fron HONDA CIVIC 2003 7.G Manual Online

Brakes
Conventional Brake Components
Special Tools ... ..... ... l9-2
Component Location Index ......................................... 19-3
Brake System Inspection and
Tests ............... .......... 19-4
Brake Pedal and Brake Pedal Position Switch
Adjustment .............. 19-6
Parking Brake Check and
Adjustment .............. 19-7
Brake System Bleeding ...................... 19-8
Brake System Indicator Circuit
Diagram ................... 19-9
Parking Brake Switch Test ................. 19-10
Brake Fluid Level Switch Test ...................................... 19-10
Front Brake Pads lnsoection and
Replacement ........... 19-11
Front Brake Disc Inspection ............... 19-13
Front Brake Calioer Overhaul ...................................... 19-14
Master Cylinder Replacement ........... 19-15
Master Cylinder Inspection ................ 19-16
Brake Booster
Pushrod Clearance Adjustment ................................ 19-16
Brake BoosterTest ................... .......... 19-18
Brake Booster Reolacement .............. 19-19
Rear Brake Pads Inspection and
Reolacement ........... 19-20
Rear Brake Disc Inspection ................ 19-22
Rear Brake Caliper Overhaul ....................................... 19-23
Brake Hoses and Lines Insoection .... 19-24
Brake Hose Reolacement ................... 19-25
Parking Brake Cable Replacement .............................. 19-26
ABS (Anti-lock Brake System)
Gomponents ... 19-29

Component Location Index
FRONT BRAKESFront Brake Pads, Inspection andReplacement, page 19-1 1Front Brake DiscInspection, page 19'13Front Brake CaliperOverhaul, page 19-14
INDICATORBrake System Indicator CircuitDiagram, page 19-9Parking Brake SwitchTest, page 19 10Brake Fluid Level SwitchTest, page 19-10
BRAKE CABLE
BRAKE BOOSTERBrake BoosterTest, page 19-18Brake EoosterReplacement, page 19 19
Parking Brake CableReplacement, page 19 26
REAR DISC BRAKERear Brake Pads Inspection andReplacement, page l9-20Rear Brake DiscInspection, page 19'22Rear Brake Caliper Overhaul,page 19'23
PARKING BRAKE LEVERParkino BrakeCheck and Adjustment, page 19-7
BRAKE PEDALBrake Pedal and Erake Pedal Position SwitchAdjustment, page l9-6
BRAKE HOSES and LINESBrake Hoses and LinesInspection, page 19 24Brake HosesReplacement, page 19 25
MASTER CYLINDERMaster CylinderFl6^1.^6m6nr ^2^o 1O-18Master Cylinder Inspection, page 19-16Brake Booster Pushrod ClearanceAdjustment, page'19-16Brake System Bleeding, page 19-8
19-3

Parking Brake Check and Adiustment
Check
1. Pull the parking brake lever {A) with 196 N (20 kgf,
44 lbf) of force to fully apply the parking brake. The
parking brake lever should be locked within the
specified number of clicks (B).
Lever locked clicks: 7-8
- l2okqf, a4lbl)
2. Adjust the parking brake if the lever clicks are not
within the specification.
Adjustment
1. Release the parking brake lever fully.
Loosen the parking brake adjusting nut, start the
engine, and press the brake pedal several times to
set the self-adjusting brake before adjusting the
parking brake.
Block the front wheels, then raise the rear of the
vehicle, and support it with safety stands in the
proper location (see page 1-8).
Make sure the parking brake arm (A) on the rear
brake caliper contacts the brake caliper pin (B),
NOTE: The parking brake arm will only contact the
brake caliper pin when the parking brake adjusting
nut is loosened.
Remove the rear console {see page 20-57).
Pull the parking brake lever up one click,
7, Tighten the adjusting nut {A} until the parking
brakes drag slightly when the rear wheels are
tu rned.
A/
Release the parking brake lever fully, and check
that the parking brakes do not drag when the rear
wheels are turned. Readjust if necessary.
Make sure the parking brakes are fully applied
when the parking brake lever is pulled up fully.
Reinstall the rear console.
8.
9.
10.
19-7

Conventional Brake Components
Brake System Bleeding
NOTE:. Do not spill brake fluid on the vehicle; it may damage
the painU if brake fluid does contact the paint. wash it
off immediately with water.. 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.. Do not reuse the drained fluid.. Always use Honda DOT 3 brake fluid. Non-Honda
brake fluid can cause corrosion and shorten the life of
the system.. Make sure no din or other foreign matter is allowed
to contaminate the brake fluid.
1. Make sure the brake fluid level in the reservoir is at
the MAX (upper) level line (A).
Slide a piece of clear plastic hose over the flrst
bleed screw, and submerge the other end in a
container of new brake fluid.
Have someone slowly pump the brake pedal
severaltimes, then apply steady pressure.
Starting at the left-front, loosen the brake bleed
screw to allow air to escape from the system. Then
tighten the bleed screw securely.
2.
19-8
5. ReDeatthe procedure for each wheel in the
sequence shown below until air bubbles no longer
appear in the fluid.
BLEEDING SEOUENCE:
OFront RightORe.r Right
O Front LeftORoar Loft
Refill the master cylinder reservoir to the MAX
{upper) level line.
FRONT BRAKE:
9 N.m 10.9 kgf.m,7 lbl.ft)
t-
REAR BRAKE:
9 N m 10.9 kgf.m, 7 lbf ft)

Frequent inhalation of brake pad dust, regardless of
material composition, could be hazardous to your
Front Brake Pads Inspection and Replacement
. Avoid breathing dust particles.
. Never use an air hose or brush to clean brake
assemblies. Use an OSHA-approved vacuum
cleaner.
lnspection
1. Raise the front of the vehicle, and support it with
safety stands in the proper location {see page 1'8).
Remove the front wheels.
2. Check the thickness of the inner pad iA) and outer
pad {B). Do not include the thickness of the brake
pad backing plate.
Brake pad thickness:
Standard: 9.5 10.5 mm (0.37 0.41 in.l
Service limit: 1.6 mm (0.06 in.)
Inner pad:
Outer pad:
lf the brake Dad thickness is less than the service
limit, replace allthe pads as a set.
Replacement
1. Remove the bolt (A), and pivot the caliper (B) upout
of the way. Check the hose and pin boots for
damage and deterioration.
'..'
, .a
&
\
A
2. Remove the pad shim iA) andpads{B).
.^h v/
\ tJ I
v ."r------B
(cont'd)
19-11

Conventional Brake Gomponents
Front Brake Pads Inspection and Replacement (cont'dl
3. Remove the pad retainers (A), and check the caliperpins for free movement.
/:-."
t-... .,.';-iri.: '1=' r
.. a.-
4. Clean the caliper thoroughly; remove any rust, andcheck for grooves and cracks.
5. Checkthe brake disc for damage and cracks.
6. Apply Dow Corning Molykote M77 grease to theretainers on their mating surfaces against thecaliper bracket.
7. Installthe pad retainers. Wipe excess grease offtheretainers. Contaminated brake discs and pads
reduce stopping ability. Keep grease off the discsand pads.
8. Apply Molykote l\477 grease to both sides of thepad shim {A), the back ofthe pads (B), and the other
areas indicated by the arrows.
Wipe excess grease off the shim. Contaminated
brake discs and pads reduce stopping ability. Keepgrease off the discs and pads.
Installthe brake pads and pad shim correctly.Install the pads with the wear indicators (C) on theinside.
lf you are reusing the pads, always reinstall thebrake pads in their original positions to prevent amomentary loss of braking efficiency.
, a .).
19-12
10. Push in the piston (A) so the caliper will fitoverthepads. Check the brake fluid level. The brake fluid
may overflow if the reservoir is too full. lvlake surethe piston boot is in position to prevent damaging itwhen pivoting the caliper down
8x1.0mm34 N.m3.5 kgt m.25 tbf.ft)
11. Pivot the caliper down into position. Being carefulnot to damage the pin boots, install the bolt (B), and
tighten it to the specified torque.
12. Press the brake pedal several timestomakesure
the brake works, then test drive.
NOTE: Engagement of the brake may require agreater pedal stroke immediately after the brakepads have been replaced as a set. Several
applications of lhe brake pedal will restore thenormal pedal stroke.
13. After installation, check for leaks at hose and linejoants or connections, and retighten if necessary.
\

Front Brake Disc lnspection
Runout
1. Raise the front of the vehicle, and support it with
safety stands in the proper location (see page 1-8).
Remove the front wheels.
2. Remove the brake pads (see page 19-11).
3. Inspect the disc surface for damage and cracks.
Clean the disc thoroughly, and remove all rust
4. lnstall suita ble flat washers (A) andwheel nuts,and
tighten the nuts to the specified torque to hold the
brake disc securely against the hub.
Set up the dial gauge against the brake disc 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 (0.00tt in.l
lf the disc is beyond the service limit, refinish the
brake disc.
Max. Retinish Limit: 19.0 mm (0.75 in.)
NOTE:. lf the brakedisc is beyondtheservice limitfor
refinishing, replace it (see page 18-1 1).
. A new disc should be refinished if its runout is
greater than 0.10 mm (0.004 in.).
Thickness and Parallelism
1. Raise the front of the vehicle, and support it with
safety stands in the proper location (see page 1-8).
Remove the front wheels.
2. Remove the brake pads (see page 19-11).
3. 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 Oisc Thickness:
Standard: 20.9 21.8 mm {0.82-0.86 in.}
Max. Refinishing Limit: 19.0 mm 10.75 in.)
Brake Disc Parallelism: 0.015 mm 10.0(X)6 in.)
max.
NOTE: This is the maximum allowable difference
between the thickness measurements
10 mm lo.it in.l
lf the smallest measurement is less than the max.
refinishing limit, replace the brake disc (see page
18-11).
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
Manufacturing Co. and the "Front Brake Disc
Lathe" offered by Snap-on Tools Co. are approved
for this operation.
4.
': . --'t-'"'-
t,.
19-13

Conventional Brake Components
{Front Brake Caliper Overhaul
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.. Avoid breathing dust particles.' Never use an air hose or brush to clean brake assemblies. use an osHA-approved vacuum cleaner.
Remove, disassemble, inspect, reassemble, and install the caliper, and note these items:' Do not spill brake fluid on the vehicle; it may damage the paint; if brakefluidgetsonthepaint,washitoffimmediately with water.. To prevent dripping, cover disconnected hose joints with rags or shop towels.. Cleanall partsinbrakefluidandairdry;blowoutall passageswith compressed air.. Before reassembling, check that all parts are free of dust and other foreign particles.. Replace parts with new ones as specified in the illustration.. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid,' When reusing pads, always reinstallthem in their original pos itio ns to prevent loss of braking efficiency.. Do not reuse drained brake fluid.'AlwaysuseHondaDOT3brakefluid.Non'Hondabrakefluidcancausecorrosionandshortenthelifeofthesvstem.
. Do not mix different brands of brake fluid as they may not be compatible.. Coatthe piston, piston seal groove, and caliper borewithclean brakefluid.. Make sure no grease or oil gets on the brake discs or pads.. Replace all rubber parts with new ones whenever disassembled.. After installing the caliper, check the brake hose and line for leaks, interference, and twistinq.
>:@:Honda caliper sreaso tplN 08C30-80234M)
Boors 3i,l'1.'"
-ffiFA / isli\ii ^ zsw ttt
/paq\tl ll /
,\L,.'iE/ [
-ffi \--l u";;;lqEtCALIPER PIN A / 3.4N.m y' >vr / {3.5 kef m, / ,,' / 25 lbf ft) //'t / SEAL|NG)- I ---=-? WASHEaS
BRAKE HOSE / /8LEEO SCREW/ / /eNm/ / / (o.s kgr'm./ / | itbt.ftl,1(}', ^ l^ /caLl
-ffi \:7 "=;lGoX-
*fL-f
/) I .===? WAStrtXS \t9..- | #.'@ RepracF /7\- (hA PAD RETATNERS !s- / \
*d':ffi
^/rkr) ,-o/
vlJ ffi
Es,lry:' E*,e,a ["fif:i#l1t*"_,,. \.==f@ tz x t.zsmm ourEB paD sHrM
19-14
108 N.m 111.0 kgf.m,80 tbt.ft)

ABS Gomponents
(Component Location Index
UNDER.HOOD FUSE/RELAY BOX
RIGHT-REAR WHEEL SENSORInspection, page 19-59Replacement, page 19-59UNDER.OASH FUSE/RELAY BOX
\L
LEFT.REARWHEEL SENSORInspection, page 19-59Replacement, page 19-59
DATA LINK CONNECTOR I16PIRIGHT.FRONT WHEEL SENSORInspection, page 19-59Replacement, page 19-59
ABS MODULATOR.CONTROL UNITRemoval and Installation, page 19'57LEFT-FRONT WHEEL SENSORInspection, page 19-59Replacement, page 19 59
19-30

ABS Gomponents
DTC Troubleshooting Index
DTCDetection ltemNote
DTC:11Rioht-front wheel sensor {ooen/short to bodv qround/short to power)(see oaoe 19-45)
DTC:12Faultv riqht-front wheel sensor oulse siqnal{see oaoe 19-46)
DTC:13Left-front wheel sensor {oDen/short to bodv qround/short to power)(see oaqe 19-45)
DTC:14Faultv left-front wheel sensor Dulse srqnal(see paqe 19-46)
DTC;15Riqht-rear wheel sensor (oDen/short to bodv qround/short to power)(see Daqe 19-45)
DTC:16Faultv riqht-rear wheel sensor oulse siqnal(see paqe 19-46)
DTC:17Left-rear wheel sensor (open/short to bodv qround/short to power)(see Daoe '19-45)
DTC:18Faultv left-rear wheel sensor Dulse siqnal(see Daqe '19-46)
Drc:2lContinuous oDeration (chioDed Dulser)(see paqe 19-47)
DTC:3'lSolenoid(see Daoe 19-48)
DTC:32Solenoid{see Daqe 19-48)
DTC:33Solenoid{see Daoe 19'48)
DTC:34Solenoidlsee oaqe 19-48)
DTC:35Solenoid(see paqe 19-48)
DTC;36So le no id(see Daqe 19-48)
DTC:37So le noid(see Daqe 19-48)
DTC:38Sole no id(see Daoe 19-48)
DTC:51lvlotor Iocked(see Daqe 19-48)
DTC:52lvlotor stuck off(see Daoe 19-49)
DTC:53lMotor stuck on(see Daoe 19-50)
DTC:54Main relav stuck off(see paqe 19-51
DTC:61lG2 voltaqe{see oaqe 19-5'l
DTC:81cPU (Central Processinq Unit){see paqe 19-52)
19-34