2003 HONDA CIVIC ERS

3.
Trailing Arm Removal/lnstallation
1.Raise the rear of the vehicle, and suppon it with
safety stands in the proper location (see page 1,8).
Remove the rear wheels.
Remove the knuckle (see page 18-28).
Place the floor jack under the trailing arm (A) to
support it.
B10 x 1.25 mm38Nm(3.9 kgl.m,28 tbf.ftl
12 x 1.25 mm61 N m (6.2 kgt m.
A 4s tbf,ft)
Remove the flange nut (B), and disconnect the
stabilizer link (C) from the trailing arm.
Remove the flange bolt {D), and disconnect the
damper (E) from the trailing arm.
Remove the trailing arm front mounting bolts (A).
A12 x 1.25 Jnm108 N.m {11.0 kgt.m,80 tbf.ft)
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7. Remove the trailing arm rear mounting bolt (A).
Do not loosen the special bolts (B) on the
trailing arm.
A12 x 1.25 mm59 N.m
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Lower the jack, and remove the trailing arm.
Install the trailing arm in the reverse order of
removal, and note these items:
. First install allthe suspension components and
lightly tlghten the bolts and nuts, then place ajack under the trailing arm, and raise the
suspension to load it with the vehicle's weight
before fully tightening the bolts and nuts to the
specified torque values.. Tighten allthe mounting hardware to the
specif ied torque values.. Before installing the wheel, clean the mating
surface of the brake disc and the inside of the
wneei.. Check the wheel alignment, and adjust it if
necessary (see page'18-4).
8.
9.
18-33

Conventional Brake Components
Brake Pedaland Brake PedalPosition Switch Adjustment
Pedal Height
1.Disconnect the brake pedal position switch
connector, turn the brake pedal position switch (A)
counterclockwise, and pull it back until it is no
longer touching the brake pedal.
Lift up the carpet and the insulator cutout (B).
l\4easure the pedal height (C) from the middle of
the left side of the pedal pad (D).
Standard Pedal Height (with carpet removed):
184 mm (7 4/16 in.)
Loosen the pushrod locknut (A), and screw the
pushrod in or out with pliers until the standard
pedal height from the floor is reached. After
adjustment, tighten the locknut firmly. Do not
adjust the pedal height with the pushrod pressed.
15 N.m(1.5 kgl m. 11 lbl ft)
19-6
7. Check the brake pedal free play as described below.
Pedal Free Play
4. With the engine off, inspect the play (A) on the
pedal pad (B) by pushing the pedal by hand.
Free Play: 0.4- 3.0 mm {0.016 0.'l18in.)
lf the pedal free play is out of specification, adjust
the brake pedal position switch (C). lf the pedal free
play is insufficient, it may result in brake drag.
Push in the brake oedal oosition switch until its
plunger is fully pressed (threaded end (A)touching
the pad (B) on the pedal arm). Then, turn the switch
45" clockwise to lock it. The gap between the brake
pedal position switch and the pad is automatically
adjusted to 0.4 to 3.0 mm (0.016 0.118 in.) by
locking the switch. Make sure the brake lights go
otf when the pedal is released.
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6.

Conventional Brake Gomponents
Front Brake Pads Inspection and Replacement (cont'dl
3. Remove the pad retainers (A), and check the caliperpins for free movement.
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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.
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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.
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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.
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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.
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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

Gonventional Brake Components
IBrake Booster Test
Functional Test
1. With the engine stopped, press the brake pedal
several times to deplete the vacuum reservoir, thenpress the pedal hard, and hold itfor 15 seconds. lfthe pedal sinks, either the master cylinder is
bypassing internally, or the brake system (master
cylinder, lines. modulator, or calipers) is leaking.
2. Start the engine with the brake pedal pressed. lf thepedal sinks slightly, the vacuum booster is workingproperly. lf the pedal height does not vary, thebooster or check valve is faulty.
3. With the engine running, press the brake pedal
lightly. lfthe brake pedal sinks more than 1O mm
{3/8 in, ) in 3 minutes, the master cylinder is faulty.A slight change in pedal height when the Ay'C
compressor cycles on and off is normal. (The A,/C
compressor load changes the vacuum available tothe booster.)
Leak Test
1. Press the brake pedal with the engine running, thenstop the engine. lf the pedal height does not vary
while pressed for 30 seconds, the vacuum boosteris OK. lf the pedal rises, the booster is faulty.
2. With the engine stopped, press the brake pedal
several times using normal pressure. When thepedal is first pressed, it should oe row.
On consecutive applications, the pedal height
should gradually rise. lfthe pedal position does notvarv, check the booster check valve.
19-18
3. Disconnect the brake booster vacuum hose (check
valve built-in) (A) at the booster side.
5.
4.Start the engine, and let it idle. There should bevacuum available. lf no vacuum is available, thecheck valve is not working properly. Repiace thebrake booster vacuum hose and check valve, andrelesI.
Reconnect the brake booster vacuum nose.
Start the engine, and then pinch the brake boostervacuum hose between the check valve and thebooster,
Turn the ignition switch OFF, and wait 30 seconds,Press the brake pedal several times using normalpressu re,
When the pedal is first pressed, it should be low.On consecutive applications, the pedal height
should gradually rise.
. lf the pedal position does notvary, replacethe
brake booster.. lf the pedal position varies, replace the brake
booster vacuum hose/check valve assembly.

Brake Booster Replacement
1.Remove the master cylinder (see page 19-15).
Remove the master cylinder brake lines {A) from
the brake line clip.
c
6x1.0mm9.8 N.m(1.0 kgf.m,7.2 tbf.ft)
Remove the vacuum hose mounting bracket (B).
Disconnect the vacuum hose {C) from the brake
booster.
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5. Remove the clip (A) and the joint pin (B). and
disconnectthe yoke from the brake pedal.
7.
{'l.3 kgf.m,9 lbf.ftl
Remove the brake booster mounting nuts (C).
Remove the brake booster (A)from the engine
comparlmenr.
INdAdEI. Be careful not to damage the booster
surfaces and threads of the booster stud
bolts.. Be careful not to bend or damage the
brake lines.
lnstallthe brake booster in the reverse order of
removal, and note these items:
. Adjust the pushrod clearance before installing
the brake booster (see page 19-16).. Use a new clip whenever installing.. After installing the brake booster and master
cylinder, fill the reservoir with new brake fluid,
bleed the brake system (see page 19-8), and
adjust the brake pedal height and free play (see
page 19-6),
19-19