Torque spec HONDA CIVIC 1997 6.G Service Manual

)
55. Installthe cylinder lines A and B.
NOTE:
. Clean the joints of the cylinder lines A and B
thoroughly. The joints must be free of foreign
materlal.
. Install the cylinder lines A and B by tighting the
flare nuts by hand first, then tighten the flare
nuts to the specified torque.
56.
57.
Grease the sliding surface of the rack guide, and
install it onto the gear housing
36 - '97 models:
Apply a thin coat of grease to the new O-ring, and
install it on the rack guide screw.
38 - '00 models:
Remove the old sealant off of the threaded section,
then apply new sealant all around the threads
Install the spring, rack guide screw and locknut on
the gear housing.
Adjust the rack guide screw (see page 17-33)'
NOTE: After adjusting, check that the rack moves
smoothly by sliding the rack right and left'
'1 l:.r1
58.
-GlO.BINGReplace.
17 N.m {1.7 kgt'm, 12 lbl.ft)
28 N.m (2.7 kgf m,20 lbf ftl
CYLINDER LINE 8 CYLINDER LINE A
l/LOCKNUTS
60, lnstall the new lockwasher in the groove in the
steering rack.
61. Screw each rack ends into the rack'
62. Hold the steering rack with a wrench ('98 -'00 mod-
els: left end onlY), and tighten the rack ends'
CAUTION: Bo cateful nol to damage ihe rack sur-
face with the wranch.
NOTE: '96 -'97 model is shown.
STEERING RACK END
54 N'm t5 5 kgt m' 40 lbl'ft)
STEERING RACK
After tightening the rack ends, stake the four sec-
tions of lock washer with a drift and a mallet.
Place the wood block on the press table. then set
the lock washer section of the rack end on the
wood block securelY.
Be sure the tool is aligned with the flst sections
of the steering rack end belore pressing.
Stake the lock washer in the center ot the flat
section of the steering rack end.
LOCK WASHER
NOTE: This drift has a flat,
to prevent puncturing
WOODEN BLOCK
{cont'd}
17-63

)
1?
12, Install the steering joint cover with the clamps and a
clrp.
Reconnect the tie-rod ends to the steering knuckles,
tighten the castle nut ('96 -'97 models) or nut ('98 -
'OO models) to the specified torque, and install new
cotter plns.
NOTE: Before connecting the tie-rod ends, wipe off
any grease contamination from the ball joint tapered
section and threads.
CAUTION: Torquo the castle nut to the lower torque
sp€cification, then tighten it only tar enough to align
the slot with the pin hole. Do not align the nut by
loosening {,96 -'97 models only).
COTTER PINSReplace.On reassembly, bend
the cotter Pin 6s shown.'96 -'97 models:'98 -'00 mod€ls:
tr
CASTLE NUT40 - a8 N'm(4.0 - 4.8 kgf'm,29 - 35 lbf.ftl
NUT&l N.m{a.5 kgf'm, 33 lbl'ftl
NE-ROD END
(l-,
17-67
14.
15.
16.
17.
18.
Install the exhaust pipe A or TWC (see section 9).
Connect the shift linkage (see section 13 or section
14).
lnstall the front wheels
Fill the system with power steering fluid, and bleed
air from the system (see page 17-331
After installation, perform the following checks
. Start the engine, allow it to idle, and turn the
steering wheel from lock-tolock several times to
warm up the fluid. Check the gearbox for leaks
(see page 17-39).
. Adjust the front toe (see section 18).
. Check the steering wheel spoke angle. Adjust by
turning the right and left tie-rods, if necessary.
NOTE: Turn the right and left tie-rods equallv

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

I
NOTE: Wash the knuckle and hub thoroughly in
high flash point solvent before reassembly.
31. Press a new wheel bearing into the knuckle using
the specialtools and a press as shown
NOTE: Place the wheel bearing onto the knuckle
with the pack seal (metal color) toward the inside
Be careful not to damage the sleeve of the pack
seal.
Press
HANOI.E07749 - 001
DRIVERATTACHMENT58x72mm07947 - 6340201
DOUBLE LIP SEAL
{BLACK COLOR)
KNUCKLE
SUPPORT BASE07965 - SD90100
Installthe circlip securely in the knuckle groove'
Installthe splash guard, and tighten the screws.
scREws5 N.m (0.5 kgd m, 4lbt'ft)
32.
33.
l-,
18-15
34. lnstall the hub on the knuckle using the specialtools
shown and a hydraulic press as shown.
CAUTION: Take care not to distort tho splash gusrd'
HUB/ASSEMBLYGUIDE ATTACHMENT07GAF- SEflt2d)
KNUCKLE
FRONT HUB
SUPPORT BASE
07966 - StXx)100SPLASH GUARD
tnstall the knuckle in the reverse order of removal'
and pay particular attention to the following items:
. Be careful not to damage the ball joint boots
when installing the knuckle.
. Torque all mounting hardware to the specified
torque valugs.
. Torque the castls nuts to the low€r torque specl-
fications, then tighten them only far enough to
align the slot with the pin hole. Do not align the
castle nut by loosening.
. lnstall new cotter pins into the castle nuts after
torquing.
. Avoid twistin0 the sensor wires when installing
the wheel ssnsor.
. Before installing the brake disc, clean the mating
surfaces of the front hub and the inside of the
brake disc.
. Before installing the wheel, clean the mating sur-
face ofthe brake disc and the inside of the wheel
. Check the front wheel alignment, and adjust it if
necessary (see page 18-4).

Front Suspension
L
Lower Ball Joint Replacement
Remove the knuckle (see page 18-11).
Remove the boot by prying the set ring off.
Check the boot for deterioration and damage.
replace if necessary.
Install the special tools onto the ball joint and tight-
en the casfle nut.
Position the special tools over
shown. then set the assembly in
ball joint out of the knuckle,
BALL JOINT REMOVER/INSTALLER07965 - SB00r00
CASTLE NUT
the ball joint as
a vise. Press the
lf
7.
BALL JOINT REMOVER BASE07JAF - SH20200
Place the ball joint in position by hand.
Install the special tools over the ball joint as shown,
then press the ball joint in.
BALL JOINT INSTALLEB BASE07965 - 5800200
BALL JOINT HOUSING SURFACE
18-16
8. Install the ball joint boot and set ring using the spe-
cial tool (see page 18-16).
ADJUSTING BOLTAdjust rhe depth byturning the bolt.
Install the knuckle in the reverse order of removal,
and pay particular attention to the following items:
. Be careful not to damage the ball joint boots
when installing the knuckle,
. Torque all mounting hardware to the specified
torque values.
. Torque the castle nuts to the lower torque speci-
fications. then tighten them only far enough to
align the slot with the pin hole. Do not align the
castle nut by loosening.
. Install new cotter pins into the castle nuts after
torquang.
. Avoid twisting the sensor wires when installing
the wheel sensor.
. Before installing the brake disc. clean the mating
surfaces of the front hub and the inside of the
brake disc.
. Before installing the wheel, clean the mating sur-
face of the brake disc and the inside of the wheel.. Check the front wheel alignment, and adjust it if
necessary {see page 18-4).

Rear Damper
Ilnstallation
'1. Lower the rear suspension, and position the
damper with the spring stop pointed toward the left
SPRING STOP
2. Loosely installthe two flange nuts
FLANGE NUTS10 x 1.25 mm49 N.m (5 kgf.m, 36 lbt'ft)
Tighten these nuts in
step 7.
lr
3. Loosely install the flange bolts.
FLANGE BOLT10 x 1.25 mm54 N.m {5.5 kgf m, 40 lbt'ft1
FLANGE BOLT10 x 1 .25 mm54 N.m {5.5 kgf.m,/r0 lb{.ft|
7.
Raise the rear suspension with a floor jack until the
vehicle just lifts off the safety stand.
!@@ Tne floor iacx must be securelY Posi-
tionod or peFonal iniury may rssull
Tighten the flange bolts.
Tighten the two flange nuts on top of the damper to
the specified torque.
Check the rear wheel alignment and adjust if neces-
sary (see page 18-4).
1A-29

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

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

Master Cylinder/Brake Booster
Pushrod Glearance Adjustment
NOTEr
. The master cylinder pushrod-to-piston clearancemust be checked and adjustments made, if neces_sary, before installing the master cylinder.. ABS type is shown, conventional brake type is similar.
1. Set the special tool on the master cylinde. body; push
in the center shaft until the top of it contacts the endofthe secondary piston by turning the adjusting nut.
Without disturbing the center shaft's Dosition, installthe specialtool upside down on the booster.Install the master cylinder nuts, and tighten to thespecified torque.
Connect the booster in-line with a vacuum gauge O _
101 kPa (0 - 760 mmHg, 30 in.Hg) to the booster,sengine vacuum supply, and maintain an enginespeed that will deliver 66 kpa (500 mmHg, 20 in.Hg)vacuum.
With a feeler gauge. measure the clearance Detweenthe gauge body and the adjusting nut as shown.
Clearance: 0 - 0.4 mm {0 - 0.02 in)
VACUUM GAUGE(Comm€rcially availeblel0 - 101 kPa{0 - 760 mm Hg, 30 in.Hg)
AOJUSTING NUT
FEELER GAUGE
19-22
10.
NOTE: lf the clearance between the gauge bodyand adjusting nut is 0.4 mm (0.02 in), the pushrod-to-piston clearance is 0 mm. However, if the clear_ance between the gauge body and adjusting nut is0 mm, the pushrod-to-piston clearance is 0.4 mm(0.02 in) or more. Therefore, it must be adjusted andrechecked.
6. lf clearance is incorrect, loosen the star locknut, andturn the adjuster in or out to adjust.
NOTE;
. Adjust the clearance while the specified vacuumis applied to the booster.. Hold the clevis while adjusting.
Tighten the star locknut securely.
Remove the special tool.
0 - 0.4 mm (0 - 0.02 in)
7.
ADJUSTERPUSHRODADJUSTMENT GAUGE07JAG - SD('1(x)
9. Adjust the pushrod length as shown if the boosterrs removed.
STAR LOCKNUT22 N.m{2.2 kg,f.m, 16lbtft)
11610.5 mm{{.571 0.02 in)
PUSHRODLOCKNUT15 N.m 11.5 kgf.m, 11 tbtftl
Install the master cylinder {see page l9-21).

Brake Hoses/Lines
LJ
Inspection/Torque Specifications
t. 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 ieaks at hose and line ioints and connections, and retighten if necessary'
4. Check the master cylinder and ABS modulator unit for damage and leakage
CAUTION: Replace tho brake hose clip whenev€r the brake hose is serviced.
ABS MODULATOR UNIT-Io-BRAKE l-lNE19 N.m (1.9 kgf.m, 14lbl.ftl
PROPOBTIONING CONTROL VALVE.io-BRAKE LINEl5 N.m (1.511 tbf.ftl
MASTER CYLINDER-Io-BMKE LINE
15 N.m (1.5 ksrf.m, 11 lbf'ft)
REAR DISG BRAKE:BRAKE HOSE-to4ALlPER
{BANJO BOLT}34 N.m (3.5 kgtm,25 lbf ftlBLEEO SCREW9 N'm (0.9 kgf.m, 6.5 lM.ftlBRAKE LINE-to-WHEEL CYLINDER15 N.m (1.5 kgl.m, 11 lbf.ftlBLEED SCREW7 N.m {0.7 kst m, 5 lbf,ttl
JBRAKE LINE-io-aRAKE HOSE15 N.m {1.511 tbtft)
BRAKE LINE-Io-BRAKE HOSE15 N.m (1.5 kgt.m, 11 lbf'ft)
(BANJO BOLT}3,1 N.m 13.5 kgf.m, 25 lbf.ft)
J
19-39