2003 HONDA CIVIC Brake line

Driveline/Axle
Intermediate Shaft Reassembly
(cont'd)
6. lnstallthe outer seal (A) intothebearingsupport(B)
using the special tool and a press.
7. Installthe set ring.
PRESS
I
Pack the interiorofthe outer seal.
16-24
Intermediate Shaft Installation
1. Use solvent or brake cleaner to thoroughly clean
the areas where the intermediate shaft {A) contacts
the transmission (differential), and dry with
compressed air. Insert the intermediate shaft
assembly into the differential. Hold the
intermediate shaft horizontal to prevent damage to
the differential oil seal (B).
2. Installthe llange bolt (A) and two dowel bolts (Bl.
A10 x 1.25 mm39Nm(4.0 kgf.m,29lbf.ft)
Bl0 x 1.25 mm39 N.m(4.0 kgf.m,29 tbf.ftl
(

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

Conventional Brake Gomponents
Front Brake Pads Inspection and Replacement (cont'dl
3. Remove the pad retainers (A), and check the caliperpins for free movement.
/:-."
t-... .,.';-iri.: '1=' r
.. a.-
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.
, a .).
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.
\

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)
Boors 3i,l'1.'"
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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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Es,lry:' E*,e,a ["fif:i#l1t*"_,,. \.==f@ tz x t.zsmm ourEB paD sHrM
19-14
108 N.m 111.0 kgf.m,80 tbt.ft)