounting nuts and
washers.
\l/
6. Remove the master cylinder from the brake booster'
7. Disconnect the vacuum hose trom the brake booster'
8. Remove the cotter pin and clevis pin from the clevis'
CAUTION: Do not disconnect the clevb by remov-
ing it from the operating rod of the brako booster' lf
the clevis is loosened, adiust the pushrod length
before installing th€ brake booster (see page 19-221'
COTTER PINReplace.
To Rear Wheel Cylinders
14.
-6.4CLEVIS PIN
To Front Caliper(Without ABS)$
t'N't'ttrnt'-''
To Front CaliperlWithout ABSi
PBOPORTIONING CONTROL VALVE
15 N.m {1.5 kgl m,11 tbtft)
15 N.m {1.5 kgif.m, 11 lbtft}(With ABS: To modulator unit)lr
19-21

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
Disassembly
@f l',lever use an air hose or dry brush to clean
assemblies.
. Use an OsHA-approved vacuum cleaner to
brake
avoid
breathing brake dust.
. Contaminated brake discs or pads reduce stopping
ability.
CAUTION:
. Do not spill brake tluid on the cal; h may damage the
paint; if brake fluid does contact the paint, wash ii
ofl immediatelY with water.
. To prevent spills, cover the hose ioints whh rags or
shop tow€ls.
. Clean all parts in brake fluid and air dry; blow out all
passagss with complessed air.
1. Remove the caliper shield (see page 19-24).
2. Remove the lock pin and clevis pin. Remove the
cable clip, and disconnect the cable from the arm
CABLE CLIP
Remove the banjo bolt and two sealing washers
Remove the two caliper mounting bolts and caliper
body from the bracket.
CALIPER MOUNTNG AOLTS
CALIPER BRACKETCheck for cracksSEALINGWASHERSReplace.BANJOBOLT
5, Remove the pins and pin boots from the caliper
bracket.
6. Remove the pad spring from the caliper body
PIN A
(cont'd)
19-27

IReassembly
HP* "n ",, hos6 or drv brush to ctoan brake assemblies.
o Use an OSHA-approved vacuum cleanel to avoid brealhing brake dust'
. Contaminated brake discs or pads reduce stopping sbility.
. When reusing the pads, in3tall thom in thoil original positions to prevent loss of braking efficiency'
CAUTION:
. Do not soill brake fluid on the vehicle; lt may damage lhe paint; if brake fluid does contacl the paint' wash it oft imme-
diately with water.
. Cl€an all Darts in brake fluid and air dry; blow out all passagss with comPressed air'
. Belore rsas3embling, check that all parts ars free ot du3t and othor tor€ign particles'
. Replace parts with new ones whenever spscifiod to do so.
o Make sur€ no dirt or othor foreign matter is allowed to contaminate the brake tluid'
. Always use Genuine Honda DOT 3 Brake fluid. Using a non-Honda brake fluid can Gtuse corrosion and decrease the
lif€ of ths system.
NOTE:
. Coat piston, piston seal, and caliper bore with clean brake fluid
. Replace all rubber parts with new ones whenever disassembled.
o .-'{@]: Use recommended silicone and pin greases in the caliper seal set.
. -ffi,Use recommended rubber grease in the caliper seal set.
RETuRN sPRTNG -"'9
8 mm FLANGE BOLT23 N.m (2.3 kgt'm, 17 lbf ftl
BLEED SCREW
@
9 N.m (0.9 kgtm,6.5lbf'ft|
CUP
=^.
PISTON BOOT
(cont'd)
19-31
BEARING A
PAO SPNING
F
\
OUTER PAD SHIM
r--- Replace..ffiPIN BOOTSReplace.
-61
@@-t-.
"l-r,r., "or"'*o " orr" I @.,23 N.m {2.3 kgtm, 17lbf.ftl \@
PISTON SEALReplace.
CALIPEBBRACKET
iiilji:ll;;
__X.,,..".^
BRAKE PAOS
PISTON
l/CALIPER BMCKET \MOUNTINGEOLTS ----.-,o,
54 N.m (5.5 kgf.m, 40lbl.ft) q%

Brake Hoses/Lines
Hose Replacement
CAUTION:
. Bgfore reagsembling, chgck that all parts are free of
dust and othor foroign particles.
. Repl8ce parts with new ones whenever specified to
do so,
. Do not spill brake fluid on th6 vehicle; it may damage
tho paint; if brake fluid does contact the paint, wash
it off immediately with water.
1.Replace the brake hose if the hose is twisted, cracked,
or if it leaks.
Disconnect the brake hose from the brake line using
a 10 mm flare nut wrench.
FLARE NUTWRENCHlCommerciallyava ilable)
BRAKE LINE
BRAKE HOSE
Remove and discard the brake hose cliD from the
brake hose.
Remove the banjo bolt, and disconnect the brake
hose from the caliper.
Remove the brake hose bracket from the knuckle.
19-40
10.
6. Install the brake hose bracket and brake hose onto
the knuckle first. then connect the brake hose to the
caliper with the banjo bolt and new sealing washers.
BRAKE HOSE
6 mm HOSE BRACKETBOLTS9.8 N.m{1.0 kgf m, 7 lbtfr}
BANJO BOI.T34 N.m{3.5 kgf.m,25 lbt.ftl
7. Install the brake hose onto the uooer brake hose
bracket with a new brake hose clip
15 N.m(1.s ks{.m, 11 lbl.ftl
Connect the brake line to the brake hose.
After installing the brake hose, bleed the brake sys-
tem (see page 19-7).
Perform the following checks:
. Check the brake hose and line joint for leaks, and
tighten if necessary.
. Check the brake hoses for interference and twist-
I ng.
8.

Troubleshooting
Wheel Sensor
Diagnostic Trouble Gode {DTC) ll-18: Wheol S€n3ol DiagnosisNoTE: The ABS indicator light comes on when only the drive wheels are turning, signal disturbance is detected, etc. Therefore,test-drive the car at a speed of 12 mph (20 krn/h) or more after turning the ignition:witch from OFF to ON fll), and if the ABSindicator light does not come on, the svstem is OK.
0TcAppropriate Terminal(0)srDE11) SrD€r 1, 12 (Right-front)No.8: FRoNo.21: FRI13, 14 (Left-front)No. 10: FLoNo.23: FL115, 16 {Right-rear)No. {: RRoNo. 17: RRl17, 18 (Left-rear)No.6: RLoNo. 19: RLI
RLl (LT BLU}FRl (GRN/BLKI
Wire side ol female terminals
NO
NOTE:. Normal voltage: Approx.2 V' 0 V: Replace the ABS controt unit.. 4 V or more indicates a short to power.
A8S CONTROL UNIT 26P CONNECTOR
RRO
IBLU/YELI
RR1 IGRN/YELIFL1 IGRN/ORN}
- With the ignition switch ON{ll), ABS indicator tighr doe.noi go off,- Aftsr driving, ABS indicatotlight comes on.- With the SCS so.vice connac-tor conn€c,ted {soe pege 19-561,DTCs 11-18 a.e indicrted.
Chock lhe wheol sensor ci.cuit:1. Disconnect the ABS controlunit 26P connector.2. lleasure the resistancebetween the appropriate wheelsensor (0) and (1) circuit termi,
. Reprir op€n in the l0l or {0 cir-cuit wiro, or shon to thc {01 cir-cuit wi.o in thc {11 circuit wircbctween ths ABS control unitand approprieto wheel a6nsor.. R.pl.ce th€ epp.opri.te wheal3€nloa.
ls the resistance OK?
/Frontr 750 - 1050 o/20"C, 68.F \\Rear: 850- 1150 O/20.C, 68"F /
Check toru short to body groundin the wheel senso. circuit:Check for continuity between theABS control unit 26P connectorappropriate wheel sensor (0) circuit terminali and body ground.
. Rapair short to body ground inth6 (0) or lll cilcuit wi..bctwa.n th6 ABS control unitand appropdaie whoel lonsor.. Rep|'c6 tho appropriatc whcelsanlor.
Chock tor a sho.t to powe. in thowheel3en3or circuit:1. Reconnect the ABS control unit26P connector,2. Start the engine.3. Measure the voltage betweenthe ABS control unit 26P con-nector appropriate wheel sen-sor (0) circuit terminal andbody ground.
Ropair rhon to powo. in the l0lor lll circuit wire batw.en th€ABS cont.ol unit and .pplopriatawhccl !€naoa,
ls there 4 V or more?
fio page 19-65)
19-64