Front HONDA CIVIC 1997 6.G Owners Manual

Component Locations
I
lndex
ERAKE PEDALInspectron andAdjustment, page 19 5
BRAKE HOSES LINESInspection/Torque specif ications, page 1 9-39Hose Replacement, page 19-40
MASTER CYLINDER/BRAKE BOOSTERRemoval/lnstallation, page 19 21Pushrod Clearance Adjustment, page 19_22
Brake Booster Inspection, page 19-23
lJ
PARKING BRAKE CASLEinspection and Replacement,page 19 41
FRONT BRAKESNOTE: There are two types offront brake calipers:The caliper types can be identitied by the "5410"
or "2056" stamped on the caliper body. Check thetype ot the brake caliper betore servicing.Front Brake Pads5410 Type: page 19-82056 Typer page 19 10Front Brake Disc, page 19-12Front Brake Caliper5410 Type: page 19-132056 Type: page 19-14
BBAKEAdiustment, page 19-6REAR ORUM BRAKESInspection, page 19-36
Brake Shoe Beplacement, page 19'37
REAR DISC BRAKESRear Brake Pads, page 19 24Rear Brake Disc, page 19 26Rear Brake Caliper, page 19'27
lJ
19-3

Inspection and Adjustment
Parking Brake
Inspection
1. Pull the parking brake lever with 196 N {20 kgf. 44 lbf)
force to fully apply the parking brake. The parking
brake lever should be locked within the sDecified
number of clicks.
Lever Locked clicks: 6 - I
Pulled up96 N 120 kgf,44lbf)
2. Adjust the parking brake if the lever clicks are out of
specification.
Adiusiment
NOTE: After servicing the rear brake pads or calipers, or
the rear brake shoe, loosen the parking brake adjusting
nut, start the engine, and depress the brake pedal sever-
al times to set the self-adjusting brake before adjusting
the parking brake.
1. Raise the rear wheels off the ground, and support
the vehicle on safety stands.
l@ Elock the front wheels bofore iackinguD the rear ot the v6hicle.
2. On vehicles with rear disc brakes, make sure theparking brake arm on the rear brake caliper contacts
the brake calioer Din.
with 1
\
19-6
Remove the rear console (see section 20).
Pullthe parking brake lever up one click,
Tighten the adjusting nut until the rear wheels drag
slightly when turned.
Belease the parking brake lever fully, and check that
the rear wheels do not drag when turned. Readjust
if necessarv.
Make sure that the parking brakes are fully applied
when the parking brake lever is pulled up fully.
Reinstall the rear console.
7.
8.
ADJUSTING NUT

I
Bleeding
CAUTION:
. Always use Genuine Honda DOT 3 Brake Fluid. Using 8
non-Honda brak€ fluid can cause corrosion and
docrea3e the life of the system.
. Make surs ||o dirt or other foteign matter is allowed
to contaminate the brake fluid,
. Do not spill brake lluid on the vehicle, it may damago
the paint; if brake lluid doos contac{ the paint, wash
it ofl imm€diately with water.
NOTE: 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.
1. Make sure the brake fluid level in the reservoir is at
the MAX lupper) level line.
MAX {UPPER) LEVEL
CYLINDER
Have someone slowly pump the brake pedsl several
times, then apply steady Pressure.
Loosen the brake bleed screw to allow air to escape
from the system. Then tighten the bleed screw
securely.
Repeat the procedure for each wheel in the sequence
shown below until air bubbles no longer appear in
the fluid.
Refill the master cylinder reservoir to the MAX (up-
per) level line.
ELEEDING SEOUENCE:
O Front Right(D Bo.r Right
O Front LeftO Rear Left1,,
19-7
FRONTT
REAR lDrum Brakel:
REAR (Disc Brake):
AIEED SCREW9 N.m (0.9 ksf m, 6.5 lbf'ft)

Front Brake Pads
Inspection and Replacement
NOTE: There are two types of front brake calipers:
The caliper types can be identified by the "5410" or"2056" stamped on the caliper body as shown below.
Check the type of the brake caliper before servicing.
5i110 Type:
NOTE: For 2056 type disassembly procedures. see page
19-'10.
Never use an air hose or dry brush lo clean brake
assgmblios.
Use an OSHA approved vacuum cleaner to avoid
breathing brake dust.
Loosen the front wheel nuts slightly, then raise the
vehicle, and support it on safety stands. Remove
the front wheels.
Remove the brake hose bracket from the knuckle.
Remove the caliper bolt, and pivot the caliper up
out of the wav.
1.
2.
NOTE: Check the hoses and pin boots for damage
and deterioration.
CALIPER BOLT
19-8
4. Remove the pad shim. pad retainers, and pads.
NOTE: When the caliper is equipped with an outer
pad shim, replace the shim together with the pads
5. Using vernier calipers, measure the thickness of
each brake pad lining. The measurement does not
include the pad backing plate thickness.
Brake Pad Thickno$:
Standard: 9.5 - 10.5 mm 10.37 - 0.41 in)
SerYico Limit 1.6 mm {0.06 in}
lf the brake pad thickness is less than the service
limit, replace the front Dads as a set.

Front Brake Pads
2056 Type:
@. Never use an air hose or dry brush to clgan brake
assemblies.
. Use an OsHA-approved vacuum cleanor lo avoid
breathing broke dust.
Inspection and Replacement (cont'dl
1. Loosen the front wheel nuts slightly. then raise the
vehicle, and support it on safety stands. Remove
the front wheels.
2. Remove the brake hose bracket from the knuckle.
3. Remove the caliper bolt B, and pivot the caliper up
out of the wav,
EOLT B
NOTE: Check the hoses and pin boots for damage
and deterioration.
Remove the pad shim, pad retainers, and pads.
NOTE: When replacing the pads, replac€ the shim
together with the pads as a set,
OUTERPAD SHIMCheck for wear.
INNER PAD
PAO RETAINERSCheck for weakness anddamage,OUTER PAD
19-10
5. Using vernier calipers. measure the thickness of
each brake pad lining. The measurement does not
include the pad backing plate thickness.
Brake Pad Thicknsss:
Standard; 8.5 - 9.5 mm 10.33 - 0.37 in)
Servica Limh: 1.6 mm {0.06 in}
lf the brake pad thickness is less than the service
limit, replace the front pads as a set,
Clean the caliper thoroughly; remove any rust. and
check for grooves and cracks.
Check the brake disc for damage and cracks,
Install the pad retainers.
7.
8.
9.

Front Brake Disc
Disc Runout Inspection
L
2.
Loosen the front wheel nuts slightly, then raise the
vehicle, and support it on safety stands. Remove
the front wheels.
Remove the brake pads (see page 19,8).
Inspect the disc surface for damage and cracks.
Clean the disc thoroughly and remove all rust.
Use wheel nuts and suitable plain washers to hold
the disc securely against the hub, then mount a dial
indicator 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 inl
WHEEL NUT ANOPLAIN WASHER'108 N.m(11 kg{.m, 80 lbf.ft)
lf the disc is beyond the service limit, refinish thebrake 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.
Max. Refinish Limit: 19.0 mm (0.75 in)
NOTE: A new disc should be refinished if its runout
is greater than 0.10 mm (0.004 in)
19-12
Disc Thickness and Parallelism
Inspection
1.Loosen the front wheel nuts slightly, then raise the
vehicle, and support it on safety stands. Remove
the front wheels.
Remove the brake pads (see page 19-8).
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 Dbc Thickn6s:
Standlrd: 20.9 - 21.8 mm (0.82 - 0.86 in)
Max. Refinishing Limit: 19.0 mm 10.75 inl
NOTE: Replace the brake disc if the smallest mea-
surement is less than the max. refinishinq limit.
Brake Disc Parallelism: 0.015 mm (0.fit06 in) max.
NOTE: This is the maximum allowable difference
between the thickness measurements.
lf 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 Manufac-
turing Co. and the "Front Brake Disc Lathe" offered
by Snap-on Tools Co. are approved for this opera-
tion.
NOTE: See section 18 for brake disc reDlacement.

Front Brake Caliper
It
Disassembly
NOTE: There are two types of front brake calipers:
The caliper types can be identified by the "5410" or"2056" stamped on the caliper body as shown below.
Check the type of the brake caliper before servicing.
5410 Type:
NOTE: For 2056 type disassembly procedures, see page
19-14.
@o Never use an air hose ot dry brush to clean brakg
assemblies.
. Use an OSHA approved vacuum clganer to avoid
breathing brake dust.
CAUTION:
. Do not spill brake lluid on the vehicls; it may damage
the paint; if brake fluid does conlact the paint, wash
it off immedistely with waier.
. To prevenl spills, covet the hose ioin$ with rags or
shop towels.
. Clean all parts in brake fluid and air dry; blow out all
passages with compressed air.
L Remove the banjo bolt, and disconnect the brake
hose from the caliDer.
CALIPER
BANJO EOLT
SEALINGReplace.BOLTS
Remove the caliper bolts, then remove the caliper
from the bracket.
lJReplace.
3. Remove the caliper pins and pin boots from the
calioer bracket,
CALTPER PIN B CAL|PER BRACKET
CALIPER PIN A
4, lf necessary. apply compressed air to the caliper
fluid inlet to get the piston out. Place a shop rag or
wooden block as shown to cushion the piston when
it is expelled. Use low pressure air in short spurts.
@. Do not place your iingers in tront ol the piston.
. Do not use high air pressure; use 8n OSHA
approved 30 PSI nozzls,
Remove the piston from the caliper, and check the
piston for scoring.
Remove the boot clip, piston boot and piston seal.
CAUTION: Take care not to damage the cylindcr
PISTON SEALReplace.
BOOT CLIPReplace.
\,
,t. (
)PISTON BOOT
CALIPER BODYCheck for scoring
(cont'd)
19-13

Front Brake Caliper
2056 Type:
@
Disassembly (cont'dl
Nevor u3e an air hos€ or dry brush to clgan brake
assomblios.
Use an OSHA approved vacuum cl6aner to avoid
braathing braks duet.
CAUTION:
. Do not spill brakefluid on ths vchicle; it may damage
the paint; if brako fluid does contact the p.int. wash
it olt immediately with wato..
. To prevsnt spills, cover the ho3o ioints whh rag3 or
shop towels.
. Cl€an all parts in brake fluid and air dry; blow out 8ll
passagss with compr63€d air.
1. Remove the banjo bolt, and disconnect the brake
hose from the caliper.
SEALING WASHERS
Remove caliper bolt B, pivot the caliper up out of
the way, then remove the caliper from the bracket.
Remove the guide pin boot from sleeve A on the
caliDer bracket.
GUIDE PIN BOOTReplace.
GALIPER BRACKETCheck tor cracks.
Check for damage.
19-14
4. Remove the pin boot, sleeve B and sleeve boot
from the caliper body.
CALIPER EODYCheck for scoringon cytinder wa .
SLEEV€ BCheck for damage.
lf necessary, apply compressed air to the csliper
fluid inlet to get the piston out. Place a shop rag or
wooden block as shown to cushion the oiston when
it is expelled. Use low pressure air in short spurts,
a
a
Do not placo your lingers in ftont ol tho pkton.
Do noi usa high air prsssure; uso an OSHA
approved 30 PSI nozzle.
Remove the piston from the caliper, and check thepiston for scoring.
WOODEN ALOCK

Front Brake Galiper
Reassembly
5410 Type:
NOTE: For 2056 type reassembly procedures, see page 19-18.
o Never use an air hose or dry brush to clean brako assemblies.. Use an OSHA approved vacuum cleanerto avoid breathing brake dust.. Contaminated brake discs or pads reduce stopping abilhy.. when reusing the pads, always reinstall the brake pads in their original positions to pr€vent loss of braking €fficiency.
CAUTION:
. Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid do€s contaci the psint, wash it oft imme"diately with water.
. Clean all parts in brake fluid and air dry; blow out all passag€s whh comp.€ssed air.. Betore reassembling, check that all parts are free ol dust and othor toreign particlos.
. Replace parts wilh new ones whenever specified to do so.. Make sure no dirt or other toreign matt€r is allowed to contaminate the brake fluid.. Always use Genuine Honda DOT 3 Brake Fluid. Using a non.Honda brake tluid can cause corrosion and decresse thelife of th€ system.
NOTE:
. Coat the piston, piston seal, and caliper bore with clean brake fluid.. Replace all rubber parts with new ones whenever disassembled.
z_..=-.q8! .9!,H: Use recommended rubber grease in the caliper seal set.
-.61' use recommended seal grease in the catiper seal set.
BRAKE PADSPIN BOOTSReplace.
OUTER PAD SHIM
-o -'''---&@CAI-IPER PIN A -
BLEED SCREWS N.m (0.9 kgt.m, 6.5 tbf.ftl
"k..6
*/\*
car-rpen prr'r e-....,-q\,
-W@{
q
1
PAD RETAINERS
CALIPER BRACKET
WEAB INDICATOR
tilfliltn
tw tfi lJlWEAB rNDrcAroR \J I Ilnsrall inner pad with lAVirs weat indicatot !pwatd/,.
CALIPER BRACKEI MOUNTING BOLT108 N.m {11.0 kgt m,80lbf.ft)
PISTON BOOTReplace.
-6r
/ eoor cr-re
I neptace.
6/vo
PISTON SEALReplace.
19-16
CALIPER BODY

Front Brake Caliper
Reassembly (cont'd)
2056 Type:
. Never use an air hose or dry b.ush to clean brake assemblies.. Uso an OSHA approved vacuum cleansr to avoid breathing brake dust.. Contaminated brake discs or pads reduce stopping ability.t when reusing the pads, always r6instsll the brake pads in their original positioos to prevent loss ol braking efficiency.
CAUTION:
' Do not spill brake tluid or th€ vehicle; it m8y damage the paint; if brake fluid does contact the paint, wash it off imme-diately with water.
. Clean all parts in brake tluid and air dry; blow out all passages with compr63ed air.. Beforo reassembling, check that all parts are fr€e of dust and other foreign particles,. Replace parts with new ones whenevea specified to do so.. Make sure no dirt or other foreign matter is allowad to contaminato the brake fluid,' Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can caus€ corrosior and decrease thelife ol the system.
NOTE:
. Coat the piston, piston seal, and caliper bore with clean brake fluid.. Replaceall rubber parts with new ones whenever disassembled.
.'=5@: Use recommended rubber grease in the caliper seal set,
-6l ' Use recommended seal grease In the caliper seal set.
@6--i#i['i,?li"..;:l]l?Y]li"'"'
I
r""'"rr r"""ip"autr, -/ffr
e"6ft 'ADRETATNERSitswearndcatoru'ward
MffiA pr
GUIDE PIN BOOT ) {I I II ) I I
% caL,PER
\I\d/ tt ' id 6
u -es'---r..'.* ".-,."oo*'J.l, ru,oonW U
**=*t
WEAR,INDICAToR. ,ffi OUTERIPAD
BLEED SCREW9 N.m (0.9 kgf.m, 6.5 lbf.ft)
\o@
CALIPER BRACKET
PISTON EOOTReplace. -.&l
BOOT CLIPReplace.
SLEEVE A
SLEEVE 8
-"-41
r{.i'""Jg*'
a,t/ c'f3!@
q.-
t\
20 tbf.ftl
CALIPER BOLT B26Nm{2.7kgf.m,
CALIPER BODY
PIN BOOTReplace.
BRAKE PAOS
19-18