1991 MITSUBISHI ECLIPSE service

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.

5-64BRAKES - Brake Line
Braketube
14w593Brake hose ,4”ooe~
1.From the hydraulic unit to the front
brake
(L.H.)2. From the hydraulic unit to the pro-
portioning valve (Rear,
R.H.)
3.From the hydraulic unit to the front
brake
(R.H.)4.
From.,the hydraulic unit to the pro-
portioning valve (Rear,
L.H.)5. From the master cylinder
(for left front and right rear)
6. From the master cylinder
(for right front and left rear)
SERVICE POINTS OF REMOVAL.m LN88K8AMll
1. REMOVAL OF FRONT BRAKE HOSE/13. REAR BRAKEr-e
HOSE(1) Holding the lock nut on the brake hose side, loosen the
iflared brake line nut.
(2) Pull off the brake hose clip and remove the brake hose
from the bracket.
12. REMOVAL OF PROPORTIONING VALVEDo not disassemble the proportioning valve because its
performance depends on the set load of the spring.
INSPECTIONNO5KCAhl Check the brake tubes for cracks, crimps and corrosion.
l Check the brake hoses for cracks, damage and leakage.
lCheck the flared brake line nuts for damage and leakage.
SERVICE POINTS OF INSTALLATIONNO5KDAJ
9. CONNECTION OF TUBE TO HYDRAULIC UNITConnect the tubes to the hydraulic unit as shown in the
illustration.

BRAKES -Front Disc Brake5-65
FRONT DISC BRAKE
’ REMOVAL AND INSTALLATIONNOSLA--13-17 Nm
9-12 ft.lbs.,
80-100 NmPre-removal Operationl Draining of Brake FluidRemoval steps
W M1. Connection for the brake hose and the
brake tubel +2. Front brake assembly3. Brake disc
14A0420
NOTE(I) Reverse the removal procedures to reinstall.(2) +I) : Refer to “Service Points of Removal”.(3) l * : Refer to “Service Points of Installation”.
SERVICE POINTS OF REMOVAL
N-LEAF
1. DISCONNECTION OF BRAKE HOSEHolding the nut on the brake hose side. Loosen the flared
brake line nut.
INSPECTIONNOSLCAD
INSPECTION OF BRAKE DISCl Check disc for wear. (Refer to P.5-47, Front Brake Disc
Thickness Check.)
lCheck disc for
runout. (Refer to P.5-47, Front Brake Disc
Run-out Check.)
l Check disc for damage

5,966BRAKES - Front Disc Brake
14A04001410399
SERVICE POINTS OF INSTALLATIONNO5LDAG
2. INSTALLATION OF FRONT BRAKE ASSEMBLY(1) Measure hub torque with pad removed to measure
brake drag torque after pad installation.
NOTETighten the nuts in order to secure the disc to the hub.
(2) After installing the caliper support to the knuckle,
expand the piston, and then install the caliper body.
1. INSTALLATION OF BRAKE HOSEInstall brake hose without twisting or kinking.
Check brake drag torque as follows.
(1) Start engine and hold brake pedal down for 5 seconds.
(2) Stop engine.
(3) Turn brake disc forward 10 times.
(4) Check brake drag torque with spring scale.
If the difference between brake drag torque and hub torque
exceeds the standard value, disassemble piston and cleanthe piston. Check for corrosion or worn piston seal.
Standard value: 70
N (15 Ibs.) or less[4 Nm (3
ft.lbs.)J or less

BRAKES -Front Disc Brake5-67DISASSEMBLY AND REASSEMBLY
64-86
46-62
64-86
46-62
ft.lbs. ;
Caliper assembly disassembly steps
l + 1. Guide pin
l + 2. Lock pin
l + 3. Bushing
4. Caliper support (Pad, clip, shim)
e+ 5. Guide pin boot
l 6. Lock pin boot
::7. Boot ring
8. Piston boot
l *** 9. Piston
4I) l + 10. Piston sealIl. Brake hosel + 12. Caliper body
Pad assembly disassembly steps
l + 1. Guide pin
l + 2. Lock pinl * 3. Bushing
4. Caliper support (Pad, clip, shim)
13. Pad and wear indicator assembly
14. Pad assembly15. Outer shim
16. Clip
NOSLE-B
.16
(1) Reverse the disassembly procedures to reassemble.(2) +e : Refer to “Service Points of Disassembly”.(3) l O : Refer to “Service Points of Reassembly”.(4) m : Non-reusable partsBrake caliper kit
3Pad repair kitSeal and boots
repair kit
14
106
13
13
1614
1614AO539
514A054(3