Caliper HONDA CIVIC 1999 6.G Workshop Manual

MEASUREMENTSTANOARO INEW}SERVICE LIMIT
algnmenlCamber FrontRearCaster FrontTotaltoe FrontBearFront wheel turning angle Inward wheelOutward wheel
0"00'1 1"-1.1 1'1'40' I 1"In'1.01 2.0 {1/16 t 1/'16)In 2.0 ljB (1/161 1/16)39.50'33'10'(Reference)
Bim runout Aluminum wheel AxialBadialSteelwheel AxialRadla I
0 0.7 (0 - 0.03)0- 0.7 (0 - 0.03)0 - 1.0 (0 0.04)0 - 1.0 (0 0.04)
2.0 (0.08)
1.5 10.06)2.0 {0.0B)1.5 (0.06)Wheel bearingEnd play FrontRear0 0.0s (0 - 0.002)0 0.05 (0 0.002)
Standards and Service Limits
Suspension - Section 18
Brakes - Section 19
*1. 5410 Stamped on the caliper body.*2. 2056 Stamped on the caliper body.
Air Conditioning - Section 22
*: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it of{.Readjust deflection or tension to used belt values.
3-18
MEASUREMENTSTANDARO INEWISERVICE LIMIT
Parklng brakePlay in stroke at 196 N (20 kgf, 44 lbfi lever forceTo be locked when pulled6 - I notchesFoot brakepeoalPedal height (with floor mat removed) M/TA/'T, CVTFree play
156.5 {6.16)161 (6 5/16)1 5(1/16-3/16)
Master cvlinderPiston to pushrod clearance0 - 0.4 (0 0.02)
Disc brakeDisc thickness FrontRearDisc runout FrontRearDisc parallelism Front and rearPad thackness Front
Rear
20.9 - 21.8 (0.82 - 0.86)8.9 - 9.1 (0.350 - 0.358)
9.5 10.5*'8.5 - 9.5*'7.0 8.0 (0.28-0.3r)
19.0 (0.75)
8.0 (0.31)
0.10 (0.004)
0.10 (0.004)
0.015 (0.0006)
1.6 (0.06)1.6 (0.06)'r.6 (0.06)
Rear brakedrumLD.Lining thickness200 17.a7l4.0 (0.16)201 \7 .9112.0 {0.08}
MEASUREMENTSTANDARD INEWI
Conditioning
SANDEN
Lubricant type: SP 10 (P/N 38897 - Pl3 - A01AH or 3889Lubricant capacity Condensermf (floz, lmp oz) EvaporatorLine or hoseReceiver
I - P13 A0li lFor refrigerant: HFC-134a (R,134a))
| 20 \2t3 0.11
I 45 (1 2/3, 1.6)10 (1/3,0.4)
10 t1/3,0.4)NIPPONDENSOLubricant type: ND'O|L8 (P/N 38899 - PR7 - 003) (For ReLubricant capacity Condensermf (floz, lmp oz) EvaporatorLine or hoseReceiver
f.igerant: HFC,134a (R-134a))25 (s/6 0.9)60 (2,2.11
10 (1/3,0.4)
10 (1/3.0.4)
CompressorSANDENLubricant type: SP-10Lubricant capacity ml lfl oz, lmp oz)Field coil resistance at 68'F (20"C) OPulley-to-pressure plate clearance
130 150 (4 1/3 4.6, 5.0 - 5.3)
0.5 r 0.15 10.020 t 0.006)
NIPPONDENSOLubricant type: ND-OlL8 {P/N 38899 - PR7 ,003 or P/N 38899 pR7 - AO1) (For Refrigerant: HFC 134a {R,134a))Lubricant capacity m{(fl oz, lrnpoz) | 14O(4.7,4.9J -15S{5.2.5.4)Stator coil resistance at 20'C (68.F) 0Pulley-to-pressure plate clearance3.4 - 3.80.510.15 (0.0210.006)
Compressorbelt*Deffection with 98 N (1Okgl.22lbllbetween pulleys7.5 - 9.5 (0.30 0.37) with used belt5.0 - 6.5 (0.20 - 0.26)with new belt
Belt tension N (kgf, lbf)Measured with belt tension gauge340 490 i35 50, 77 - 110) with used bell690 - 830 (70 - 85, 150 190) with new belt

ITEMMETRICENGLISHNOTESTEERINGSYSTEMTvpe P/sM/SOverall Ratio p/S
M/STurns, Lock-to Lock p/S
M/SSteering Wheel Dia.
Power assisted, rack and pinionRack and pinion1l.120.33.64..1380 mm 15.0 inSUSPENSIONTYPe Front and RearFront and RearIndependent double wishbone, coil springTelescopic, hydraulic nitrogen gas-filled
WHEELALIGN| 4ENTCamber FrontRearCaster F.ontTotalToe FrontRear
0.00,- 't'
1.40'ln 1 mm ln 1/16In 2 mm In 1/16EBAKE SYSTEMType FrontRea r
Pad Surface Area Front
Rea r
Parking Brake Type
Power assisted self adjusting ventilated discPower assisted self adiustjng solid discPower assisted sell adjusting dr!m37.5 cm'x 4 5.8 sq in x 4
44.1ctn,x4 ] 6.84sq-inxa
67.2 cmz x 4 | to.+ sq in ' I21.2 cm, x 4 3.3 sq in x 4Mechanical actuating, rear two wheelbrakes
5410 stamped onthe caliper body2056 stamped onthe caliper bodyDrumDisc
TIRESize and PressureSee lire intormation label
WASHERCapacity 2door Coupe/4,door Sedan
2,door Hatchback
2.5 f (2.6 LJS qt, 2.2 lmp qt)4.5 | (4.8 US qt,4.0lmp qt)2.51 (2.6 US qt, 2.2 lmp qt)4.5 f (4.8 US qt, 4.0 lmp qt)
USA modelCanada modelDXExcept DXELECTRICALBafteryStarterAlternatorFuses In Under dash Fuse/Felay BoxIn Under-hood Fuse/Belay 8oxIn Under hood ABS FLrse/Relay BoxHeadlightsFront Turn Signal/Parking LightsRear Turn Signal LaghtsBrake/TaillightsInner Taillights*,High Mount Brake LightBack up LightsLicense Plate LightsCeiling Light
Trunk LightsGauge LightsIndicator Lightslllumination and Pilot LightsHeater Control Panel Lights
12 V 38 AH/5 HR12 V 1.0 kW, 1.2 kW12V 75 A,80 A7.5 A, t0 A, 15 A, 20 A7.5 A, 10 A, 15 A, 20 A, 30 A, 40 A, 80 A7.5 4.20 A, 40 A12V_60/55W12V -2115W
12V - 21W12V - 21/5W12V-5W12 V 18 W*" 21 W+" *3
12V 21W12v-5wl2V-8W(Withmoonroofl12 V - 5W (Without moonroof)
12V-1.4W,3W't2 v 1.12W. 1.4 W12v-0.84w, 1.4 W12V 1.4 W
Design Specifications
(cont'd)
P/S: Power Steering M/S: Manual Steering*l: 2-door Coupe *2: 2door Hatchback *3: 4-door Sedan*4: USA (HAM), Canada (HCM) produced *5: Japan produced
3-22
L'

ILubrication Points
For the details of lubrication points and types of lubricants to be applied, refer to the lllustrated Index and various workprocedures (such as Assembly/Reassembly, Replacement, Overhaul. Installation, etc.) contained in each section.
No.LUBRICATION POINTS
Engine
LUBRICANT
"Energy Conserving" grade oil,The oil container may also display the Apl Certification markshown below. Make sure it says ,,For Gasoline Engines.,,SAE Viscosity: See chart below,
I
TransmissionManualGenuine Honda MTF*1
Genuine Honda Premium FormulaAutomatic Transmission Fluid (ATF)*,
Genuine Honda CVT Fluid*3
Genuine Honda DOT3 Brake Fluid*a
Automatic
CVT
3Brake Line
ClL,tci t""e4
I
Genuine Honda DOT3 Brake Fluid*aPower steering gearboxSteering grease P/N 08733 - BO70EShift lever pivots (manual transmission)Grease with molybdenum disulfide7-:ti
9
10'l'l
l3
14
't7
18
19
20
2122
Release fork (manual trancmi<si^nl
Steering bootsTailgate hinges and latches (2-door HatchbacklSteering ball joints
Shift lever (automatic transmission)Pedal linkageBrake master cylinder pushrod
Super High Temp Urea crease (p/N 08798 - 9OO2)
i Multi-purpose grease
I
I
Honda White Lithium Grease
Multi-purpose grease
Silicone grease
@
Trunk hinges and latch (4-door Sedan and 2-doorCoupe)Door hinges upper and lowerDoor opening detentsHood hinge and hood latch-FUet T ter ttd
Clutch master cylinder pushrodThrottle cable end and throttle linkageRear brake shoe linkagesSteering wheel (back side)
23
E-
Caliper piston seal, dust seal,caliper pin. pistonThrottle cable end (dashboard lower panel)
Power steering system (for cars with p/S)
Air conditioning compressorComDressor oil:SANDEN: SPlo P/N 38897 - p13 -A01AH or 38899 - p13_ A01{For Refrigerant: HFC-134a (R-134a))
CERTIFICATION SEAL
ffi
NorE: The items m arked * 1, *2, +3, *4 and +5 on above chan are described as folows:*1: Always use Genuine Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because itdoes not contain the proper additives.*2: Always use Genuine Honda premium Formula Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affectshift quality.+3: Use Genuine Honda cVTfluid only usingotherfluid can affect tra nsmission operation and may reduce transmission life.*4: Always use Genuine Honda DoT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and dec.ease the lifeof the svstem.*5: Always use Genuine Honda Power steering Fluid. using any other type of power steering fluid or automatrc transmissionfluid can cause increased wear and poor steering in cold weather.
4-2
Recommended Engine Oil
Engine oil viscosity forambrent temperature ranges
API SERVICE LABEL

Mainshaft Thrust Shim
Adjustment
Remove the thrust shim and oil
the transmission housing.
1.gu ide plate from
THRUST SHIM
OIL GUIDEPLATE
TBANSMISSIONHOUSING
Install the 3rd/4th synchro hub, spacer collar, 5th
synchro hub, ball bearing, and thrust washer on themainshaft. Install the assembly in the transmission
h ousing.
@ gnol+lx syNcHRo HUB
THRUST WASHER
SPACER COLLAR
4.
Measure the distance @ between the end of thetransmission housing and thrust washer.
NOTE:
. Use a straight edge and vernier caliper.. Measure at three locations and average the read-
Ings.
Measure the distance @ between the surfaces ofthe clutch housing and bearing inner race.
NOTE:
. Use a straight edge and depth gauge.
. Measure at three locations and average the read-
Ings.
sTH SYNCHRO IIUB
BALL EEARING
CLUTCH
L
HOUSINGENO OF
13-36
INNER RACE OF BALL AEARING
\
5.Select the proper shim on the basis of the followingcalculations:
NOTE: Use only one thrust shim.
(Basic Formula)(B) + {C). 0.95 = shim thickness
Example of calculation:
Distance @ (2.00 mm) + Distance @= 2.09 mm
subtract the spring washer height (0.95
required thrust shim (1.14 mm)
65 mm THRUST SHIM: D16Y7 engine:
(0.09
mm)
mm)
= tne
r1
Part NumborThickness
23931 - PL3 A100.60 mm (0.0236 in)23932 - PL3 A100.63 mm 10.0284 in)c23933 - PL3 A100.66 mm {0.0260 iniD23934 PL3 - A100.69 mm (0.0272 in)
E23935-PL3-4100.72 mm 10.0283 in)
F23936-PL3-4100.75 mm 10.0295 in)G23937-PL3-A100.78 mm {0.0307 in}
23938 PL3 - A100.81 mm (0.0319 in)I23939 - PL3 At00.84 mm (0.0331 in)J23940-PL3-Ar00.87 mm (0.0343 in)
23941 - PL3 - A100.90 mm (0.0354 in)
L23942 - PL3 A100.93 mm (0.0366 in)
23943-PL3-A100.96 mm (0.0378 in)N23944 PL3 - A100.99 mm 10.0390 in)
o23945-PL3-A101.02 mm {0.0402 in}23946 - PL3 A101.05 mm (0.0413 in)o23947 PL3 - 4101.08 mm (0.0425 in)R23948-PL3-A101.11mm (0.0437 in)s23949 PL3 - A101.14 mm {0.0449 in}T23950-PL3-A101.17 mm (0.0461 in)
U23951 PL3 - A101.20 mm (0.0472 in)
23952-PL3-Ar01.23 mm {0.0484 in)
23953-PL3-A101.26 mm {0.0496 in}X23954 - P13, A101.29 mm (0.0508 in)23955 - PL3 A101.32 mm (0.0520 in)z23956-PL3-Ar01.35 mm {0.0531 in)
23957-PL3-A101.38 mm (0.0543 in)
AB239s8 - PL3 A101.41 mm (0.0555 in)AC23959 PL3 - A101.44 mm (0.0567 in)
AD23960 - PL3 A101.47 mm (0.0579 in)23961 - PL3 4101.50 mm (0.0591 in)23962 PL3 - A101.53 mm (0.0602 in)AG23963-PL3-4101.56 mm (0.0614 in)AH23964 - PL3 A101.59 mm (0.0626 in)AI23965-PL3-A101.62 mm {0.0638 in)
23966 PL3 - A101.65 mm (0.0650 in)AK23967-PL3-A101.68 mm {0.0661 in)
23968 PL3 - A101.71 mm {0.0673 in)23969-PL3-A101.74 mm (0.06a5 iniAN23970- PL3 -A101.77 mm (0.0697 in)AO23971 - PL3 - A101.80 mm 10.0709 in)

Mainshaft Thrust Clearance
Adjustment
1. Remove the 72 mm thrust shim and oil guide platefrom the transmission housing.
4.
TFANSMISSIONHOUSING
72 mm THRUST SH|M
TRAt{SMtSStONHOUSINGOIL GUIOE PLATE
lnstall the 3rd/4th synchro hub. spacer collar,5thsynchro hub. spacer, and ball bearing on the main_shaft, then install the above assembly in the trans_mission housing.
lnstall the washe[ on the mainshaft,
Measure distance @ between the end of the trans-mission housing and washer.
NOTE;
. Use a straight edge and vernier caliper.. Measure at three locations and average the read_ing.ENO otlnA sMtsstoNHOUSINGMAINSHAFT
3RD/irTH SYNCHRO HUB
SPACCR COLLAR
5TH SYNCHRO HUB
o
B
13-88
AALL BEARING
V.
5. Measure distance @ between the end of the clutchhousing and bearing inner race.
NOTE;
. Use a straight edge and depth gauge.. Measure at three locations and average the read-ings.
Select the prcpet 72 mm thrust shim from the chartby using the formula below.
NOTE: Us€ only one 72 mm thrust sntm.
Shim Selection Formula:
From the measurements you made in steps 4 and 5:. Add distance O lstep 5) to distance @ (step 4).
. From this number, subtract 0.93 (which is themidpoint of the flex range of the clutch housingbearing spring washer).
. Take this number and compare it to the availableshim sizes in the chart.
{For example)
B;2.39
+ C: 0.22- 0.93
2.61 = 1.68
Try the 1.68 mm (0.0661 in) shim.
INNER RACE ot EALL BEARING

Front Suspension
Knuckle/Hub Replacement
CAUTION:
. Replaco tho salf-locking nuts after romoval.
. The vehiclo should be on tho ground bsfore any bohs or nuls connected to rubber mounb or bushings are tightened.. Torqu€ th€ castle nut to the lowor torque specification, ihen tighton it only far enough to align th€ slot whh the pin
hole. Do not align the nut by loosening.
NOTE:
. Use only genuine Honda wheel weights for aluminum wheels. Non-genuine wheel weights may corrode and damagethe aluminum wheels.
. On the aluminum wheels, remove the center cap from the inside of the wheel after removing the wheel,. Before installing the brake disc, clean the mating surfaces of the front hub and brake disc,. Before installing the wheel, clean the mating surfaces of the brake disc and wheel.o Wipe off the grease before tightening the nut at the ball joint.
CALIPER MOUNTING BOLT12 x 1.25 mm108 N.m {11.0 kgl.m, 80lbf.ft)
LOWER BALL JOINTInspect for faultymovement and wear.
CASTLE NUT10 r 1.25 mm39 - ia7 N.m (4.0 - 4.8 kgf.m, 29 - 35 lbf,ftl
COTTER PINReplace.
WHEEL BEARINGReplace.Replacement, page 18-14
CIRCLIP
SCREW5x0.8mm5 N.m {0.5 ksl.m, 4 lbf.ftlReplacement, page 18-16
SET RING
BALL JOINT BOOT
FRONT HUBCheck for damage andcracks.Replacement,page 18-10Check for deteriorationand damage.
CASTLE NUT12 x 1.25 mm49 - 59 N.m l5.O - 6.0 kg{.m. 36 - /(} lbf,ftl
SPINDI.T ]{UT22 r 1.5 mmlEl N.m {18.5 kgf.rn, 13{ lbl.ttlReplace.NOTE:. Before instelling the spindle nut. apply6n9ine oilto th6 seating surface ofthe nut.. Atter tightening, uso a drift to stake thespindle nut should6r against the driveshaft.
BRAKE DISCCheck for wear andrust.Replacement, page 18-11lnspection, section 19.
WHEEL NUT12 x 1.5 mm'108 N.m1r1.0 kgf.m, 8lt lbf.ft)
6 mm BRAKE DISC RETAINING SCREW9.8 N.m 11.0 kgf.m, 7 lbtft)
18-10

)
1.Loosen the wheel nuts slightlY.
Raise the front of the vehicle, and support it with safe-
ty stands in the proper locations (see section 1).
Remove the wheel nuts and wheel.3.
l)
WHEEL NUT'108 N.m
18'l N.m 118.5 kgf m, 134lblfti
Replace.NOTEI Before installing the spandle nut, apply
engine oil to the seating surface of the nut After
tightening, use a drift to stake the spindle nut
shoulder againsl the driveshaft
Raise the locking tab on the spindle nut, then remove
the nut.
Remove the brake hose mounting bolts.
BRAKE HOSE MOUNTING BOLT
I x 1.25 mm12 N.m (1,2 kgtm,8,7 lbf'ftl
6. Remove the caliper mounting bolts and hang the
caliper assembiy to one side
CAUTTON: To prevent accidental damage to the
caliper assembly or brake hoso' use a short piece of
wire to hang the caliPer tlom lhe undelcarriage.
{11 kgf m, 80 lbl.ft)
CALIPER MOUNTING BOLTS12 x 1.25 mm108 N.m {'11.0 kgtm, 80 lbt.ft)
7. Remove the 6 mm brake disc retaining screws.
8.
I x 1.25 mm BOLTS
Screw two 8 x 1.25 mm bolts into the disc to push it
away from the hub,
NOTE: Turn each bolt two turns at a tame to prevent
cocking the disc excessivelY.
Remove the brake disc from the knuckle.
Check the front hub for damage and cracks.
Remove the wheel sensor from the knuckle (for
vehicles with ABS).
NOTE: Do not disconnect the wheel sensor connec-
tor.
N.m
6 mm BRAKE OISCRETAINING SCREWS9.8 N.m t1.0 kgf.m, 7 lbf'ft)
{'1.0 kgf m,
7 tbf.ft)
10.
11.
MOUNTING
WHEEL
BOLTS9.8 N.m11.0 kgf,m, 7 lbf'ft)(cont'd)

Rear Suspension
Hub Bearing Unit Replacement (cont'dl
NOTE: Disc type {'99 2D Si and Si-R modets)
1. Loosen the wheel nuts slightly.
2. Raise the rear of vehicle, and support it with safetystands in the proper locations {see section 1).
3. Remove the wheel nuts and rear wheel.
4. Pull the parking brake lever up.
5. Remove the hub cap.
6. Raise the locking tab on the spindle nut, thenremove the nut. SPINDLE NUT22 x 1.5 mrn181 N.m (18.5 kgf'm, 134lbf.fi)Replace.NOT€:. Eefore installing the spindle nut,apply engine oil to the seatingsurface of the nut.. After tightening, use a drift tostake the spindle nut shoulderagainst the spindle.
lFor vehictes \\with drum brakes;/
WHEEL NUT12 x 1.5 mm108 N.m
I I 1 kgt m, 80 lbf.ftl
HUB CAPReplace-NOTE: Take care not to damage the hub untton disassembly.
Remove the 6 mm brake disc retaining screws.7.
6 mm BRAKE DISCRETAINING SCBEWS9.8 N.m 11.0 kgl.m, 7 lbf.frl
1A-24
8.
9.
Release the parking brake lever.
Remove the brake drum, hub unit bearing, andspindle washer lfor vehicles with drum brakes).
BRAKE DRUM
SPINDI-E WASHER
10. Remove the 6 mm flange bolts and caliper shield.
CALIPER SHIELOCheck for bending and damage.
6 mm FLANGE BOLTS9.8 N.m {1.0 kgf.m, 7 lbf,ft)

T
11.
1)
Remove the two brake hose mounting bolts
Remove the caliper b.acket mounting bolts, and
hang the caliPer to one side
CAUTION: To prevent accidental damage to the
caliper or brake hose, use a short piece of wile to
hang the caliper from the undercarriage.
BRAKE HOSE MOUNTING BOLTS
22 N'm {2.2 kgf'm, 16lbt"ft}
CALIPER 10 x 1.25 mm38 N'm (3.9 kgf'm, 28 lbf'ftl
Screw two 8 x 1.25 mm bolts into the disc to push it
away from the hub.
NOTE: Turn each bolt two turns at a time to pre-
vent cocking the disc excessively.
Remove the brake disc.
Remove the hub unit bearing from the spindle
SPINOLE WAS}IER
lr
14.
15.
lt
16. lnstall in the reverse order of removal.
1A-25
Upper Arm Bushing RePlacement
1. Remove the upper arm bushing and upper arm
jnner bushing as shown
UPPER ARM INNER BUSHING UPPER ARM BUSHING
REAR UPPER ARM
Scribe a line on the upper arm inner bushing so that
it is in line with the bolt mounting surface
Mark to points on the upper arm so that they are In
line and make a right angle with the arm as shown
in the drawing.
BOLT MOUNTINGSURFACE
Drive in the upper arm inner bushing with the marks
aligned.
Drive the upper arm bushing into the upper arm
NOTE: Drive in the upper arm bushing and upper
arm inner bushing until their leading edges are
flush with the uPPer arm
ttI
5.
UPPER ARM

t
Conventional Brake
Speciaf Tools .............19'2
Component Locations
lndex ................ ...... 19-3
Inspection and Adiustment
Brake System Rubber Parts
and Brake Booster ...........,.,............. 19-4
Brake Pedal ............ 19-5
Parking Brake ........ 19-6
Bleeding ................. 19-7
Front Brake Pads
Inspection and Replacement .......... 19-8
Front Erake Disc
Disc Runout Inspection ................... 19-12
Disc Thickness and Parallelism
Inspection .......... 19-12
Front Brake Caliper
Disassembly .......... 19'13
Reassembly ........... 19-16
Master Cylinder/Brake Booster
Removal/lnstallation ....................... 19-21
Pushrod Clearance Adiustment ...... 19-22
Brake Booster Inspection ................ 19-23
Rear Brake Pads
Inspection and Replacement ,,........ 19-24
Rear Brake Disc
Disc Runout lnspection ................... 19-26
Disc Thickness and Parallelism
Inspection .......... 19-26
Rear Brake Caliper
Disassembly ...........19-27
Reassembly ........." 19-31
Rear Drum Brake
Index/lnspection .............................. 19-35
Inspection ....,.,....... 19-36
Brake Shoe Disassembly ..............." 19-37
Brake Shoe Reassembly ...............'.. 19-37
Brake Hoses/Lines
Inspection/Torque Specifications ..... 19-39
Hose Replacement ........................... 19-40
Parking Brake Cable
lnspection and Replacement ........,. 19-41
l-l