Brake master cylinder HONDA CIVIC 2003 7.G Workshop Manual

ItemM€asurementOualificationStandard or NewService LimitParking brake
lever
Distance traveled when lever pulled
with 196 N (20 kgf, 44 lbs) ol force
7 8 clicks
Brake pedalPedal height (carpet removed)184 mm (7 4/16 in.)
Free play0.4 3.0 mm (0 016 0 '118 in.)Master cylinderPiston-to-pushrod clearance0 0.4 mm (0 0.02 in.)Erake discThicknessFront21.0 mm (0.83 in.)19.00 mm (0.75 in.)
Rear9.0 mm {0.35 in.)8-0 mm (0.31 in.iRunoutFront0.10 mm (0.004 in.)
Rear0.10 mm (0.004 in.)ParallelismFront and rear0.015 mm (0.0006 in.)Brake padsThicknessFront10.0 mm (0.39 in.)1.6 mm (0.06 in.)
llear9.0 mm {0.35 in.)1.6 mm (0.06 in.)
Standards and Service Limits
Brakes
a
e-o
Air Gonditionin
ItemMoasurementOualilicationStandard or New Service LimitRefrige.antTvpeHFC 134 a (B-134 a)
Capacity of system500 550 g 117.6 19.4 oz)Refrigerant oilTypeSP 1O
(P/N 38897-P13-A01AH or 38899-P13-A01 )Capacity ofcomponentsCondenser25 m0, 15/6 fl ozl
Evaporator45 mA 11 1/2 fl ozt
Each line and
hose
10 m0 (1/3 fl or)
Compressor130 150 m014 1/3 5floz)CompressorStarter coil resistanceAt 68"F (20"C)3.05 3.35 0Pulley-to-pressure plate clearance0.35 0.6 mm (0.014 0.024 in.)Drive beltAuto tensioner lneeds no adjustment)
2-10
q

Do the items in parts A, B, C, D, and E as required for mileage/time interval listed.
AReplace engine oillsee page 8-5i. Capacity without lilter change: 4.0 S (4.2 US qt, 3.5 lmp qt)Rotate tires. Follow the pattern shown in the Owner's Manual Checktire information and condition.
BReplace engine oil filter lsee page 8-6). Capacity with filter change: 4.20 (4.4 US qt, 3.7 lmp qt)Inspect front and rear brakes (see page 19 3i.. Check pads and djscs for wear (thickness), damage, and cracks.' Check calipers tor damage, leaks, and tjghtness ot mount bolts.Check parking brake adjustment. Should be Iully applied within 7 to I clicks.Inspect tie rod ends, steering gearbox, and boots {see page 17 5).. Check rack grease and steering linkage.. Check boots for damage and leaking grease. Chack fluid line {or damage and leaks.lnspect suspension components.. Chock bolts fo r tig htness.. Check condition of ball ioint boots lor deterioration and damage.Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3).Insp€ct brake hoses and lines {including ABS). Checkthe mastercylinder, proponioning control valve, and ABS modulator{or damageand leakage.Check all fluid levels and condition ot tluids; check for leaks. lf necessary, add MTF lsee page 13'3), engioe coolant, brake fluid, and
Lwindshield washer fluid.lnspectexhaust system*. Check catalytic converter heatshield, exhaust pipe and mufflerfordamage,leaks, and tightness {soe page 9,8).lnspect {uel lines and connections*. Check for loose connections, cracks and deterioration; retighten loose connoctions and replacedamaged parts (s€e page 11 146).
InsDect and adiust drive belt.. Look for cracks and damage, and inspect auto tensioner (needs no adjustment).Replace the dust and pollen lilter (see page 21 39).. Replacethe dustand pollen filter whenever airf low lrom the heating and cooling system is lessthan normal.
Replace air cleaner element every 30,000 miles (48,000 km) (independent of time).
l
D
Ei I Replace brake fluid every 3 years (independent oI mileage).
According to state and federal regulations, failure to do the maintenance items marked with asterisk( * ) will not void customer's emissionswarranties. However, Honda recommends that all maintsnance service be done at the recommended interval to ensure long term reliability.
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3-5

L
A
I
Do the items in parts A, B, C, D, E, F, and G as required for mileage/time interval listed.
Feplace engine oil(see pageS 5). Capacity withoutlilter change:4.0 q (4.2 US qt,3.5lmp qt)
Replace engjne oil filter (see page I 6). Capacity with filter change: 4.2 0 14.4 US qt, 3.7 lmp qt)Insoect front and rear brakes,. Check pads and discsforwearlthickness), damage, andcracks.. Check calipers for damage, leaks, and tightness of mount bolts.Lubricate door locks, latches and hinges with Honda white lithium grease.Rotate tires, if the vehicle has been driven the distance listed. Follow the pattern shown in the Owner's Manual-Check tire inflaron aoocondition,Inspecttie rod ends, steering gearbox, and boots (see page 17,5).. Check rack grease and steering linkage.. Check boots for damage and leaking grease.. Checklluid linefordamage and leaks.Inspect suspensron components. Check bolts for tightness.. Check condition of ball joint boots for deterioration and damage.Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3).
Check parking brake adjustment. Should be fully applied within 7 to 9 clicks.Insp€ct brake hoses and lioes. (including ABS). Check the master cylinder, proportioning control valve, and ABS modulator for damageand leakage (see page 19-24).Check all fluid levels and condition ot lluids; check for leaks. lf necessary, add MTF (see page 13 3), engine coolant, brake fluid, andwindshield washer f luid.Inspect exhaust system*. Check catalytic converter heat shield, exhaust pipe and muffler for damage, leaks, and tightness (see page 9 8).Inspect fuel lines and connections*. Check for loose connections, cracks and deterioration; retighten loose connections and replacedamaged pans (seo page 11'146).Check alllights. Checkfunction otallinterior and exterior lights, andthe position ofthe headlights (see page 22-68).Inspect the v€hicle underbody. Check the paint for damage, scratches, stone chippin0, and dents.
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D
E
F
H
InsDect and adiust drive belt.. Look tor cracks and damage, and inspect auto tensioner {needs no adjustment).Reolace dust and oollen filter.
Replace air cleaner element every 15,000 miles 124,000 km) in dustv condition {independent ol timei otherwise use Normal Conditionsscredule (see page 11-162).
lReplaceaircleanerelementevery30,000miles(48,000km)(independento{timei(seepagell-162).
Replace brake fluid every 3 years (independent oJ mileagei.
Replacethe dust and pollen Iilter every 15,000 miles ifvehicle is driven mostlywhere air has high concentration olsootfrom industryanddiesel powered vehiclesj also replace the dust and pollen filter anytime aarflow is less than ussal (see pags 21-39).
According to state and federal regulations, failure to do the maintenance items marked with asterisk (*) will not void customer's emissionswarranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability,
3-7

Clutch Master Cylinder Replacement
NOTE: Do not spill brake fluid on the vehicle; it may
damage the paint; if brake fluid does contact the paint,
wash it off immediatelV with water.
1. Pry out the lock pin (A), and pullthe pedal pin (B)
out of the yoke. Remove the master cylinder
mounting nuts (C).
Remove the air cleaner housing cover and the air
cleaner housing (see step 6 on page 5-2).
Remove the brake fluid from the clutch master
cylinder reservoir with a syringe.
Remove the clutch line bracket from the frame rail,
and remove the clutch line clip.
Remove the clutch master cylinder (A), and pull it
toward the middle of the engine compartment.
Remove the retaining clip (B). Disconnect the clutch
line (C). Plug the end of the clutch line with a shop
towelto prevent brake fluid from coming out.
g-E
3.
6. Disconnect the reservoir hose (D) fromtheclutch
master cylinder reservoir. Plug the end of the
reservoir hose with a shop towel to prevent brake
fluid from coming out.
7. Remove the O-ring (E) and the clutch master
cylinder seal (F) from the master cylinder.
8. Installthe clutch master cylinder in the reverse
order of removal. Install a new O-ring.
9. Make sure the hose clamps (A) are positioned on
the master cylinder (B) and reservoir (C) as shown.
(cont'd)
UP
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12-5

Clutch
Slave Cylinder Replacement (cont'd)
11. Bleed the clutch hydraulic system.
. Aftach a hose to the bleeder screw (A), and
suspend the hose in a container of brake fluid.. Make sure there is an adequate supply offluid in
the clutch master cylinder, then slowly pump the
clutch pedal until no more bubbles appear atthe
bleeder hose.. lt may be necessary to llmit the movement of the
release fork (B) with a block of wood to remove
all the air from the system.. Tighten the bleed screw to I N.m (0.8 kgf.m, 6 lbf
ft); do not ovenighten it,. Refill the clutch master cylinder with fluid when
done.. Always use only Honda DOT 3 brake fluid.
Install the intake air duct (see step 36 on page 5-14).
Installthe air cleaner housing (see step 37 on page
5-15).
Install the battery tray.
Install the battery, connect the positive (+) cable
first, then the negative (- ) cable.
Reset the frequencies for the radio station preset
buttons,
12.
13.
14.
t5.
16.
12-8
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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

Gonventional Brake Components
ComponentProcedureAlso check for:
l\4aster CylinderLook for damage or signs of fluid leakage at;. Reservoir or reservoir grommets
. Line joints
. Between master cvlinder and booster
Brake HosesLook for damage or signs of fluid leakage at:. Line joints and banjo bolt connections. Hoses and lines. also inspect for twisting or
damaqe
Bulging, twisted or bent lines.
CaliperLook for damage or signs of fluid leakage at:. Piston seal. Banjo bolt connections. Bleeder screw
Seized or sticking caliper pins.
ABS l\ilodulatorLook for damage or signs of fluid leakage at:. Line joints
. Modulator
Brake System Inspection and Tests
Brake System Test
Brake pedal sinks/fades when braking
1. Start the engine, and let it warm up to operating temperature.
2. Attach a 2-inch pieceof masking tape along the bottom of the steering wheel, and draw a horizontal reference
mark across it.
With the transmission in Neutral, press and hold the brake pedal lightly, then release the parking brake.
While still holding the brake pedal, hook the end of the tape measure behind it. Then pull the tape up to the
steering wheel, noting where the tape measure lines up with the reference mark you made on the masking tape.
Apply steady pressure to the brake pedal for 3 minutes.
Watch the tape measure.
. if it moves less than 10 mm, the master cylinder is OK.
. if it moves more than 10 mm replace the master cylinder.
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3.
5.
6.
19-4

Rapid brake pad wear. Vehicle vibration {after a long
drivel, or High, hard brake pedal
1. Drive the vehicle until the brakes drag or untilthe
pedal is high and hard. This can take 20 or more
brake pedal applications during an extended test
drive.
2. With the engine running, raise the vehicle on a lift,
and spin all four wheels by hand.
ls there btake drag at any of the wheels?
YES Go to step 3.
NO Look for other causes of the pad wear, high
pedal, or vehicle vibration.I
3. Turn the engine off, pump the brake pedal to
deplete the vacuum in the brake booster, and then
spin the wheels again to check for brake drag.
ls therc brake dtag at any ot the wheels?
YES-Go to step 4.
NO Replace the brake booster.I
4. Without removing the brake lines, unbolt and
separate the master cylinder from the booster, then
spin the wheels lo check for brake drag.
ls there btake drag at any of the wheels?
YES Go to step 5,
NO-Check the brake pedal position switch
adjustment and pedal free play.I
5. Loosen the hydraulic lines at the master cylinder,
then spin the wheels to check for brake drag.
ls there brake drag at any of the wheels?
YES Go to step 6.
NO- Replace the master cylinder.l
6. Loosen the bleeder screws at each caliper, then
spin the wheels to check for brake drag.
Is there brake drag at any of the wheels?
YES Disassemble and repair the caliper on the
wheel(s) with brake drag.l
NO Inspect brake hose (s)/line (s).
19-5

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)
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REAR BRAKE:
9 N m 10.9 kgf.m, 7 lbf ft)