brake fluid HONDA INTEGRA 1998 4.G User Guide

Front Brake Caliper
Disassembly/Reassembly
. Never use an air hoss or dry brush to claan b.ake assemblies.. Use an OsHA-approvod vacuum cleane. to avoid breathing braks dust,. Contaminated brake discs or pads roduce stopping ability.. When rausing tha pads. always rein3tall the brake p8d3 in thoir original positions to prevont loss of braking etticlency.
GAUTION: Do not spill brake fluid on the vehicle; it may damags the paint; it brake fluid do6s contast the paint, wash hoff imm€diately with wator.
NOTE:
. Coat the piston, piston seal, and caliper bore with clean brake fluid.. Replace all rubber pans with new ones whenever disassembled,. Clean all pans in brake fluid and air dry; blow out all passages with compressed air,. Before reassembling, check that all parts are free of dust and other foreign particles.
. Replace parts with new ones whenever specified to do so.. Make sure no din or other foreign matter is 8llowed to contaminate the br8ke fluid.. Always use Genuine Honda DOT3 Brake Fluid. Using non-Honda brake fluid can caus6 corrosion and d€crease the liftof the system.
ffl; Use recommended rubber grease in the caliper seal set.
.61, Use recommended seal grease ,n the caliper seal set.
All except Type R Model:
INNER PAD SHIM A
BRAKE PADS
OUTER PAD SHIMCheck for wear.CALIPER BOLT Apply Molykote M7732 N.m {3.3 kgf.m, 2,1 lbtftl to pad side of shim.
WEAR INDICATORInstall inner pad withits wear ;ndicator upward.
nh/t I
T)2
,V--6&,
PAD RETAINERS
'12 x 1.25 mm108 N.m (r1.0 kgl.m.80 tbtftl
CALIPER BMCKET
{cont'd)
PIN BOOT
PIN 8
INNER PAD SHIM B
BANJO BOLT3a N.m {3.5 kgf.m, 25 lbf.ftl
Check for wear.Apply Molykote M77to pad side of shim.
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19-1 1

Front Brake Caliper
Disassembly/Reassembly (cont'd)
@o ?,lever use an air hosg qr dry brush to clean brake asaemblies.
o Use an OSHA-approved vacuum cleanor to avoid breathing braks du3t.
. Contaminatod brake disca or pads rsduce stopping sbility.
. Whan reusing the pads, alvyays reinstall the brake pads in their original pGitions to provent lo$ of braking etficiency'
CAUTION: Do not spitl brake fluid on the vohicle; h may damage tho paini; il btake tluid does contact the paint, wash it
off immediately with water.
NOTE:
. Coat the piston, piston seal, and caliper bore with clean brake fluid.
. Replace all rubber parts with new ones whenever disassembled.
. Cleanall parts in brake fluid and 8ir dry; blow out all passages with compressed air.
. Before reassembling, check that all parts are free of dust and other foreign particles.
. Replace parts with new ones whenever specified to do so.
. Make sure no din or other foreign matter is allowed to contaminate the brake fluid.
. Always use Genuine Honda DOT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the liJe
of the system.
.ff: Use recommended rubber grease in the caliper seal set.
.6|lruse recommended seal grease in the caliper seal set.
Typs R Modol:
WEAR II{DICATORInstall inner pad withits we6r indicator upward.
PAD SHIM
PISTON EOOTReplace.
ARAKE PADSFLANGE BOLT12 r 1.25 mmlO8 N.m 111.O kgl.m, 80 lbf.ftl
CAUPER ARACKET
Ch€ck for wear.Apply Molykote M77to pad side of shim.
BANJO BOLT34 .m 13.5 kgt.m, 25 lbf'ft|
BLEEO SCREWs N.n|n to.g kst.m, 6.5 lbtftl __..-r'4
aott"a aor,r /
ag N.m 15.0 kgt m, 36 lbfttl
PIN B(Blrckl
I PIN BOOr
I
Reptace.
tl
\6o
PAD SPRING
CALIPER BOOY
19-12

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)

Master Cylinder/Brake Booster
Master Cylinder InspectionPushrod Clearance Adjustment
NOTE: Master cylinder pushrod'to piston clearance must
be checked and adjustments made, if necessary, before
installing master cylinder.
1. Set the special tool on the master cylinder body;
push in the center shaft until the top of it contacts the
end of the socondary piston by turning the adjusting
nut.PUS'IROD ADJUSTTTiENT GAUGE07JAG - SDiOl(xl
SECOITDARYPISTON
CEl{IERSHAFT
MASTER CYLINDER
Without disturbing the center shaft's position,
the soecial tool upside down on the booster.
3. Install the master cylinder nuts and tighten to the
sDecified toroue.
4. Connect the booster inline with a vacuum gauge 0 -
101 kPa {0 - 760 mmHg, 30 in.Hg) to the booster's
engine vacuum supply, and maintain an engine
speed that will deliver 66 kPa (500 mmHg, 20 in.Hg)
vacuum.
5. With a feeler gauge, measure the clearance between
the gauge body and the adjusting nut as shown.
Clsarance: 0 - 0,i[ mm (0 - 0.02 inl
VACUUM GAUGElCommelcially availabl€|0 - 101 kPal0 - 760 mm H9,30 in.Hgl
AINUSTING NUT
BRAKEBOOSTEB
MAS'ER CYLINDER NUT15 N.m ll.5 kgf.m. 11 lbl.ftl
CAUTION:
. Do not spill blake fluid on the vohicle; it may damago
th6 paint; if brake fluid does contast ths paint, wash
it off immsdiately with water.
. Before reassembling. chock that all parts are tree of
dust and othor toreign particlgs,
. Do not trv to dissssemblo the master cylinder
assembly. Replace the mast€r cylinder assembly
with s new part if nocossary.
. Make sure no dirt or othor toroign matter is allowed
to contaminate th€ brako fluid.
RESERVOIR SEALCheck for damage and
deterioration.
ROD SEALCheck for damageand deterioration.
AIIUSNNG NUT
19-14
FEELER GAUGE

Rear Brake Caliper
Disassembly/Reassembly
o Never use an air hose or dry brush to clean brake assemblies.o Use an OSHA-approv€d vacuum cleaner to avoid breathing brake dust.. Conlaminated brake discs or pads reduce stopping ability.. When reusing the pads, always reinstall the brake pads in their original positions to prevent loss of braking efficiency,
CAUTION: Do not spill brake fluid on the vehicle; it may damags the paint; it brake fluid does contast the paint, wash itoff immediately with water,
NOTE:
. Coat the piston. piston seal, and caliper bore with clean brake fluid.. Beplace all rubber parts with new ones whenever disassembled.o Clean all parts in brake fluid and air dry; blow out all passages with compressed air.a Before reassembling, check that all parts are free of dust and other foreign particles.
. Replace parts with new ones whenever specified to do so.. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.. Always use Genuine Honda DOT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the lifeof the svstem.
Type R Model:10 mm FLANGE BOLT34 N.m 13.5 kg{.m,25 tbtftlAll 6xc€pt Typ6 R Modet:8 mm FLANGE BOLT23 N.m {2.3 kgf.m, 17 tbf.ft)
BANJO BOLT3,0 N.m (3.5 kgt m, 2s tbtftl
Replace.
;,'"]@: Use recommended rubber grease in the caliper seal set.
.61, Use recommended seal grease in the catiper seal set.
PARKING NUTRETURN SPRING
27 N.m 12.8 kgt m, \2rtbt.frl \
ar"t"o *or"a"=-\9_r.r,e=
LEVER -------rCF
c^M Boor ---f
Re'lace
-==': /t8
"':sst /-
CALIPER BOLTS23 N.m12.3 kgf.m, 17 lbf.ft)
TNNERPADSHTM cAM
lAll except Typs R CALIPER EODYModel)
OUTER PAO SHIM
-db
PAD SPRTNG
a71 ^ V
BRAKEPA''
vUffifi*
,*,
^rrorr /Y'
,/ ^,
O.RINGBeplace.
PINS
BLEED SCREW9 N.m (0.9 kg{.m, 6.5 tbf.ft)
SEALING WASHERSReplace.
PIN BOOT

Hose Replacement
CAUTION:
a Betore reassembling, check thal all parts are free of
dust and othet foreign particles.
a Replace parts with new ones whenever specilied tooo so.
a Do not spill brake tluid on the car; it may damage thepaint; if biake fluid does contact the paint, wash it
off immediatelv with water.
1. Replace the brake hose if the hose is twisted,
cracked, or il ir leaks.
2. Disconnect the brake hose from the brake line using
a 10 mm llare nut wrench.
BRAKE LINEFLARE NUTWRENCH(Commercially
available)
BRAKE HOSE
Remove and discard the brake hose clip from thebrake hose.
Remove the banjo bolt, and disconnect the brakehose from the caliper.
5.
BRAKE HOSEMOUNTING BOLTRS, LS, GS{8 x 20 mm)
Install the brake hose on the knuckle and damper
first, then connect the brake hose to the caliDer with
the banjo bolt and new sealing washers.
BRAKE HOSEERAKE HOSE MOUNTINGEOLT 18 x 16 mm)22 N.m{2.2 kgt.m, 16 tbf.ftl
GS-R and Type R{8 x 25 mm)22 N.m(2,2 kgf.m, 16lbf.ftl
BANJO EOLTtO r 1.0 mm34 N.m(3.5 kgf.m, 25 lbf.ft)
CAUTION: Do not twist the brake hose excessively.
Install a new brake hose clip on the brake hose.
Connect the brake line to the brake hose.
6.
7.
BRAKE HOSE MOUNTINGBOLT9.8 N.m {'1.0 kst.m, 7 tbt.fi}
BRAKE LINE15 N.m (1.5 kgt m, 11 lbf.ftl
BRA(E HOSE CLIPReplace.
After installing the brake hose, bleed the brake sys-tem (see page 19-7).
Perlorm the following checks.a Check the brake hose and line joint for leaks, andtighten it necessary.
a Check the brake hoses for interference orrwrslrng.
.:2-.--l
L
19-21

.,i
,I
Anti-lock Brake SYstem (ABS)
when the brake pedal is depressed during driving, the wheels can lock before the vehicle comes to a stop. In such an event.
the maneuverability of the vehicle is reduced if the front wheels are locked, and the stability of the vehicle is reduced if the
rear wheels are locked, creating an extremely unstable condition. The ABS precisely controls the slip rate o{ the wheels to
ensUre maximum grip force from the tires, and it thereby ensures maneuverbiIity and stabiIity of the vehicIe.
The ABS calculates the slip rate of the wheels based on the vehicle speed and the wheel speed. then it controls the brake
fluid oressure to attain the target slip rate
Features/Gonstructio n
Grip Foact ot Ti.c tnd Rotd Surfuco
COEFFICIEUT OFFNIG"TPN
Slip Rrtr
BRAKINGSTART POINT
i'l
A: f'3t rp withoul .lip
B: SIDp.d dirt.nc.G Actu.ldtt nc.io.top
sr.n arrr = f =
STOP POINTTARGET SUP RATE
SUP FATEVEHICT.C S'EEO - wlCEL SPEED
NO: Notm.lly oP.n
l{C: Noirnrly qo..d
19-26

Anti-lock Brake System (ABS)
Features/Construction (cont'd)
ABS Modulatol
The ABS modulator consists of the inlet solenoid valve, outlet solenoid valve, reservoir, pump, pump motor and the
damping chamber.
The modulator reduces the caliper fluid pressure directly. lt is a circulating-type modulator because the brake fiuid circulates
through the caliper, reservoir and the master cylinder.
The hydraulic control has three modes: pressure reduction, pressure retaining and pressure intensiiying
The hvdraulic circuit is the independent four channel-type, one channel tor each wheel'
L-__
RF LR
Pressure intensifying mode: Inlet valve open, outlet valve closed
Master cvlinder fluid is pumped out to the caliper.
Inlet valve closed, outlet valve closed
Caliper fluid is retained by the inlet valve and outlet valve.
lnlet valve closed, outlet valve open
Caliper fluid flows through the outlet valve to the reservolr'
When starting the pressure reduction mode, the pump motor is ON.
When stopping ABS operation, the pump motor is OFF.
The reservoir fluid is pumped out by the pump, through the damping chamber, to the master
cylinder.
\
Pressure retaining mode:
Pressure reduction mode:
Motor operation mode:
sott orD vALvE
@@-@@
TASIEF CYLI'OEF
19-24

Troubleshooting Precautions
Kickback
L The motor operates when the ABS is functioning, and the fluid in the reservoir is forced out to the master cylinder,
causing kickback at the brake pedal.
Pump Motol
1. The pump motor operates when the ABS is functioning.
2. The ABS control unit checks the pump motor operation during initial diagnosis and when the vehicle is started. You
mav hear the motor operate at this time, but it is normal
Brake Fluid Replacement/Air Bleeding'1. Brake fluid replacement and air bleeding procedures are the same as vehicles without ABS. To ease bleeding, start
with the front wheels.
Troubleshooting
1. The troubleshooting flowcharts procedures assume that the cause of the problem is still present and the ABS indica-
tor is still on. Following the flowchart when the ABS indicator does not come on can result in incorrect diagnosis.
2. Ouestion the customer about the conditions when the problem occurred, and try to reproduce the same conditions
for troubleshooting.
Find out when the ABS indjcator came on. such as during initial diagnosis. during ABS control, after ABS control,
when vehicle speed was at a certain speed, etc.
3, When the ABS indicator does not come on during the test-drive, but troubleshooting is performed based on the DTC,
check for loose connectors, poor contact at the terminals, etc. before you start troubleshooting'
4. After troubleshooting, erase the DTC and test-drive the vehicle. Be sure the ABS indicator does not come on.
5. The connector illustrations show the female terminals with a single outline and the male terminals with a double outline.

Modulator Unit
Removal/lnstallation
CAUTION:
. Do not spill brake fluid on lhe vehicle; it may damage the paint; il brake fluid does contact the paint, wash it offimmediately with water.
. Tak€ care notto damage or delorm the brake lines during removal and installation.. To provont the brake fluid ftom flowing, plug and cover the hos€ ends and ioints with a shop towel or equiyalent material.
Removal
1. Disconnect the modulator unit and DUmD motor connectors.
2. Disconnect the brake lines, then remove the modulator unit.
Installation
1. lnstall the modulator unit, then connect the brake lines. Tighten the flare nuts to 15 N.m (1.5 kgf.m, 11 lbf.ft).2. Connect the modulator unit and pump motor connectors.
3. Bleed the brake system, starting with the front wheels.
4. Start the engine, and check that the ABS indicator goes off.
5. Test-drive the vehicle, and check that the ABS indicator does not come on.
From master cylinder
from master cylinderprimary side
PUMP MOTOB CONNECTOR
MOUNT
UNlT
MODULATOR UNIT CONNECTOR
toright front
8 mm EOLT22 N.m {2.2 kg[.m, 16 lbl.ftl
6 mm NUT9.8 N.m 11.0 ks{.m,7.2lbtftl
9-6