caliper HONDA CIVIC 2003 7.G Workshop Manual

Lubricants and Fluids
For details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work
ures {such as Assemoverhaul. lnstallation. etc.) contained in each section.
NO.LUBBICATION POINTSLUBBICANT
1E ng ineHonda Motor Oil (P/N 08798-9023). The oil container
must disolav the API Cenification seal shown below.
Make sure it says "For Gasoline Engines." SAE
Viscositv: See chart below.
2TransmissionHonda MTF*' (P/N 08798-9016)
3Brake svstem (includes ABS line)Honda DOT 3 Brake Fluid*' (P/N 08798-9008)
4Clutch line
5
6
Release fork (manual transmissionl
Throftle cable end (throttle Iink)
Super High Temp Urea Grease {P/N 08798-9002)
7
I
Shift and select cable ends (manual
transmission)
Throttle cable end (dashboard lower panel hole)
Silicone grease
9
10
111'
14
16
17
Brake booster clevis
CIutch booster clevis
Shift lever pivot
Pedal linkage
Battery terminals
Fuel f ill door
Hood hinges and hood latch
Hatch hinges
Door hinoes, uoDer and lower
Multi-purpose grease
18Caliper piston boot, caliper pins and bootsHonda CaliDer Grease (P/N 08C30-80234lvl)
19Air conditioning compressorCompressoroil: SP-10 (P/N 38897-P13-A01AH or
38899-P'13-A01)
For refriqerant; HFC'134 a (R-134 a)
I
Recommond6d Engine OilEngine oilviscosily for amb enttemperalure fanges
-30 -20 -10 0 t0 20
*1:
"2:
Always use Honda Manual Transmission Fluid (MTF). Using motor oii can cause stiffer shifting because it does
not contain the Drooer additives.
Always use Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of
the system.
3-2

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.
Y
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.
L
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

Charging System
Alternator Overhaul (cont'd)
Rectitier Test
16. Check for continuity in each direction, between the
B terminal and P terminals, and between the E
terminal and P terminals of each diode pair.
All diodes should have continuity in only one
direction. Because the rectifier diodes are designed
to allow current to pass in one direction, and the
rectifier is made up of eight diodes (four pairs). you
musttest each diode in both directions for
continuity with an ohmmeter that has diode
checking capability: a total of 16 checks.
. lf any diode is faulty. replace the rectifier
assembly. {Diodes are not available separately.)' lf all the diodes are OK, go to step 17.
/--:',t- -L . --- -o \-- l'-=
BP"
P,
P.
P,
P.
4-34
19.
'a
Alternator Brush Inspection
17. Measure the length of both brushes (A)with a
vernier caliper {B).
. lf either brush isshorterthanthe service limit,
replace the brush assembly.. lf brush length is OK, go to step '18.
Alternator Brush Length:
Standard (New): 10.5 mm (0.41 in.)
Service Limit: 1.5 mm (0.06 in.)
Rotor Slip Bing Test
18. Check that there is continuity between the slip rings
{A).
. lf there is continuity, go to step 19.. lf there is no continuity, replacethe alternator.
Check that there is no continuity between each slip
ring and the rotor (B) and the rotor shaft (C).
. lf there is no continuity, goto step 20.. lf there is continuity, replace the alternator.
\"

Mainshaft Thrust Clearance Adiustment
Special Tools Required. Mainshaft base 07GAJ-PG20130. Mainshaft holder 07GAJ-PG20110
1. Remove the 72 mm shim (A) and oilguide plate M
from the transmission housing (B).
,5---ov/
Installthe 3rd/4th synchro hub (A), the distance
collar (B), the 5th synchro hub {C). distance collar
(D), and ball bearing (E) on the mainshaft (F), then
installthe assembled mainshaft in the transmission
housing (G).
lnstall the washer (H) on the mainshaft.
Measure distance O between the end of the
transmission housing and washer with a straight
edge and vernier caliper. Measure at three
locations and average the reading.
5.Measure distance @ between the end of the clutch
housing (A) and the bearing inner race (B)with a
straight edge and depth gauge. Measure at three
locations and average the readings.
A
Shim Selection Formula:
6, Select the proper 72 mm shim from the chan.
Follow the example below, and use the
measurements you made in steps 4 and 5:
(Basic Formula)
O+@ (0.8 * 0.11) = shim thickness (maximum)
O + O (0.8 + 0.17) = shim thickness (minimum)
. Add distance O (step 5) to distance O (step 4)
. 0.8 mm (0.031 in): Spring washer, a dimension in
the installation.. 0.11 mm (0.004 in): lvlinimum thrust clearance
. 0.17 mm (0.007 in): Maximum thrust clearance.
(For example)
2.32 + 0.15 - (0.8 + 0.11)= 1.56 mm (0.061 in.)
2.32 + 0.15 - (0.8 + 0.17)= 1.50 mm (0.059 in.)
Take the middle value of the minimum value and
the maximum value, and select the 1.53 mm
(0.060 in.) shim.
{cont'd)
13-/li|

EPS Components
Steering Gearbox Overhaul (cont'd)
'll. Check the slider guide for damage and cracks.Using vernier calipers to measure the thickness ofthe slider guide. lf the thickness is less than servicelimit, replace the slider guide,
f Z,-----:-r-.--------.t.t'E-r
I (fr--', -.----
/i Il il ( t t , ,)))
|i@r
25.3 mm{0.925 in.}
Remove and discard the stop ring {A)on the
cylinder by expanding it with snap ring pliers.
Remove and discard the lock screw {B}.
13. Install the new lock screw on the rack housing.
14. Installthe new stop ring in the groove (C)on thecylinder by expanding it with a snap ring pliers. Becareful not to scratch or damage the housing
surface with the stop ring edges.
25.3 mm{0.925 in.l
12
17-58
15. Apply multipurpose grease to the indicated part
{shaded part) of the outer surface of the rackhousing. Do not apply to the dents and grooves.
\
I

Front Suspension
Knuckle/Hub/Wheel Bearing Replacement {cont'dl
Special Tools Required. Hub dis/assembly tool 07GAF-SE00100. Balljoint remover,2S mm 0TlvlAC-S100200. Attachment 62 x 68 mm 07746-0010500. Driver 07749-0010000. SuDDort base 07965-5D90'100
1. Raise the front of the vehicle, and support it with
safety stands in the proper location (see page 1-8).
2. Remove the wheel cap, wheel nuts, and front wheel.
3. Remove the brake hose bracket mounting bolt (A).
108 N.m(11.0 kgf m,80 rbf.ftl
A8 x 1.25 mm22N.m12.2ksl.m,26 tbf.ftl
B12 x 1.25 mm108 N.m{11.0 kgf.m,80 rbf.ftl
4.Remove the caliper bracket mounting bolts (B), and
remove the caliper assembly (C) from the knuckle.
To prevent damage to the caliper assembly or
brake hose, use a short piece of wire to hang the
caliper assembly from the undercarriage. Do not
twist the brake hose with force.
18-12
5. Raise the stake (A), and remove the spindle nut (B).
-B
' 22x1.5mm, 181 N.m('18.s kgf.m,134 tbt.ft)
6. Remove the brake disc retaining flat screws (A).
A6x1.0mm9.8 N.m{1.0 kgt.m,7.2 tbl.ttl
7. Screw two 8 x 1.25 mm bolts (B) into the disc to
oush it awav from the hub. Turn each bolt two turns
at a time to prevent cocking the disc excessively,
\
\

1.Raise the rear of the vehicle, and support it with
safety stands in the proper location (see page 'l-8).
Remove the wheel cap. wheel nuts, and rear wheel.
108 N.m (11.0 kgf.m,80 lbf ftl
Remove the hub cap (A), raise the stake (B), and
remove the spindle nut (C).
O
\A
22 x 1,5 mm181 N.m(18.5 kgf.m, 134lbf.ftl
5.
7.
Release the parking brake lever.
Remove the brake hose mounting bolt (A).
B10 x 1.25 mm55NmC {5.6 kgf m.41 lbf.ft}
(2.2 kgt m, 16lbt.ftl
Remove the caliper bracket mounting bolts (B), and
hang the caliper (C) to one side. To prevent damage
to the caliper or brake hose, use a short piece of
wire to hang the caliper from the undercarriage.
Remove the brake disc retaining screws (A).
Screw two 8 x 1.25 mm bolts (B) into the disc {C) to
oush it awav from the hub. Turn each bolt two turns
at a time to prevent cocking the disc excessively.
Remove the brake disc.
(cont'd)
ap
t
\
IA6x1.0mm9.8 N.m(1.0 kgf.m, ?.2lbf.ftl
18-27

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