brakes HONDA CIVIC 1997 6.G User Guide

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
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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
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19-3

Inspection and Adjustment
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Brake System Rubber Parts and Brake Booster
Brake Boostet
Check brake operation by applying the brakes.
lf the brakes do not work properly, check the brake
booster, Replace the brake booster as an assembly
if it does not work properly or if there are signs of
leakage.
Piston Cup and Pressure Cup Inspeqtion
. Check brake operation by applying the brakes.
Visually check for damage or signs of fluid leak-
age.
Replace the master cylinder as an assembly if
the pedal does not work properly or if there is
damage or signs of fluid leakage.
. Check for a difference in brake pedal stroke
between quick and slow brake applications.
Replace the master cylinder if there is a differ-
ence in oedal stroke.
Brake Hoses
Visually check for damage or signs of fluid leakage.
Replace the brake hose with a new one if it is dam-
aged or leaking.
Caliper Piston Seal and Piston Boots
Check brake ope.ation by applying the brakes.
Visually check for damage or signs of fluid leakage.
lf the pedal does not operate properly, the brakes
drag. or there is damage or signs of fluid leakage,
disassemble and inspect the brake caliper. Replace
the boots and seals with new ones whenever the
brake caliDer is disassembled.
Wheol Cylindor Piston Cup and Dust Cover
Check brake operation by applying the brakes.
Visually check for damage or signs of fluid leakage.
lf the pedal does not operate properly, the brakes
drag, or there is damage or signs of fluid leakage,
disassemble and inspect the wheel cylinder. lf nec-
essary, replace the wheel cylinder as an assembly.
19-4

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

)
It
7. Clean the caliper thoroughly; remove any rust, and
check for grooves and cracks.
8. Check the brake disc for damage and cracks.
9. lnstall the pad retainers,
10. Apply grease to the points indicated by the arrows
in the following illustration:
NOTE: Use the pad grease included in the pad set
or Molykote Nl77 grease, and apply a thin coat of
grease evenly to the designated points.
o Piston end and inner Dad contact surface
. Pad and calioer bracket contact surface
. Outer pad and caliper body contact surface
. Outer pad shim and outer pad contact surface
. Outer pad shim and caliper body contact surface
WEAR INDICATOB
INNER PAD
OUTER PAD
1 1. Install the brake pads and pad shim correctly.
. Whon reusing the pads, always reinstall the
brake pads in their original positions to prevont
loss of braking efticiency.
. Contaminated brake discs or pads teduce stop-
ping ability. Keep grease oft the discs and pads'
NOTE: lnstall the Dad with the wear indicator on
the inside.l.t
'12. Push in the piston so that the caliper will fitoverthe
pads, Make sure that the piston boot is in position
to prevent damaging it when pivoting the caliper
down.
Pivot the caliper down into position, then install the
caliper bolt and tighten it.
CAUTION: Be caretul not damage the pin boot
when pivoting the caliper dowr.
lnstall the brake hose bracket on the knuckle
NOTE: Inspect the brake hose for interference or
twisting.
Depress the brake pedal several times to make sure
the brakes work. then test-drive.
NOTE: Engagement of the brake may require a
greater pedal stroke immediately after the brake
pads have been replaced as a set. Several applica-
tions of the brake pedal will restore the normal
Dedal stroke.
After installation. check for leaks at hose and line
joints or connections, and retighten if necessary.
13.
14.
15.
16.
(cont'd)
19-9
CALIPER BOLTN m (3.3 kgf m,2a lbf.ft)

)
lO. Apply grease to the points indicated by the arrows
in the following illustration:
NOTE: Use the pad grease included in the pad set
or Molykote M77 grease, and apply a thin coat of
grease evenly to the designated points.
. Piston end and inner pad contact surface
o Pad and caliper bracket contact surface
. Outer pad and caliper body contact surface
. Outer pad shim and outer pad contact surface
. Outer pad shim and caliper body contact surface
OUTER PAD
OUIERPAD SHIM
I 1. Install the brake pads and pad shim correctly
@o When reusing the pads, always reinstall the
brake pads in their original positions to plevent
loss of braking etticiencY.
. Contaminated brake discs ol pads reduce stop-
ping ability. Keep grease oft the discs and pads.
NOTE: Install the pad with the wear indicator on
the inside.
WEAR INDICATOR
12. Push in the piston so that the caliper will fit over the
pads. Make sure that the piston boot is in position
to prevent damaging it when pivoting the caliper
CALIPER BOLT B26 N.m {2.7 kgt m,
20 rbl.ftl
14.
13.Pivot the caliper down into position, then install
caliper bolt B and tighten it.
lnstallthe brake hose bracket on the knuckle.
NOTE: Inspect the brake hose for interference and
twisting.
Depress the brake pedal several times to make sure
the brakes work, then test-drive
NOTE: Engagement of the brake may require a
greater pedal stroke immediately after the brake
pads have been replaced as a set. Several applica-
tions ot the brake pedal will restore the normal
pedal stroke.
After installation, check for leaks at hose and line
joints and connections, and retighten if necessary.16.
PISTON
19-1 1

I
7.
11.
Clean the caliper thoroughly; remove any rust, and
check for grooves and cracks.
Check the brake disc for damage and cracks.
lvlake sure that the pad retainers are installed in
their correct positions.
PAD RETAINERS
Apply grease to the points indicated by the arrow in
the following drawing:
NOTE: Use the pad grease included in the pad set
or lMolykote M77 grease, and apply a thin coat of
grease evenly to the designated points.
. Piston end and inner pad contact surface
. Pad and caliper bracket contact surface
. Outer pad shim and outer pad contact surface
. Outer pad shim and caliper body contact surface
lnstall the brake pads and outer pad shim on the
caliper bracket. Install the inner pad with its wear
indicator facing downward.
@iwhen reusing the pads, always reinstall the
brake pads in iheil original posiiions lo prevont
loss ol braking efficiency
. Contaminaled brake discs or pads reduce stop-
ping ability. Keep grease off the discs and pads.
t./
19-25
12. Rotate the caliper piston clockwise into the cylinder'
then align the cutout in the piston with the tab on
the inner pad by turning the piston back
CAUTION: Lubricate ths boot with rubber grease
to avoid twisting the piston boot. lf the piston boot
is twisted, back it out so it sits properly.
CALIP€R MOUNTINGBOLTS23 N,m {2.3 kg{.m, 17 lbt'ft)
13.
14.
15.
CUTOUT
BRAKE CALIPER
Install the brake hose clamp on the trailing arm.
Install and tighten the caliper mounting bolts.
Install the caliper shield.
After installation. check for leaks at hose and line
joints and connections, and retighten if necessary.
Depress the brake pedal several times to make sure
the brakes work, then test-drive
NOTE: Engagement of the brake may requrre greater
pedal travel immediately after the brake pads have
been replaced as a set. Several light applications of
the brake pedal will restore the normal pedal travel.
Greater than normal pedal travel may damage the
master cylinder.
16.
17.

tJ
t\
Kickback
1. The 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.
2. TheABScontrol unit operates the solenoid valve when the brake pedal is released afterthe initial diagnosis Youmay
hear the faint solenoid valve operation sound at this time. but it is normal.
Pump Motor
1. The pump motor operates when the ABS is functioning
2. The ABS control unit checks the pump motor operation during acceleration. You may hear the faint operation sound
at this time. but it is normal.
Brake Fluid Replacament/Air Blsading
1. Brake fluid replacement and air bleeding procedures are the same as for conventional brakes
Troubleshooting
1. The troubleshooting flowcharts explain the procedures on the assumption that the cause of the problem is still pre-
sent and the ABS indicator light is still on.
Note that troubleshooting following the flowchart when the ABS indicator light does not come on can result in incor-
rect judgment.
2. Ouestion the customer about the conditions when the problem occurred, and try to reproduce the same conditions
for troubleshooting.
self,diagnosis is made at various times such as the initial diagnosis, except ABS control. during ABS control, during
acceleraiion, during the specified vehicle speed, etc. Therefore, the symptom cannot be checked unless the check
conditions match with the problem conditions
3. When the ABS indicator light does not come on during the test drive, but the troubleshooting is performed based on
the DTC, check for the loose connectors. poor contact of the terminals, etc, before troubleshooting.
4. After troubleshooting, erase the DTC and test-drive the car. Be sure that the ABS indicator light does not come on.
5. The connector illustrations show the female connectors with a single outline and the male connectors with a double
ouflrne.
6. The connector terminal cavities containing female terminals are always numbered by looking at the connector from
the wire side. and the cavities containing male terminals are always numbered by looking at the connector from the
terminal side.
r'
19-55

Power Distribution
Circuit ldentification (cont'd)
Canada:
COMBINATIONLIGHT SWITCH
N0.48 {30A)
RED/BLU - Right headlighl (High boam)
FEDiBLU ----< REstsTOR
REo/GRN - HiJh beam indicator lighl
BEo/GRN - Left headlighl iH,gh beam)
L Fight headlight {Low beam)
FEo/YEL - L€ll headlight (Low beam)
(Fuse/lelay box sockel)Optional conneclor (oash lighs)
Inleg6led conlrcl unil
- Hazard wanirE swilch lighl
i- Gauge lEhts
l- Audio unil
l- Re& Yrindow delogg8r swili
t- Ctuise main swrdr ligh
l- C/uise indEator l
E g"ffiry:'l,:1':::1
Refi window delog$r swildr light
Ctuise indicalor 1 dimming,T geal posilion indicator J circu(Dasn lghls brignmess co oller
BRAKESYSTEMLIGHT
V
I
l- GFf
,,4,,0*,lf tIFLUDII ,j I LEVEL
Y
SWTCH
I8LKI
I
I
I:
G401G402
REo/BLK - l/T ged position console lqhl- Hqalor codrot panel tighl
REO/BLK -F- Lefi ) .l- g;n1J lron 9arrn! qm
FEDiBLK + Letl I
F Rqn J ouer larrqns
- I Al, I
{- i'-;*; inne' raittiotts
E fifi]t'"nt"o't't'sn"
*ro,rru -$ RcHT HEADLIGHT (Hrgh beam)
BEDiGRN -+ LEFI H EADLIGHT (High beam)
I BLK
IIPARKING IEFAKE IswrrcH I
I:
G401G402
UNDER,DASH FUSE/RELAY 8OX
lo| | PASSTNGto
/Fforn page\\a-68 l
N0.48 {304)FUSE/From page\\23-72 )
N0.18 (7.54)FUSE/From page \\?3-69 J
v
YIYEUBLK
N0.48 (40A)FUSE/From paqe \\23-68 - ,/
RED6RN
23-74

BRAKESYSTEMLIGHI(1.4w)
RED/GRN GFN/RED
TA
Yimi+" Yo
l[3&1" ;i:l"la',.l l,,1!:,iT "*,,
I lrb'ff" ;i#il;-"1
I'i
_,L J-:-l
G401G()2
GRN/REO
I
TCM
(cont'd)
23-133
8LK
I
G552

ie----1
\{
i____J
WIIT/FED
FUSE 54OPNOI404
c351
vtEw 34
c419
FUSE 52HOAT. ST(IP LT154
c352
vlEw2/
FUSE 53NAZABO
c352
vtEw 27
c4't 1
UNDER-HOODFUSE/RELAYgox
15
_",":IWH'/BLK
(Not (Not 7Used) Used)
UNDER-DASHFUSE/RELAY BOXPHOTA 58
c419 C926110!0,63 oPTtoNCONNECTOBPHOTO 62
WHT/GRN
{with CruiseControl 4)
WHT
'9&'98 modelspre'wked toracteEsorysacurity system
""'l
o
;l10
vtEw 6a
cs16
'99'0O modelspre-wired foraccessorysecurfy system
SECURIrySYSTEMCONNECTOR(oPTroN)Page 133-4
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BRAKESWITCHPages 23-4 , 24 4 ,25-4, 34-1, 39,39-4, 39-8, 39-12,44-2,110-15,110-16, 110 17,'138, and 138-1
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HAZARDWARNINGswrTcHPage 110'6or 110-8vtEw 32
,rr rrRt3,:i]L-
SECURITYSYSTEMCONNECTOR(oPTlON)Page 133-4
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I Uoll UonEcI I
tlL------JHORN BELAYPage 40, 40-1,ot 40-2
PHOTO 58 (96 97 models)PHOIo 129 (98 mode)
c447
wEw 5a
sEcuRrwSYSTEMCONNECTOR(oPTroN)Page 133
10-13