1997 HONDA CIVIC Shaft

Rear Brake Galiper
Disassembly (cont'd)
7. Remove the piston by rotating the piston counter-clockwise with the tool, and remove the piston
boot.
CAUTION: Avoid damaging the piston.
PISTON BOOTReplace.
Remove the piston seal.
CAUTION: Take care not to damage the cylinderbore.
CALIPER BODYCheck for scoring on
9. Install the special tool between the caliper bodv andspnng cover.
CAUTION: Be caretul not to damags the inside ofthe caliper cylinder during caliper disassembty.
BRAKE SPRINGCOMPRESSOR07HAE - SG00100
11.
LOCKNUTS
Position the locknuts as shown. then turn the shaftuntil the plate just contacts the caliper body.
NOTE: Do not compress the spring under thespring cover.
Turn the shaft clockwise 1/4 -'ll2 tu.n to comoressadjusting spring B in the caliper body.
CAUTION: To preyant damage to the inner compo-nonts. do not turn the shaft mor€ than 1/2 turn.
SHAFT
LOCKNUTS
PISTON SEALReplace.
ADJUSTII{GSPRING 8
19-28

\
13.
Lower the locknuts fully, and tighten them securely.
NOTE: Keep the locknuts in this position until you
reinstallthe circlip.
Remove the circlip with snap ring pliers.
SNAP RINGPLIERS07914 - SA50001
't 4.Hold the plate with your fingers, and turn the shaft
counterclockwise. Remove the special tool from the
calioer.
LOCKNUTS
l./
15. Remove the adjusting bolt.
Remove the spring cover, adjusting spring B, spacer,
bearing A, and cup from the adjusting bolt.
Remove the sleeve piston, and remove the pin from
the cam in the caliper body.
'17 .
SLEEVE PISTONCheck lor wear anddamage,
i
I
I
6-50-awl \
IO-RIITGRepl6ce.
(cont'd)
19-29

Rear Brake Galiper
Disassembly (cont'dl
18. Remove the return spring.
PARKING LEVER/CAM ASSEMBLYCheck lor damage.
Remove the parking lever and cam as an assemblvfrom the caliper body.
CAUTION: Do not loosen the parking nut with thecam inslalled in the caliper body, lf the leyer andshaft must be separated, hold the lever in a vise,and loosen the parking nut,
Remove the cam boot.
RETURNSPRING
19.
19-30

10. lnstall the special tool onto the spring cover, and
turn the shaft until the locknut contacts the plate.
Check that the flared end of the spring cover is below
the circlip groove.
Install the circlip into the groove. then remove the
special tool.
NOTE: Check that the circlip is seated in the groove
properly.
11.
12.
CIRCLIP
t.t
SPRING COVER
13. Coat a new piston seal with recommended silicone
grease in the caliper seal set, and install it in the cali-
per.
PISTON BOOTReplace. RUBBER GREASE
Apply recommended rubber grease in the caliper
seal set to the sealing lips and inside of a new pis-
ton boot, and install it in the caliper.
Coat the outside of the piston with brake fluid, and
install it onto the adjusting bolt while rotating it
clockwise with the tool.
CAUTION: Avoid damaging the piston and piston
boot.
PISTON SEALReplace.
-6l
14.
PISTON
(cont'd)
19-33

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

Compressor {SANDEN)
Clutch Overhaul
1. Remove the center nut while holding the armatureplate with the tool.
CENTER NUT17.6 N.m {1.8 kg{.m,'t3 tbnft}
2. Remove the armature plate by pulling it up by hand.
ARMATURE PLATE
A/C CLUTCH HOLDER{Commerciallv aveilable)Robinair: P/N 10204Kent-Moore: P/N J37872
22-34
3. Remove snap ring B with snap ring pliers.
NOTE:
. Be careful not to damage the rotor pulley and
compressor during removal/installation.. Once snap ring B is removed, replace it with anew one.
A
\/
G::.
Remove the rotor pulley from the shaft with a puller
and the special tool.
NOTE: Place the claws of the puller on the back of
the rotor pulley, not on the belt area; otherwise the
rotor pulley can be damaged.
. r \:g2rl -/ /
.-!L;j'/
TWO JAW PULLER{Commercially

A/G GomPressor Belt
Adjustment
Detlection Method
'1. Apply a force of 98 N (10 kgf, 22 lbf), and measure
the deflection between the A,/C compressor and the
crankshaft PulleY
A/C ComPressor Belt
Used Belt: 816A2 engine
6.0 - 9.5 mm 10 2'l - 0.37 inl
Except 816A2 engine
7.5 - 9.5 mm (0.30 - 0.37 in)
New Belt: 816A2 engine
4.5- 6 5 mm (0.18-0.26 in)
Except 815A2 engine
5.0-5 5 mm (0.20-0.26 inl
Note these items when adjusting belt tens'on:
. lf there are cracks or any damage evident on the
belt, replace it with a new one.
. "Used belt" means a belt which has been used
for five minutes or more.
. "New belt" means a belt which has been used
tor less than five minutes.
2. Loosen, the center nut ofthe idler pulley (SANDEN), or
the pivot bolt of the idler pulley bracket and the lock
nut ofthe adjusting bolt (DENSO).
3. Turn the adjusting bolt to get proper belt tension'
4. Retighten the center nut of the idler pulley (SANDEN),
or the pivot bolt of the idler pulley bracket and the lock
nut of the adjusting bolt (DENSO).
5. Recheck the deflection of the A,/C compressor belt'
Tension Gauge Method
1. Attach the special tool to the IVC compressor belt as
shown below, and measure the tension of the belt
A/C Compressor Belt
Used Belt: 816A2 engine
390 - 540 N (40 - 55 kgf, 88 - 120 lbll
Except 816A2 engine
340 - 490 N (35 - 50 ksf, 77 - 110 lbfl
New Belt: B16A2 engine
?40 - 880 N {75 - 90 ksf' 170 - 200 lbf)
Except Bl642 engine
690 - 830 N (70 - 85 ksf, 150 - 190 lbf)
Note these items when adjusting belt tension:
. Follow the manufacturer's instructions for the
belt tension gauge.
. lf there are cracks or any damage evident on the
belt, rePlace it with a new one.
. "Used belt" means a belt which has been used
for five minutes or more.
. "New belt" means a belt which has been used
for less than five minutes
2 Loosen the center nut of the idler pulley (SANDEN)' or
the pivot bolt of the idler pulley bracket and the lock
nut of the adjusting bolt (DENSO).
3. Turn the adjusting bolt to get proper belt tension
4. Retighten the center nut of the idler pulley (SANDEN),
or the pivot bolt of the idler pulley bracket and the lock
nut of the adjusting bolt (DENSO)
5. Recheck the tension of the A/C compressor belt'
22-43

Connector ldentification and Wire Harness Routing
Engine Wire Harness lD16Y5, D16Y8 enginss): '96 - 98 models
Connector or
Torminal
Numbsr of
CavitissLocationConnects toNot€s
c 101c102c103c104c104c105c106c107c108c 109c110c111c112c113c114c115c116cl17c118c119c120cl21
c122c123cl23c124
c125
c127c12Ac129c130c131c132c 133c134c135
c136
c138c139c140c 141c142c 143c144cl44c145c'146cl47
10
1
22
14l4322l0I
2
2
2
2120
3l
14
14
1222
2
2
22
Left side of engine compartmentMiddle of engineMiddle of engineLeft side of engine companmentLeft side of engine compartmentMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of enginefvliddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineLeft side of engine compartmentMiddle of engineMiddle of engineMiddle of engineMiddle of engine
Middle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineMiddle of engineRight side of engine companmentBehind right kick panelUnder right side of dashUnder riOht side of dashUnder right side of dashUnder right side of dashUnder right side of dashUnder right side of dash
Under right side of dash
Under right side of dash
Middle of engineMiddle ot enginel iddle of engineMiddle of engineMiddle of ongineMiddle of engineLeft side of engine compartmentMiddle of engineMiddle of engineRight side of engine compartmentRight side of engine compartmentRight side of engine compartment
USACanada
Afi
USA
-' (A/r)
Main wire harness (C303)Crankshaft speed fluctuation (CKF) sensorEngine oil pressure switchAlternatorAlternatorNo. 'l fuel injectorNo. 2 fuel injectorNo.3 fuel injectorNo. 4 fuel injectorIAC valveThrottle position (TP) sensorl\4anifold absolute pressure (MAP) sensorIntake air temperature (lAT) sensorPower steering pressure {PSPI switchEVAP purge control solenoid valveJunction connectorJunction conn€ctorVehicle speed sensor {VSS}Countershaft speed sensorEngine coolant temp€rature (ECT) switch ADistributorEngine coolant temperature (ECT) sendingunrtEngine coolant temperature (ECT) sensorPrimary HO2S (sensor'l)Primary HO2S (sensor 1)Back-up light switchLock-up control solenoid valveSecondary HO2S (sensor 2)Mainshaft speed sensorLinear solgnoid valveShift control solsnoid valveStarter solenoidJunction connectorMain wire harnesE (C446)ECM/PCMPCMECMiPCMECM/PCMMain wire harness (C305)
Main wire harness (C305)
Main wire harness (C305)
Knock sensor (KS)IAC valveVTEC solenoid valveVTEC pressure switchEVAP control canister vent shut valveEGR control solenoid valveSecondary gear shaft speed sensorEGR valveEGR valveDrive pulley speed sensorSolenoid connector {CVT)Driven pulley speed sensor
*, (M/T)M/T*" INT\
*, tAtf)
NT:'96 model*,(A,/T):'97 - 98mooets
moqets
M/T
-1 (l,/T)*, (A,/T)-,(4,/T)*1 {M/T)*, (A,/T)*1 (CW)*, (A,T)
T101r102Left side of engine companmentRight side of engine companmentAlternatorUnder-hood fuse/relay boxG 101Middle of engineEngine ground, via engine wire harness
2
*1: Dl6Y5 engine*2: D16Y8 engine*3: D16Y5 (Ay'T), D16Y8 engines
3-16