lock HONDA INTEGRA 1998 4.G Workshop Manual

Disassembly/lnspection
Disassembly
1. Compress the damper sp.ing with the spring com-pressor according to the manufacturer's instruc-
tions, then remove the self-locking nut.
CAUTION: Do not compre3s the spring more thannecessary to removo th€ sslf-locking nut.
SELF.LOCKING NUT10 x '1.25 mmReplace.
COMPRESSOR:(Comm.rcially.v.il.blol
BRANICKo T/N MST-580A, T/N 72dt, or.quiv.t.nr
Remove the spring compressor, then disSssemble
the damper as shown on the next page.
Inspection
1. Reassemble all parts, except the spring.
2. Push on the damper as shown.
3. Check for smooth operation through a full stroke,both compression and sxtension.
NOTE: The damper should move smoothly. lf it
does not (no compression or no enension), the gas
is leaking. and the damper should be replaced.
WOODEN BLOCK
4.Check tor oil leaks. abnormal noises or binding dur-ing these tests.
(cont'd)
18-37

Rear Damper
Disassembly/lnspection {cont'd}
Inspestion
All oxcspt Typo R Models:
DAMPERMOUNTING
Check for
Check Ior weaknessand damag6.
DAMPERRUEBERCheck ford€t6riorationano damage.
DAMPER MOUNTINGCOLLAR
DAMPER
SELF.LOCKING NUT10 x 1.25 mm29 N.m 13.0 kgf.m, 22 lbt'ft)R6place.
Type R Model:
BUMP STOP PLATE
SELF-LOCKING NUTt0 r 1.25 mm29 N.m (3.o kgt m, 22 lbf'ft)Rep|aco. -.\-.--...\
_____6
DAMPTRMoUNnNG -.-__re
Check fordeterioration DAMPERMOUNnNG -----+,and damag6. @L!AR Ag-
liillffi*"*,--@
DAMPTR MoU.{nNG __-_____*e
DUST COVEBCh6ck for b€ndingand oamage.
DUST OOVER BOOTCh€ck for deterioralionand damage.
MOUNNNG BASE
DAMPEB MOUNTINGRUBBERCheck lordeteriorationano oamage.
SPRING MOUNTINGRUBBERCheck for deteriorationano oamage.
Check for weakness,compression and damage.
DUST COVER PLAT€
DUST COVERCheck for bendingano oamage.
DUST COVER BOOTChock for deteriorationano oamage,
AUMP STOP PLAYE
1€')
I t_--tlg:z
q._
Y
Check for weaknessand damage.
BUMP STOP
18-38
DAMPER UNTTDAMPER UN]T

Reassembly
Installthe damper unit on a spring compressor.
NOTE: Followthe manufacturer's instructions.
Assemble the damper in reverse order of disassem-
bly except the damper mounting washer and self-locking nut.
NOTE: Align the bottom of damper spring andspring lower seat as shown.
Position the damper mounting base on the damper
unit as shown.
STRUT SPRING COMPRESSOR:lComm.rci.llv availabls)BRANICKO T/N MST.58OA, T/N 7200,or oquivalent
DAMPER MOUNTTNG
a
a
18-39
Compress the damper spring with the spring com-pressor.
lnstall the damper mounting washer, and loosely
install a new self-locking nut.
Hold the damper shaft with a hex wrench and tight-en the self-locking nut.
SELF.LOCKING NUT10 x 1.25 mm29 N.m (3.0 kstm.22 lbl.ft)Replace.

Brakes
Conventional Brakes ........ lg-1
Anti-lock Brake System (ABS) ............. 19-23

a
BrakePedal
Pedal Height
1. Disconnect the brake switch connector, loosen thebrake switch locknut, and back oll the brake switchuntil it is no longer touching the brake pedal.
2. Turn up the jloor mat, and measure the pedal heightfrom the lett srde center of the pedal pad.
PUSHROD ERAKE SWITCHLOCKNUT LOCKNUT
swtTcH
BRAKE PEOAL PAOI
MEASURINGPOINT
Standard Pedal Hsight (wiih ftoor m8t removedl:
M/T: 160 mm {6 5/16 in}
A/T: 165 mm (6 1/2 in)
3. Loosen the pushrod locknut, 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 depressed.
{1.5 kgf.m, 11 lbt.ftl
19-5
Screw in the brake switch until its plunger is fully
depressed (threaded end touching the pad on thepedal arm). Then back off the switch 1/4 turn tomake 0.3 mm (0.01 in) of clearance between thethreaded end and the pad. Tighten the locknut firm-ly. Connect the brake switch connector.
CAUTION: Make sure that the brake lights go oflwhen the pedal is released.
5. Check the brake pedal free play as described below.
Pedal Free Play
1. Stop the engine, and inspect the play on the pedal
pad by pushing the pedal by hand.
Free Play: 1 - 5 mm {l/16 - 3/16 in)
2. lf the pedal free play is out of specification, adjustthe brake switch. tf the pedal free play is insuffi_cient, it may result in brake drag.
PEDAL PAD

Inspection and Adiustment
Parking Brake
Inspection
1. Pull the parking btake lever with 196 N
lbf) of force to Jully apply the parking
parking brake lever should be locked
soecified notches.
Lever Locked Notches: 6- l0
{20 kgf, 44
brake. The
within the
Pulled up with 196 N {2O kgf, 44 lbf)
LEVER LOCKED NOTCHES
2, Adjust the parking brake if the lever notches are out
of specification.
Adjustment
NOTE: After rear brake caliper servicing.loosen the park-
ing brake adjusting nut, start the engine, and depress the
brake pedal several times to set the self-adjusting brake
before adiusting the parking brake
1. Raise the rear wheels oIt the ground. and suppon
the car on safety stands.
!!@ ato"t the trort whoels bsfore jacking
up the roal ot tha car'
2. Make sure the parking brake arm on the rear brake
caliDer contacts the brake caliper pin.
19-6
8.
3. Pullthe parking brake lever up one notch'
Remove the rear console {see section 20)'
Tighten the adjusting nut until the rear wheels drag
slightly when turned.
7.
Release the parking brake lever fully, and check that
the rear wheels do not drag when turned. Readjust
if necessary.
Make sure the parking brakes are fully spplied when
the parking brake lever is pulled up fully.
Install the cap onto the parking brake cable end, and
reinstall the rear console.

Master Cylinder/Brake Booster
I'RemovaUlnstallation
CAUTION: Do not spill brake tluid on the vehicle; it may
damage the paint; if brake fluid does contact the paint,
wash it oft immediatoly with water.
l. Disconnect the brake fluid level switch connectors.
2. Remove the reservoir cap from the master cylinder.
3. Remove the brake fluid from the master cvlinder
reservoir with a syringe.
4. Disconnect the brake lines from the master cylinder.
Be careful not to bend or damage the brake lines
when removing the master cylinder.
5. Remove the master cylinder mounting nuts and
washers.
6. Remove the master cylinder from the brake booster.
To prevent spills, cover the line joints with rags or
shoD towels.
7. Disconnect the vacuum hose from the brake booster.
8. Remove the lock pin and clevis pin from the clevis.
Do not disconnect the clevis by removing it from
the operating rod of the brake booster. lf the clevis
is loosened, adjust the pushrod length before
installing the brake booster.
13 N.m (1.3 kgf'm, 9 lbl'ft)
LOCX PIN
9. Remove the four booster mounting nuts.
10. Pull the brake booster forward until the clevis is
clear of the bulkhead.
11. Remove the brake booster from the enqine com-
panmenL
12, Install the brake booster and master cylinder in the
reverse order of removal and note these items:
. When connecting the brake lines, make sure that
there is no interference between the brake lines
and other parts.
. Be careful not to bend or damage the brake lines
when installing the master cylinder.
. lf replacing the master cylinder or brake booster,
check and adiust the DUshrod clearance before
installing the master cylinder (see page 19-14).
13. Fill the master cylinder reservoir, and bleed the
brake system (see page 19-7).'14. After installation, check the brake pedal height and
brake pedal free play and adjust if necessary (see
page 19-5).
BRAKE FLUID LEVEL
SW]TCH CONNECTORS
MASTER CYLINOERVACUUM HOSE
J
15 N.m t1.5 kgl'm, 11 lbf'ft)

1.
8.
NOTE: lf the clearance between the gauge body
and adjusting nut is 0.4 mm (0.02 in), the pushrod-
to-piston clearance is 0 mm. However, if the clear-
ance between the gauge body and adjusting nut is
0 mm, the pushrod-to-piston clearance is 0.4 mm(0.02 in) or more. Therefore it must be adjusted and
rechecked.
lf clearance is incorrect, loosen the star locknut and
turn the adjuster in or out to adjust.
NOTE:
. Adjust the clearance while the specified vacuum
is applied to the booster.
. Hold the clevis while adjusting.
Tighten the star Iocknut securely.
Remove the special tool.
0 - o.il mm l0 - 0.02 inl
Brake Booster Inspection
Functions Tgst
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. ll
the pedal sinks, either the master cylinder is
bypassing internally; or the brake system (master
cylinder, lines, modulator proportioning valve, orcaliper) are leaking.
Start the engine with the pedal depressed. lf thepedal sinks slightly, the vacuum booster is operat-
ing normally. lf the pedal height does not vary, the
booster or check valve is faulty.
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 cylinder is faulty. A slight change inpedal height when the A,,/C compressor cycles on
and off is 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
fau lty.
2. With the engine stopped, depress the brake pedal
several times using normal pressure. When thepedal is first depressed, it should be low. On con-
secutive applications, the pedal height should grad-
ually rise. lf the pedal position does not vary, check
the booster check valve.
Boostor Ch€ck Valve T6st
1. Disconnect the brake booster vacuum hose at the
booster,
Start the engine and let it idle. There should be vac-
uum available. It no vacuum is available. the check
valve is not working properly. Replace the brake
booster vacuum hose and check valve, and retest.
VACUUM HOSE(Check valve built-in)
STAR LOCKNUT22 t{.m12.2 ksl.m, 16lbf.ftl
cLEVtS
ADJUSTER
ADJUSTMENT GAUGE07JAG - SD40t00
9. Adjust the pushrod length as shown if the booster
is removed.
1161 0.5 mm14.61 0.02 inl
PUSHRODLOCKNUT15 N m 11.5 kgf m, 11 lbf'ftl
10. Instali the master cylinder.

Rear Brake Pads
Inspection and Replacement
Never use an air hose or dry b.ush to clean brake
assemblies.
Use an OSHA-approved vacuum cleaner to avoid
breathing brake dust.
Block the front wheels. loosen tha rear wheel nuts
slightly, support the rear of vehicle on sstety
stands, then remove the rear wheels.
Relaase the parking brake,
Remove the caliper shield.
Remove the two caliper mounting bolts and the
caliper trom the bracket.
CAUTION:
. Thoroughly clesn the out3ide ol tho csliper to
prsvent dust and dirt from entering in3ido,
. Support the caliper with a pi€c€ ot wire so that
it doss not hang lrom ths brako hose.
PARKING BRAKE CAALE cALtpEB MOUTTT|NGEOLTS
PAD SPRING
Replace.CALIPER
NOTE: Check the hoses and pin boots for damage
or deterioration.
\PIN EOOT
19-16
4. Remove the pad shims, pads and pad retainer.
PAD RETAINERS
'l
VINNER PAD SHIMCheck for weakness.(All exc.pt Type Rmod.ll
Using vernier calipers, measure the thickness of
each brake pad lining. The measurement does not
include the pad backing plate thickness.
Brake Pad Thickn..s:
Standard:
Typo R Model:
8.5 - 9.5 mm (0.33 - 0.37 in)
All except Type R Model:
7.0 - 8.0 mm {0.27 - 0.31 in)
Sorvie Limit: 1.6 mm {0.06 inl
BACKIiIG PLATE
lf the pad thickness is less than the service limit,
replace the pads and shims together as a set.

7.Clean the caliper thoroughly; remove any rust, and
check for grooves and cracks.
Check the brake disc for damage and cracks.
Make sure that the pad retainers are installed in the
correct positions.
PAD RETAINERS
Apply Molykote M77 to both sides of the shims and
to the back of the pads, Wipe excess grease off the
snrms.
Install the brake pads and pad shims on the caliper
bracket. Install the inner pad with its wear indicator
facing downward.
r When reusing the pads, always reinstall the
brake pads in their original positions to prsvent
loss of braking efficiency.
. Contaminated brake discs or pads reduce stop,ping ability. Keep grease off the discs and pads.
1 'I.
INNER PAO SI{IM
lAll oxcopt Typo Rmod.ll
Apply Molykote[I77 grease toboth sides of thePADS shim.
Apply MolykoteM77 grease toboth sides of the
Rotate the caliper piston clockwise into place in the
cylinder, then align the cutout in the piston with the
tab on the inner pad by turning the piston back.
CAUTION: Lubricato th€ boot with rubbor grease
to avoid twisting the piston boot. lf the piston boot
is twist€d, back it out so it sits properly.
Install the brake caliper.
lnstall and tighten the caliper mounting bolts,
15. Installthe caliper shield.
CALIPER SHIELD
After installation, check for leaks at hose and linejoints or connections, and retighten if necessary.
Depress the brake pedal several times to make sure
the brakes work, then road-test.
NOTE: Engagement of the brake may .equire agreater pedal stroke immediately after the brake pads
have been replaced as a set. Several applications of
the brake pedal will restore the normal pedal stroke.
13.
14.
16.
't7.
19-17