1991 MITSUBISHI ECLIPSE brake

5-56BRAKES -Master Cylinder
MASTER CYLINDERREMOVAL AND INSTALLATION
Pre-removal Operation
l Draining of Brake FluidPost-installation Operationl supplying Brake Fluidl Bleeding(Refer to P.5-45.1l Adjustment of Brake Pedal(Refer to P.5-41.)
Removal steps
/8-12 Nm
6-S Mbs.
14A02491. Fluid level sensor connector
2. Brake tubes
3. Reservoir hoses
4. Master cylinder
5. Reservoir
6. Bracket
NOTE
l 4Adjustment of clearance between brake(I) Reverse the removal procedures to reinstall.
booster push rod and primary piston(2) l + : Refer to “Service Points of Installation”.
14110053SERVICE POINTS OF INSTALLATIONNWlDAOa
. ADJUSTMENT OF CLEARANCE BETWEEN BRAKE
BOOSTER PUSH ‘ROD AND PRIMARY PISTONAdjust the clearance (A) between the brake booster push
rod and primary piston as follows:
m
J

14110064BRAKES - Master Cylinder5-57
(1) Measure the dimension (B) between the master cylinder
end face and piston.
NOTETo obtain
(B), first take measurement with a square placed
on the master cylinder end face. Then, subtract the
thickness of the square to arrive at (B).
14110065(2) Obtain the dimension
(C) between the brake booster
mounting surface on the master cylinder and the end face.(3) Measure the dimension
(D) between the master cylinder
mounting surface on brake booster and the push rod end.
NOTE
To obtain (D), first take measurement with a square placedon the brake booster. Then, subtract the thickness of the
square to arrive at
(D).(4). Using the measured values obtained in (1) through
(3),obtain the clearance (A) between the brake booster push
rod and primary piston.
Standard value: [A (A = B-C-D)]
9 inch brake booster0.8-1.0 mm
(.031-.039 in.)
7 +8 inch brake booster0.5-0.7 mm
(.020-.028 in.)
(5) If the clearance is not within the standard value range,
adjust by changing the push rod length by turning the
adjustable end of the push rod.
Caution
Improper clearance may cause excessive brake drag.

5-58BRAKES - Master Cylinder
IISASSEMBLY AND REASSEMBLYNOMA-
r------1
11414UO125
Iii
Brake master cylinder kit
6
:.5i340,b;m- . .
; .5F3h0,bfm
- . - +-10
.3.0 Nmft.lbs.
Disassembly steps
1. Reservoir cap assembly2.Diaphragm3.Reservoir cap4.Filter;: ;3r&e fluid level sensor
7.ReservoirI)+8.Nipple9.Reservoir seal
4+10. Piston stopper bolt
MAO57511. Gasket
aLI)12. Piston stopper ring+e ~~ 13. Primary piston assembly+e W 14. Secondary piston assembly
~~ 15. Master cylinder body
FrEeverse the disassembly procedures to reassemble.
(2) 4e : Refer to “Service Points of Disassembly”(3) l + : Refer to “Service Points of Reassembly”I;! m : Non-reusabje parts*: Vehicles with ABS

BRAKES - Master Cbhder5-59
I14LO211
14AO237SERVICE POINTS OF DISASSEMBLY
’ NOSH&
10. DISASSEMBLY OF PISTON STOPPER BOLTRemove the piston stopper bolt, while depressing the
piston.
12. DISASSEMBLY OF PISTON STOPPER RINGRemove the piston stopper ring, while depressing the
piston.
13. DISASSEMBLY OF PRIMARY PISTON ASSEMBLY
Caution
Do not disassemble the primary piston assembly.
14. DISASSEMBLY OF SECONDARY PISTON ASSEMBLY
NOTEIf it is hard to remove the secondary piston from the
cylinder, gradually apply compressed air from the outlet
port on the secondary end of the master cylinder.
Caution
Do not disassemble the secondary piston assembly.
INSPECTIONNOWDAC
lCheck the inner surface of master cylinder body for rust or
pitting.
lCheck the primary and secondary pistons for rust, scoring,
wear, damage or wear.
l Check the diaphragm for cracks and wear.
SERVICE POINTS OF REASSEMBLYNOWCAI
15. APPLICATION OF FLUID TO MASTER CYLINDER
BODY / 14. SECONDARY PISTON ASSEMBLY/ 13. PRI-
MARY PISTON ASSEMBLYApply the specified brake fluid sufficiently to the inner
surface of the master cylinder body and to the entire
surface of the secondary and primary pistons.
Specified brake fluid: MOPAR Brake Fluid/
Conforming to
DOT3
8. INSTALLATION OF NIPPLESBe sure that the primary side nipple and secondary side
nipple are not mistaken one for the other when installed.

5-60BRAKES - Brake Booster
BRAKE BOOSTER
REMOVAL AND INSTALLATION
IPre-removal Operationl Drainino of Brake FluidI6
Removal steps
1. Relay box (for air conditioner)
2. Solenoid valve assembly
3. Brake fluid level sensor connector4. Brake tube
5. Master cylinder, hose, reservoir assembly
+I) e+6. Vacuum hoses with check valve+a 7. Fitting
8. Cotter pin
I)4 9. WasherI)4 10. Clevis pin11. Fuel return tube installation bolt
12. Brake tube installation bolt
13. Brake booster
14. Sealer
MA0392
NOTE(1) Reverse the removal procedures to reinstall.(2) ** : Refer to “Service Points of Removal”.(3) l * : Refer to “Service Points of Installation”.(4) m : Non-reusable parts

BRAKES - Brake Booster5-61Vacuum hose
MAO394
14uoo50
14Y626Vacuum hose
mm (in.)
14A0395
SERVICE POINTS OF REMOVALNow9Al
6. REMOVAL OF VACUUM HOSE WITH CHECK VALVE
NOTE
Since the check valve is fit to the vacuum hose, replace thecheck valve as an assembly unit together with the vacuum
hose if the check valve is defective.
SERVICE POINTS OF INSTALLATIONNOWDAV
10. APPLICATION OF GREASE TO CLEVIS PIN/g. WASHERAfter applying the specified grease to the
clevis pin and
washer, insert the clevis pin and bend the cotter pin tightly.
Grease: MOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent
7. APPLICATION OF SEALANT TO
FITTINGWhen installing the vacuum hose fitting, apply semi-drying
sealant to its threaded portion.
6. INSTALLATION OF VACUUM HOSE WITH CHECK
VALVE(1) Attach the vacuum hose so that it may be inserted to a
dimension illustrated.
Caution
Prevent interference between the check valve and
brake booster.(2) The vacuum hose at the engine should be securely
connected until it contacts the hexagonal edge of the
fitting, and then should be secured by the hose clip.

5-62BRAKES - Brake Line
BRAKE LINEREMOVAL AND INSTALLATIONr/ehicles without ABS
Pre-removal Operation
eDraining of Brake Fluid6
/
NOSKA-
>/Flared brake line nuts
13-17 Nm
9-12 ft.lbs.I
14FO3825-35 Nm
/ 18-25 ftlbs.17-26 Nm
12-19 ft.lb!
5.25-35 Nm
18-25 ftlbs.12-19
ft.lbs.
1. Front brake hose2. Strut brake tube
3. Front brake tube
(R.H.)4. Front brake tube (L.H.)5. Brake tube (A)6. Brake tube (9)11. Main brake tube (R.H.)12. Main brake tube (L.H.)13. Proportioning valve
14. Rear brake hose
15. Rear axle brake tube
16.BracketMAO583

--
BRAKES - Brake Line5-63
Vehicles with ABSPre-removal Operation
*Draining of Brake FluidZonnecting part of14A057i
!
4*1. Front brake hose2. Strut brake tube
3. Front brake tube
(R.H.)4. Front brake tube (L.H.)5. Brake tube (A)6. Brake tube (9)7. Rear brake tube (R.H.)8. Rear brake tube (L.H.)~~ 9. Hydraulic unit10. Main brake tube (R.H.)11. Main brake tube (L.H.)2:12.Proportioningvalve
13. Rear brake hose
14. Rear axle brake tube
15.Bracket17-26 Nm
12-19
ftlbs.17-26 Nm
12-19 ft.lbs.14A0585