1999 HONDA CIVIC Caliper

Front Brake Caliper
Reassembly (cont'dl
7.Apply the recommended seal grease in the caliperseal set to the sliding surface of sleeve A and theinside of a new guide pin boot.
Install the guide pin boot into the groove in thesleeve A.
Make sure that the brake pad retainers and brakepads are in their original positions (see page 19-10).
Install the caliper onto sleeve A, and pivot it downinto position.
NOTE: Install the guide pin boot into the groove inthe caliper properly.
BRACKET
SLEEVE A
19-20
11.Connect the brake hose to the caliper with new seal-ing washers, and tighten the banjo bolt.
Tighten the caliper bolt B.
Fill the brake reservoir and bleed the brake svstem(see page 19-7).
Perform the following checks.. Check for leaks at hose and line ioints and con-nectaons, and retighten if necessary.. Check for brake hoses for interference and twist-Ing.
13.
14.
BANJO BOLT
26 N.m (2.7 kgl.m, 20 lbtftl

Master Cylinder/Brake Booster
IRemovaUlnstallation
CAUTION:
. Be care{ul nol to bend or damage the brake lines when
rsmoving the mastsr cYlinder.
. Do not soill brakefluid on the vehicle; it may damage
the paint; if brake fluid does contact the paint, wssh
it off immediatelY with water'
. To prevent spill3, cover the hose ioints with rags or
shop towels.
9. Remove the four booster mountlng nuts
10. Pull the brake booster forward until the clevis is
clear of the bulkhead.
11. Remove the brake booster from the engine com-
panmenr.'12. Install the brake booster and master cylinder in the
reverse order of removal.
CAUTION:
. When connecting the brake lines. make sure
that there is no inte erence between the brake
lines and oth6r Parts.
r Be careful not to bend or damage the brake lines
when installing the master cylinder.
NOTE: lf replacing the master cylinder or brake
booster, check and adiust the pushrod clearance
be{ore installing the master cylinder (see page 19-221'
Fill the master cylinder reservoir, and bleed the
brake svstem (see Page 19-7).
After installation. check the brake pedal height and
brake pedal tree play (see page l9-5) and adjust if
necessary.
BRAKE BOOSTER(With ABS: 7" + 8" tandem brake booster)
BRAKE FLUIO LEVELSWITCH CONNECTORS
MASTER CYLINDER
VACUUM HOSE
1.
2.
3,
5.
Disconnect the brake fluid level switch connectors'
Remove the reservoir cap from the master cylinder'
The brake fluid may be sucked out through the top
of the master cylinder reservoir with a syrlnge.
Disconnect the brake lines from the master cylinder'
Remove the master cylinder mounting nuts and
washers.
\l/
6. Remove the master cylinder from the brake booster'
7. Disconnect the vacuum hose trom the brake booster'
8. Remove the cotter pin and clevis pin from the clevis'
CAUTION: Do not disconnect the clevb by remov-
ing it from the operating rod of the brako booster' lf
the clevis is loosened, adiust the pushrod length
before installing th€ brake booster (see page 19-221'
COTTER PINReplace.
To Rear Wheel Cylinders
14.
-6.4CLEVIS PIN
To Front Caliper(Without ABS)$
t'N't'ttrnt'-''
To Front CaliperlWithout ABSi
PBOPORTIONING CONTROL VALVE
15 N.m {1.5 kgl m,11 tbtft)
15 N.m {1.5 kgif.m, 11 lbtft}(With ABS: To modulator unit)lr
19-21

Brake Booster InsPection
FunctionalTest
1. With the engine stopped, depress the brake pedal
several times to deplete the vacuum reservoir, then
depress the pedal hard and hold it for 15 seconds lf
the pedal sinks' either the master cYlinder is
bypassing internally, or the brake system (master
cylinder. lines. modulator, proportioning control
valve, or caliPer) is ieaking.
2. Start the engine with the pedal depressed lf the
pedal sinks slightly, the vacuum booster is operating
normally. lf the pedal height does not vary, the
booster or check valve is faultY.
3. With the engine running. depress the brake pedal
lightly. Apply just enough pressure to hold back
automatic transmission creep. lf the brake pedal
sinks more than 25 mm (1.0 in.) in three minutes,
the master cvlinder is faulty. A slight change in
pedal height when the A'lC compressor cycles on
and off if normal. (The A/C compressor load
changes the vacuum available to the booster')
Leak Test
1. Depress the brake pedal with the engine running.
then stop the engine. lf the pedal height does not
vary while depressed for 30 seconds, the vacuum
booster is OK. lf the pedal rises. the booster is
faulty.
2, With the engine stopped, depress the brake pedal
several times using normal pressure When the
Dedal is first depressed, it should be low On con-
secutive applications, the pedal height should grad-
uallv rise. lf the pedal position does not vary, checK
the booster check valve.
l./
19-23
Booster Check Valve Test
1. Disconnect the brake booster vacuum hose at the
booster.
2. Stan the engine and let it idle. There should be vac-
uum. lf no vacuum is available, the check valve is
not working properly. Replace the brake booster
vacuum hose and check valve, and retest.
BRAKE BOOSTERVACUUM HOSE(Check valve
built-in)

Rear Brake Pads
Inspection and Replacement
Never use an air hose or dry brush to clean brakeassemblies.
Use an OsHA-apptoved vacuum cl€aner to avoidbreathing brake dust,
Block the front wheels, loosen the rear wneet nutsslightly, support the rear of the vehicle on safetystands, then remove the rear wheels.
Release the parking brake, and remove the calioersh ield.
CALIPER SHIELD
Remove the brake hose clamp bolt from the trailingarm first, then remove the two caliper mountingbolts and the caliper from the bracket.
CAUTION:
. Thoroughly clean the outside of the caliDer toprevent dust and dirt trom entering inside.. Support the calipor with a pieco of wire so thatit does not hang fuom the brake hose.
NOTEr Check the hoses and pin boots for damageor deterioration.
PARKING BRAKE CABLE ^.. ._-_ ---.
'L
19-24
4. Remove the outer pad shim, pads, and pad retainers.
PAO RETAINERS
OUTER PAOSHIMCheck for
REAR BRAKE PADSCheck for wear.
Using vernier calipers, measure the thickness ofeach brake pad lining. The measurement does notanclude the pad backing plate thickness.
Brake Pad Thickness:
Standard: 7.0 - 8.0 mm {0.28 - 0.31 in}Service Limit: 1.5 mm {0.06 in}
lf the pad thickness is less than the service limit,replace the pads and shims together as a set.
BACKING PI-ATE

I
7.
11.
Clean the caliper thoroughly; remove any rust, and
check for grooves and cracks.
Check the brake disc for damage and cracks.
lvlake sure that the pad retainers are installed in
their correct positions.
PAD RETAINERS
Apply grease to the points indicated by the arrow in
the following drawing:
NOTE: Use the pad grease included in the pad set
or lMolykote M77 grease, and apply a thin coat of
grease evenly to the designated points.
. Piston end and inner pad contact surface
. Pad and caliper bracket contact surface
. Outer pad shim and outer pad contact surface
. Outer pad shim and caliper body contact surface
lnstall the brake pads and outer pad shim on the
caliper bracket. Install the inner pad with its wear
indicator facing downward.
@iwhen reusing the pads, always reinstall the
brake pads in iheil original posiiions lo prevont
loss ol braking efficiency
. Contaminaled brake discs or pads reduce stop-
ping ability. Keep grease off the discs and pads.
t./
19-25
12. Rotate the caliper piston clockwise into the cylinder'
then align the cutout in the piston with the tab on
the inner pad by turning the piston back
CAUTION: Lubricate ths boot with rubber grease
to avoid twisting the piston boot. lf the piston boot
is twisted, back it out so it sits properly.
CALIP€R MOUNTINGBOLTS23 N,m {2.3 kg{.m, 17 lbt'ft)
13.
14.
15.
CUTOUT
BRAKE CALIPER
Install the brake hose clamp on the trailing arm.
Install and tighten the caliper mounting bolts.
Install the caliper shield.
After installation. check for leaks at hose and line
joints and connections, and retighten if necessary.
Depress the brake pedal several times to make sure
the brakes work, then test-drive
NOTE: Engagement of the brake may requrre greater
pedal travel immediately after the brake pads have
been replaced as a set. Several light applications of
the brake pedal will restore the normal pedal travel.
Greater than normal pedal travel may damage the
master cylinder.
16.
17.

Rear Brake Caliper
Disassembly
@f l',lever use an air hose or dry brush to clean
assemblies.
. Use an OsHA-approved vacuum cleaner to
brake
avoid
breathing brake dust.
. Contaminated brake discs or pads reduce stopping
ability.
CAUTION:
. Do not spill brake tluid on the cal; h may damage the
paint; if brake fluid does contact the paint, wash ii
ofl immediatelY with water.
. To prevent spills, cover the hose ioints whh rags or
shop tow€ls.
. Clean all parts in brake fluid and air dry; blow out all
passagss with complessed air.
1. Remove the caliper shield (see page 19-24).
2. Remove the lock pin and clevis pin. Remove the
cable clip, and disconnect the cable from the arm
CABLE CLIP
Remove the banjo bolt and two sealing washers
Remove the two caliper mounting bolts and caliper
body from the bracket.
CALIPER MOUNTNG AOLTS
CALIPER BRACKETCheck for cracksSEALINGWASHERSReplace.BANJOBOLT
5, Remove the pins and pin boots from the caliper
bracket.
6. Remove the pad spring from the caliper body
PIN A
(cont'd)
19-27

Rear Brake Galiper
Disassembly (cont'd)
7. Remove the piston by rotating the piston counter-clockwise with the tool, and remove the piston
boot.
CAUTION: Avoid damaging the piston.
PISTON BOOTReplace.
Remove the piston seal.
CAUTION: Take care not to damage the cylinderbore.
CALIPER BODYCheck for scoring on
9. Install the special tool between the caliper bodv andspnng cover.
CAUTION: Be caretul not to damags the inside ofthe caliper cylinder during caliper disassembty.
BRAKE SPRINGCOMPRESSOR07HAE - SG00100
11.
LOCKNUTS
Position the locknuts as shown. then turn the shaftuntil the plate just contacts the caliper body.
NOTE: Do not compress the spring under thespring cover.
Turn the shaft clockwise 1/4 -'ll2 tu.n to comoressadjusting spring B in the caliper body.
CAUTION: To preyant damage to the inner compo-nonts. do not turn the shaft mor€ than 1/2 turn.
SHAFT
LOCKNUTS
PISTON SEALReplace.
ADJUSTII{GSPRING 8
19-28

\
13.
Lower the locknuts fully, and tighten them securely.
NOTE: Keep the locknuts in this position until you
reinstallthe circlip.
Remove the circlip with snap ring pliers.
SNAP RINGPLIERS07914 - SA50001
't 4.Hold the plate with your fingers, and turn the shaft
counterclockwise. Remove the special tool from the
calioer.
LOCKNUTS
l./
15. Remove the adjusting bolt.
Remove the spring cover, adjusting spring B, spacer,
bearing A, and cup from the adjusting bolt.
Remove the sleeve piston, and remove the pin from
the cam in the caliper body.
'17 .
SLEEVE PISTONCheck lor wear anddamage,
i
I
I
6-50-awl \
IO-RIITGRepl6ce.
(cont'd)
19-29