2003 HONDA CIVIC Brake system

Rear Brake Caliper Overhaul
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
' Avoid breathing dust particles.
. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner'
Remove, disassemble, inspect, reassemble, and installthe caliper, and note these items:
. Donotspill brake fluid on the vehicle; it may damage the paint; if brake f luid gets on the paint, wash it off
immediately with water.. To prevent dripping. cover disconnected hose joints with rags or shop towels.
. Cleanall partsinbrakefluidandairdry;blowoutall passageswith compressed air'
. Before reassembling, check that all parts are free of dust and other foreign particles
. Replace pans with new ones as specified in the illustration.. Make sure no dirt or other foreign matter contaminates the brake fluid.
. When reusing pads, always reinstallthem in their original positions to prevent loss of b ra king efficie ncy.
. Do not reuse drained brake fluid.
. Use only clean Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the
system.. Do not mix different brands ot brake fluid as they may not be compatible.
. Coatthe piston, piston seal groove, and caliper bore with clean brake fluid.
. Make sure no grease or oil gets on the brake discs or pads.
. Replaceall rubber parts with new ones whenever disassembled.
. After installing the caliper, check the brake hose and line for leaks, interference. and twisting.
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19-23

Brake Hose Replacement
NOTE:. Do not spill brake fluid on the vehicle; it may damage
the paint; if brake fluid gets on the paint, wash it off
immediately with water.. To prevent dripping, cover disconnected line joints
with rags or shop towels.. Before reassembling, check that all parts are free of
dust and other foreign particles.
. Replace parts with new ones whenever specified to
do so.
1 . Replace the brake hose (A) if the hose is twisted,
cracked, or if it leaks.
Disconnect the brake hose from the brake line (B)
using a 10 mm flare nut wrench {C)
Remove the flange bolt (A), and remove the brake
hose brackets from the damper.
Remove and discard the hose clip (B).
Remove the banjo bolt (C), and remove the brake
hose (D) {rom the caliper.
4.
I x 1.25 mm
6. Installthe brake hose bracket (A)on the damper
with the flange bolt (B) first, then connect the brake
hose (C) to the caliper with the banjo bolt {D) and
new sealing washers (E).
7. lnstallthe hose onto the hose bracket on the bodv
with a new hose clip (A).
10 x 1.0 mm15 N.mi (1.5 kgf.m,
! 1t tbt.ftl
Connect the brake line to the brake hose.
After installing the brake hose, bleed the brake
system (see page l9-8).
Do the following checks:
. Check the brake hose and line joint for leaks, and
tighten if necessary.. Check the brake hoses for interference and
twisting.
9.
10.
19-25

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

4. The blinking frequency indicates the DTC. DTCS are
indicated by a series of long and short blinks. One
long blink equals 10 shon blinks. Add the long and
short blinks together to determine the DTC. After
determining the DTC, refer to the DTC
Troubleshooting Index.
NOTE:. lf the DTC is not memorized, the ABS indicator
will go off for 3.6 seconds, and then come back
on.. lf the ABS indicatorstays on, troubleshootfor"ABS indicator does not go off" (see step 1 onpage 19-53).
Th€ system will not indicate the DTC unless these
conditions are met:. The brake pedal is not pressed.. The ignition switch is turned ON {ll).. The SCS circuit is shorted to body ground before
the ignition switch is turned ON (ll).
Example ot DTC 15
Long blinkShort blinks{five timesl
Examole of DTC 22
Long blinks (two times)
Turn the ignition swltch OFF,
Disconnect the Honda PG M Tester from the DLC.
5.
How to Clear ABS DTCs
Honda PGM Tester Method:
1. With the ignition switch OFF, connect the Honda
PGM Tester (A)to the l6Pdata link connector (DLC)
{B} under the driver's side of the dashboard.
Turn the ignition switch ON (ll), and clearthe
DTC(s) by following the screen prompts on the
PGM Tester.
NOTE: See the Honda PG l\4 Tester user's manual
for sDeclf ic instructions.
Cycling the lgnition Switch Method:
Clear the DTC by turning the ignition switch ON (ll) then
OFF at least 20 times.
19-33

Symptom Troubleshootin g Index
SymptomDiagnostic procedureAlso check forABS indicator does nol come onABS Indicator Circuit Troubleshooting (see page
19-52)
ABS indicator does not go off and no
ABS DTC is stored
ABS Indicator Circuit Troubleshooting {see step 1
on Daqe 19-53)
Brake system indicator does nol come
on
Brake System lndicator Circuit Troubleshooting(see paqe 19-55)
Brake system indicator does not go off
and no ABS DTC is stored
Brake System Indicator Circuit Troubleshooting(see steo 1 on Daqe 19-55)
19-35

Terminal
number
Wire
color
TerminalsignDescriptionMeasurement
TerminalsConditions {lgnition
switch oN lll))
Voltage
14WHT/
BLK
STOPDetects brake
switch siqnal
I4-G NDBrake pedalPressedEattery
voltaoeReleased
t5BLV
ORN
rG2Power source for
activating the
svstem
15-GNDBaftery
voltage
16BLKM-GNDGround for the
0umD motor
16-GN DBelow 0.3 V
WHT/
RED
+ B-MRPower source for
the oumD motor
17-GNDAt alltimesBattery
voltaoe
18WHT/
GRN
+ B-FSRPower source for
the valve relav
,18-GNDAt alltimesBattery
voltaoe'19BLKGNDGround for the
modulator
assemDtv
19.GNDBelow 0.3 V
20B LU/
RED
ABSDrives ABS
indicator
20-GNDABS
indicator
ONAbout 11 V
OFFBelow 1 V
BRN/
YEL
EBD(Electronic brake
distribution)
Drives brake
system indicator
21-GNDBrake system
indicator
OFFBelow 0.3 V
ON for
bulb
cnecK
8attery
voltage
(cont'd )
19-37

ABS Gomponents
System Description (cont'd)
Features
When the brake pedal is pressed during driving, the wheels can lock before the vehicle comes to a stop. In such an
event. the maneuverability of the vehicle is reduced if the front wheels are locked, and the stability of the vehicle is
reduced if the rear wheels are locked, creating an extremely unstable condition. The ABS precisely controls the slip
rate of the wheels to ensure maximum grip force from the tires, thereby ensuring the maneuverability and stability of
the vehicle.
The ABS calculates the slip rate of the wheels based on the vehicle speed and the wheel speed, then it controls the
brake fluid pressure to reach the target slip rate.
Grip Force of Tire and Road Surface
TARGET SLIP RATE
COEFFICIENT OFFRICTION
SLIP RATE
19-38