2002 HONDA CIVIC tow

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)
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-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
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19-14
108 N.m 111.0 kgf.m,80 tbt.ft)

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 immediately with water,
1, Remove the air cleaner assembly (A).
2, Disconnect the brake fluid level sensor connector
(A).
15 N.m{1.5 kgt.m, 11 lbt.ft)
3. Remove the clutch reservoir (B) andenginewire
harness clip (C)from the master cylinder mounting
base (D).
4. Remove the reservoir cap and brake fuid from the
reservoir.
5. Remove the reservoir (E) on the master cylinder
mountrng Dase.
6, Disconnect the brake lines (F)from the master
cylinder (G). To prevent spills, cover the hose joints
with rags or shop towels.
7. Remove the master cylinder mounting nuts {H) and
washers.
8. Remove the master cylinder from the brake booster.
Be careful not to bend or damage the brake lines
when removing the master cylinder.
9. Remove the rod seal (l) from the master cylinder.
10. Installthe master cylinder in the reverse order of
removal, and note these items:
. Replace all the rubber parts with new ones
whenever the master cylinder is removed.
. Check the pushrod clearance before installing the
master cylinder. and adjust it if necessary (see
page 19-16).. Use a new rod seal on reassemblY. Coat the inner bore lip and outer circumference
of the new rod seal {A) with the recommended
seal grease in the master cylinder set.
. Installthe rod seal ontothe master cylinder with
its grooved side (B)toward the master cylinder.
. Check the brake pedal height and free play after
installing the master cylinder, and adjust it if
necessary (see page 19-6).
19-15

Rear 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 installthe caliper, and note these items:
. Donotspill brake fluid on the vehicle; it may damage the paint; if brake f luid gets on the paint, wash it off
immediately 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 pans with new ones as specified in the illustration.. Make sure no dirt or other foreign matter contaminates the brake fluid.
. When reusing pads, always reinstallthem in their original positions to prevent loss of b ra king efficie ncy.
. Do not reuse drained brake fluid.
. Use only clean Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the
system.. Do not mix different brands ot brake fluid as they may not be compatible.
. Coatthe piston, piston seal groove, and caliper bore with clean brake fluid.
. Make sure no grease or oil gets on the brake discs or pads.
. Replaceall rubber parts with new ones whenever disassembled.
. After installing the caliper, check the brake hose and line for leaks, interference. and twisting.
oG , nonau."rip6r qreas€ lP/N 08c30-aoa4Ml34 N.m (3.5 kgf m,25lbtft)BOLT
WASHERS
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: 10 MM FLANGE BOLTS.:r=,9!q!q}l 55 N m (5.6 lgf-m, 4r lbt ft)
19-23

Brake Hose Replacement
NOTE:. Do not spill brake fluid on the vehicle; it may damage
the paint; if brake fluid gets on the paint, wash it off
immediately with water.. To prevent dripping, cover disconnected line joints
with rags or shop towels.. Before reassembling, check that all parts are free of
dust and other foreign particles.
. Replace parts with new ones whenever specified to
do so.
1 . Replace the brake hose (A) if the hose is twisted,
cracked, or if it leaks.
Disconnect the brake hose from the brake line (B)
using a 10 mm flare nut wrench {C)
Remove the flange bolt (A), and remove the brake
hose brackets from the damper.
Remove and discard the hose clip (B).
Remove the banjo bolt (C), and remove the brake
hose (D) {rom the caliper.
4.
I x 1.25 mm
6. Installthe brake hose bracket (A)on the damper
with the flange bolt (B) first, then connect the brake
hose (C) to the caliper with the banjo bolt {D) and
new sealing washers (E).
7. lnstallthe hose onto the hose bracket on the bodv
with a new hose clip (A).
10 x 1.0 mm15 N.mi (1.5 kgf.m,
! 1t tbt.ftl
Connect the brake line to the brake hose.
After installing the brake hose, bleed the brake
system (see page l9-8).
Do the following checks:
. Check the brake hose and line joint for leaks, and
tighten if necessary.. Check the brake hoses for interference and
twisting.
9.
10.
19-25

ABS Modulator-Control Unit Removal and lnstallation
NOTE:. Donotspill brake fluid on the vehicle; it may damage the painU if brakefluidgetsonthepaint,washitoff
immediately with water.. Becareful not to damage or deform the brake lines during removal and installation.. To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel orequivalent
malenal.
Removal
'1. Turn the ignition switch OFF.
2. Pull upthelock(A) oftheABScontrol unit3lPconnector(B),thendisconnecttheconnector.
FLARE NUTl5 N.m (1.5 kgt.m,11 lbt.ftl
6)o
CII mm NUT8.8 N.m {0.9 kgl m.6.5lbf ft)
6 mm BOLT9.8 N.m11.0 ksf.m,7.2lbf.ft)
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(cont'd)
19-57

Door Weatherstrip Replacement
NOTE:. Take care not to scratch the door.. Use a clip remover to remove the clips.
1. At the A-pillar, remove the door stop mounting bolt
(A).
Fastener Locations
A>:Bott, 1 B>:Clip,1 C>:Clip, 18
Detach the clips (8, C), then remove the door
weatherstrip (D).
Install the weatherstrip in the reverse order of
removal and note these items:
. Replace any damaged clips.. Make sure the weatherstrip is installed ln the
holder (E) securely.. Apply liquid thread lock to door stop mounting
bolt before installation.. Check for water leaks (see step 7 on page 20-'121.. Test-drive and check for wind noase.
14.----'
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Door Glass Adjustment
NOTE:. Check the weatherstrips and glass run channelfor
damage or deterioration, and replace them if
necessary.. Wipe the run channel clean with a shop towel.. Lubricate the run channel with Shin-Etsu grease
P/N 08798-9013.
1. Place the vehicle on a firm, level surface.
2. Remove these items:
. Door panel (see page 20-4). Plastic cover {see page 20'2)
3. Carefully move the glass (A) until you can see the
glass mounting bolts (B), then loosen them.
B6x1.0mm9.8 N.m (1.0 kgf.m, 7.2lbf.ft)
Push the glass against the channel (C), then tighten
the glass mounting bolts.
Check that the glass moves smoothly.
(cont'd)
20-11

Doors
Door Glass Adiustment {cont'd)
6. Raise the glass fully, and check for gaps. Check that
the glass (A) contacts the glass run channel (B)
evenrv.
7.Check for water leaks. Run water over the roof and
on the sealing area as shown, and note these items:
. Use a 12 mm (1/2 in.) diameter hose (A).. Adjust the rate of water flow as shown {B).. Do not use a nozzle.. Hold the hose about 300 mm (12 in.) awayfrom
the door (C).
12mm1112in,l !
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Attach the plastic cover, and installthe door panel(see page 20-4).
9. Test-drive and check for wind noise.
300 mm {12 in.l
20-12
Door Position Adiustment\
NOTE; Check for equal gaps between the front, rear,
and bottom door edges and the body. Check that the
door and body edges are parallel.
1. Place the vehicle on a firm, level surface when
adjusting the door.
2. Adjust at the hinges {A):
. Remove the front inner fender (see page 20-102)
and front fender fairing (see page 20-103).
Loosen the hinge mounting bolts (B) slightly, and
move the door backward or forward, uD or down
as necessary to equalize the gaps.. Place a shop towel (C) on the jack (D) to prevent
damage to the door when adjusting the door.
t, 8x1.25mm29 N.m (3.0 kgf.m,22 tbt.trl
\

3. Check that the door and body edges are parallel. lf
necessary, adjust the door cushions (A) to make the
rear of the door flush with the bodv.
Apply body paint to the hinge mounting bolts and
around the hinges.
Check for water leaks (see step 7 on page 20-12).
Test-drive and check for wind noise.
5.
Door Striker Adjustment
Make sure the door latches securely without slamming
it. lf necessary, adjust the striker (A): The striker nuts
are fixed, but the striker can be adjusted slightly up or
down, and in or out.
1. Loosen the screws (B), rhen insert a shop towel (C)
between the body and striker.
Lightly tlghten the screws.
Wrap the striker with a shop towel, then adjust the
striker by tapping it with a plastic hammer (D). Do
not tap the striker too hard.
Loosen the screws, and remove the shop towel.
Lightly tighten the screws.
Hold the outer handle out, and push the door
against the body to be sure the striker allows a
flush fit, lf the door latches properly, tighten the
screws and recheck.
5.
6.
8 x 1.25 mm18 N.m 11.8 kgf m, 13 lbf.ft)
20-13