tow HONDA INTEGRA 1998 4.G Owner's Guide

Power Steering Gearbox
Installation (cont'dl
11. Install the steering joint cover with the clamps and
clips.
lnstall the rear beam brace rod and return line
clamp on the rear beam.
NOTE: lnstall the rear beam brace toward the
return line clamp.
12.
CLIP
38 N.m 13.9 kgl'm,28 lbf tl)
17-60
13. Install the three way catalytic converter with the
new gaskets and new self-locking nuts, and connect
the secondary heated oxygen sensor (HO2S) con-
nector.
SECONOARYHEATED OXYGEN SENSOR CONNECTOR
22 N.m {2.2 kgf.m, 16lbIft)
Connect the shift linkage (M/T model: see section
13, A,,/T model; see section 14).
Thread the right and left tie-rod ends onto the rack
an equal number of turns.
14.

\
NOTE; Wash the knuckle and hub thoroughly in high
flash point solvent before reassembly.
5. Press a new wheel bearing into the knuckle using
the old bearing, a plate and a p.ess.
NOTE: Press the wheel bearing into the knuckle
with the pack seal (metal color) toward the inside. Be
careful not to damage the sleeve of the pack seal.
Installthe circlip securely in the knuckle groove.
SCREWS5x0.8mm4.9 N'm (0.5 kgf.m,3.5lbtftl
SPLASH GUARO
7. Install the splash guard and tighten the screws.
18-15
Installthe front hub on the knuckle using the special
tools and a press as shown,
CAUTION: Tako csro not to distort tho splash guard.
pre3s
DRIVER I0??a9 - 0010000 v
ATTACHMENT,62x68mm07746 - 00t0500
SPLASH GUARD
KNUCKLE
FRONT HUB
{cont'd)

Rear Damper
Lower the rear suspension and position the damper
with the welded nut pointed toward the front of the
vehicle.
DAMPER
2. Loosely install the two flange nuts.
Hatchback:Sedan:
lnstallation
. ',.?7,:..r9\,ir '..
EY
FLANGE NUTS10 x 1.25 mmTighten these nuts in step 7 on the next page.
18-40
3. Install the wheel sensor wire bracket.
NOTE: Be careful when installing the sensors to
avoid twisting wires.
Raise the rear suspension with a floor iack until the
vehicle just lifts off the safety stand.
@ The floor jack must be securely posi-
tionod or personal iniury may result.
5. Install the damper mounting bolt and the flange
bolt, then tighten the bolts.
NOTE: The damper mounting bolt and the flange
bolt should be tightened with the damper under
vehicle load.
FLANGE EOLT10 x 1.25 m.n54 N.m (5.5 kgf m, 40 lbt.ftl
FLANGE BOLT10 x 1-25 mm54 N.m ls.s kgf m, 40 lbtft)
6. Tighten the three wheel sensor wire bracket bolts
{for vehicles with ABS).
9.8 N.m {1.0 kg{.m, 7.2 lbtftlBOLTS

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)

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

Outer Handle Replacement
NOTE: Raise the glass fully.
1. Remove:
a Door panel (see page 2O-4)
a Plastic cover (see page 20 4)
2. Remove the rod protector.
>: Screw localion, 1
INNER HANDLEROD
Push here.
Lalch srde.Rod protector side.
3. Disconnect the connector, and remove the harness
clamp and clips.
>: Screw location, 1
CONNECTORDetach the connector{rom the door.
8OD PFOTECTOR
4. Remove the bolts.
>: Bolt locations, 2
6 x 1.0 mm9.8 N.m {1.0 ksf m.1 .2 thl.tt)
5.Pull out the outer handle.
Pry the outer handle rod out of its joint using diagonal
cuners.
NOTE:
a To ease reassembly, note location @of the outer
handle rod on the joint before disconnecting it.a Take care not to bend the outer handle rod.
a Use a shop towel to protect the opening in the
door.
BUSHINGReplace.
h
SHOP TOWEL
(cont'd)
20-7

Doors
Outer Handle Replacement (cont'dlLatch Replacement
NOTEr Raise the glass fully.
'1. Remove:
a Door panel (see page 20 4)
a Plastic cover lsee page 20-4)
a Outer handle (see page 20 7)
2. Disconnect the inner handle rod and lock rod from
the latch.
Detach the inner handle rod and lock rod, then
remove the inner handle.
NOTE: Take care not to bend the rods.
>: Screw locations, 2
@t" ,
J
INNER HANDLEROD
INNER I{ANDLE
-1"'-
\
\LOCK ROD
)
INNER HANDLEROD
6.
8.
Disconnect the cylinder rod as shown.
NOTE: Take care not to damage the lock cylinder
joint.
OUTERHANDLECYLINDERROD
7.
V
SHOP TOWEL
Remove the cylinder switch lrom the outer handle.
: Scrsw location, 1
OUTERHANDLE
i4) cYLtNDERswtTcH
Pull out the retainer clip, then
cylinder and cylinder protector.
LOCK CYLINDER
li) clrPReplace
S*-.o"* .YLTNDER
CYLINDERPROTECTOR
RETAINERCLIP
Installation is the reverse of the removal procedure.
NOIE:
a Make sure the outer handle rod and connector are
connected securely.
a Make sure the wire harness is routed properly.
a Make sure the door locks and opens properly.
20-8

Outer Handle Replacement
NOTEr Raise the glass jully.
'1. Removel
a Door panel {see page 20-20)
a Plastic cover (see page 20 20)
2. Remove the rod protector.
>: Screw location, 1
-
-
Latch side. side.
3. Remove the bolts and disconnect the connector.
>: Bolt locatiohs, 2
I
f$iT'r.*' 6 x 1.0 mm I\4/l* 9.4 N.m {1.0 ksf.m,i
ryty!! J
>: Clip locations, 2
20-23
- -<--
INNERHANDLE
CONNECTOR
4. Remove the latch.
>: Screw locations, 3
6 x '1.0 mm6 N.m {0.6 kgl4 tbf.tr)
5.Pull out the outer handle with the latch.
Pry the outer handle rod out ol its joint using diagonal
culters.
NOTE:
a To ease reassembly, note location @ of the outer
handle rod on the joint before disconnecting it.
a Take care not to bend the outer handle rod.
a Use a shop towel to protect the opening in the
door.
BUSHINGReplace.
h
SHOP TOWEL
{cont'd )

Doors
Outer HandleReplacement (cont'd)
irl
lii
,l
r
LatchReplacement
NOTE: Raise the glass fully.
1. Remove:
a Door panel (see page 20 20)
a Plastic cover (see page 20 20)
a Outer handle (see page 20'23)
2- Remove the screws and disconnect the connector,
then remove the inner handle and latch.
NOTEr Take care not to bend the rods.
> | Screw locations, 2
6bD l
:)CYLINDER ROO
>: Clip locaiions, 2
3.Installation is the reverse of the removal procedure.
NOTE: Make sure the inner handle rod, lock rod and
connector are connected properly.
6.
7.
v:
Disconnect the cylinder rod as shown.
NOTE: Take care not to damage the lock cylinder
Jornt.
OUTERHANDLE
SHOP TOWEL
Remove the cylindef switch from the outer handle.
Pull out the retainer clip, then remove the lock
cylinder and cylinder protector.
8.
L
g--.-.o"*
cYLTNDER
lnstallation is the reverse of the removal procedure.
NOTE:
a Make sure the outer handle rod and connector are
connected securely.
a Make sure the wire harness is routed properly.
a Make sure the door locks and opens properly.
LOCK CYLINOEB

Doors
Outer Handle Replacement
NOTE: Raise the glass fully.
'1. Remove:
a Door panel (see page 20-32,
a Plastic cover (see page 20 32)
2. Remove the screws and clip, then move the latch.
^ 6x 1.0mm
[tJM o N.m {0.6 ksr m.
l Y llqr:llle
> : Screw locations, 3
3. Remove the bolts.
>: 8oh locations, 2
6 x 1.0 mm
A : Clip location, 'l
9.8 N.m {1.0 kgl m, I, ,,:otn , __)
TUBE
Pull out the outer hbndle with the latch.
Pry the outer handle rod out of its joint using diagonal
cuners.
NOTE:
a To ease reassembly, note location @ of the outer
handle rod on the joint belore disconnecting it.
a Take care not to bend the outer handle rod.
a Use a shop towel to protect the opening in the
door.
BUSHINGReplace.
h
5. Installation is the reverse of the removal procedure.
NOTE: Make sure the door locks and opens
properly.IaI
I
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