1991 MITSUBISHI ECLIPSE ECU

BRAKES - Service Adjustment Procedures5-47switch
switch
v14F516
Idown ,./
F14517
F14518
F14519
SERVICE ADJUSTMENT PROCEDURES
BRAKE PEDAL INSPECTION AND ADJUSTM&g
1.Measure the brake pedal height as illustrated. If the brake
pedal height is not within the standard value, adjust as
follows.
Standard value (A): 176181 mm (6.9-7.1 in.)(1) Disconnect the stop light switch connector, loosen the
lock nut, and move the stop light switch to a position
where it does not contact the brake pedal arm.
(2) Adjust the brake pedal height by turning the operating
rod with pliers (with the operating rod lock nut
loosened), until the correct brake pedal height is
obtained.(3) After screwing in the stop light switch until it contacts
the brake pedal stopper (just before the brake pedal is
caused to move), return the stop light switch
l/2 to 1turn and secure by tightening the lock nut.
(4) Connect the connector of the stop light switch.
(5) Check to be sure that the stop light is not illuminated
with the brake pedal unpressed.
Reference value (B): 0.5-1.0 mm
(.02-M in.)
2. With the engine stopped, depress the brake pedal two or
three times. After eliminating the vacuum in the power
brake booster, press the pedal down by hand, and confirmthat the amount of movement before resistance is met
(the free play) is within the standard value range.
Standard value
(C): 3-8 mm (.l-.3 in.)
If the free play is less than the standard value, confirm thatthe clearance between the stop light switch and brake
pedal is within the standard value.
If the free play exceeds the standard value, it is probably
due to excessive play between the
clevis pin and brake
pedal arm. Check for excessive clearance and replace
faulty parts as required.
3. Start the engine, depress the brake pedal with approxi-
mately 500 N (110 Ibs.) of force, and measure the clearancebetween the brake pedal and the floorboard.
Standard value (D): 80 mm (3.1 in.) or moreIf the clearance is less than the standard value, check for
air trapped in the brake line and for brake fluid leaks. If
necessary, check the brake system mechanism (excessiveshoe clearance due to faulty auto adjuster) and repair
faulty parts as required.

BRAKES - Service Adjustment Procedures5-43When engine is
stoppedNo good
0
wtwo061
VV;Videngine is
t4uoo60
Caution
If the number of brake lever notches engaged is less
than the standard value, the cable has been pulledexcessively, and failure of the automatic adjuster
mechanism will result. Be sure tti adjust it to within the
standard value.(6) After making the adjustment, check to be sure that there is
no play between the adjusting nut and the pin. Also check
to be sure that the adjusting nut is securely held at the nut
holder.(7) After adjusting the lever stroke, jack up the rear of the
vehicle.(8) With the parking brake lever in the released position, turn
the rear wheel to confirm that the rear brakes are not
dragging.
PARKING BRAKE SWITCH CHECKN05FDAB
(1) Disconnect the connector of the parking brake switch, and
connect an ohmmeter to the parking brake switch and the
switch installation bolt.
(2) The parking brake switch is good if there is continuity whenthe parking brake lever is pulled and there is no continuity
when it is returned.
BRAKE BOOSTER OPERATING
lNSPECTIONNoSFcuFor simple checking of brake booster operation, carry out the
following tests.
(1) Run the engine for one or two minutes, and then stop it.
(2) Step on the brake pedal several times with normal
pressure.If the pedal depressed fully the first time. but gradually
becomes higher when depressed succeeding times, the
booster is operating properly.
If the pedal height remains unchanged, the booster is
faulty.(3) With the engine stopped, step on the brake pedal several
times with the same pressure to make sure that the pedal
height will not change.
Then step on the brake pedal and start the engine.
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is faulty.
(4) With the engine running, step on the brake pedal and then
stop the engine.
Hold the pedal depressed for 30 seconds. If the pedal
height does not change, the booster is in good condition.
If the pedal rises, the booster is faulty.
If the above three tests are okay, the booster performance canbe determined as good.
If one of the above three tests is not okay at last, the check
valve, vacuum hose, or booster will be faulty.

5-46BRAKES - Service Adjustment ProceduresWhen new
When worn
14G0017
14LO169
14A0403
\14AO400
FRONT DISC BRAKE PAD CHECK AND REPLACE-
MENiNWFOAF
NOTE
The brake pads have wear indicators that contact the brake discd’when the brake pad thickness becomes 2 mm
(.08 in.), and
emit a squealing sound to warn the driver.
1. Check brake pad thickness through caliper body check
port.Limit: 2.0 mm
(.08 in.)
Caution1. When the limit is exceeded, replace the pads at
both sides, and also the brake pads for the wheelson the opposite side at the same time.
2.If there is a significant difference in the thicknesses
of the pads on the left and right sides, check the
sliding condition of the piston, lock pin sleeve and
guide pin sleeve.
2.Remove lock or guide pin. Lift caliper assembly and retain
with wires.
Caution
Do not wipe off the special grease that is on the guide
-pin or allow it to contaminate the guide pin.
3. Remove the following parts from caliper support.
=Qg@-(4)
(1)
(2)
(3)
(4)Pad and wear
indicator assembly
Pad assembly
Outer shimPad clips
-4. 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.
5. Securely attach the pad clip to the caliper support.a

BRAKES - Service Adjustment Procedures5-47
14AO399-6. Clean piston and insert into cylinder with tool.
7. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin.8. 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 torqueexceeds the standard value, disassemble piston and clean
the piston. Check for corrosion or worn piston seal, and
check the sliding condition of the lock pin and guide pin.
Standard value: 70
N (15 Ibs.) or less
[4 Nm (3 ftlbs.)] or less
FRONT BRAKE DISC THICKNESS CHECK
NQ5FRASRemove dirt and rust from brake disc surface. Measure disc
thickness at 4 locations or more.
Limit: 22.4 mm
(.882 in.)
Replace the discs and pad assembly for both sides left and
right of the vehicle if they are worn beyond the specified limit.
FRONT BRAKE DISC RUN-OUT CHECKNOIFSAB
1.Remove the caliper support; then raise the caliper assem-
bly upward and secure by using wire.
2. Place a dial gauge approximately 5 mm
(2 in.) from the
outer circumference of the brake disc, and measure the
run-out of the disc.
Limit: 0.08 mm
(.0031 in.)
NOTETighten the nuts in order to secure the disc to the hub.

BRAKES - Service Adjustment Procedures5-494. Remove the following parts from caliper support.
14AO405
14AOs
grooves
Q
0 0
Projection
14R0037
14A0401
14AO406
MAO204Outer shim
Pad assembly
Pad clips
CPad clips
B
5.Measure hub torque with pad removed to measure brake
drag torque after pad installation.
NOTETo secure the disc to the hub, tighten the nuts.
6. Securely attach the pad clip to the caliper support.
Caution
Do not deposit grease or other dirt on pad or brake disc
friction surfaces.7. Clean the piston; then use the special tool to thread the
piston into the cylinder.
Be sure, at this time, that the stopper groove of the piston
correctly fits to the projection on the pad’s rear surface.
8. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the lock pin.
With the engine running, forcefully depress the brake pedalfive or six times, and then check whether or not the stroke
of the parking brake lever is within the standard value.
If there is a deviation from the standard value, adjust the
stroke of the parking brake lever.
(Refer to
P.5-42.)9. 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 torqueexceeds the standard value, disassemble piston and clean
piston. Check for corrosion or worn piston seal, and check
the sliding condition of the lock pin sleeve and guide pin
sleeve.Standard value: 70
N (15 Ibs.) or less
[4 Nm (3 ft.lbs)] or less
REAR BRAKE DISC THICKNESS CHECKNOSWAB
1. Remove dirt and rust from brake disc surface.
2. Measure disc thickness at 4 locations or more.
Limit: 8.4 mm
(.331 in.)
Replace the discs and pad assembly for both sides left andright of the vehicle if they are worn beyond the specified
limit.

5-50BRAKES - Service Adiustment Procedures
14A.0067
MAO409-
REAR BRAKE DISC RUN-OUT CHECKNOSWAB
1.Remove the caliper support, raise the caliper assembly, and Ir.secure it by using a wire, etc.
-u/2. Place a dial gauge approximately 5 mm
(2 in.) from the
outer circumference of the brake disc, and measure the
run-out of the disc.
Limit: 0.08 mm
(.0031 in.)
NOTETo secure the disc to the hub, tighten the nuts.
REAR BRAKE DISC RUN-OUT CORRECTIONNWFXAA
1.If the run-out of the brake disc is equivalent to or exceeds
the limit specification, change the phase of the disc and
hub, and then measure the run-out again.
rc
NOTEThe procedures for checking by changing the installation
phase of the disc are the same as those for the front brakediscs. (Refer to
P.5-48.)
2.If the problem cannot be corrected by changing the phase
of the brake disc, replace the disc.

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.

5,966BRAKES - 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