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02-03 Honda Civic Si Service Manual

1. ABS CONTROL UNIT 31 CONNECTOR Wire side of female terminals DATA LINK CONNECTOR 16P WHEEL SENSOR 2P CONNECTORS FRONT Terminal side of female terminals RIGHT REAR LEFT REAR ni TEJI JJ pe Terminal side of male terminals 19 44 DTC Troubleshooting DTC 11 13 15 17 Wheel Sensor Open Short to Body Ground Short to Power 1 Disconnect the ABS control unit 31P connector 2 Start the engine 3 Measure the voltage between the appropriate wheel sensor circuit terminal of the ABS 5 Check for continuity between the appropriate wheel sensor circuit terminal and body ground see table DTC Appropriate Terminal 11 Right front No 5 FRS 13 Left front No 7 FLS 15 Right rear No 2 RRS 17 Left rear No 9 RLS control unit 31P connector and body ground see table ABS CONTROL UNIT 31P CONNECTOR DTC Appropriate Terminal FRS GNR BLK FLS IBLU ORN 11 Right front No 5 FRS RRS RLS 13 Left front No 7 FLS ONA YE 15 Right rear No 2 RRS 17 Left rear No 9 RLS J ABS CONTROL UNIT 31P CONNECTOR FRS GNR BLK FLS BLU ORN RRS RLS GNR YEL YEL RED m 1217151611892 2021444444 L VAVAVAVAVA Wire side of female terminals Is there continuity
2. Be careful not to bend or distort the cable Make sure the parking brake cable clip is fully seated on the cable housing Do the parking brake cable adjustment see page 19 7 19 27 Brakes Conventional Brake Components 19 1 ABS Anti lock Brake System Components Component Location Index eee 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 Circuit Troubleshooting 19 52 Brake System Indicator Circuit Troubleshooting 19 55 ABS Modulator Control Unit Removal and Installation esee eene 19 57 Wheel Sensor Inspection 19 59 Wheel Sensor Replacement 19 59 ABS Components Component Location Index RIGHT REAR WHEEL SENSOR Inspection page 19 59 Replacement page 19 59 UNDER DASH FUSE RELAY BOX UNDER HOOD FUSE RELAY BOX LEFT REAR WHEEL SENSOR Inspection page 19 59 a Replacement page 19 59 DATA LINK CONNECTOR 16P RIGHT FRONT WHEEL SENSOR Inspection page 19 59 Replacement page 19 59 ABS MODULATOR CONTROL UNIT Removal and Installation page 19 57 LEFT FRONT WHEE
3. YES Go to step 6 to step 7 Wire side of female terminals 6 Disconnect the harness 2P connector from the appropriate wheel sensor then check for continuity between the and terminals of the harness and body ground Is there battery voltage YES Repair short to power in the circuit wire between the ABS modulator control unit and the appropriate wheel sensor Is there continuity YES Repair short to body ground in the or circuit wire between the ABS modulator control unit and the wheel sensor NO Go to step 4 4 Turn the ignition switch OFF NO the wheel sensor cont d 19 45 ABS Components SS mmaa N DTC Troubleshooting cont d 7 Check the resistance between the appropriate wheel sensor and circuit terminals see table DTC Appropriate Terminal Side Side 11 Right front _ No 5 FRS 4 FRS C 13 Left front 7 FLS No 6 FLS 15 Right rear No 2 RRS No 1 RRS 17 Left rear No 9 RLS No 8 RLS ABS CONTROL UNIT 31P CONNECTOR 112714 Ts 61789 I7 TT 2L LI Wire side of female terminals Is the resistance between 450 2 000 Q YES Check for a loose ABS control unit 31P connector If necessary substitute a known good ABS modulator control unit and recheck lil NO to step
4. 12x 1 25 mm OUTER PAD SHIM 108 N m 11 0 kof m 80 Ibf ft 19 14 Master Cylinder Replacement NOTE Do not spill brake fluid on the vehicle it may damage the paint if brake fluid does contact the paint wash it off immediately with water 1 Remove the air cleaner assembly A 2 Disconnect the brake fluid level sensor connector A 9 8 1 0 kgf m 7 2 Ibf ft A 15 N m 1 5 kgf m 11 Ibf ft F 15N m 1 5 kgf m 11 Ibf ft 10 Remove the clutch reservoir B and engine wire harness clip from the master cylinder mounting base D Remove the reservoir cap and brake fuid from the reservoir Remove the reservoir E on the master cylinder mounting base Disconnect the brake lines F from the master cylinder G To prevent spills cover the hose joints with rags or shop towels Remove the master cylinder mounting nuts H and washers Remove the master cylinder from the brake booster Be careful not to bend or damage the brake lines when removing the master cylinder Remove the rod seal I from the master cylinder Install the master cylinder in the reverse order of removal and note these items Replace all the rubber parts with new ones whenever the master cylinder is removed Check the pushrod clearance before installing the master cylinder and adjust it if necessary see page 19 16 Use new rod seal on reassembly
5. Is there battery voltage YES Go to step 5 NO Repair open in the wire between the No 8 20A fuse and the ABS control unit cont d 19 53 ABS Components ABS indicator Circuit Troubleshooting cont d 5 Turn the ignition switch ON II 6 Measure the voltage between the ABS control unit 31P connector terminal No 15 and body ground ABS CONTROL UNIT 31 CONNECTOR 162 BLK ORN 4567892 17 18 10 2144444 Wire side of female terminals 112 Is there battery voltage YES Go to step 7 NO Repair open in the wire between the No 11 7 5A fuse and the ABS contro unit 7 Turn the ignition switch OFF 8 Check for continuity between the ABS control unit 31P connector terminal No 19 and body ground ABS CONTROL UNIT 31P CONNECTOR 20 21 DENN VA VAVAVAVA GND BLK Wire side of female terminals Is there continuity YES Go to step 9 NO Repair open in the wire between the ABS control unit and body ground G202 8 9 Turn the ignition switch ON 19 54 10 Connect the ABS control unit 31P connector terminal No 20 and body ground with a jumper wire ABS CONTROL UNIT 31 CONNECTOR 1 2L 14T5Te 7 8 9 7T 17 I LU ABS BLU RED JUMPER WIRE Wire side of female terminals Does the ABS indicator go off YES Check for loose terminals in the ABS control unit 31P connector If necessary substit
6. 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 OSHA approved vacuum cleaner Remove disassemble inspect reassemble and install the caliper and note these items 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 hose joints with rags or shop towels Clean all parts in brake fluid and air dry blow out all passages with compressed air Before reassembling check that all parts are free of dust and other foreign particles Replace parts with new ones as specified in the illustration Make sure no dirt or other foreign matter contaminates the brake fluid When reusing pads always reinstall them in their original positions to prevent loss of braking efficiency 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 of brake fluid as they may not be compatible Coat the piston piston seal groove and caliper bore with clean brake fluid Make sure no grease or oil gets on the brake discs or pads Replace all rubber parts with new ones whenever disassembled After installing the
7. 8 8 Disconnect the harness 2P connector from the appropriate wheel sensor and check the resistance between the and terminals of the wheel sensor Is the resistance between 450 2 000 Q YES Repair open in the or circuit wire or short between the circuit wire and the circuit wire between the ABS modulator control unit and the wheel sensor NO Replace the wheel sensor 19 46 DTC 12 14 16 18 Wheel Sensor Pulse Signal NOTE If the ABS indicator comes on for the reasons described below the indicator goes off when you test drive the vehicle at 31 mph 50 km h Only the drive wheel rotated The vehicle spun Electrical noise 1 Visually check for appropriate wheel sensor and pulser installation and condition see table DTC L Appropriate Wheel Sensor 12 Right front 14 Left front 16 Right rear 18 bs Left rear Are they installed correctly and not damaged YES Go to step 2 NO Reinstall or replace the appropriate wheel sensor or pulser io 2 Disconnect the ABS control unit 31P connector 3 Measure the resistance between the appropriate wheel sensor and circuit terminals see table DTC Appropriate Terminal Side Side 12 Right front No 5 FRS No 4 FRS 14 Left front 7 FLS No 6 FLS 16 Right rear No 2 RRS _ No 1 RRS 18 Left
8. Coat the inner bore lip and outer circumference of the new rod seal A with the recommended seal grease in the master cylinder set Install the rod seal onto the master cylinder with its grooved side B toward the master cylinder Check the brake pedal height and free play after installing the master cylinder and adjust it if necessary see page 19 6 MASTER CYLINDER SIDE 19 15 Conventional Brake Components Master Cylinder Inspection NOTE Before reassembling check that all parts are free of dust and other foreign particles Do not try to disassemble the master cylinder assembly Replace the master cylinder assembly with a new part if necessary Do not allow dirt or foreign matter to contaminate the brake fluid RESERVOIR CAP Check for blockage Ni of vent holes RESERVOIR SEAL Check for damage and deterioration s TRAINER Remove accumulated sediment RESERVOIR RESERVOIR HOSES Inspect hoses for damage leaks and deterioration MASTER CYLINDER Check for leaks rust and damage 19 16 Brake Booster Pushrod Clearance Adjustment Special Tools Required Pushrod adjustment gauge 07JAG SD40100 NOTE Brake booster pushrod to piston clearance must be checked and adjustments made if necessary before installing the master cylinder 1 Set the special tool A on the master cylinder body B push in the center shaft C until the top of it contacts the end of
9. caliper check the brake hose and line for leaks interference and twisting BANJO BOLT pu Honda caliper grease P N 08C30 80234M 34 N m 3 5 kgf m 25 SEALING WASHERS Replace w 7 HOSE BLEED SCREW Tees 9 N m 0 9 kgf m 7 Ibf ft ADJUSTING BOLT Qe cam PIN sieeve PISTON BEARING Guitar CORE e SPASER Ee Op f ADJUSTING 8 5 27 LEVER e r COVER CALIPER BODY OE a CIRCLIP ARM SPRING RETURN O RING CUP WASHER SPRING ANGE Replace Replace Vo PARKING NUT 23 N m 2 3 s 27 N m 2 8 kgf m 17 c GREASEX 20 Ibf ft SPRING CALIPER BOLTS 2s PISTON a PISTON BOOT PISTON SEAL ope Replace m PAD SHIM s AC Eod PAD SHIM Sg BRAKE PADS RETAINER PIN BOOT EARN BRACKET Replace 10mm d ds BOLTS 55 N m 5 6 kgf m 41 19 23 Conventional Brake Components Brake Hoses and Lines Inspection 1 Inspect the brake hoses for damage deterioration leaks interference and twisting 2 Check the brake lines for damage rusting and leakage Also check for bent brake lines 3 Check for leaks at hose and line joints or connections and retighten if necessary 4 Check the master cylinder and ABS modulator unit for damage and leakage NOTE Replace the brake hose clip whenever the brake hose is serviced BRAKE LINE to BRAKE HOSE 15 N m 1 5 kgf m
10. for brake drag Rapid brake pad wear Vehicle vibration after a long drive or High hard brake pedal 1 Drive the vehicle until the brakes drag or until the Is there brake drag at any of the wheels pedal is high and hard This can take 20 or more brake pedal applications during an extended test drive With the engine running raise the vehicle on a lift and spin all four wheels by hand 15 there brake drag at any of the wheels YES Go to step 3 NO Look for other causes of the pad wear high pedal or vehicle vibration W Turn the engine off pump the brake pedal to deplete the vacuum in the brake booster and then spin the wheels again to check for brake drag Is there brake drag at any of the wheels YES Go to step 4 NO Replace the brake booster Without removing the brake lines unbolt and separate the master cylinder from the booster then spin the wheels to check for brake drag Is there brake drag at any of the wheels YES Go to step 5 NO Check the brake pedal position switch adjustment and pedal free play I YES Go to step 6 NO Replace the master cylinder 6 Loosen the bleeder screws at each caliper then spin the wheels to check for brake drag Is there brake drag at any of the wheels YES Disassemble and repair the caliper on the wheel s with brake drag NO Inspect brake hose s line s 19 5 Conventional Brake Co
11. is pumped out by the pump through the damping chamber to the master cylinder 19 40 amp ABS Wheel Sensors The wheel sensors are the magnetic contactless type As the gear pulser teeth rotate past the wheel sensor s magnetic coil AC current is generated The AC frequency changes in accordance with the wheel speed The ABS control unit detects the wheel sensor signal frequency and thereby detects the wheel speed GEAR PULSER WHEEL SENSOR at HIGH SPEED VOLTAGE Wheel Speed and Modulator Control SPEED _NEHICLE SPEED REFERENCE VEHICLE SPEED WHEEL SPEED TIME OUTLET VALVE on m OFF H Ye ont e 100 OFF PRESSURE MOTOR ont OFF When the wheel speed drops sharply below the vehicle speed the inlet valve closes and if necessary the outlet valve opens momentarily to reduce the caliper fluid pressure The pump motor starts at this time As the wheel speed is restored and the outlet valve closes the inlet valve opens momentarily to increase the caliper fluid pressure 19 41 ABS Components Circuit Diagram BATTERY UNDER HOOD g FUSE RELAY BOX BRAKE PEDAL POSITION SWITCH Closed Brake pedal pressed No 7 d De WHT GRN 69 WHT BLK 19 80A IGNITION SWITCH No 20 404 YEL BIK gt WHT BLK O YEL 491 Hotin ON UD and START 1G2 Hatin ON WJ UNDER DASH FUSE RELAY BOX GA
12. rear No 9 RLS No 8 RLS ABS CONTROL UNIT 31P CONNECTOR 12014 BA 19 2921 Wire side of female terminals Is there less than 450 Q YES Go to step 1 NO Go to step 4 4 Check for continuity between the appropriate wheel sensor circuit terminal and other wheel sensor circuit terminals see table DTC Appropriate Other Terminal Terminal 12 No 5 No 7 No 2 No 9 FRW 14 No 7 5 2 Nog FLW 16 2 5 7 9 RRW 18 No 9 No 5 No 7 No 2 RLW Is there continuity YES Repair short in the wires between the appropriate wheel sensor and the other wheel sensor harnesses NO the DTC disconnect the Honda PGM Tester and test drive the vehicle If the ABS indicator comes on and the same DTC is indicated replace the ABS modulator control unit 5 Disconnect the harness 2P connector from the appropriate wheel sensor and check the resistance between the side and the side of the wheel sensor Is there less than 450 Q YES Replace the wheel sensor NO Repair short to wire between the appropriate wheel sensor and circuits to DTC 21 Continuous Operation Chipped pulser 1 Clear the DTC then disconnect the Honda PGM tester 2 Test drive the vehicle at 19 mph 30 km h o
13. slip rate is high The pressure reduction control has three modes pressure reducing pressure retaining and pressure intensifying ABS CONTROL UNIT p em 4 T T DETECT REFERENCE VEHICLE SPEED SLIP RATE REAR DETECT ABS SLIP RATE gt CONTROL RIGHT REAR DETECT WHEEL SENSOR WHEEL SPEED DRIVE RIGHT REAR SOLENOID SOLENOID LEFT REAR SOLENOID SOLENOID LEFT REAR DETECT WHEEL SENSOR WHEEL SPEED RIGHT FRONT DETECT SLIP RATE RIGHT FRONT RIGHT FRONT WHEEL SENSOR DETECT ABS DRIVE WHEEL SPEED CONTROL SOLENOID SOLENOID K LEFT FRONT LEFT FRONT DETECT WHEEL SENSOR WHEEL 5 ABS DRIVE LEFT FRONT CONTROL SOLENOID SOLENOID Self diagnosis Function 1 The ABS control unit is equipped with a main CPU and a sub CPU Each CPU checks the other for problems 2 The CPUs check the circuit of the system 3 The ABS control unit turns on the ABS indicator when the unit detects a problem and the unit stops the system 4 The self diagnosis can be classified into these two categories Initial diagnosis Regular diagnosis On board Diagnosis Function The ABS can be diagnosed with the Honda PGM Tester The ALB Checker cannot be used with this system For air bleeding and checking wheel sensor signals use the Honda PGM Tester See the Honda PGM Tes
14. the multiplex control unit and the ABS control unit NO Go to multiplex control system troubleshooting see page 22 172 19 56 b fo ABS Modulator Control Unit Removal and Installation 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 Becareful not to damage or deform the brake lines during removal and installation To prevent the brake fluid from flowing plug and cover the hose ends and joints with a shop towel or equivalent material Removal 1 Turn the ignition switch OFF 2 Pull up the lock A of the ABS control unit 31P connector B then disconnect the connector FLARE NUT n d 15 N m 1 5 kgf m 11 Ibf ft 8mmNUT 8 8 N m 0 9 kgf m 6 5 Ibf ft SANZ 6 mm BOLT 9 8N m 1 0 kgf m 7 2 Ibf ft cont d 19 57 ABS Components ABS Modulator Control Unit Removal and Installation cont d 3 Disconnect the six brake lines 4 Remove the two 8 mm nuts 5 Remove the ABS modulator control unit C Installation 1 Install the ABS modulator control unit then tighten the two 8 mm nuts 2 Align the connecting surface of the ABS control unit 31P connector 3 Push in the lock of the ABS control unit 31P connector until you hear it click into place then connect the connector 4 Connect the six brake lines 5 Bleed the brake system starting with the front wheels 6 Connect
15. the secondary piston D by turning the adjusting nut E A 07JAG SD401000 2 Without disturbing the center shaft s position install the special tool A backwards on the booster c 0 101 kPa A 0 760 mmHg 30 in Hg 07JAG SD40100 3 install the master cylinder nuts B and tighten them to the specified torque 4 Connect the booster in line with a vacuum gauge C 0 101 kPa 0 760 mmHg 30 in Hg to the booster s engine vacuum supply and maintain an engine speed that will deliver 66 kPa 500 mmHg 20 in Hg vacuum 5 With a feeler gauge A measure the clearance 9 Check the pushrod length A as shown if the between the gauge body and the adjusting nut B booster is removed If the length is incorrect as shown loosen the pushrod locknut B and turn the clevis If the clearance between the gauge body and the C in or out to adjust adjusting nut is 0 4 mm 0 02 in the pushrod to piston clearance is 0 mm However if the clearance s mm 4 6 in between the gauge body and the adjusting nut is 0 mm the pushrod to piston clearance is 0 4 mm 0 02 in or more Therefore it must be adjusted and rechecked Clearance 0 0 4 mm 0 0 02 in 10 x 1 0 mm 1 5 1 5 kgf m 11 Ibf ft 10 Install the master cylinder see page 19 15 6 If the clearance is incorrect loosen the star locknut A and turn the adjuster B in or out to adjust Adjus
16. to step 10 10 Disconnect the gauge assembly connector B 22P 11 Check for continuity between gauge assembly connector B 22P terminal No 12 and body ground GAUGE ASSEMBLY CONNECTOR B 22P 2 lt 16 718 9 ho is reba 2122 Wire side of female terminals Is there continuity YES Check for loose terminals in the gauge assembly connectors If the connectors are OK replace the gauge assembly M NO Repair open in the wire between the gauge assembly and body ground G501 8 ABS indicator does not go off 1 Check the No 8 20A fuse in the under hood fuse relay box and reinstall the fuse if it is OK 15 the fuse OK YES Go to step 2 NO Replace the fuse and recheck If the fuse is blown check for a short to body ground in this fuse circuit If the circuit is OK replace the ABS modulator control unit Check the No 11 7 5A fuse in the under dash fuse relay box and reinstall the fuse if it is OK Is the fuse OK YES Go to step 3 NO Replace the fuse and recheck If the fuse is blown check for a short to body ground in this fuse circuit If the circuit is OK replace the ABS modulator contro unit Disconnect the ABS control unit 31P connector Measure the voltage between terminal No 18 and body ground ABS CONTROL UNIT 31P CONNECTOR RTZLZTSTSTSTTISTS ZEIT 19 B FSR WHT GRN Wire side of female terminals
17. two times two times 5 Turn the ignition switch OFF 6 Disconnect the Honda PGM Tester from the DLC fo How to Clear ABS DTCs Honda PGM Tester Method 1 With the ignition switch OFF connect the Honda PGM Tester to the 16P data link connector DLC B under the driver s side of the dashboard 2 Turn the ignition switch ON II and clear the DTC s by following the screen prompts on the PGM Tester NOTE See the Honda PGM Tester user s manual for specific instructions Cycling the Ignition Switch Method Clear the DTC by turning the ignition switch ON II then OFF at least 20 times 19 33 ABS Components DTC Troubleshooting Index 19 34 DTC Detection Item Note DTC 11 Right front wheel sensor open short to body ground short to power see page 19 45 DTC 12 Faulty right front wheel sensor pulse signal see page 19 46 DTC 13 Left front wheel sensor open short to body ground short to power see page 19 45 DTC 14 Faulty left front wheel sensor pulse signal see page 19 46 DTC 15 Right rear wheel sensor open short to body ground short to power see page 19 45 DTC 16 Faulty right rear wheel sensor pulse signal see page 19 46 DTC 17 Left rear wheel sensor open short to body ground short to power see page 19 45 DTC 18 Faulty left rear wheel sensor pulse signal see page 19 46 DTC 21
18. 11 Ibf ft BRAKE HOSE to CALIPER BANJO BOLT 34 N m 3 5 kgf m 25 Ibf ft BLEED SCREW 9 N m 0 9 kgf m 7 Ibf ft ABS MODULATOR UNIT to BRAKE LINE 15 N m 1 5 kgf m 11 Ibf ft MASTER CYLINDER to BRAKE LINE 15 N m 1 5 kgf m 11 Ibf ft BRAKE HOSE to CALIPER PROPORTIONING CONTROL VALVE to BANJO BOLT SONU 15 Nm 15 kgfm 11 Ibit D SCREW k 9Nm BRAKE LINE to BRAKE HOSE 0 9 kgf m 7 Ibf ft 15 N m 1 5 kgf m 11 Ibf ft 19 24 i r 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 2 Disconnect the brake hose from the brake line B using a 10 mm flare nut wrench C 3 Remove the flange bolt A and remove the brake hose brackets from the damper 8x1 25 mm 4 Remove and discard the hose clip B 5 Remove the banjo bolt C and remove the brake hose D from the caliper 0 6 Install the brake hose bracket on the damper with the flange bolt B first then connect the brake hose to the caliper with the banjo D and new s
19. 2 14 16 18 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 11 to Diagnostic Trouble Code DTC 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 right after the 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 contro
20. 31P CONNECTOR 5 6 7 8 Un AR 18 19 LUV VAVAVAVAVA Wire side of female terminals Is there continuity YES Check for loose terminals in the ABS control unit 31P connector If necessary substitute a known good ABS modulator control unit and recheck NO Repair open in the wire between the ABS control unit and body ground G202 19 50 DTC 53 Motor Stuck ON 1 Clear the DTC then disconnect the Honda PGM Tester Test drive the vehicle Does the ABS indicator come on and is DTC 53 indicated YES Go to step 3 NO Intermittent failure the system is OK at this time Disconnect the ABS control unit 31P connector Check for continuity between the ABS control unit 31P connector terminal No 16 and body ground ABS CONTROL UNIT 31 CONNECTOR 20121 Br AAA M GND BLK Wire side of female terminals Is there continuity YES Replace the ABS modulator control unit NO Repair open in the wire between the ABS control unit and body ground 6202 DTC 54 Main Relay Stuck OFF 1 Check the No 8 20A fuse in the under hood fuse relay box and reinstall the fuse if it is OK 15 the fuse to step 2 NO Replace the fuse and recheck 2 Disconnect the ABS control unit 31P connector 3 Measure the voltage between the ABS control unit connector terminal No 18 and body ground ABS CONTROL UNIT 31P
21. Brakes Conventional Brake Components Special Tools uo L 19 2 Component Location Index 19 3 Brake System Inspection and Test an aqu WAS Nee 19 4 Brake Pedal and Brake Pedal Position Switch 19 6 Parking Brake Check Adjustment Brake System Bleeding Brake System Indicator Circuit Diagram 19 9 Parking Brake Switch Test 19 10 Brake Fluid Level Switch Test 19 10 Front Brake Pads Inspection and Replacement l AW u qaya Q 8 Front Brake Disc Inspection Front Brake Caliper Overhaul Master Cylinder Replacement 19 15 Master Cylinder Inspection 19 16 Brake Booster Pushrod Clearance Adjustment 19 16 Brake Booster Test Brake Booster Replacement Rear Brake Pads Inspection and Inr gn MMC H P X Rear Brake Disc Inspection Rear Brake Caliper Overhaul Brake Hoses and Lines Inspection 19 24 Brake Hose Replacement ve Parking Brake Cable Replacement 19 26 ABS Anti lock Brake System Components 19 29 Conventional Brake Components Special T
22. CONNECTOR 12714151617 18 9 iia VAVAVAVA 20 IA B FSR WHT GRN Wire side of female terminals 15 there battery voltage YES Replace the ABS modulator control unit NO Repair open in the wire between the ABS control unit and the under hood fuse relay box DTC 61 162 Voltage NOTE Check the No 11 7 5A fuse in the under dash fuse relay box before troubleshooting T Clear the DTC then disconnect the Honda PGM tester Test drive the vehicle Does the ABS indicator come on and is DTC 61 indicated YES Go to step 3 NO The system is OK at this time Disconnect the ABS control unit 31P connector Turn the ignition switch ON 1 Measure the voltage between the ABS control unit 31P connector terminal No 15 and body ground ABS CONTROL UNIT 31P CONNECTOR 1G2 BLK ORN 1 2 1415 6 7 8 9 1112 1415 E 18 19 2021 Wire side of female terminals Is there battery voltage YES Replace the ABS modulator control unit NO Repair open in the wire between the ABS control unit and the under hood fuse relay box 19 51 ABS Components DTC Troubleshooting cont d ABS Indicator Circuit Troubleshooting DTC 81 CPU Central Processing Unit 1 Clear the DTC then disconnect the Honda ABS indicator does not come on Tester 1 Turn the ignition switch ON II and watch the ABS 2 Test drive the vehicle indicator Do
23. Continuous operation chipped pulser see page 19 47 DTC 31 Solenoid see page 19 48 DTC 32 Solenoid see page 19 48 DTC 33 Solenoid see page 19 48 DTC 34 Solenoid see page 19 48 DTC 35 Solenoid see page 19 48 L DTC 36 Solenoid see page 19 48 DTC 37 Solenoid see page 19 48 DTC 38 Solenoid see page 19 48 DTC 51 Motor locked see page 19 48 DTC 52 Motor stuck off see page 19 49 DTC 53 Motor stuck on see page 19 50 DTC 54 Main relay stuck off see page 19 51 DTC 61 162 voltage see page 19 51 see page 19 52 fo 8 Symptom Troubleshooting Index Symptom Diagnostic procedure Also check for ABS indicator does not come on ABS Indicator Circuit Troubleshooting see page 19 52 ABS indicator does not go off and no ABS Indicator Circuit Troubleshooting see step 1 ABS DTC is stored on page 19 53 Brake system indicator does not come Brake System Indicator Circuit Troubleshooting on see page 19 55 Brake system indicator does not go off Brake System Indicator Circuit Troubleshooting ABS DTC is stored see step 1 on page 19 55 19 35 ABS Components System Description ABS Control Unit Inputs and Outputs for 31P Connector Wire side of female terminals Terminal Wire Terminal sign Description Measurement number color Terminals Conditions Ignition Voltage switch ON it 1 BLU RR
24. L SENSOR Inspection page 19 59 Replacement page 19 59 19 30 General Troubleshooting Information ABS Indicator If the system is OK the ABS indicator goes off 2 seconds after turning the ignition switch ON II 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 unit is turned on by the 62 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 conditions into consideration When a problem is detected and the 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 DTC 1
25. Left Rear Left 6 Refill the master cylinder reservoir to the MAX upper level line FRONT BRAKE 9 N m 0 9 kgf m 7 Ibf ft REAR BRAKE 9 N m 0 9 kgf m 7 Ibf ft to Brake System Indicator Circuit Diagram BATTERY UNDER DASH NDER IGNITION 1 UNDER HOOD FUSE RELAY FUSE RELAY BOX No 19 80A No 20 40A No 10 7 5A g WHT BLK YEL YEL CANADA 50 IG1 HOT in ON Il and START III GAUGE ASSEMBLY BRAKE SYSTEM INDICATOR WHT GRN UNDER DASH FUSE RELAY BOX IMMOBILIZER CONTROL UNIT RECEIVER GRN ORN GRN RED 13 DAYTIME RUNNING LIGHTS CONTROL GRN RED unm GRNORN i usaj GRN ORN LEVEL SWITCH PARKING BRAKE GLOSED Most down CLOSED Lever up OPEN Lever down 19 9 Conventional Brake Components Parking Brake Switch Test Brake Fluid Level Switch Test 1 Remove the rear console and disconnect the Check for continuity between the terminals with the connector A from the switch float in the down position and the up position Remove the brake fluid completely from the reservoir With the float down there should be continuity Fill the reservoir with brake fluid to MAX upper level B With the float up there should be no continuity 2 Check for continuity between the swi
26. S Detects right rear 1 2 YEL wheel sensor i 2 GRM RRS signa YEL 4 BLU FRS Detects right front 4 5 Spin wheel at AC 0 053 V or wheel sensor 1 turn second above signa 5 GRN FRS Wheel Oscilloscope BLK 0 15 Vp p or i above 6 BRN FLS Detects left front 6 7 WHT wheel sensor 7 BLU FLS signal ORN 8 GRY RLS Detects left rear 8 9 RED wheel sensor 9 YEL RLS signa RED 11 LT BLU DIAG K Communications DIEA NOM with Honda PGM tester 12 BRN DIAG L DTC indication 19 36 fo Wire Terminal sign Description Measurement number color Terminals Conditions Ignition Voltage switch ON 1 14 WHT STOP Detects brake 14 GND Brake pedal Pressed Battery BLK switch signal Released voltage 15 BLK 162 Power source for 15 GND Battery ORN activating the voltage system 16 BLK M GND Ground for the 16 GND Below 0 3 V pump motor 17 WHT B MR Power source for 17 GND At all times Battery RED the pump motor voltage 18 WHT B FSR Power source for 18 GND At all times Battery GRN the valve relay voltage 19 BLK GND Ground for the 19 GND Below 0 3 V modulator assembly 20 BLU ABS Drives ABS 20 GND ABS ON About 11 V RED indicator indicator OFF Below 1V 21 BRN EBD Drives brake 21 GND Brake system OFF Below 0 3 V YEL Electr
27. UGE ASSEMBLY ABS INDICATOR BLU RED WHT BLK 6501 No 117 CEJ KORN q No 8 120A WHTIGRN WHT GRN r Q ano No 10 1408 WHEEL SENSOR LEFT BLU ORN FRONT BRN RIGHT MONT BLU LEFT YEL RED REAR Qg DATA LINK RIGHT Q CONNECTOR 16 REAR c I G muy WHT RED BRN YEL A w BAN Gin 19 42 s to ABS MODULATOR CONTROL UNIT coNTROL UNIT MODULATOR UNIT rx WHT BLK G BRAKE LIGHT MULTIPLEX CONTROL UNIT To brake system To brake eH BRN VEL ee SOLENOID 8 lt s P I GAN BLK es ico eave RIGHT REAR SOLENOID 9202 cont d 19 43 ABS Components Circuit Diagram cont d UNDER HOOD FUSE RELAY BOX CONNECTORS BRAKE PEDAL POSITION CONNECTOR 12 CONNECTOR 2P SWITCH 4P CONNECTOR RA 111891041 3 X14 UNDER DASH FUSE RELAY BOX CONNECTORS MULTIPLEX CONTROL CONNECTOR I 5P CONNECTOR K 17P UNIT 13P CONNECTOR Ta 101112131415117 GAUGE ASSEMBLY CONNECTORS CONNECTOR 22 22 02 T
28. Using a micrometer measure disc thickness at eight points approximately 45 apart and 10 mm 0 4 in in from the outer edge of the disc Brake Disc Thickness Standard 20 9 21 8 mm 0 82 0 86 Max Refinishing Limit 19 0 mm 0 75 in Brake Disc Parallelism 0 015 mm 0 0006 in max NOTE This is the maximum allowable difference between the thickness measurements 10 mm 0 4 in If the smallest measurement is less than the max refinishing limit replace the brake disc see page 18 11 If the disc is beyond the service limit for parallelism refinish the brake disc with an on car brake lathe The Kwik Lathe produced by Kwik way Manufacturing Co and the Front Brake Disc Lathe offered by Snap on Tools Co are approved for this operation 19 13 Conventional Brake Components Front 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 install the caliper and note these items 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 hose joints with rags or shop towels Clean all parts in brake fluid an
29. ckness Standard 8 5 9 5 mm 0 33 0 37 in 2 Remove the caliper bolts C and remove the Service limit 1 6 mm 0 06 in caliper D from the caliper bracket 3 Remove the pad shims A and pads B 3 If the brake pad thickness is less than the service limit replace all the pads as a set gt 19 20 4 Remove the pad retainers A and check the caliper pins for free movement 5 Clean the caliper thoroughly remove any rust and check for grooves and cracks 6 Check the brake disc for damage and cracks 7 Apply Dow Corning Molykote M77 grease to the retainers on their mating surfaces against the caliper bracket 8 Install the pad retainers Wipe excess grease off the retainers Contaminated brake discs and pads reduce stopping ability Keep grease off the discs and pads 9 Apply Dow Corning Molykote M77 grease to both sides of the pad shims the back of the pads and the other areas indicated by the arrows Wipe excess grease off the shim Contaminated brake discs and pads reduce stopping ability Keep grease off the discs and pads Lo ant 10 Install the brake pads and pad shims correctly Install the pads with the wear indicators C on the inside If you are reusing the pads always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency 11 12 13 14 15 16 Rotate the caliper
30. d may overflow if the reservoir is too full Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down e 8x 1 0 mm 34 3 5 kgf m 25 Ibf ft 4 Clean the caliper thoroughly remove any rust and check for grooves and cracks 5 Check the brake disc for damage and cracks 6 Apply Dow Corning Molykote M77 grease to the retainers on their mating surfaces against the 11 Pivot the caliper down into position Being careful caliper bracket not to damage the pin boots install the bolt B and tighten it to the specified torque 7 Install the pad retainers Wipe excess grease off the retainers Contaminated brake discs and pads 12 Press the brake pedal several times to make sure reduce stopping ability Keep grease off the discs the brake works then test drive and pads NOTE Engagement of the brake may require a 8 Apply Molykote M77 grease to both sides of the greater pedal stroke immediately after the brake pad shim A the back of the pads B and the other pads have been replaced as a set Several areas indicated by the arrows applications of the brake pedal will restore the Wipe excess grease off the shim Contaminated normal pedal stroke brake discs and pads reduce stopping ability Keep grease off the discs and pads 13 After installation check for leaks at hose and line joints or connections and retighten if necessary 9 Install the brake pads and pad shim correctly Insta
31. d air dry blow out all passages with compressed air Before reassembling check that all parts are free of dust and other foreign particles Replace parts with new ones as specified in the illustration Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid When reusing pads always reinstall them in their original positions to prevent loss of braking efficiency Do not reuse drained brake fluid Always use Honda DOT 3 brake fluid Non Honda brake fluid can cause corrosion and shorten the life of the system Do not mix different brands of brake fluid as they may not be compatible Coat the piston piston seal groove and caliper bore with clean brake fluid Make sure no grease or oil gets on the brake discs or pads Replace all rubber parts with new ones whenever disassembled After installing the caliper check the brake hose and line for leaks interference and twisting ea Honda caliper grease P N 08C30 B0234M BOOTS 3 5 kgf m 25 Ibf ft BRAKE HOSE BLERO SCREW 0 9 kgf m 7 Ibf ft CALIPER BODY TIT o CALIPER PIN A p PISTON SEAL 25 Ibf ft 4 SEALING ue WASHERS MJ E m PAD RETAINERS Q s BRAKE PADS BUSHING Qy EARS Oo d E d 20 9 PISTONBOOT BOOT CLIP CALIPER PIN B A Replace piace a WEAR INDICATOR PISTON BOOT CALIPER install inner pad with eplace BRACKET its wear indicator downward
32. damage or signs of fluid leakage at Reservoir or reservoir grommets Line joints Between master cylinder and booster Brake Hoses Look for damage or signs of fluid leakage at Bulging twisted or bent lines Line joints and banjo bolt connections Hoses and lines also inspect for twisting or damage Caliper Look for damage or signs of fluid leakage at Seized or sticking caliper pins Piston seal Banjo bolt connections Bleeder screw ABS Modulator Look for damage or signs of fluid leakage at Line joints Modulator Brake System Test Brake pedal sinks fades when braking 1 Start the engine and let it warm up to operating temperature 2 Attach a 2 inch piece of masking tape along the bottom of the steering wheel and draw a horizontal reference mark across it 3 With the transmission in Neutral press and hold the brake pedal lightly then release the parking brake 4 While still holding the brake pedal hook the end of the tape measure behind it Then pull the tape up to the steering wheel noting where the tape measure lines up with the reference mark you made on the masking tape 5 Apply steady pressure to the brake pedal for 3 minutes 6 Watch the tape measure if it moves less than 10 mm the master cylinder is OK if it moves more than 10 mm replace the master cylinder 19 4 5 Loosen the hydraulic lines at the master cylinder then spin the wheels to check
33. ealing washers E 34N m 3 5 kgf m 25 Ibf ft 7 Install the hose onto the hose bracket on the body with a new hose clip A 8 Connectthe brake line to the brake hose 9 After installing the brake hose bleed the brake system see page 19 8 10 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 19 25 Conventional Brake Components Parking Brake Cable Replacement Exploded View PARKING BRAKE LEVER Check for smooth operation Sliding surface Lee ee ADJUSTING NUT ELIT Z 2 E amm 6 q PARKING BRAKE SWITCH 1 PARKING BRAKE CABLE oie Check for stiffness binding and damage 2 2 kgf m 16 Ibf ft wid 19 26 a NOTE The parking brake cables must not be bent or distorted This will lead to stiff operation and premature failure Refer to the Exploded View as needed during this procedure 1 Release the parking brake lever fully 2 Remove the rear console see page 20 57 3 Loosen the parking brake cable adjusting nut A A m 4 Remove the parking brake cable clip A from the brake cable B 5 Disconnect the parking brake cable from the lever 6 Remove the parking brake cable mounting hardware then remove the cable 7 Install the new cable in the reverse order of removal and note these items
34. es the ABS indicator come on and is DTC 81 Does the ABS indicator come on indicated YES The system is OK at this time YES Replace the ABS modulator contro unit lil NO Go to step 2 NO The system is OK at this time 2 Pull up the parking brake lever Does the brake system indicator come on YES Go to step 3 NO Repair open in the indicator power source circuit If necassary substitute a known good ABS modulator control unit and recheck Blown No 10 7 5A fuse Open in the wire between the No 10 7 5A fuse and the gauge assembly Open circuit inside the fuse box 3 Turn the ignition switch OFF 4 Disconnect the ABS control unit 31P connector 5 Turn the ignition switch ON 0 Does the ABS indicator come on YES Check for loose terminals in the ABS control unit 31P connector If necessary substitute a known good ABS modulator control unit and recheck NO Go to step 6 6 Turn the ignition switch OFF 7 Remove the gauge assembly see page 22 64 19 52 4 8 Disconnect the gauge assembly connector 22 9 Check for continuity between gauge assembly connector A 22P terminal No 12 and body ground GAUGE ASSEMBLY CONNECTOR A 22P 5 Esfera a 1 2 ABS BLU RED Wire side of female terminals Is there continuity YES Repair short to body ground in the wire between the gauge assembly and the ABS control unit NO Go
35. he hub 9450 4 in 108 N m 11 0 kgf m 80 Ibf ft 5 Set up the dial gauge against the brake disc as shown and measure the runout at 10 mm 0 4 in from the outer edge of the disc Brake Disc Runout Service Limit 0 10 mm 0 004 in 6 If the disc is beyond the service limit refinish the brake disc Max Refinish Limit 9 0 mm 0 35 in NOTE If the brake disc is beyond the service limit for refinishing replace it see page 18 26 Anew disc should be refinished if its runout is greater than 0 10 mm 0 004 in 19 22 Thickness and Parallelism 1 Raise the rear of the vehicle and support with safety stands in the proper location see page 1 8 Remove the rear wheels 2 Remove the brake pads see page 19 20 3 Using a micrometer measure disc thickness at eight points approximately 45 apart and 10 mm 0 4 in from the outer edge of the disc Brake Disc Thickness Standard 9 9 10 1 mm 0 389 0 397 in Max Refinishing Limit 9 0 mm 0 35 in Brake Disc Parallelism 0 016 mm 0 0006 in max NOTE This is the maximum allowable difference between the thickness measurements 10mm Lig 0 4 Nes 4 If the smallest measurement is less than the max refinishing limit replace the brake disc see page 18 26 5 If the disc is beyond the service limit for parallelism refinish the brake disc with an on car brake lathe te
36. is OK at this time M NO Go to step 3 Check the brake fluid level Isthe level OK YES Go to step 4 NO Refill the brake fluid and recheck Bi Check the ABS indicator Does the ABS indicator stay on YES Read the ABS DTC see step 1 on page 19 32 and do the applicable troubleshooting for the DTC to step 5 Turn the ignition switch OFF Disconnect the ABS control unit 31P connector Connect the ABS control unit 31P connector terminal No 21 and body ground with a jumper wire ABS CONTROL UNIT 31P CONNECTOR 112774 TS er7 e T9 T T2 16 17 18 19 VAVAVAVAVA EBD BRN YEL JUMPER WIRE Wire side of female terminals 19 55 ABS Components Brake System Indicator Circuit Troubleshooting cont d 8 Turn the ignititon switch ON II 9 Check the brake system indicator Does the brake system indicator go off YES Replace the ABS modulator control unit NO Go to step 10 10 Turn the ignition switch OFF 11 Connect the multiplex control unit 13P connector terminal No 1 and body ground with a jumper wire MULTIPLEX CONTROL UNIT 13P CONNECTOR EBD BRN YEL Mer VI 718 9 o t1112 JUMPER WIRE Wire side of female terminals 12 Turn the ignition switch ON II 13 Check the brake system indicator Does the brake system indicator go off YES Repair open the wire between
37. l unit checks the pump motor operation when the vehicle is started the first time after the ignition switch is turned ON 1 You may hear the motor operate at this time but it is normal cont d 19 31 ABS Components General Troubleshooting Information cont d How to Troubleshoot ABS DTCs 2 Turn the ignition switch ON Il and follow the prompts on the PGM Tester to display the DTC s The troubleshooting flowchart procedures assume that on the screen After determining the DTC refer to the cause of the problem is still present and the ABS the DTC Troubleshooting Index indicator is still on Following the flowchart when the ABS indicator does not come on can result in incorrect NOTE See the Honda PGM Tester user s manual diagnosis for specific instructions The connector illustrations show the female terminal connectors with a single outline and the male terminal Service Check Signal SCS Circuit Method connectors with a double outline 1 With the ignition switch OFF connect the Honda PGM Tester A to the 16P data link connector DLC 1 Question the customer about the conditions when B under the driver s side of the dashboard the problem occured and try to reproduce the same conditions for troubleshooting Find out when the ABS indicator came on such as during ABS control after ABS control when the vehicle was at a certain speed etc 2 When the ABS indicator does not come on during the test drive but tro
38. lights go off when the pedal is released 7 Check the brake pedal free play as described below Parking Brake Check and Adjustment Check 1 Pull the parking brake lever A with 196 N 20 kgf 44 Ibf of force to fully apply the parking brake The parking brake lever should be locked within the specified number of clicks B Lever locked clicks 7 8 pulled up with 196 N 20 kgf 44 Ibf 2 Adjust the parking brake if the lever clicks are not within the specification Adjustment 1 Release the parking brake lever fully 2 Loosen the parking brake adjusting nut start the engine and press the brake pedal several times to set the self adjusting brake before adjusting the parking brake 3 Block the front wheels then raise the rear of the vehicle and support it with safety stands in the proper location see page 1 8 4 Make sure the parking brake arm A on the rear brake caliper contacts the brake caliper pin B NOTE The parking brake arm will only contact the brake caliper pin when the parking brake adjusting nut is loosened 5 Remove the rear console see page 20 57 6 Pull the parking brake lever up one click r VE a 7 Tighten the adjusting nut A until the parking brakes drag slightly when the rear wheels are turned 8 Release the parking brake lever fully and check that the parking brakes do not drag when the rear wheels are t
39. ll the pads with the wear indicators C on the inside If you are reusing the pads always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency 19 12 Front Brake Disc Inspection Runout 1 Raise the front of the vehicle and support it with safety stands in the proper location see page 1 8 Remove the front wheels 2 Remove the brake pads see page 19 11 3 Inspect the disc surface for damage and cracks Clean the disc thoroughly and remove all rust 4 Install suitable flat washers A and wheel nuts and tighten the nuts to the specified torque to hold the brake disc securely against the hub 10mm 0 4 in 11 0 kgf m 80 Ibf ft 5 Set up the dial gauge against the brake disc as shown and measure the runout at 10 mm 0 4 in from the outer edge of the disc Brake Disc Runout Service Limit 0 10 mm 0 004 in 6 If the disc is beyond the service limit refinish the brake disc Max Refinish Limit 19 0 mm 0 75 in NOTE If the brake disc is beyond the service limit for refinishing replace it see page 18 11 Anew disc should be refinished if its runout is greater than 0 10 mm 0 004 in amp Thickness and Parallelism 1 Raise the front of the vehicle and support it with safety stands in the proper location see page 1 8 Remove the front wheels Remove the brake pads see page 19 11
40. minal No 16 and body ground ABS CONTROL UNIT 31P CONNECTOR TE 17118 19 BALA VAVAVAVAVA M GND BLK Wire side of female terminals Is there continuity YES Go to step 5 NO Repair open in the wire between the ABS control unit and body ground G202 5 Reconnect the ABS control unit 31P connector 6 Clear the DTC then disconnect the Honda PGM tester 7 Test drive the vehicle at 6 mph 10 km h or more Does the ABS indicator come on and is DTC 51 indicated YES Replace the ABS modulator control unit NO The system is OK at this time to DTC 52 Motor Stuck OFF 1 Check the No 10 40A fuse in the under hood fuse relay box Is the fuse YES Reinstall the fuse and go to step 2 NO Replace the fuse and recheck 2 Disconnect the ABS control unit 31P connector 3 Measure the voltage between the ABS control unit 31P connector terminal No 17 and body ground ABS CONTROL UNIT 31P CONNECTOR 1211256118091 A Ci 18 19 PUT nu B MR WHT RED Wire side of female terminals Is there battery voltage YES Go to step 4 NO Repair open in the wire between the No 10 40A fuse and the ABS control unit i cont d 19 49 ABS Components DTC Troubleshooting cont d 4 Check for continuity between the ABS control unit 31P connector terminal No 16 and body ground ABS CONTROL UNIT
41. mponents Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1 Disconnect the brake pedal position switch connector turn the brake peda position switch A counterclockwise and pull it back until it is no longer touching the brake pedal 2 Lift up the carpet and the insulator cutout B Measure the pedal height C from the middle of the left side of the pedal pad D Standard Pedal Height with carpet removed 184 mm 7 4 16 in 3 Loosen the pushrod locknut A and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached After adjustment tighten the locknut firmly Do not adjust the pedal height with the pushrod pressed the pedal A 45 N m 1 5 kgf m 11 Ibf ft 19 6 Pedal Free Play 4 With the engine off inspect the play A on the pedal pad by pushing the pedal by hand Free Play 0 4 3 0 mm 0 016 0 118 in 5 If the pedal free play is out of specification adjust the brake pedal position switch C If the pedal free play is insufficient it may result in brake drag 6 Push in the brake pedal position switch until its plunger is fully pressed threaded end A touching the pad B on the pedal arm Then turn the switch 45 clockwise to lock it The gap between the brake pedal position switch and the pad is automatically adjusted to 0 4 to 3 0 mm 0 016 0 118 in by locking the switch Make sure the brake
42. om the brake pedal 8x 1 25 mm 13 N m 1 3 kgf m 9 Ibf ft Remove the brake booster mounting nuts C Remove the brake booster A from the engine compartment NOTICE Be careful not to damage the booster surfaces and threads of the booster stud bolts Becareful not to bend or damage the brake lines Install the brake booster in the reverse order of removal and note these items Adjust the pushrod clearance before installing the brake booster see page 19 16 Use new clip whenever installing After installing the brake booster and master cylinder fill the reservoir with new brake fluid bleed the brake system see page 19 8 and adjust the brake pedal height and free play see page 19 6 19 19 Conventional Brake Components Rear Brake Pads Inspection and Replacement Replacement Frequent inhalation of brake pad dust regardless of 1 Remove the bolt A and brake hose B from the material composition could be hazardous to your mounting bracket health Avoid breathing dust particles Never use an air hose or brush to clean brake assemblies Use an OSHA approved vacuum cleaner Inspection 1 Raise the rear of the vehicle and support it with safety stands in the proper location see page 1 8 Remove the rear wheels 2 Check the thickness of the inner pad A and outer pad B Do not include the thickness of the brake pad backing plate Brake pad thi
43. onic brake system indicator indicator ON for Battery distribution bulb voltage check cont d 19 37 ABS Components 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 ROTATIONAL DIRECTION COEFFICIENT OF FRICTION RADIAL DIRECTION OF THE ROTATIONAL DIRECTION SLIP RATE 19 38 te 5 ABS Control Unit Main Control The ABS control unit detects the wheel speed based on the wheel sensor signal it received then it calculates the vehicle speed based on the detected wheel speed The control unit detects the vehicle speed during deceleration based on the rate of deceleration The ABS control unit calculates the slip rate of each wheel and transmits the control signal to the modulator unit solenoid valve when the
44. ools Ref No Tool Number Description Oty 07JAG SD40100 Pushrod Adjustment Gauge aE ae 19 2 fo o Component Location Index INDICATOR Brake System Indicator Circuit Diagram page 19 9 Parking Brake Switch Test page 19 10 Brake Fluid Level Switch Test page 19 10 PARKING BRAKE CABLE Parking Brake Cable Replacement page 19 26 REAR DISC BRAKE Rear Brake Pads Inspection and Replacement page 19 20 Rear Brake Disc Inspection page 19 22 Rear Brake Caliper Overhaul page 19 23 FRONT BRAKES Front Brake Pads Inspection and Replacement page 19 11 Front Brake Disc Inspection page 19 13 Front Brake Caliper Overhaul page 19 14 PARKING BRAKE LEVER Parking Brake BRAKE BOOSTER Check and Adjustment page 19 7 Brake Booster Test page 19 18 Brake Booster BRAKE PEDAL Replacement page 19 19 Brake Pedal and Brake Pedal Position Switch Adjustment page 19 6 BRAKE HOSES and LINES Brake Hoses and Lines Inspection page 19 24 Brake Hoses Replacement page 19 25 MASTER CYLINDER Master Cylinder Replacement page 19 15 Master Cylinder Inspection page 19 16 Brake Booster Pushrod Clearance Adjustment page 19 16 Brake System Bleeding page 19 8 19 3 Conventional Brake Components Brake System Inspection and Tests Component Inspections Component Procedure _ Also check for Master Cylinder Look for
45. piston clockwise into the cylinder then align the cutout A in the piston with the tab B on the inner pad by turning the piston back so the caliper can be installed on the pad Lubricate the boot with rubber grease to avoid twisting the piston boot If the piston boot is twisted back it out so it is positioned properly 8 x 1 25 mm 22 2 2 kgf m 16 Ibf ft Install the brake caliper C and caliper bolts D and tighten the bolts to the specified torque Install the brake hose E Press the brake pedal several times to make sure the brake works then test drive NOTE Engagement of the brake may require a greeter pedal stroke immediately after the brake pads have been replaced as a set Several applications of the brake pedal will restore the normal pedal stroke Check the parking brake adjustment see page 19 7 After installation check for leaks at hose and line joints or connections and retighten if necessary 19 21 Conventional Brake Components Rear Brake Disc Inspection Runout 1 Raise the rear of the vehicle and support it with safety stands in the proper location see page 1 8 Remove the rear wheels 2 Remove the brake pads see page 19 20 3 Inspect the disc surface for damage and cracks Clean the disc thoroughly and remove all rust 4 Install suitable flat washers A and wheel nuts and tighten the nuts to the specified torque to hold the brake disc securely against t
46. r more Does the ABS indicator come on and is DTC 21 indicated YES Go to step 3 NO The system is OK at this time 3 Check the pulser gear for a chipped tooth Is the pulser OK YES Check for a loose ABS control unit 31P connector If necessary substitute a known good ABS modulator control unit and recheck IM NO Replace the driveshaft or hub unit chipped pulser gear 19 47 ABS Components DTC Troubleshooting cont d DTC 31 32 33 34 35 36 37 38 Solenoid DTC 51 Motor Locked 1 Clear the DTC then disconnect the Honda PGM 1 Check the No 10 40A fuse in the under hood fuse Tester relay box 2 Test drive the vehicle 13 the fuse OK Does the ABS indicator come on and are DTCs 31 YES Reinstal the fuse and go to step 2 32 33 34 35 36 37 38 indicated Replace the fuse and recheck YES Replace the ABS modulator control unit 2 Disconnect the ABS control unit 31P connector NO The system is OK at this time 3 Measure the voltage between the ABS control unit 31P connector terminal No 17 and body ground ABS CONTROL UNIT 31P CONNECTOR ny VAVAVAVA B MR WHT RED Wire side of female terminals 15 there battery voltage YES Go to step 4 NO Repair open in the wire between the No 10 40A fuse and the ABS control unit 19 48 4 Check for continuity between the ABS control unit 31P connector ter
47. rises the booster is faulty With the engine stopped press the brake pedal several times using normal pressure When the pedal is first pressed it should be low On consecutive applications the pedal height Should gradually rise If the pedal position does not vary check the booster check valve 19 18 4 Start the engine and let it idle There should be vacuum available If no vacuum is available the check valve is not working properly Replace the brake booster vacuum hose and check valve and retest 5 Reconnect the brake booster vacuum hose Start the engine and then pinch the brake booster vacuum hose between the check valve and the booster 6 Turn the ignition switch OFF and wait 30 seconds Press the brake pedal several times using normal pressure When the pedal is first pressed it should be low On consecutive applications the pedal height should gradually rise If the pedal position does not vary replace the brake booster If the pedal position varies replace the brake booster vacuum hose check valve assembly Wr Brake Booster Replacement 1 Remove the master cylinder see page 19 15 2 Remove the master cylinder brake lines A from the brake line clip 3 Remove the vacuum hose mounting bracket B 4 Disconnect the vacuum hose C from the brake booster Remove the clip A and the joint and disconnect the yoke fr
48. tch terminal and body ground With the brake lever up there should be continuity With the brake lever down there should be no continuity 19 10 1 Front Brake Pads Inspection and Replacement Replacement Frequent inhalation of brake pad dust regardless of 1 Remove the bolt A and pivot the caliper B up out material composition could be hazardous to your of the way Check the hose and pin boots for health damage and deterioration Avoid breathing dust particles Never use an air hose or brush to clean brake assemblies Use an OSHA approved vacuum pea Se cleaner Inspection 1 Raise the front of the vehicle and support it with safety stands in the proper location see page 1 8 Remove the front wheels 2 Check the thickness of the inner pad A and outer pad B Do not include the thickness of the brake pad backing plate Brake pad thickness Standard 9 5 10 5 mm 0 37 0 41 in Service limit 1 6 mm 0 06 in Inner pad Outer pad 3 If the brake pad thickness is less than the service limit replace all the pads as a set 20 19 11 Conventional Brake Components Front Brake Pads Inspection and Replacement cont d 3 Remove the pad retainers A and check the caliper 10 Push in the piston A so the caliper will fit over the pins for free movement pads Check the brake fluid level The brake flui
49. ter user s manual for specific operating instructions cont d 19 39 ABS Components System Description cont d ABS Modulator The ABS modulator consists of the inlet solenoid valves outlet solenoid valves reservoir pump pump motor and the damping chamber The modulator reduces the caliper fluid pressure directly It is a circulating type modulator because the brake fluid circulates through the caliper reservoir and the master cylinder The hydraulic control has three modes pressure intensifying pressure retaining and pressure reducing The hydraulic circuit is an independent four channel type one channel for each wheel ABS MODULATOR CONTROL UNIT b UNIT MODULATOR UNIT m ee 7 i IN L J AL FR IN INLET VALVE NORMALLY OPENI OUT OUTLET VALVE NORMALLY CLOSED Pressure intensifying mode Inlet valve open outlet valve closed Master cylinder fluid is pumped out to the caliper Pressure retaining mode Inlet valve closed outlet valve closed Caliper fluid is retained by the inlet valve and outlet valve Pressure reducing mode Inlet valve closed outlet valve open Caliper fluid flows through the outlet valve to the reservoir Motor operation mode When starting the pressure reducing mode the pump motor is ON When stopping ABS operation the pump motor is OFF The caliper fluid
50. the PGM Tester and do the solenoid function test for each wheel 7 Bleed the brake system again starting with the front wheels 8 Start the engine and check that the ABS indicator and brake system indicator go off 9 Disconnect the Honda PGM Tester Test drive the vehicle and check that the ABS indicator and brake system indicator do not come on 19 58 1 Wheel Sensor Inspection IN Wheel Sensor Replacement 1 Inspect the front and rear pulsers for chipped or NOTE Install the sensors carefully to avoid twisting the damaged teeth wires 2 Measure the air gap between the wheel sensor and Front the pulser all the way around while rotating the pulser Remove the rear brake disc to measure the gap on the rear wheel sensor If the gap exceeds 1 0 mm 0 04 in check for a bent suspension arm 6 mm BOLT 9 8 1 0 kgf m 7 2 Ibf ft Standard Front 0 4 1 0 mm 0 02 0 04 Rear 0 2 1 0 mm 0 01 0 04 in Front 0 02 0 04 in 0 4 1 0 mm LAE 0 kgfm 7 2 Ibf ft d 0 kgf m 7 2 0 01 0 04 in 0 2 1 0 mm i 1 WHEEL SENSOR 19 59
51. tthe clearance while the specified vacuum is applied to the booster Hold the clevis C while adjusting A 0 0 4 mm 0 0 02 in 22 2 2 kgf m 16 Ibf ft D 07JAG SD40100 7 Tighten the star locknut securely a 8 Remove the special tool 19 17 Conventional Brake Components Brake Booster Test 4 Functional Test 3 Disconnect the brake booster vacuum hose check valve built in A at the booster side 1 With the engine stopped press the brake pedal several times to deplete the vacuum reservoir then press the pedal hard and hold it for 15 seconds If the pedal sinks either the master cylinder is bypassing internally or the brake system master cylinder lines modulator or calipers is leaking Start the engine with the brake pedal pressed If the pedal sinks slightly the vacuum booster is working properly If the pedal height does not vary the booster or check valve is faulty With the engine running press the brake pedal lightly If the brake pedal sinks more than 10 mm 3 8 in in 3 minutes the master cylinder is faulty A slight change in pedal height when the A C compressor cycles on and off is normal The A C compressor load changes the vacuum available to the booster Leak Test 1 Press the brake pedal with the engine running then stop the engine If the pedal height does not vary while pressed for 30 seconds the vacuum booster is OK If the pedal
52. ubleshooting is done based on the DTC check for loose connectors poor terminal contact etc before you start troubleshooting 3 After troubleshooting clear the disconnect the Honda PGM Tester and test drive the vehicle Make sure the ABS indicator does not come on How to Retrieve ABS DTCs 2 Short the SCS circuit to body ground using the Honda PGM Tester Method Honda PGM Tester 1 With the ignition switch OFF connect the Honda PGM Tester A to the 16P data link connector DLC 3 Turn the ignition switch ON Il B under the driver s side of the dashboard 19 32 L 4 The blinking frequency indicates the DTC DTCs are indicated by a series of long and short blinks One long blink equals 10 short blinks Add the long and short blinks together to determine the DTC After determining the DTC refer to the DTC Troubleshooting Index NOTE If the DTC is not memorized the ABS indicator will go off for 3 6 seconds and then come back on If the ABS indicator stays on troubleshoot for ABS indicator does not go off see step 1 on page 19 53 The system will not indicate the DTC unless these conditions are met The brake pedal is not pressed The ignition switch is turned ON 1 The SCS circuit is shorted to body ground before the ignition switch is turned ON II Example of DTC 15 Short blinks Long blink five times Example of DTC 22 Short blinks Long blinks
53. urned Readjust if necessary 9 Make sure the parking brakes are fully applied when the parking brake lever is pulled up fully 10 Reinstall the rear console 19 7 Conventional Brake Components Brake System Bleeding NOTE Do not spill brake fluid on the vehicle it may damage the paint if brake fluid does contact the paint wash it off immediately with water The reservoir on the master cylinder must be at the MAX upper level mark at the start of the bleeding procedure and checked after bleeding each brake caliper Add fluid as required Do not reuse the drained fluid Always use Honda DOT 3 brake fluid Non Honda brake fluid can cause corrosion and shorten the life of the system Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid 1 Make sure the brake fluid level in the reservoir is at the MAX upper level line A 2 Slide a piece of clear plastic hose over the first bleed screw and submerge the other end in a container of new brake fluid 3 Have someone slowly pump the brake pedal several times then apply steady pressure 4 Starting at the left front loosen the brake bleed screw to allow air to escape from the system Then tighten the bleed screw securely 19 8 5 Repeat the procedure for each wheel in the sequence shown below until air bubbles no longer appear in the fluid BLEEDING SEQUENCE Front Right Rear Right Front
54. ute a known good ABS modulator control unit and recheck step 11 11 Remove the gauge assembly and leave the connectors connected Connect the gauge assembly connector A 22P terminal No 12 and body ground with a jumper wire GAUGE ASSEMBLY CONNECTOR A 22P Ce Clara pts ABS BLU RED e JUMPER WIRE Wire side of female terminals Does the ABS indicator go off YES Repair open in the wire between the gauge assembly and the ABS control unit Check for loose gauge assembly connectors If the connectors are OK replace the printed circuit board in the gauge assembly fo Brake System Indicator Circuit Troubleshooting Brake system indicator does not come on 1 Disconnect the multiplex control unit 13P connector and the ABS control unit 31P connector 2 Check for continuity between the ABS control unit 31P connector terminal No 21 and body ground ABS CONTROL UNIT 31P CONNECTOR EBD BRN YEL Wire side of female terminals Is there continuity YES Repair short to body ground in the wire between the multiplex control unit and the ABS control unit NO Go to multiplex contro system troubleshooting see page 22 172 1 2 Brake system indicator does not go off Turn the ignition switch ON Il Release the parking brake Does the brake system indicator go off after several seconds YES The system

02-03 Honda Civic Si Service Manual

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