1996 HONDA CIVIC length

CHECK BALL
w
MAIN VALVE BODY(Sectional viewl
SPRING SPECIFICATIONS
CHECK BALLS
CHECK BALLS
Unit: mm (in)
No.Springs
Standard (New)
Wire Dia.o.D.Free LengthNo. ot Coils
o
@
@
@
@
@
Relief valve spring
Modulator valve spring
CPB valve spring
1-2 shift valve spring
2nd orifice control valve spring
Servo control valve spring
1.1 (0.043)'1.4 (0.055)
0.9 (0.035)
0.9 (0.035)
0.7 (0.028)
1.0 (0.039)
8.6 (0.342)
9.4 (0.374)
8.1 t0.3221
7.6 {0.302)
6.6 (0.262)
8.'t to.322l
37.1 (1.461)
35.0 (1.378)
47.2 (1.8s8)
41.3 (1.6261
34.8 (1.370)
52.1 t2.O51l
13.4
10.91C ?'15.3
22.0
20.8
1+143

Servo Body
Disassembly/lnspection/Reassembly
NOTEI
. clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.. Replace the valve body as an assembly if any parts are worn or damaged.. Coat all parts with ATF during assembly.
. Replace the O-rings.
. The servo body shows the '96 - 98 models: the '99 - 00 models have an integrally molded servo detent.
SERVO BODYInspect for wear, scratches and scoring.
,______.- g
1l
v
"-------'g
ZruO lCCUr,irUr-nrOn ---rrr___-p
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3,ii11---------*5
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I
O.RINGReplace.
3RO ACCUMULATOR PISTON
4TH ACCUMULATOR PISTON
SPRING SPECIFICATIONS
SNAP RINGS
1ST ACCUMULATOR PISTON
Unit: mm (in)
No.SpringsStandard {New)
Wire Dia.o.D.Free LengthNo. of Coils
o(a
@)
o
@
'I st accumulator spring
4th accumulator spring A
4th accumulator spring B
3rd accumulator spring A
3rd accumulator spring B
2nd accumulator spring C
2nd accumulator spring A
2nd accumulator spring B
2.1 (0.083)
2.6 (0.102)
2.3 (0.091)
2.8 (0.110)
2.210.0871
2.2 t0.0a7l
2.4 (0.094)'1.6 (0.063)
16.0 (0.636)
17.0 (0.676)
10.2lo.402J
17.5 (0.695)
31.0 11.220)
14.5 (0.576)
29.0 (1.152)
9.0 (0.358)
89.1 (3.s08)
87.0 (3.425)
51.6 (2.031)
89.3 (3.516)
35.1 (1.382)
68.012.677)
39.0 (1.535)
20.7 (0.815)
14.2
13.8
'13.9
L
14-146

Driveshafts
Reassembly (cont'dl
8. Fit the inboard joint onto the driveshaft, and note
these items:
. Reinstall the inboard joint onto the driveshaft by
aligning the marks on the inboard joint with the
marks on the rollers.
. Hold the driveshaft so that the inboard joint
points up to prevent it from falling off.
Adjust the length of the driveshafts to the figure
below, then adjust the boots to halfway between
full comDression and full extension. The ends of the
boots seat in the groove of the driveshaft and joint.
Right driveshaft, 1600 OOHC VTEC model:475 - 480 mm (18.7 - 18.9 in)Left driveshaft, all othei models:774-779 mm (30.5 - 30.7 in)Right driveshaft, all other models:501 - 506 mm 119.7 -'19.9 inl
Left driveshaft. 1600 DOHC WEC model:475 - 480 mm 118.7 - 18,9 inl
16-12
OYNAMIC DAMPEROUTBOARD JOINT
10. lf necessary position the dynamic damper as shown
Detow.
. Install a new dynamic damper band. and bend
down both sets of locking tabs.
. Lightly tap on the doubled-over ponjon of the
band to reduce its height.
Loft:
1600 DOHC VTEC model: 26 i 2 mm (1.0 t 0.1 inl
All other models: 9,1t 2 mm (3.7 10.1 inl
With "SR1" mark: 7512 mm 12.9 ! 0.1 inl
Right:
16dl DOHC VTEC models: 2612 mm 11.0 t 0.1 inl
All other modelii
DYNAMIC DAMPER
-SR1" MARK
U.S. and Canada-Produced ITPE BOOTI
Left 53612 mm {21.1 10.1 in}
Right: 2txt 12 mm {10.it 1 0.1 in}
5512 mm (2.2 t 0.1 inl
INBOARO JOINT
DYNAMIC DAMPER BAND

Steering Gearbox
Disassembly (cont'dl
10. Slide the steering rack out of the cylinder housing.
CAUTION: Be carelul not to damage the bushing in
the cylinder housing.
11. Remove the rack end bushing.
GEARBOX MOUNTING CUSHION
Inspect inner wall tor wear or damage.
17-8
12. Replace the gearbox mounting cushion if necessary:
. To remove the cushion, use a sharp knife and make
a cut down the length of the cushion. Be careful not
to damage the paint on the outside of the cylinder
housing. Remove the old cushion.. Apply weatherstrip adhesive to the inside of the
new cushion. Install the cushion onto the cylinder
housing and position it 20 - 22 mm (0.79 - 0.87 in)
from the end of the cylinder housing as shown.
NOTE: After installing the cushion, wipe off any
excess adhesive that may have dripped into the
inside of the cylinder housing.
20 - 22 mm 10.79 - 0.87 in)

It
12.
13.
lnstall the new lock washer in the groove in the
steering rack.
Installthe steering rack end into the rack
LOCK WASHER RACK END 54 N m ts.s kgf'm, 40 lbtft)
Replace.
TAB
(l*v
14.
15.
RACK END
Hold the steering rack with a wrench and tighten
the rack end with another.
CAUTION: Be careful not to damage the tack sur-
fac€ with the wrench.
After tightening the rack ends, stake the four sec-
tions of the lock washer with a roll pin drift and a
mallet.
. Place the wood block on the press table. then set
the lock washer section of the rack end on the
wood block securelY.
. Be sure the tool is aligned with the flat sections
of the steering rack end before pressing
. Stake the lock washer in the center of the flat
section of the steering rack end.
ROLL PIN DnlFTl(Commorci.lly .Yril.blolSnap-On No. PPRS or oquival.nt
NOTE: This drift has a flat
tip, to prevent puncturing
of metal washer.
srEEatruG nlCr/rl,WOODEN BLOCK
TIE.ROO CLIP
16. Apply grease around the outside ot the rack end
housing.
Apply a light coat of silicone grease to the boot
grooves on the rack ends.
lnstall the boots in the rack end with the tie-rod
clips.
NOTE: Install the boot band with the rack in the
straight ahead position (right and left tie-rods are
equal in length).
=-..r=-q!q!!.n
SILICONE GREASE
17.
(cont'd)
17-11
NOTE| WiPe grease off
the thread sectlon

Steering Gearbox
Reassembly (cont'dl
64. Apply grease to the circumference of the rack endhousing.
RACK END GROOVE
=^.#-q!:s!!H
SILICONE GREASE
Apply a light coat of silicone grease to the bootgrooves on the rack ends.
lnstall the boots in the rack end with the tie-rodclips.
NOTE: Install the boots with the rack in the straightahead position (right and left tie-rods are equal inlength).
66.
RACK END
NOTE: Wipe the grease offthe thread section.
17-64
TIE.ROD CLIP
67. Adjust the air hose fitting position of the boots bvturning it as shown below.
LEFT BOOT(Viewed from theleft side)
RIGHT BOOT{Viewed from theright side)
AIR HOSE FITTING
Install new boot bands on the boot, and bend bothsets of locking tabs.
CAUTION: Stlke ths band locking tabs firmly.
Lightly tap on the doubled-over portions to reducetheir height.
Slide the rack right and left to be certain that theboots are not deformed or twisted.

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

Master Cylinder/Brake Booster
Pushrod Glearance Adjustment
NOTEr
. The master cylinder pushrod-to-piston clearancemust be checked and adjustments made, if neces_sary, before installing the master cylinder.. ABS type is shown, conventional brake type is similar.
1. Set the special tool on the master cylinde. body; push
in the center shaft until the top of it contacts the endofthe secondary piston by turning the adjusting nut.
Without disturbing the center shaft's Dosition, installthe specialtool upside down on the booster.Install the master cylinder nuts, and tighten to thespecified torque.
Connect the booster in-line with a vacuum gauge O _
101 kPa (0 - 760 mmHg, 30 in.Hg) to the booster,sengine vacuum supply, and maintain an enginespeed that will deliver 66 kpa (500 mmHg, 20 in.Hg)vacuum.
With a feeler gauge. measure the clearance Detweenthe gauge body and the adjusting nut as shown.
Clearance: 0 - 0.4 mm {0 - 0.02 in)
VACUUM GAUGE(Comm€rcially availeblel0 - 101 kPa{0 - 760 mm Hg, 30 in.Hg)
AOJUSTING NUT
FEELER GAUGE
19-22
10.
NOTE: lf the clearance between the gauge bodyand adjusting nut is 0.4 mm (0.02 in), the pushrod-to-piston clearance is 0 mm. However, if the clear_ance between the gauge body and adjusting nut is0 mm, the pushrod-to-piston clearance is 0.4 mm(0.02 in) or more. Therefore, it must be adjusted andrechecked.
6. lf clearance is incorrect, loosen the star locknut, andturn the adjuster in or out to adjust.
NOTE;
. Adjust the clearance while the specified vacuumis applied to the booster.. Hold the clevis while adjusting.
Tighten the star locknut securely.
Remove the special tool.
0 - 0.4 mm (0 - 0.02 in)
7.
ADJUSTERPUSHRODADJUSTMENT GAUGE07JAG - SD('1(x)
9. Adjust the pushrod length as shown if the boosterrs removed.
STAR LOCKNUT22 N.m{2.2 kg,f.m, 16lbtft)
11610.5 mm{{.571 0.02 in)
PUSHRODLOCKNUT15 N.m 11.5 kgf.m, 11 tbtftl
Install the master cylinder {see page l9-21).