brake fluid HONDA CIVIC 1997 6.G Owner's Manual

Transmission
Reassembly
CAUTION: While reassembling. be sure not to sllow dust and othor foreign particles to enter into the transmission.
NOTE:
. Coat all parts with CVT Fluid.
. Replace the following parts:- O-rings- Sealing rings- Sealing washers- Gaskets- Start clutch assembly and secondary drive gear assembly8 x 1.25 mm37 N.m {3.8 kgf.m,27 lbtftl
MANUAL VALVE
6x1.0mm12 N m 11.2 kgf.m,8.7 lbl.ft)
LINESREVERSE BRAKEEND PLATE
Dtsc
PLATE
DISC SPRING
THRUST WASHER
CARRIER ASSEMBLY
THRUST WASHER
THRUST NEEDLEBEARING
END COVEB
DOWELPIN
END COVER GASKET
6x1.0mm12 N.m 11.2 kgtm,8.7 lbtft)THRUST SHIM,25 x 31 mmSelective part
RING GEAR
THRUST WASHER
THRUSTBEARING
8 x 1.25 mm29 N.m 13.0 kgl m, 22 lbtftl
INTERMEDIATEHOUSING ASSEMBLY
ROLI.IR
SNAPRINGeBH^cMANUALVALVEBOOY
SUN GEAR
INPUT SHAFT
(RUBEERI
ATF FEED PIPE
O-RINGSTRANSMISSIONHOUSING GASKETSNAP RING
FORWARD CLUTCH
SNAP RING
SHAFTASSEMALY
DOWEL PtN
SPRING RETAINER/RETURN SPRINGASSEMBLY
REVERSE BRAKE PISTON
O.RINGS
SNAP RING
ATF FEED PIPES
14-338
SNAP RING RETAINERTRANSMISSION HOUSING

1.
7.
lnstall the ATF feed pipe in the transmission hous-
ing, and install the three ATF feed pipes with new
O-rings in the transmission housing,
Install the two dowel pins and new transmission hous-
ing gasket on the transmission housing.
Push the control shaft assembly toward the outside
of the transmission housing, then install the inter-
mediate housing assembly (four bolts).
lnstall the manual valve body separator plate and
the two dowel pins on the intermediate housing,
then install the rnanual valve body with the detent
spring (five bolts).
Put the control shaft assembly back, then install the
roller in the intermediate housing.
lnstall the reverse brake piston in the intermediate
housing.
Install the spring retainer/return spring assembly on
the reverse brake Piston.
NOTE: Installthe return springs on the spring guides
of the reverse brake piston securely
tnstall the special tool to compress the return spring
as shown.
REVERSE BRAKESPRING COMPRESSOR07TAE - P4V0110
6.
L
1
CAUTION: lf the spring retainer tab is on the reverse
brakc piston, the spring rstainer may be damaged'
Be sure the spring retainer tab is not on the piston'
rp
SPECIALTOOL REVERSEBRAKE
-^
14-339
10.
9.
14.
Compress the return springs, then install the snap
ring in the intermediate housing above the spring
retainer.
Verify that the snap ring end gap is correct'
Mini
/,,- '-t,,,,.
// \i/ ',r
'1 ,
.r' //'/. .-J?RINGSNAP
mum 15 mm 10.59 in)
Soak the reverse brake discs thoroughly in CVT
Fluid for minimum 30 minutes.
Installthe disc spring on the reverse brake piston'
Starting with a reverse brake plate, alternately
install the reverse brake plates and discs lnstall the
reverse brake end plate, and the snap ring'
Measure the clearance between the reverse brake
end plate and the top disc with a dial indicator' Zero
the dial indicator with a reverse brake end plate
lowered, and lift it up to the snap ring The distance
that the reverse brake and plate moves is the clear-
ance between the reverse end plate, and the top
disc.
NOTE: Take measurements in at least three places'
and use the average as the actual clearance'
STANDARD: 0.45 - 0.75 mm (0.018 - 0'030 in)
{cont'd)
11.
12.
13.

22. Install the shift cable end on the control lever, and
install the shift cable on the shift cable bracket'
CAUTION: Take care not to bend the shift cable'
23. lnstall the clip in the direction shown.
LOCKNUT
SHIFI CABLE 29 N m {3.0 kg{ m, 22lblftl
SHIFT CABLEERACKET
WASHERIPLASTIC)
CONTROL LEVER
24, Connect the solenoid harness connector. the drive
pulley speed sensor connector. and the ground
cable terminals.
6x1.0mm12 N.m {1.2 kgf.m.8,7 rbtft)
GROUND CABLETERMINAL 6x1.0mm
GROUNDTERMINAL
12 N.m {1.2 kgf'm,8.7lbtfrl
DRIVE PULLEYSPEED SENSORCONNECTOR
SOLENOID HARNESS
CONNECTOR
25. Connect the starter motor cable on the starter motor.
and install the cable holder.
NOTE: When installing the staner motor cable. make
sure that the crimped side of the ring terminal is
facing out (see section 23).
STARTEB
BMOUNTING NUT
9 N.m (0.9 kgf m,7 lbf ft)
26. Install all removed connectors and clamps'
27. Install the distributor.
28. Install the intake air duct and air cleaner housing
29.
assemDly.
Refill the transmission with the recommended
Genuine Honda CVT Fluid (see page 14-2991
CAUTION: While filling the CvT Fluid, bs surs not io
allow dust and other fotoign particles to entor into
the transmission.
Connect the battery positive (+) terminal first, then
the negative (-l terminal to the battery'
Check the ignition timing (see section 23).
Start the engine. Set the parking brake, and shift the
transmission through all gears three times Check
shift cable adjustment (see page 14-355).
Check the front wheel alignment (see section 18)
Let the engine reach operating temperature (the
radiator fan comes on) with the transmission in lXl
or E position, then turn it off and check fluid level'
Perform the start clutch calibration procedure on
page 14-293.
Road test as described on pages 14-296 and 14-297
30.
31.
34.
36.
STARTER MOTOR
14-351

3. lnsert the inboard end of the driveshaft into the dif-
terential or intermediate shaft until the set ring
locks in the groove
NOTE: Clean the areas where the driveshaft contact
the transmission (differential) thoroughly with solvent
or carburetor cleaner, and dry with compressed air'
INBOARD JOINT
INBOARD JOINTReplace.
GROOVE
an
DIFFERENTIAL
lnstall the knuckie on the lower arm. then trghten
the castle nut and install a new cotter pin
NOTE: wipe off the grease before tightening the
nut at the ball ioint.
CAUTION:
. Be careful not to damago the ball ioint boot'
. Torque the castle nut to the lower torque sp€ci-
fication, thsn tighten it only far enough to align
the slot with th€ pin hol6. Do not align the nut
by loosening.
CASTLE NUT12 x 1 .25 mm
COTTER PINReplace.On reassemblY,bend the cotter pinJi$ - 59 N.m 15.0 - 6.0 kgl m,35 - 43 lbf ftl
16-19
5. lnstall the damper tork over the driveshaft and onto
the lower arm. Install the damper in the damper
fork so the aligning tab is aligned with the slot in
the damPer fork.
FLANGE BOLTl0 r 1.25 mmrit N.m t4.a kgf.m, 32 lbf.ft) AIIGN|NG TAB
1.
SELF-LOGKING NUT12 x 1.25 mm6,1N.m 16.5 kgi.m, a7 lbfftl
Replace.
Loosely install the flange bolts and the new self-
locking nut.
Apply oil to the seating surface of the new spindle
nut.
181 N m 118.5 kgt'm, 13il lbt'ftl
NOTE: Aftortightening, use a drift to
stake the spindle nut shoulder against the drivoshaft'
8. Install a new spindle nut, then tighten the nut'
9. Clean the mating surfaces ot the brake disc and the
wheel. then install the front wheel with the wheel
nuts.
10. Tighten the flange bolts and the new self-locking
nut with the vehicle's weight on the damper.
11. Refill the transmission with recommended fluid (see
section 13 or 14).'t2. Check the front wheel alignment and adjust if nec-
essary (see section 18),
FRONT WHEEL
SPINDLE NUT 22 x 1.5 mm
WHEEL NUT 12 x 1.5 mm108 N.m (11.0 kgl'm, g) lbl ftl

Inspection and Adjustment
€)
@
@
@
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

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 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

'1.Clean the piston and caliper bore with brake fluid,
and inspect for wear and damage.
Coat the new piston seal with the recommended
rubber grease in the caliper seal set. and install the
seal in the cylinder groove.
Apply the recommended seal grease in the caliper
seal set to the sealing lips and inside of a new pis-
ton boot, and securely install it in the caliper with the
new boot clip.
CAUTION: Be careful nol to damage the caliper
cylinder wall.
PISTON SEALReplace.
--^.,:=-qE!!!-HRUBBER GREASE
Lubricate the caliper and piston with brake fluid,
then install the piston in the cylinder with the dished
end facing in.
IJPISYON BOOTReplace.
j@i
SILICONE GREASE
CALIPER
-6lCALIPEB PIN B
Apply the recommended seal grease in the caliper
seal set to the sliding surface of the pins and the
lnside of the new pin boots.
lnstall the pin boots into the grooves in the caliper
bracket properly.CALIPER ERACKET
7. Insert pin A and pin B into the caliper bracket.
8. Install the pin boots into the grooves in the pans
propeny.
9. Install the brake pads in their original positions (see
page 19-9).
10. Push in the piston so that the caliper will fit over the
pads, and install the caliPer.
11. Tighten the caliper bolts.
12. Connect the brake hose to the caliper with new seal-
ing washers, and tighten the banjo bolt.
-6.lPIN BOOTSReplace.
-6lCALIPER PIN
BANJO EOLT34 N.m (3.5 kg{ m, 25 lbflt}SEALING WASHERSReplace.
'13.
CALIPER BOLT32 N.m 13.3 kgt.rn, 24lblft)
Fill the brake reservoit and bleed the brake system
{see page 19-7).
Perform the following checks:
. Check for leaks at hose and line joints and con-
nections. and retighten if necessary.
. Check for brake hoses for interference and twisting.(cont'd)
14.
19-17