height adjustment HONDA INTEGRA 1998 4.G Workshop Manual

Clutch Pedal
Adjustment
NOTE:
a To check the clutch interlock switch and clutch
switch, see section 23.
a The clutch is self-adjusting to compensate Ior wear.
CAUTION: ll there is no clealance between the master
cylinder piston and push rod, the release bearing is held
against the diaphragm spring, which can result in clutch
slippage or other clutch problems.
1. Loosen locknut A, and back off the clutch switch
(or adjusting bolt) until it no longer touches the clutch
peoal.
2. Loosen locknut C. and turn the push rod in or out
to get the specified stroke (@) and height {O) at the
clutch Dedal.
3. Tighten locknut C.
4. Turn the clutch switch (or adjusting bolt) until it con-
tacts the clutch pedal.
ASSIST SPRING
@{
{PiN 08798-9002t
(STROKE at PEDAL): 130-140 mm (5.12-5.51 in){TOTAL CLUTCH PEDAI- FREE PLAYI: 12-21 mm (0.47-0.83 inl including tho p6dal play{CLUTCH PEDAL HEIGHT): 164 mm 16.46 inl to the tloor(CLUTCH PEDAL DISENGAGEMENT HEIGHTI: 83 mm {3.27 inl minimum to the floo.
t?
5.Turn the clutch switch (or adjusring bolt) in 3/4 to
1 full turn further.
Tighten locknut A.
Loosen locknut B on the clutch interlock switch.
Measure the clearance between the floor board and
clutch pedal with the clutch pedal tully depressed.
Release the clutch pedal 15-20 mm (O.59-O.79
in) from the fully depressed position and hold it there.
Adjust the position of the clutch interlock switch so
that the engine will stan with the clutch pedal in this
position.
Turn clutch interlock switch 3/4 to 1 full turn further.
Tighten locknut B.
9.
6.
7.
8.
10.
11.
LOCKNUT B9.8 N.m 11.0 kgt.m, 7 lbl.ft)
CLUTCH INTERLOCKswrTcHPUSH ROD
CLUTCH MASTER CYLINDER
CLUTCH SWITCH(or AOJUSTING BOLT)
LOCKNUT A9.8 N.m (1.0 kgf.m, 7 lbt.frl
l
{P/N 0879a-9002)
12-4
1- 10 mm (0.O4-O.39 inl

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

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.

OpeningDragGheck
(Motor Removedl
Before installing the motor, measure the effort required
to open the glass using a spring scale as shown.
CAUTION: Wh€n using a spring scale, piotect the lead-
ing odge of the glass with a shop towel.
lf load is over 40 N 14 kgf, 9lbf), check side clearance
and glass height adjustment (see page 20-78).
Closing Force Check
(Motor Installedl'1. After installing all removed parts, have a helper hold
the switch to close the glass whjle you measure
{orce required to stop it. Attach a spring scale as
shown. Read the force as soon as the glass stops
moving, then immediately release the switch and
spflng scate.
CAUTION: When using a sp.ing scale, protect the
leading edge of the glass with a shop towel.
Closing Fo.ce: 200-29O N
{2O- 30 kst. 44-66 lbf)
SPRINGscAt_E
lf the force is not within specification, install a new
lock washer, adjust the tension by turning the mo
tor clutch adjusting nut, and bend the lock washer
against the motor clutch adjusting nut.
2.
LOCKWASHERReplace.
COUNTERcLocKwtsETo decrease
GLASS
t;-<
20-83

)
Troubleshooting
Glass Height Adjustment
The rooJ panel should be even with the glass weather
strip, to within 1.8 t 0.5 mm (O.O7 tO.O2 in) allthe way
around. It not, slide the sunshade back, and:
1. Tilt-up the glass.
2. Loosen the bolts and adjust the glass.
3. Repeat on opposite side if necessary.
1.810.5 mm {0.07 } 0.02 inl
Gr_ASS
4-(.'
ROOF PANELGLASS BRACKET
GLASS WEATHERSTRIP
4. Side-to-side fit oI glass weatherstrip can be adjust-
ed by loosening the frame mounting bolts and mov
ing the frame right or left and forward or backward
by hand (see page 20-87).
GLASS BRACKET
SymptomProbable Cause
Water leaks1. Clogged drain tube.
2. Gap between glass weatherstrip and roof panel.
3. Detective or improperly installed glass weatherstrip.
4. Gap between drain seal and roof panel.
Wind noise1. Excessive clearance between qlass weatherstriD and roof oanel.
Motor noiseI
2
3
Loose motor.
Worn gear or bearing.
Cable assembly deformed.
Glass does not move, but motor
turnS
1
2
3
Clutch out of adjustment.
Foreign matter stuck between guide rail and slider.
lnner cable loose.
Cable assembly not attached properly.
Glass does not move and motor
does not turn (glass can be moved
with moonroof wrench)
I
2
3
Blown fuse.
Faulty switch.
Battery run down.
Defective motor.
Faulty relay.5
{
s
I
20-85

Moonroof
Opening Drag Check
(Motor Removedl
Before installing the motor, measure the effort required
to open the glass using a spring scale as shown.
CAUTION: When using a spring scale, protecl the lead-
ing edge ot the glass with a shop towel.
lf load is over 40 N (4 kgl, 9 lbfi, check side clearance
and glass height adjustment (see page 20-85)
Closing Force Check
{Motor Installed}
'1 . Alter installing all removed parts, have a helper hold
the switch to close the glass while you measure
Jorce required to stop it. Attach a spring scale as
shown. Read the lorce as soon as the glass stops
moving, then immediately release the switch and
spring scale.
CAUTION: when using a spring scale, protecl the
leading edge oI the glass with a shop towel.
Closing Force: 200-290 N
(20-30 ksf,44-66 lbtl
lf the force is not within specitication, install a new
lock washer, adiust the tension by turnlng the mo-
tor clutch adjusting nut, and bend the lock washer
against the motor clutch adjusting nut.
GLASS
\
clocKwrsE /?l a COUNTER-
To Increase \1, CLOCKWISE
force I lo oecreaseforce
20-90
--

NOTE: Before adjusting the hood, loosen each bolt slightly.
1. Adjust the hood hinges right and left, as well as lore and aft, by using the elongated holes.
2. Turn the hood edge cushions, as necessary, to make the hood ,fit flush with the body at front and side edges.
3. Adjust the hood latch to obtain the proper height at the forward edge.
HOOD EDGECUSHION
NOTEi Move the hood latch right or lett until the striker
is centered in the hood latch as shown.HOOD LATCH
HOOO LATCH
7.2lblltl
4. After adjustment, tighten each bolt securely.