1900 MITSUBISHI DIAMANTE Repair Manual

2. Raise the vehicle and support safely.
3. Remove the appropriate tire and wheel as-
semblies. 11. Road test the vehicle and check brakes for
proper operation. *Be careful that the piston boot does not be-
come caught when lowering the caliper onto
+ha n,.nnnr) lh nnt t&at thm hr&a hnra rlnr-
4. Remove the calmer auide and lock Dins and
REAR
lift the caliper assembly’from the caliper support. Tie
the caliper
out of the way using wire. 00 not allow the
caliper to hang by the brake line.
*On some vehicles, the caliper can be
flipped up by leaving the upper pin in place
and usinu it as a oivot ooint.
---- sa - . -.
5. Remove the brake pads, spring clip and
cl7knr T&n nn+n ,-A nrdtinninntn sir-4 inc+alhtinn
u See Figures 32 and 34 13. Lubricate, install and tighten the lower pin.
*
14. Install the tire and wheel assemblies. Lower
1, Remove some of the brake fluid from the the vehicle.
master cylinder reservoir. The reservoir should be no 15. Test the brakes for proper operation:
more than half full. When the p istons are depressed
into the calioers. excess fluid

3 111,113. ,(lhC ,,“LC “I p”3”‘““H’y I” a,u IIIaLcuIaLt”II. 6. Install two wheel lug nuts onto the studs and
:
lightly tighten. This is done to hold the disc on the
hub.
To install:
7. Use a large C-clamp to compress piston(s)
back into caliper bore. On two piston calipers both
pistons will have to be retracted together.
8. Lubricate slide points and install the brake
pads, shims and spring clip ont- +‘- --“n-* n**nnnA reservoir. /ill flow up into the
2. Raise the vehicle and support safely.
s tire and wheel as- 3. Remove the appropriate
semblies.
4. Loosen the parking bra
from inside the vehicle.
5. Disconnect the parking brake cable end in-
stalled to the rear brake caliper assembly.
6. Remove the caliper lower pin and swing the
caliper assembly upwards. Tie the caliper out of the
way using wire. Dlamante and 1994-00 Galant
k See Figures 29,30,31,35 thru 47
Brake pads and shoes contain asbestos,
which has been determined to be a cancer
causing agent. Never clean the brake sur-
faces with compressed air! Avoid inhaling
any dust from brake surfaces! When cleaning
brakes. use commerciallv avallable brake Ike cable adjustment
Install the caliper over the brake ,..uuG. 7. Remove the outer shim, brake pads and
.
ie caliper support. Take note of soring clips from tl
nositibning of eact
8
IndalI twn cleaning flutds. -
*Be careful that the piston boot does not be-
come caught when lowering the caliper onto
the support. Do not twist the brake hose dur-
ing caliper installation. I to aid in installation.
“. llluLull L..V of the wheel lug nuts onto the
studs and lightly tighten. This is done to hold the
disc on the hub.
Cl Thrm-l the nictnn into thP r!alinar hnre rlnrk-
*Unlike most rear disc brake designs, this
system does not incorporate the parking
brake system, into the rear brake caliper,
therefore, the rear brake system is serviced
9. Lubricate and install the caliper guide and
lock pins in their original positions. Tighten the
: caliper guide and locking pins.
10. Install the tire and wheel assemblies. Lower
the vehicle.
t *Pump the brake pedal several times, until
i
firm, before attempting to move the vehicle. V. ,,,lV”” ,,,V ~,“L”,’ III1” .IIV “..*.prv, ““I., “.“-a.
wise using disc brake driver tool MB9f52 or its
equivalent.
To install:
10. Lubricate all sliding and pivot points.
11. Install the brake pads, shims and spring clip
to the caliper support.
12. Install the caliper over ”
’ -’ ---I~ me oraxe paas. the same as the front system.
1. Remove some of the brake fluid from the
master cylinder reservoir. The reservoir should be no
more than r/a full. When the pistons are depressed
into the calipers, excess fluid will flow up into the
reservoir.
93159#2 Fig. 34 Retracting brake caliper piston and Fig. 35 Use mechanic’s wire or a similar
aligning pad to piston-hlirage device to support the caliper out of the way Fig. 36 Remove the inner brake pad and
. . .
93159p33 Fig, 37 . . . also the outer pad from the
caliper Fig. 39 The caliper piston can be depressed
Fig. 38 Remove the spring clips and replace
if necessary using a special tool, such as this one from
Lisle@ or . . .

l
9-10 BRAKES
Fig. 40 . . . a large C-clamp will also work
to compress the caliper piston then make sure to lubricate the
Fig. 46
. . . then install the shim on the pads Fig. 47 Apply more brake quiet over the out-
/, the vehicle .Is/l*
wde of the sham before installing the pads
2. Raise the vehicle and support safely.
3. Remove the appropriate tire and wheel as-
semblies.
4. Remove the caliper guide and lock pins and
lift the caliper assembly from the caliper support. Tie
the caliper out of the way using wire.
( I ’ 5. Remove the brake pads, spring clip and
shims. Take note of positioning to aid installation.
6.
Do not allow the caliper to hang by the brake ’
line.
*On some vehicles, the caliper can be
flipped up by leaving the upper pin in place
and using it as a pivot point. Install the wheel lug nuts onto the studs and
lightly tighten. This is done to hold the disc on the
hub.
To install:
7. Use a large C-clamp to compress the pis-
ton(s) back into caliper bore.
_
8. Lubricate slide points and install the brake
pads, shims and spring clip onto the caliper support.
9. Install the caliper over the brake pads.
*Be careful that the piston boot
does not be- come caught when lowering the caliper onto
the support. Do not twist the brake hose dur-
ing caliper installation. Older brake pads or shoes may contain as-
bestos, which has been determined to be
cancer causing agent. Never clean the
brake
surfaces with compressed air! Avoid inhaling any dust from any brake surface! When
cleaning brake surfaces, use a commercially
available brake cleaning fluid. IO. Lubricate and install the caliper guide and
lock pins in their original positions.
11. Tighten the guide and locking pins to 54 ft.
Ibs. (75 Nm) on the front, and 20 ft. Ibs. (27 Nm) on
the rear,
12. install the tire and wheel assemblies.
13. Lower the vehicle.
Pump brake pedal several tlmes, until firm,
before attempting to move vehicle.
14. Road test the vehicle and check brakes for
proper operation.
INSPECTION
p See Figures 48 and 49
The disc brake pads have wear indicators that
contact the brake disc when the brake pad thickness
becomes 0.08 in. (2.0mm) and emit a squealing
sound to worn the driver.

BRAK& 9-11
1, Disconnect the battery negative cable.
2. Raise the vehicle and support safely.
3. Remove the appropriate tire and wheel as-
---L,:--
SeIIIUIIM. 4. Loosen the parking brake cable adjustment
from inside the vehicle.
B957wJ FIQ. 48 Inspect front disc pad thickness Brake pads an
which has bee
causing agent
faces with con
any dust fmm
brakes, use cf Id shoes contaln
asbestos, !n determined to be a cancer
. Never clean the brake SUP
npressed air! Avoid inhaling
brake surfaces! When cleaning
lmmercially available brake
c
cleaning fluid 5. Remove the retaining clips, and disconnect
the parking brake cable from the rear brake caliper
assembly.
rflo not let ali into the master cylinder by
allowing the reservoir to empty or complete
system bleeding will be required.
6. On FWD models, to disconnect the brake
nose rrom me canoer. remove me
oamo
DOII nom me
through caliper body check port
Mirage and 199Q-93 Galant brake caliper. ’
7. On AWD models, hold the nut on the brake
hose side and loosen the flared brake line nut. With
the hose disconnected at the line, remove the brake
hose from the caliper.
8. Remove the caliper lock pin. Pivot the caliper
Inspect the thickness of the brake linings by look-
ing through the brake caliper body check port. The
standard value of the brake pad is 0.39 in. (1Omm).
The thickness limit of the lining is 0.08 in. (2.0mm).
When the limit is exceeded, replace the pads on
both sides of the brake disc and also the brake pads
on the wheel on the opposite side of the vehicle. Do
not replace 1 pad on a caliper because the wear indi-
cator is hitting, without replacing the other pad on the
same wheel as well as the brake pads on the other
front or rear wheel, as applicable.
If there is a significant difference in the thickness
of the pads on the left and right sides, check the slid-
ing condition of the piston,
IDCk pin sleeve and guide
pin sleeve. *Do not let air into the master cylinder by
allowing the reservoir to empty or complete
system bleeding will be required.
3. To disconnect the front brake hose, hold the
nut on the brake hose side and loosen the flared
brake line nut. With the hose disconnected at the line,
remove the brake hose from the caliper.
4.
RfXIIDVe the caliper guide and lock pins.
5. Remove the caliper assembly from the caliper
support.
To install:
6. Position the brake caliper onto the caliper
SUppOrt. 7. Install and tighten the guide and lock pins.
8. Reconnect the brake hose.
*Use caution not to twist brake hose during
installation.
9. Bleed the brake system.
10. Apply brake pedal and inspect the system for
proper operation and no leakage.
11. Install tire and wheel assembly.
REAR
Q See Figure 17 upward, and slide the caliper assembly from the
caliper support.
To install:
9. On FWD models, install the rear brake hose
onto the caliper with new washers in place and
tighten the brake hose retainer.
10. On AWD models, connect the brake hose to
the caliper and tighten the fitting to 9-12 ft. Ibs.
(13-17 Nm). Then connect the hose at the bracket to
the steel line and tighten the fitting to 9-12 ft. Ibs.
(13-17 Nm).
rDo not twist the brake hose during installa-
tlon.
11. Install the caliper over the brake pads, making
sure stopper grove lines up with pad projection.
12. Lubricate and install the lock pin and tighten
to 23 ft. tbs. (32 Nm).
13. Bleed the brake system.
14. Inspect the brake system for leaks and ensure
proper operation.
15. Install tire and wheel assemblies.
16. Properly adjust parking brake cable.
Diamante and 1994-08 Galant
8 See Ffgures 50
thN 55
Unlike most rear disc brake designs, this system
does not incorporate the parking brake system into
the rear brake caliper. Therefore, the rear brake sys-
tem is serviced the same as the front system.
FiQ. 50 The brake caliper is mounted to the Fig. 52 Grasp the caliper and Ilft it from the
eaiiper support with two bolts support retaining bolts caliper assembly from the caliper support

l
942 BRAKES
I 93155~46 Fig, 53 Loosen the caliper hose banjo bolt
1 Fig. 54 . . , then remove the bolt from the . * . fitting
1 I Raise the vehicle and support safely.
2. Remove the appropriate tire and wheel as-
sembly.
*Do not allow the master cylinder reservoir
to empty. An empty reservoir will allow air to
enter the entire brake system and complete 7. Install the guide pin and lock pin. Tighten to
23 ft. Ibs. (32 Nm).
8. Reconnect the brake hose of install the banjo
bolt with new washers.
*Use caution not to twist the brake hose
during installation.
system bleeding will be required.
9. Bleed the brake system.
3. To disconnect the brake hose on models with
a banjo-bolt connecting the brake hose to the caliper
assembly, simply remove the bolt at the hose con-
nection. To disconnect the brake hose on all other
systems, hold the nut on the brake hose side and
loosen the flared brake line nut. Clean, high quality brake fluid is essential to
the safe and proper operation of the brake
system. You should always buy the highest
quality brake fluid that is available. If the
brake fluid becomes contaminated, drain and
flush the system, then refill the master cylin-
Brake fluid contains polyglycol ethers and
poly~lycols. Avoid contact with the eves and
wash your hands thoroughly after handling
brake fluid. if you do get brake fluid In your
eyes, flush your eyes with clean, running wa-
ter for 15 minutes. If eye irritation persists,
or if you have taken brake fluid internally,
IMMEDIATELY seek medical assistance.
4. Once the hose has been disconnected from der with new fluid. Never reuse any brake
fluid. Anv brake fluid that is removed from
the systum should be discarded. Also, do not
allow any brake fluid to come in contact with
a painted surface; it will damage the paint.
10. Apply brake pedal and inspect the system for
leaks. Ensure proper operation and no leakage.
11. Install tire and wheel assembly. Torque lug
nuts to 87-101 ft. Ibs. (120-140 Nm).
the line, remove the brake hose from the caliper,
5. Remove the caliper guide and lock pins and
lift the caliper assembly from the caliper support,
To install:
6. Position the caliper onto the caliper support.
OVERHAUL
b See Figures 56 thru 63 1 Fig. 55 Make sure that you remove the cop-
per washers and replace them with new
ones during reassembly
*Some vehicles may be equipped dual pis-
ton calipers. The procedure to overhaul the
caliper is essentially the same with the ex-
ception of multiple pistons, D-rings and dust
boots.
1. Remove the caliper from the vehicle and
place on a clean workbench.
NEVER place your fingers in front of the pis-
tons in an attempt to catch or protect the pis-
tons when applying compressed air. This
could result in personal injury!
*Depending upon the vehicle, there are two
different ways to remove the piston from the
caliper. Refer to the brake pad replacement
procedure to make sure you have the correct
procedure for your vehicle.
2. The first method is as follows:
a. Stuff a shop towel or a block of wood into
the caliper to catch the piston.
b. Remove the caliper piston using com-
pressed air applied into the caliper inlet hole. In-
spect the piston for scoring, nicks, corrosion
and/or worn or damaged chrome plating. The
piston must be replaced if any of these condi-
tions are found.

BRAKiS 9-13
Fig. 59 Use a prytool to carefully pry around 1
the edge of the boot , , . caiper housing, taking care not to score or 1
damage the bore ing the piston seal; DO NOT scratch the
15. Use a suitable driving tool to seat the boots in
the housing.
16. Install the caliper in the vehicle.
17. Install the wheel and tire assembly, then care-
fully lower the vehicle.
18. Properly bleed the brake system.
REMOVAL &INSTALLATION
Fig. 62 Use the proper size driving tool and
a mallet to properly seal the boots in the Fig. 63 There are tools, such as this Mighty-
Vat, available to assist in proper brake sys- Brake pads and shoes contain asbestos,
which has been determined to be a cancer
calmer housino
1 tam hlasrlinn . --~-~~~v
3. For the second method, you must rotate the
piston to retract it from the caliper.
4. If equipped, remove the anti-rattle clip.
5. Use a prytool to remove the caliper boot, be-
ing careful not to scratch the housing bore.
6. Remove the piston seals from the groove in
the caliper bore.
7. Carefully loosen the brake bleeder valve cap
~nrl \I~IWJ frnm the r~linor hnlwinn
I causina aaent. LL.....” rlrr.. .I.,. l.uLr I..”
Yll” .UI”Y ll”lll LIIb rro,spl tI”“Jlly. 8. Inspect the caliper bores, pistons and mount-
ing threads for scoring or excessive wear,
--... -.---...= ’ I.twla lilci(lll Lllli uranl$ au,- faces with-compressed air! Avoid Inhaling
9. Use crocus cloth to polish out light corrosion any dust from brake surfaces! When cleaning
from the piston and bore. brakes, use commercially available brake
10. Clean all parts with denatured alcohol and cleaning fluids.
dry with compressed air.
To assemble:
11. Lubricate and install the bleeder valve and 1993-09 Mirage, Diamante, and Galant
NP. 6 See Figures 64 thru 70
12. Install the new seals into the caliper bore
nrnnlrhr m”lr;nn Clln-. M..-.., nrn n.4 h..‘“‘“~ The following procedure is applicable to both the ytvvvca, lllanllly 3”IC o,ey ale II”, IWI~LCL. 13. Lubricate the piston bore.
14. Install the pistons and boots into the bores of
the calipers and push to the bottom of the bores. ’ front and rear brakes.
1. Raise the vehicle and support safely.
2. Remove the appropriate wheel.
3. Remove the caliper and brake pads.
Fia. 64 Suoaarl the calmer usina me-
., -----= -..- chanic’s wire or another suitable device, Do
NOT let it hang by the brake hose Fig. 65 Remove the caliper bracket retain-
ing bolts . . . Fig. 66 m . . then remove the caliper bracket
from the vehicle

l
9-14 BRAKES
-
two threaded hoks to- Fig. 68 tnstatt a suitable size bolt into the Fig. 69 Tighten the bolts until they force the
threaded holes rotor off of the hub . . .
1 hub assembly
4. Support the caliper out o
5. On some models the rote
by two small threaded screws. Remove the screws
.mrl n,,ll nff thn rntnr
6. Remove the brake pads.
7. Remove the ball joint and tie rod end from
., 3
me lower control arm.
8. Use and puller to push the halfshaft through f the way using a wire.
)r is held to the hub
ml” p”” “II crw l”L”l. To install:
6. Position the rotor on the hub and install the
mounting screws.
7. Install the caliper holder and brake pads.
8. Slide the caliper over the brake pads and
tighten the guide pins.
9. Install the wheel and tighten the lug nuts. the rotor/hub assembly.
9. Remove the lower strut bolts and remove the
bly from the vehicle.
To separate the rotor from the hub assembly,
sallluly. To install:
7. Position the rotor on the hub. Install a couple
of lug nuts and lightly tighten to hold rotor on hub.
asseml
10.
remove the rotor retainer bolts and separate using
tool MB991001 or equivalent.
To Install:
11. Assemble the rotor and hub. Tighten the nuts
to 40 ft. Ibs. (54 Nm) and install the assembly to the 8. Install the caliper holder and place brake
pads in holder.
9. Slide caliper over brake paAl- --,I inr+*.rli
guide pins. Once caliper is secure1
ho
mmnmrl
I”> a, I” II 13m11
YI, the lug nuts can
U” IUIII”“““.
10. Reconnect parking brake cable and install
wheel(s).
INSPECTION
venae.
12. Install the washer so the chamfered edge Using a micrometer, measure the disc thickness at
.I LL- *.* 1 I
faces outward. Install the nut and tighten temporarily. eignr posmons, approxlmarely
43 aegrees apan ana
Pump the brake pedal several times before
13. Install the ball joint and tie rod end. 0.39 in. (10mm) in from the outer edge of the disc.
attempting to move vehicle.
14. Install the brake components. The minimum thickness is 0.882 in. (22.4mm) for

15. Install the wheel and lower the vehiclk to the front rotors or 0.331 in. (8.4mm), with a maximum
floor. thickness variation of 0.0006 in. (0.015mm).
If the disc is beyond limits for thickness, remove it
and install a new one. If the thickness variation ex-
ceeds the specifications, replace the disc or turn rotor
with on the car type brake lathe.
I

_,

.I. _
BRAKis 9-15

t
9-16 BRAKES
1. Raise and safely support the vehicle.
2. Remove the rear wheel.
: REMOVAL&INSTALLATION 3. Loosen the parking brake adjusting nut.
4. Pull the drum from the rear hub assembly. Tap INSPECTION
the drum with a soft mallet if necessary.
To install:
u See Figure 77
5. Install the drum on the rear hub assembly.
Brake pads and shoes contain asbestos, 6. Install the wheel and adjust the parking brake.
which has been determined to be a cancer 7. Lower the vehicle to the floor.
causing agent. Never clean the brake sur-
'INSPECTION Brake pads and shoes contain asbestos,
faces with compressed air! Avoid inhaling
which has been determined to be a cancer
any dust from brake surfaces! When cleaning
‘b See Figure 76 causing agent. Never clean the brake sur-
brakes, use commercially available brake
faces with compressed air! Avoid inhaling
cleaning fluids.
1. With the brake drum removed from the vehicle, any dust from brake surfaces! When cleaning
measure the inside diameter of the hub and drum at brakes, use commercially available brake
1996-92 Mirage two or more locations. cleaning fluids.

: $ See Figure 71 2. The service limit specification is 9.1 in.
(231mm). 1. Remove the brake drum.
1. Raise the vehicle and support safely. 3. Replace the brake drums and shoe and lining 2. Measure the wear of the brake lining at the
2. Remove the wheel and tire assembly. assemblies when the wear exceeds the limit or is place worn the most. The service limit for replace-
3. Remove the dust cap. badly out of balance. ment is 0.039 in. (1 .Omm).
4. Remove the self-locking nut.
5.. Remove the outer wheel bearing.
’ 6. Remove the drum with the inner wheel bear-
ing from the spindle.
7. Remove the grease seal.
To install:
8. To determine if the self-locking nut is
reusable:
a. Screw in the self-locking nut until about
l/e in. (3mm) of the spindle is showing.
b. Measure the torque required to turn the
self-locking nut counterclockwise.
c. The lowest allowable torque is 48 inch Ibs.
(5.5 Nm). If the measured torque is less than the
specification, replace the nut.
9. Lubricate and install the inner wheel bearing.
10. Install a new grease seal.
11. Install the drum to the spindle.
12. Lubricate and install the outer wheel bearing.
13. Tighten the self-locking nut to 108-145 ft.
Ibs. (150-200 Nm).
14. Install the grease cap.
Galant and 1993-90 Mirage
b See Figures 72, 73, 74, and 75
Fig. 76 Measura the inside diameter of the
brake drum