Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Mitsubishi Eclipse & Laser & Talon 1990-1999 Approved Mitsubishi Eclipse 1992-1994 92-94ECB

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92-94ECB


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                                                                                                                    GROUP INDEX                                                                       NOSAl



      Service Manual                                                           Introduction and
                                                                               Master Troubleshooting . . . . . . . . . . . . . . . . . . i
                                                                                                                                         .-I

                   LASER                                                       Lubrication and Maintenance . . . . . . . .
                                                                                                                                                                                                      E
                                                                                                                                                                                                       l



                   TALON
                                                                               Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . ..A.                                               i
                                                                                                                                                                                                      t
                                                                              Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~. .

                        & Eclipse                                                                          Service
                                                                            ' Brakes- Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

                                                                              Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~. . .
                     Volume-l
                                                                              Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~. . .~~..
                  Engine, Chassis
                      & Body                                                  Engine . . . . . . . . . . . . . . . . . . . . . . . . ..*..............................

                                                                              Intake and Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
                         FOREWORD
   This Service Manual has been prepared with the
                                                                              Fuel System . . . . . . . . . . . . . . . . . . ..*........................ .*4
                                                                                                                                           `,,,
   latest service information available at the time of
   publication. It is subdivided into various group                           Propeller Shaft ..,.....,....,.................m.......
   categories and each section contains diagnosis,
   disassembly, repair, and installation procedures
   along with complete specifications and tightening                          Rear Suspension .*........s........................
   references. Use of this manual will aid in properly
                                                                                       Manual
   performing any servicrng necessary to maintain or                          Steering-po,er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .h\.$
   restore the high levels of performance and reliability
   designed into these outstanding vehicles.                                             Manual                                     i :
                                                                              Transaxle-Automatic . . . . . , . . . . . . . . . . . . . . r+:,
                                                                              Wheels                      and              Tires                                    _.
                                                                                                                                               .......................               .&......

                                                                                                                                                                    j 8
                                                                                                                                                                                                : >

                                                                              Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*...**...

                                                                              Heater & Air CondjtJoning ..,.. ,.,. . . ...'

               CHRYSLER                                                      Emission Control Systems . . . . . . . . . . . . . . 1
               CORPORATION
  Chrysler Corporation reserves the right to make changes in design or to
  make additions to or improvements in its products without imposing
  any obligations upon itself to install them on its products previously
  manufactured.




 0 1992 Mitsubishi)                                     Printed in U.S.A.
L-."
  :
                                   BRAKES
   SERVICE AND PARKING
                                                  CONTENTS

ANTI-LOCK BRAKING SYSTEM                                    Front Disc Brake Pad Check and
TROUBLESHOOTING .........................             9     Replacement ..................................                           51
                                                            Front Disc Brake Rotor Inspection .........                              53
BRAKE BOOSTER ..............................         71
                                                            Inspection of Hydraulic Unit .................                           59
BRAKE LINE ....................................      73     Measurement of Wheel Speed Sensor
                                                            Output Voltage ................................                          57
BRAKE PEDAL ..................................       63     Parking Brake Lever Stroke Check .........                               48
ELECTRONIC CONTROL UNIT                                     Parking Brake Switch Check ................                              49
 ................... 102                 Proportioning Valve Function Test ..........                             50
                                                            Rear Brake Disc Run-out Check ............                               57
FRONT DISC BRAKE ..........................          76
                                                            Rear Brake Disc Run-out Correction .......                               57
G-SENSOR  ................... 101                  Rear Brake Disc Thickness Check ..........                               56
                                                            Rear Disc Brake Pad Check and
HYDRAULIC UNIT                                              Replacement ..................................                           55
 ...................              92
                                                            Run-out Check ................................                           54
MASTER CYLINDER ...........................          67     Run-out Correction ...........................                           54
                                                            Thickness Check ..............................                           55
PARKING BRAKES .............................      103
                                                          SPECIAL TOOLS ...............................                               6
REAR DISC BRAKE ............................         65
                                                          SPECIFICATIONS ...............................                              2
SERVICE ADJUSTMENT PROCEDURES ..a                    47
                                                            General Specifications . . . . . . . . . . . . . . . . . . . . . . . .    2
  ABS Power Relay Check ....................         62
                                                            Lubricants .....................................                          5
  Bleeding .......................................   50
                                                            Service Specifications ........................                           4
  Brake Booster Operating Inspection .......         49
                                                            Torque Specifications .................. .:. ...                          4
  Brake Fluid Level Sensor Check ...........         48
  Brake Pedal Inspection and Adjustment ...          47   TROUBLESHOOTING ..........................                                  7
  Check Valve Operation Check ..............         49
                                                          WHEEL SPEED SENSOR
  Flat Battery Remedy .........................      62    ....................                                   95

CAUTION
When servicing brake assemblies or components, do not create dust by sanding, grinding or by cleaning
brake parts with a dry brush or with compressed air. A WATER DAMPENED CLOTH SHOULD BE USED.
Many brake components contain asbestos fibers which can become air-borne if dust is.created during
service operations. Breathing dust which contains asbestos fibers can cause serious bodily harm.
5-2                                   BRAKES - Specifications

SPECIFl,CATIONS
GENERAL SPECIFICATIONS

Items                                                Vehicles without ABS               Vehicles with ABS

Master cylinder
  J-w                                                Tandem type                        Tandem type
                                                     (with level sensor)                (with level sensor)
  I.D.         ' ,, ' ,;!               mm (in.)     22.2 (78)                          23.8 P5/1d
Brake booster
  Tvw                                                Vacuum type                        Vacuum type
  Effective dia. of power cylinder      mm (in.)     230 (9.0)                          Front side: 180 (7.0)
                                                                                        Rear side: 205 (8.0)
  Boosting ratio [Brake pedal depressing force]      5.0 [at 220 N (48 Ibs.)l           5.5 [at 220 N (48 Ibs.)l

Proportioning valve
  Type                                               Dual type                          Dual type
  Split point                           kPa (psi)    4,200 (597)                        4,200 (597)
  Decompression ratio                                0.3                                3.3
Front brakes
  Type                                               Floating caliper, single-piston,   Floating caliper, single-piston,
                                                     ventilated disc (M-R44V)           ventilated disc (M-R44V)
  Disc O.D.                             mm   (in.)   256 (10.1)                         256 (10.1)
  Disc thickness                        mm   (in.)   24 i.94)                           24 i.94)
  Pad thickness                         mm   (in.)   16.0 (.63)                         16.0 (.63)
  Wheel cylinder I.D.                   mm   (in.)   53.9 (2 l/8)                       53.9 (2 %)
  Clearance adjustment                               Automatic                          Automatic
Rear drsc brakes
  Type                                               Floating caliper, single-piston,   Floating caliper, single-piston,
                                                     ventilated disc (AD30P)            ventilated. disc (AD30P)
  Disc O.D.                             mm   (in.)   265 (10.43                         265 (10.4)
  Disc thickness                        mm   (in.)   10 (39)                            10 l.39)
  Pad thickness                         mm   (in.)   14.5 (.57)                         14.5 (.57)
  Wheel cylinder I.D.                   mm   (in.)   30.1 (1 Yl6)                       30.1 (1 3/6)
  Clearance adjustment                               Automatic                          Automatic
Rotor teeth
  Front wheel side                                   -                                  47
  Rear wheel side                                    -                                  47
Speed sensor                                         -                                  vlagnet coil type
Parking brakes'
  Tvw                                                Mechanical brake acting            Vlechanical brake acting
                                                     on rear wheels                     3n rear wheels
  Brake lever type                                   Lever type                         -ever type
  Cable arrangement                                  V-type                             V-type
! y+
       ..
fr
`i
                                                      BR&gES - Specifications                                                         513
            -

             

              Items                                                 FWD                                   AWD
              Master cylinder
                Type                                             Tandem type                              Tandem type
                                                                 (with level sensor)                      (with level sensor)
                I.D.                                   mm (in.) 25.4 (1)                                  25.4 (1)
              Brake booster
                Type                                            Vacuum type                               Vacuum type
                Effective dia. of power cylinder      mm (in.) Front side: 188 (7.4)                      Front side: 188 (7.4)
                                                                Rear side: 215 (8.5)                      Rear side: 215 (8.5)
                Boosting ratio [Brake pedal depressing force]   6.0 [at 220 N (48 Ibs.)]                  6.0 [at 220 N (48 Ibs.)]
                                                                                                     `.
             Proportioning valve
                Type                                              Dual type                               Dual type
                Split point                            kPa (psi) 2,500 (363)                              3,500 (508)
                Decompression       ratio                         0.25                                    0.25
                                                                                                           ,,' I
             Front brakes
                Type                                               Floating caliper, single-piston, Floating caliper, double-piston
                                                                   ventilated disc (M-R46V)         ventilated disc (M-R56W)
               Disc O.D.                               mm   (in.) 256(10.1)                         2 7 6 ( 1 0 . 9 )
               Disc thickness                          mm   (in.) 24 (94)                           24 (.94)
               Pad thickness                           mm   (in.) 16.0 (63)                         16.0 (63)
               Wheel cylinder I.D.                     mm   (in.) 60.3 (2?,)                        41.3 (l"/*) x 2
               Clearance adjustment                                Automatic                     Automatic
             ?ear disc brakes
               Type                                                   Floating caliper, single-piston,    Floating caliper, single-piston,
                                                                      ventilated disc (AD30P)             ventilated disc (AD35P)
               Disc O.D.                               mm   (in.) 265 (10.4)                              265 (10.4)
               Disc thickness                          mm   (in.) 10 (39)                                 10 f.39)
               Pad thickness                           mm   (in.) 14.5 (.57)                              14.5 (.57)
               Wheel cylinder I.D.                     mm    ( i n . ) 30.1 (1 3/16)                      34.9 (1 3h)
               Clearance adjustment                                   Automatic                           Automatic
             3otor teeth*
               Front wheel side                                    47                                     47
               Rear wheel side                                     47                                     47
             speed sensor*                                         Magnet coil type                       Magnet coil type
             `arking brakes
               We                                                 Mechanical brake acting                 Mechanical brake acting
                                                                  on rear wheels                          on rear wheels
                   Brake lever type                               Lever type                              Lever type
                   Cable arrangement                              V-type                                  V-type
            k ,.-YT--
            Nult
            The *symbol indicates vehicles with ABS.
-


    5-4                                            BRAKES - Specifications

    SERVICE SPECIFICATIONS

        Items                                                               Specifications

        Standard value
           Brake pedal height                                  mm (in.)     176-181 (6.9-7.1)
           Brake pedal free play                               mm (in.)     3 - 8 (.l-.3)
           Brake pedal to floorboard clearance                 mm (in.)     80 (3.1) or more
           Parking brake lever stroke.                                      5-7 notches
           Output pressure proportioning valve                MPa (psi)
              Split point
                                                                       3.95-4.45 (561-633)
                                                                       3 . 4 5 - 3 . 9 5 (491-561).
              Output pressure [input pressure]
                                                                       5.15-5.65 (732-804) i8.2 (1,163)1
                                                                       4.65-5.15 (661-732j.17.7 (1,095))
           D ISC brake dragging force at hub bolt
                                                  N (Ibs.) [Nm (ft.lbs.)l   7 0 (15) or less I4 (3) or less]
           Booster push rod to master cylinder piston clearance
                                                               mm (in.)
              9 inch brake booster                                          0.8-1.0 (.031-,039)
              7 + 8 inch brake booster                                      0.5-0.7 (.020-.028)
           Speed sensor's internal resistance                        k&     0.8-1.2"
           Clearance between the speed pole piece and
           the toothed rotor                                   mm (in.)     0.3-0.9           (.012-,035)"
                                                                                                        6
        Lrmtt
           Left/right proportioning valve out pressure difference
                                                              MPa (psi)     0.4 (57)
           DISC brake pad thrckness                            mm (in.)     2.0 (.08)
           Front drsc thickness                                mm (in.)     22.4 (.882)
           Rear dtsc thrckness                                 mm (in.)     8.4 (.331)
           DISC runout                                         mm (in.)
              Front                                                         0.07 (.0028)
              Rear                                                          0.08 l.0031)
           Hub end play                                        mm (In.)     0.2 (.008)

    NOTE
    l: Vehicles with ABS

    TORQUE SPECIFICATIONS
        Items                                                                      Nm                      Tft.lbs.
        Pedal support bracket installation bolts                                   8-12                      6-9
        Pedal support bracket installation nut                                     IO-15                     7-11
        Pedal rod to pedal support bracket                                         17-26                     12-19
        Pedal rod to clutch pedal bracket                                          17-26                     12-19.
        Clutch pedal bracket installation bolt                                     8-12                      6-9
        Turn-over spring mounting bolt                                             17-26                     12-19
        Stop lamp switch mounting nut                                              10-15                     7-11
        Clutch master cylinder installation nuts                                   10-15                     7-11
        Clutch pedal installation nut                                              20-25                     14-18
        Lever assembly (A) installation nut                                        20-25                     14-18
        Lever assembly (B) installation nut                                        20-25
                                                                               I
                                              ~~ -__ :: ::I .:`i j ,:
        .                                        -, .`- `+`+gg&p.~j: j
                                                           ;.;1--?.+.k
                                         BRAKES - Specifications
-
Items                                                         Nm                  ft.lbs.
Master cylinder to brake booster                             8-12                 6-9
Piston stopper bolt                                          1.5-3.0              l-2
Nipple installation screw                                    1.5-3.0              l-2
Brake booster installation nuts                              11-17                8-12
Fitting                                                      15-18                11-13
Flared brake line nuts                                       13-17                9-12
Brake hose bracket installation bolts                        17-26                12-19
Front disc brake assembly installation bolts                 80-100               58-72
Lock pin (front)                                             64-86                46-62
Guide pin (front)                                            64-86                46-62
Bleeder screw                                                7-9                  5-7
Wheel bearing nut                                            200-260              144-188   "
Dust shield to axle beam                                     9-14                 7-10
Rear disc brake assembly installation bolts                  50-60                36-43
Drive shaft to companion flange                              55-65                39-47
Companion flange to rear axle shaft                          160-200              116-159
Brake hose to caliper body (rear)                            25-35                18-25
Lock pin (rear)                                              22-32                16-23
Guide pin (rear)                                             22-32                16-23
Spindle lever to parking brake lever                         40-55                29-40
Rear speed sensor installation bolt                          9-14                 7-10
Speed sensor bracket installation bolt                       9-14                 7-10
Rotor to front hub                                           7-l 1                5-a
Rotor to rear hub                                            9-14                 7-10



LUBRICANTS                                                                                      No!xD-
Items                                                   Specified lubricant
Brake fluid                                             MOPAR Brake Fluid/
                                                        Conforming to DOT3 or DOT4
Brake pedal bushing inner surface
Clevls pin and washer                                   MOPAR Multi-mileage Lubricant
Parking brake lever sliding parts                                        equivalent
                                                        Part No. 2525035 or
Bushing inner surface
5-50                           BRAKES - Service Adjustment Proi?edur&

                                                  2. Check the operation of the check valve by using a vacuul
                                                      pump.
                                       Brake        Vacuum pump connection Accept/reject criteria
                                       booster
                                       side        Connection at the brake A negative pressure (vacuum) is
       Spring             '                        booster side @           created and held.
        /
                  Valve                            Connection at the -intake       A negative pressure (vacuum) is not
                                                    manifold side @                created.

                                                  Caution
   Pressure
                                                  If the check valve is defective, replace it as an assemb!
   gauge      Pressure                            unit together with the vacuum hose.


                                                  PROPORTIONING VALVE FUNCTION TEST                                  NO!iR(r

                                                  1. Connect two pressure gauges, one each to the input sid
                                                     and output side of the proportioning valve, as shown,
                                                  2. Air bleed the brake line and the pressure gauge.
                                                  3. While gradually depressing the brake pedal, make th
                                                     following measurements and check to be sure that th
                PropGtioning   valve    14LO181
                                                     measured values are within the allowable range.
                                                     (1) Output pressure begins to drop relative to inpl
                                                          pressure (split point).
                                                          Standard value:
                                                                             3.95-4.45 MPa (561-633 psi
                                                                             3.45-3.95 MPa (491-561 ps
                                                      (2) Output fluid pressure when input fluid pressure are a
                                                          follows.
                                                          Standard value:
                                                                           5.15-5.65 MPa (732-804 ps
              input pressure                                                     [at 8.2 MPa (1,163 psi))
                                       14uoo55                             4.65-5.15 MPa (661-732 ps
                                                                                [at 7.7 MPa (1,095 psi)]
                                                      (3) Output pressure difference between left and rig1
                                                          brake lines
                                                          Limit: 0.4 MPa (57 psi)
                                                  4. If the measured pressures are not within the permissibl
                                                      ranges, replace the proportioning valve.


                                                  BLEEDING                                                           No5FY
                                                   When the master cylinder is empty of brake fluid, bleed i
                                                   from the master cylinder by proceeding with procedures (
                                                   thru (6). (Because this master cylinder is not equipped with
                                                   check valve.)
                                                   When brake fluid remains in the master cylinder, proceed wi
                                                   step (6).
                                                  (1) Disconnect the brake tube from the master cylinder.
                                                  (2) Two persqs should conduct the air bleeding, one perso
                                                      slowly depressing the brake pedal and holding the ped:
                                                      depressed.                           i        .I. - .~ j, Z':. ~. jl
                                                                                              .[ j, `I2;:`,.Y .`.:
                                                                                              ./ `:" `: , . 8,
                                                                                        , . .;$y; i ; :: 1 . . i;, d
                            BRAKES                      - Service Adjustment Procedures                               5-51
                                                           (3) In this condition, the other person should use a finger to
                                                               close the outlet part of the, master cylinder, and then the
                                                               first person should release the brake pedal.
                                                           (4) Steps (2) and (3) should be repeated three or four times,
                                                               and then the master cylinder should be filled with brake
                                                               fluid to the specified level.
                                                               NOTE
                                                               The air is completely bled from the master cylinder by steps
                                                               (1) to (4).
                                                           (5) Connect the brake tube to the master cylinder.
                                                           (6) Start the engine; then, in the sequence shown in the
                                                               illustration, bleed the air from each wheel cylinder.
                                                              Specified brake fluid: MOPAR Brake Fluid/
                                                                                       Conforming to DOT3 or DOT4
                                                              Caution
                                                              1. Use the specified brake fluid. Avoid using a mixture
                                                                  of the specified brake fluid and other fluid.
                                                             2. If brake fluid is exposed to the air, it will absorb
                                                                  moisture; as water is absorbed from the atmos-
                                                                  phere, the boiling point of the brake fluid will
   2                         3                                   decrease and the braking performance will be
                                 14A0454
                                                                 seriously impaired. For this reason, use a hermeti-
                                                                 cally sealed 1 lit. (1.06 qt.) or 0.5 lit. (0.52 qt.) brake
                                                                 fluid container.
                                                             3. Firmly close the cap of the brake fluid container
                                                                 after use.
                                                             4. For vehicles with the anti-lock braking system, be
                                                                 sure to install a filter to the master cylinder
                                                                 reservoir tank when supplying brake fluid.

                                                          ORDINARY AIR-BLEEDING PROCEDURES
                                                          (1) Depress the brake pedal several times until resistance is
                                                              felt; then, with the pedal depressed, loosen the bleeder
                                                              screw l/3 to l/2 turn and then tighten it before the fluid
                                                              pressure is all gone.
When new            When worn                             (2) Release the brake pedal. Repeat this procedure until there
                                                              are no more air bubbles in the brake fluid.
                                                          FRONT DISC BRAKE PAD CHECK AND
                                                          REPLACEMENT                                                 N05FOAF

                                                          NOTE
                                                          The brake pads have wear indicators that contact the brake
                                                          disc when the brake pad thickness becomes 2 mm (.08 in.),
                                                          and emit a squealing sound to warn the driver.
                                 14G0017
                                                          1. Check brake pad thickness through caliper body check
                                                             port.
                                           1                 Standard value: 10.0 mm (.39 in.)
                                                             Limit: 2.0 mm (.08 in.)
                                                             Caution
                                                             1. When the limit is exceeded, replace the pads at
                                                                 both sides, and also the brake pads for the wheels
                                                                 on the opposite side at the same time.
                                                             2. If there is a significant difference .in the thick-
                                                                 nesses of the pads
                                                                 check the sliding co
       14 LO169                     WsTm~
                                       3
                                  ..".W% ,Y :                    sleeve and guide pin
                  -~ . _.
                  I         ;;                  :i `.
5-52
                      2. Remove guide pin. Lift caliper assembly and retain wit
                         wires.
                         Caution
                         Do not wipe off the special grease that is on the guid
                         pin or allow it to contaminate the guide pin.




                      3.   Remove the following parts from caliper support.
                           0 Pad &wear indicator assembly
                           0 Pad assembly
                           @ Clip
                           @I Inner shim
                           @ Outer shim

                      1 -piston type                   P-piston type



           14LO291




                                        14N0284



                      4. With the pad removed, use a spring balance to measure
                         the rotation sliding resistance of the hub in the forward di
                         rection.
                         NOTE
                         Tighten the nuts in order to secure the disc to the hub.
                      5. Securely attach the pad clip to the caliper support.



       \    14AO400


                      6. Clean piston and insert into cylinder with tool.
                      7. Be careful that the piston boot does not become caughl
                         when lowering the caliper assembly and install the guidt
                          pin.
                                                                    Apply repair kit grease to both sides of the inner shims.
                           Pad assembly                             Specified grease: Brake grease SAE 5310,
                                                                                       NLGI No.1
g u i    luter shim                                                 Caution
                                                                    1. Make sure that the friction surfaces of pads and
         nner shim                                                     brake discs and free of grease and other contami-
                                                                       nants.
                                                                    2. The grease should never squeeze out from around
                                                                       the shim.
                       43l           a        14FOO97



                                                               9.   Check the disc brake drag force as follows.
                                                                    (1) Start the engine, and after depressing the brake pedal
                                                                        hard two or three times, stop the engine.
                                                                    (2) Turn brake disc forward 10 tie&.
                                                                    (3) Use a spring balance to meastiie fh-e rotation Sliding re-
                                                                        sistance of the hub in the forward direction.




                                              14A0399



                                                                   (4) Calculate the drag torque of the disc brake (difference
                                                                       between measured values in 3 and 4).
                                                                       Standard value: 70 N (15.4 Ibs.) or less
                                                               10. If the disc brake drag force exceeds tlie standard value,
                                                                  disassemble piston and clean the piston. Check for corro-
                                                                  sion or worn piston seal, and check the sliding condition of
                                                                  the lock pin and guide pin.




isur    FRONT DISC BRAKE ROTOR INSPECTION
dd      CAUTION
        When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within the
        allowable service values in order to maintain normal brake operation.
        Before re-finishing or re-processing the brake disc surface, the following conditions should be checked.

                      Inspection items                                                      Remarks
        Scratches, rust, saturated lining materials     l   If the vehicle is not driven for a certain period, the sections of the discs
        and wear                                            that are not in contact with lining will become rusty, causing noise and
                                                            shuddering.
                                                        l   If grooves resulting from excessive disc wear and scratches are not re-
                                                            moved prior to installing a new pad assembly, there will momentarily
lght                                                        be inappropriate contact between the disc and the lining (pad).
clidc
        Run-out or drift                                Excessive run-out or drift of the discs will increase the pedal depression
                                                        resistance due to piston knock-back.
        Ehange in thickness (parallelism)               If the thickness of the disc changes, this will cause pedal pulsation, shud-
                                                        dering and surging.
           RUN-OUT CHECK
           1.   Remove the caliper support; then raise the caliper ass
                bly upward and secure by using wire.
           2.   Inspect the disc surface for grooves, cracks, and rust. Cl
                the disc throughly and remove all rust.




           3. Place a dial gauge approximately 5 mm (.2 in.) from thi
               outer circumference of the brake disc, and measure tt$
               run-out of the disc.                                  _i
                Limit: 0.07 mm (.0028 in.)                                   -2
                NOTE
                Tighten the nuts in order to secure the disc to the hub..       `l;
                                                                                  i,!
                                                                             . ,;




          RUN-OUT CORRECTION                                            NOSFTAB


          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.
                (1) Before removing the brake disc, chalk both sides of the
                     wheel stud on the side at which run-out is greatest.



14A0391



                (2) Remove the brake disc, and then place a dial gauge 2s
                    shown in the illustration; then move the hub in the axial
                    direction and measure the play.
                   Limit: 0.2 mm (.008 in.)
                   If the play is equivalent to or exceeds the limit, disas-
                   semble the hub knuckle and check each part.




             (3) If the play does not exceed the limit specification, and
                  then check the run-out of the brake disc once again.
                  Mount the brake disc on the position dislocated from
                  the chalk mark.
          2. If the run-out cannot be corrected by changing the phase
             of the brake disc, replace the disc or turn rotor with on the
             car type brake lathe (MAD DL-8700PF or equivalent).'


                                                                               .,
                            ",   .   .   .   -..
                                 THl,~,KNES~i;CHECK                                                                              , .`i
                                .- _d                                                       --.-.--.
                                 1: `Using $.$i,crometer, measure disc thickness at eight posi- I
                                     tions;:`.@`proximately 45" apart and 10 mm (.39 in.) in f,r$,m;,
                                  i theouter'edge of the disc.                                   `I
                                      + Brbke.Disc Thickness
                                          ..!+@Card value: 24 mm (94 in.)
                                i ,,~~~:-~4!-~~~t;:22.4 mm (.882 in.)
                                  : ,aThrckness Variation (At least 8 position)
                                        _ The `*difference between any thickness. measure-
                                           ments should not be more than 0.015 mm (.0006:
                                                             ,,                               7.9'-,... .J .
                                           in.).
    : : :..   t   ,:...!b   : .A12fi: If~thei;di& is beyond t& Jim@ for thickneT.%, `ie'mdv
                                           .,.
                                                      one. If thickness variation exceeds the
                                                   ace the:disc"or turn. rotor with on the.
                                                    (MAD, DL-87OOPF or equivalent).       -




                                                                                                                 ;               !
                                   `_,     _:.j :: I                                                                                i
                                              ..;, `I                                                                ., . .:L"" cn:


                                 t&;&C BRAKE PAD CHECK AND

                            ,., 1. ~:"ch&ii -brake pad thickness through, caliper body$%ck.~
                            :?;{&:?p., d ii,; ,i..i                                  . . /I..: "j. -.`-`: (~~#&q
                                  ; I&+# ~4:                      ` " :'                                          ,,I,. y;.
                                                                                                                     :
                                    /~~Tl$$$`~&b m m (08 cn.)
                                     .
                                          C&&ion"                                                       ,- `-, -,       ,t"`?
                                                                                                                        I.
                                                                                                                        iii,,,




                                     --. +-When the limit is exceeded, replace the pad&at-:
                                                 ,--both&sides, and also the brake pads for the wheels
                                                   onth-e opposite side at the same time.
                                         &.Jf,tb@re is a signjfjcant difference in the thicknesses
                                                   of the pads on the left and right sides, check the
                                   A .J. :%!idi,~g!~ondStion.of the piston, `lock p,in sleeve ;a,$$
                                         _,f * ,:,midq py I sleye.
                                                    .' i.                                                          . . ii'.
                                 2. Loosen the parking brake cable (from the vehicle interior),
                                         an$dis.co-nnect the parking brake end installed to the rear
                                         I I                 I I
                                         orake,. assemory.
                                 3. f5$_move.,lock pin. Lift caliper assembly and retain `&h,
                                         yps.. ,
                                         (y&on,
                                    D O r$$v$e off. the stiecial!.grease. that' is on the &ck
                                    pi" cii'@!fow it to..c,ontait;inate tl;


                                                                            16
                                                                            /



           64-86
           46-62




                                                              w"!                   14N0284




                   64-86
                   46-62




                                                                                    i         14AO537




                                                                   Brake caliper kit
      Caliper assembly disassembly steps
          M 1. Guide pin
          l + 2. Lock pin
          l + 3. Bushing
               4. Caliper support (Pad, clip, shim)
          l + 5. Guide pin boot
          MI 6. Lock pin boot
      **       7. Boot ring
      4*       8. Piston boot
      l *** 9. Piston
      +I) l * IO. Piston seal
              11. Brake hose
          l + 12. Caliper body

      Pad assembly disassembly steps
         e+ 1. Guide pin
         l + 2. Lock pin                                                                                 Seal and boots
                                                                   Pad repair kit                        repair kit
         *+ 3. Bushing
              4. Caliper support (Pad, clip, shim)
             13. Pad and wear indicator assembly
             14. Pad assembly                                                                                     10        6
         ++ 15. Outer shim
             16. Clip
         e+ 17. Inner shim
      NOTE
      (1) Reverse the disassembly procedures to reassemble.    1
                                                                                                             5'    8    7
      (2) ~~ : Refer to "Service Points of Disassembly".
      (3) l + : Refer to "Service Points of Reassembly".                                                               14AD54(
      (4) m : Non-reusable parts                                                                  -.I.
                                    SERVICE POINTS OF DISASSEMBLY                            NOSLFAJ

                                    When disassembling the front disc brakes, disassemble both
                                    sides (left and right) as a set.
                                    7. REMOVAL OF BOOT RING
                                       Remove boot ring with flat tip (-1 screwdriver.




    Boot. ring   14KO54   1460054
L
                                    8. REMOVAL OF PISTON BOOT/g. PISTON
                                       Protect caliper body with cloth. Blow compressed air
                                       through brake hose to remove piston boot and piston.
                                       Caution
                                       Blow compressed air gently.




                                    10. REMOVAL OF PISTON S



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