1996 HONDA CIVIC vacuum lines

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Fue| Tank Pr€ssure sensor 196 Dr6Y8 engine (coupe},,97 D16Y7 angino (coupo: KL mode|' 3edan: KL (Lxl modg||',97
Dl6Y8 engine (coupe: all modeb, sedan: Ki model.'98'all modols) 39 - 0O Dl6Y5 ongins with M/Tl:
rFoG'l::;Jl"too|indicatesDiagnosticTroub|ecode(oTc)P0453;Ahighvo|tageprob|emintheFue|TankPressure
ECM/PCM CONNECTOR D Il6PI
PTANKILT GRNI
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Wire side of tgmale torminals
FUEL TANKPRESSURE SENSOR3P CONNECTOR (C792)
vcc2(YEL/BLU}
sG2(GRN/BLKI
Wire sid€ of female terminals
I
sG2IGRN/BLKI
PTANKIGBN/RED}
(cont'd)
11-279
The MIL has beon reponed on
DTC P0453 b stored.
Check the vacuum lines:
Check the vacuum lines oI the
fueltank pressure sensor for mis-
routing, leakage, breakage and
clogging.
Are the vacuum lines OK?
Problem verification:1. Do the ECM/PCM Reset Proce-
dure.2. Femove the fuel fill cap
3. Turn the ignition switch oN (ll).
4. Monitor the FTP Sensor volt-
age with the Honda PGM
Tester, or measure voltage
between bodY ground and
ECM/PCM connector termrnal
D15.
lntormittont t iluro, 3Ystem is OK
at this time. Check lot Poor con_
noctiona or loo3e wirat at C131
{loc.ted undor right 3id6 of d8hl,
CaOl llocatod rbov. under-dalh
fus6/relay boxl, C574 (C568lr
llocatod und6l accoss Pan6ll,C792 lfuel tank Preasulo aonlorl
end ECM/PCM.
ls there approx. 2 5 V?
Check for an oPen in the wire(SG2line):1. Turn the ignition switch OFF.
2. Reinstall the fuellill cap
3. Disconnect the fuel tank Pres-sure sensor 3P connector.
4. Turn the ignition switch ON (ll)
5. Measure voltage between the
fuel tank Pressure sensor 3P
connector terminals No. 1 and
No.2.
Ropair opon in the wira b€tw€sn
the fuel tank prasure sonlor and
ECM/PCM (Dl1).ls there aPProx. 5 V?
Check for an open in the wire(PTANK line):Measure voltage between the
fueltank Pressure sensor 3P con-
nector No. 3 terminal and No. 2
termrnal,
ls there approx. 5 V?
*: coupe
{To page 11-280)

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'99 - 0O modols except Dl5Y5 engine with M/T:
rFo45'::n":"tooIindicatesDiagnosticTroub|ecode(DTc)P0453:Ahighvo|tageprob|emintheFUelTankPressure
Wire side of temale terminals
FUEL TANKPRESSUNE SENSOR
SUB.HARNESS6P CONNECTOR {C574 (C568)}}
vcc2{YEL/BLUI
sG2IGRN/BLK)
Wire side of female terminals
PTANK{LT GRNI
(cont'd)
11-281
ECM/PCM CONNECTOR A {32P)
PTANK {LT GRN)
The MIL has been reported on.
DTC P0453 is stored.
Check the vacuum lines:
Check the vacuum lines ot the
fuel tank pressure sensor for mis-
routing, leakage, breakage and
clogging.
Are the vacuum lines OK?
Problem verilication:1. Do the ECM/PCM Reset Proce-
du re,2. Remove the fuel fill caP
3. Turn the ignition switch ON (ll).
4. Monitor the FTP Sensor volt'
age with the Honda PGM
Tester, or measure voltage
between body ground and
ECM/PCM connector terminalA.29.
lntermittent failuro. svstem b OK
at this time. Check for Poor con_
noctions or loo3€ wire3 at C131
{located under tight side of dash),
C4Ol {located above underdash
fuse/relay boxl, C57{ (C5681'
llocaled unde. access Panell,C792 {fuel tank Pressure sensorl
aod ECM/PCM.
ls there approx.2.5 V?
Ch€ck for an open in the wira
{SG2line):1. Turn the ignition switch OFF.
2. Reinstall the fuel fill caP
3. Remove the access Panellrom the floor.
4. Disconnect the fuel tank Pres-sure sensor sub-harness 6P
5. Turn the ignition switch ON (ll)
6, At the access Panelside, mea-
sure voltage between the fuel
tank pressure sensor sub_har-
ness 6P connector termlnals
No.5 and No.6.
Repair open in the wire between
the fueliank Pres3ure 3ensor and
ECM/PCM {Cl8).ls there approx.5 V?
Check lor an oPen in the wire
{PTANK linel:At the access Panel side, mea
sure voltage between the fuel
tank pressure sensor suo_harness
6P connector No. 2 terminal and
No. 6 terminal.
ls there approx. 5 V?
(To page 11.282)

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

Brake Booster InsPection
FunctionalTest
1. With the engine stopped, depress the brake pedal
several times to deplete the vacuum reservoir, then
depress the pedal hard and hold it for 15 seconds lf
the pedal sinks' either the master cYlinder is
bypassing internally, or the brake system (master
cylinder. lines. modulator, proportioning control
valve, or caliPer) is ieaking.
2. Start the engine with the pedal depressed lf the
pedal sinks slightly, the vacuum booster is operating
normally. lf the pedal height does not vary, the
booster or check valve is faultY.
3. With the engine running. depress the brake pedal
lightly. Apply just enough pressure to hold back
automatic transmission creep. lf the brake pedal
sinks more than 25 mm (1.0 in.) in three minutes,
the master cvlinder is faulty. A slight change in
pedal height when the A'lC compressor cycles on
and off if normal. (The A/C compressor load
changes the vacuum available to the booster')
Leak Test
1. Depress the brake pedal with the engine running.
then stop the engine. lf the pedal height does not
vary while depressed for 30 seconds, the vacuum
booster is OK. lf the pedal rises. the booster is
faulty.
2, With the engine stopped, depress the brake pedal
several times using normal pressure When the
Dedal is first depressed, it should be low On con-
secutive applications, the pedal height should grad-
uallv rise. lf the pedal position does not vary, checK
the booster check valve.
l./
19-23
Booster Check Valve Test
1. Disconnect the brake booster vacuum hose at the
booster.
2. Stan the engine and let it idle. There should be vac-
uum. lf no vacuum is available, the check valve is
not working properly. Replace the brake booster
vacuum hose and check valve, and retest.
BRAKE BOOSTERVACUUM HOSE(Check valve
built-in)

A/C System Service
Pressure Test Chart
NOTE: Performance Test is on page 22-24,
Test resultsRelated symptomsProbabl€ causeRemedy
Discharge (high)
pressure aDnor-
mally high
After stopping compressor. pres-
sure drops to about 200 kPa
{2.0 kgflcm,,28 psi) quickly, and
then falls gradually.
Air in systemRecover, evacuate, and
recharge with specified amount.
Evacuation: see page 22-45
Charging: see page 22-46
Reduced or no air flow through
condenser
. Clogged condenser fins. Condenser fan not work-
ing properly
Clean.
Check voltage and fan rpm.
Check fan direction.
Line to condenser is excessively
hot.
Restricted flow of refriger-
ant in system
Restricted lines
Discharge pres-
sure abnormally
High and low pressures are bal-
anced soon after stopping compres-
sor, Low side is higher than normal.
. Faulty compressor dis-
charge valve. Faulty compressor seal
Replace the compressor.
Outlet of expansion valve is not
frosted, low pressure gauge indi-
cales vacuum.
. Faulty expansion valve. Moisture in system
. Replace,. Recover, evacuate, and
recharge with specified
amount.
Suction (low)
pressure abnor-
mally low
Expansion valve is not frosted, and
low oressure line is not cold. Low
pressure gauge indicates vacuum.
. Frozen expansion valve. Faulty expansion valve
ReDlace the exoansion valve.
Discharge temperature is low. and
the air flow from vents is restricted.
Frozen evaporatorRun the fan with compressor
off. then check A,/C thermostat.
Exoansion valve is frosted.Clogged expansion valveClean or replace.
Receiver/dryer outlet is cool, and
inlet is warm (should be warm
during operation).
Clogged receiver/dryerReplace.
Suction pres-
sure abnormally
hig h
Low pressure hose and check
joint are cooler than the tempera-
ture around evaporator.
. Expansion valve open too
long. Loose expansion capillary
tube
Repair or replace.
Suction oressure is lowered when
condenser is cooled bv water.
Excessive refrigerant in sys-
tem
Recover. evacuate, and
recharge with specified amount.
High and low pressure are equal-
ized as soon as the compressor is
stopped, and both gauges fluctu-
ate while running.
Faulty gasket
Faulty high pressure valve
Foreign particle stuck in
high pressure valve
Replace the compressor.
Suction and dis-
charge pres-
sures abnormally
h igh
Reduced air flow through con-
denser.
. Clogged condenser fins. Condenser fan not work-
ing properly
Clean condenser.
Check voltage and fan rpm.
Check fan direction.
Suction and dis-
charge pressure
abnormally low
Low pressure hose and metal end
areas are cooler than evaporator.
Clogged or kinked low pres-
sure hose parts
Repair or replace.
Temperature around expansion
valve is too low compared with
that around receiver/dryer.
Clogged high pressure lineRepair or replace.
Refrigerant leaksCompressor clutch is diny,Compressor shaft seal leakingReplace the compressor.
Compressor bolt{s) are diny.Leaking around bolt(s)Tighten bolt(s) or replace com-
pressor.
Compressor gasket is wet with oil.Gasket leakingReplace the compressor.
22-26