Mitsubishi MOTORS Laser 1993 User manual

Partial BACKUP
Service Manual
.i’
GROUP INDEX
NOSAl
LASER
TALON
1993
Volume-l
Engine, Chassis
&Body
FOREWORD
This Service Manual has been prepared with the
latest service information available at the time of
publication. It is subdivided into various group
categories and each section contains diagnosis,
disassembly, repair, and installation procedures
along with complete specifications and tightening
references. Use of this manual will aid in properly
performing any servicrng necessary to maintain or
restore the high levels of performance and reliability
designed into these outstanding vehicles.
This BACKUP DSM manual IS to be used ONLY as a BACKUP. Please DO NOT REDISTRIBUTE
WHOLE SECTIONS. This BACKUP was sold to you under the fact that you do indeed OWN
a GENUINE DSM MANUAL. It CANNOT BE considered a REPLACEMENT (Unless your orlglnal
manual was lost or destroyed.)
Please See README.N or README.HTML for additional Information.
Thank you. G~mm~emymanual@hotma~l.com
CHRYSLER
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.
Introduction and
Master Troubleshooting
.-I
. . . . . . . . . . . . . . . . . . i
Lubrication and Maintenance . . . . . . . .
E
l
Front Suspension
. . . . . . . . . . . . . . . . . . . . . . . . . . . ..A..
t
i
Rear Axle
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~...
Service
’ Brakes- Parking
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~.....
Cooling
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~.....~~..
Engine
. . . . . . . . . . . . . . . . . . . . . . . . ..*..............................
Intake and Exhaust
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System
‘,,, .*
. . . . . . . . . . . . . . . . . . ..*........................
4
Propeller Shaft
..,.....,....,.................m.......
Rear Suspension
.*........s........................
Manual
Steering-po,er
.h
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..$\
Manual
i
Transaxle-Automatic
:
. . . . . , . . . . . . . . . . . . . . r+:,
Wheels and Tires
_. .;,:.;*&i
. . .. . . . . . . . . . . . . . . . . . . .
.&......
j 8 .A$
: >
Body
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*...**...
Heater & Air CondjtJoning ..,.. ,.,. . . ...’
Emission
Control
Systems
1
. . . . . . . . . . . . . .
0 1992 Mitsubishi)
L-.” :
Printed in U.S.A.

BRAKES
SERVICE AND PARKING
CONTENTS
ANTI-LOCK BRAKING SYSTEM
TROUBLESHOOTING .........................
9
BRAKE BOOSTER
..............................
71
BRAKE LINE
.................................... 73
BRAKE PEDAL ..................................
63
ELECTRONIC CONTROL UNIT
<VEHICLES WITH ABS>
...................
102
FRONT DISC BRAKE .......................... 76
G-SENSOR <AWD-ABS>
...................
101
HYDRAULIC UNIT
<VEHICLES WITH ABS>
...................
92
MASTER CYLINDER ........................... 67
PARKING BRAKES .............................
103
REAR DISC BRAKE ............................
65
SERVICE ADJUSTMENT PROCEDURES ..a 47
ABS Power Relay Check ....................
62
Bleeding
.......................................
50
Brake Booster Operating Inspection .......
49
Brake Fluid Level Sensor Check ...........
48
Brake Pedal Inspection and Adjustment ... 47
Check Valve Operation Check ..............
49
Flat Battery Remedy .........................
62
Front Disc Brake Pad Check and
Replacement
..................................
51
Front Disc Brake Rotor Inspection .........
53
Inspection of Hydraulic Unit .................
59
Measurement of Wheel Speed Sensor
Output Voltage ................................
57
Parking Brake Lever Stroke Check .........
48
Parking Brake Switch Check ................
49
Proportioning Valve Function Test ..........
50
Rear Brake Disc Run-out Check ............
57
Rear Brake Disc Run-out Correction .......
57
Rear Brake Disc Thickness Check ..........
56
Rear Disc Brake Pad Check and
Replacement
..................................
55
Run-out Check ................................
54
Run-out Correction ...........................
54
Thickness Check
..............................
55
SPECIAL TOOLS ...............................
6
SPECIFICATIONS ...............................
2
General Specifications ........................
2
Lubricants
.....................................
5
Service Specifications
........................
4
Torque Specifications .................. .:.
... 4
TROUBLESHOOTING ..........................
7
WHEEL SPEED SENSOR
<VEHICLES WITH ABS>
.................... 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
<Non-Turbo>
Items
Master cylinder
J-w
I.D. ’ ,, ’ ,;!
mm (in.)
Brake booster
Tvw
Effective dia. of power cylinder mm (in.)
Boosting ratio [Brake pedal depressing force] 5.0 [at 220 N (48 Ibs.)l
Proportioning valve
Type
Split point
Decompression ratio
kPa (psi)
Front brakes
Type
Disc O.D.
Disc thickness
Pad thickness
Wheel cylinder I.D.
Clearance adjustment
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Rear drsc brakes
Type
Disc O.D.
Disc thickness
Pad thickness
Wheel cylinder I.D.
Clearance adjustment
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Rotor teeth
Front wheel side
Rear wheel side
Speed sensor
-
Parking brakes’
Tvw
Brake lever type
Cable arrangement
Vehicles without ABS Vehicles with ABS
Tandem type
(with level sensor)
22.2 (78)
Tandem type
(with level sensor)
23.8 P5/1d
Vacuum type
230 (9.0)
Vacuum type
Front side: 180 (7.0)
Rear side: 205 (8.0)
5.5 [at 220 N (48 Ibs.)l
Dual type
4,200 (597)
0.3
Dual type
4,200 (597)
3.3
Floating caliper, single-piston,
ventilated disc (M-R44V)
256 (10.1)
24 i.94)
16.0 (.63)
53.9 (2 l/8)
Automatic
Floating caliper, single-piston,
ventilated disc (M-R44V)
256 (10.1)
24 i.94)
16.0 (.63)
53.9 (2 %)
Automatic
Floating caliper, single-piston,
ventilated disc (AD30P)
265 (10.43
10 (39)
14.5 (.57)
30.1 (1 Yl6)
Automatic
Floating caliper, single-piston,
ventilated. disc (AD30P)
265 (10.4)
10 l.39)
14.5 (.57)
30.1 (1 3/6)
Automatic
-
-
47
47
vlagnet coil type
Mechanical brake acting
Vlechanical brake acting
on rear wheels
3n rear wheels
Lever type -ever type
V-type
V-type

! y+
fr
. .
‘i
BR&gES - Specifications
513
-
<Turbo>
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
Front brakes
,,’ I
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)
276 (10.9)
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 (in.)
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
Standard value
Brake pedal height mm (in.)
Brake pedal free play mm (in.)
Brake pedal to floorboard clearance mm (in.)
Parking brake lever stroke.
Output pressure proportioning valve
MPa (psi)
Split point
<FWD>
<AWD>
Output pressure [input pressure]
<FWD>
<AWD>
DISC brake dragging force at hub bolt
N (Ibs.) [Nm (ft.lbs.)l
Booster push rod to master cylinder piston clearance
mm (in.)
9 inch brake booster
7 +8 inch brake booster
Speed sensor’s internal resistance k&
Clearance between the speed pole piece and
the toothed rotor mm (in.)
Lrmtt
Left/right proportioning valve out pressure difference
MPa (psi)
DISC brake pad thrckness mm (in.)
Front drsc thickness
mm (in.)
Rear dtsc thrckness mm (in.)
DISC runout mm (in.)
Front
Rear
Hub end play
mm (In.)
NOTE
l : Vehicles with ABS
TORQUE SPECIFICATIONS
Specifications
176-181 (6.9-7.1)
3-8 (.l-.3)
80 (3.1) or more
5-7 notches
3.95-4.45 (561-633)
3.45-3.95 (491-561).
5.15-5.65 (732-804) i8.2 (1,163)1
4.65-5.15 (661-732j.17.7 (1,095))
70 (15) or less I4 (3) or less]
0.8-1.0 (.031-,039)
0.5-0.7 (.020-.028)
0.8-1.2"
0.3-0.9 (.012-,035)"
6
0.4 (57)
2.0 (.08)
22.4 (.882)
8.4 (.331)
0.07 (.0028)
0.08 l.0031)
0.2 (.008)
Items
Pedal support bracket installation bolts
Pedal support bracket installation nut
Pedal rod to pedal support bracket
Pedal rod to clutch pedal bracket
Clutch pedal bracket installation bolt
Turn-over spring mounting bolt
Stop lamp switch mounting nut
Clutch master cylinder installation nuts
Clutch pedal installation nut
Lever assembly (A) installation nut
Lever assembly (B) installation nut
I
:: ::I .:‘i j ,:
~~ -__
j
.
-, .‘- ‘+‘+gg&p.~j:
;.;1--?.+.k
Nm
8-12
IO-15
17-26
17-26
8-12
17-26
10-15
10-15
20-25
20-25
20-25
T
ft.lbs.
6-9
7-11
12-19
12-19.
6-9
12-19
7-11
7-11
14-18
14-18

-
BRAKES - Specifications
Items
Master cylinder to brake booster
Piston stopper bolt
Nipple installation screw
Brake booster installation nuts
Fitting
Flared brake line nuts
Brake hose bracket installation bolts
Front disc brake assembly installation bolts
Lock pin (front)
Guide pin (front)
Bleeder screw
Wheel bearing nut
Dust shield to axle beam
Rear disc brake assembly installation bolts
Drive shaft to companion flange
Companion flange to rear axle shaft
Brake hose to caliper body (rear)
Lock pin (rear)
Guide pin (rear)
Spindle lever to parking brake lever
Rear speed sensor installation bolt
Speed sensor bracket installation bolt
Rotor to front hub
Rotor to rear hub
Nm
8-12
1.5-3.0
1.5-3.0
11-17
15-18
13-17
17-26
80-100
64-86
64-86
7-9
200-260
9-14
50-60
55-65
160-200
25-35
22-32
22-32
40-55
9-14
9-14
7-l 1
9-14
ft.lbs.
6-9
l-2
l-2
8-12
11-13
9-12
12-19
58-72
46-62
46-62
5-7
144-188 ”
7-10
36-43
39-47
116-159
18-25
16-23
16-23
29-40
7-10
7-10
5-a
7-10
LUBRICANTS
No!xD-
Items
Brake fluid
Specified lubricant
MOPAR Brake Fluid/
Conforming to DOT3 or DOT4
Brake pedal bushing inner surface
Clevls pin and washer
Parking brake lever sliding parts
Bushing inner surface
MOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent

5-50
BRAKES - Service Adjustment Proi?edur&
Brake
booster
side
Spring ’
/
Valve
Pressure
gauge Pressure
PropGtioning valve
14LO181
input pressure
14uoo55
2. Check the operation of the check valve by using a vacuul
pump.
Vacuum pump connection Accept/reject criteria
Connection at the brake A negative pressure (vacuum) is
booster side @
created and held.
Connection at the -intake
manifold side @
A negative pressure (vacuum) is not
created.
Caution
If the check valve is defective, replace it as an assemb!
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
measured values are within the allowable range.
(1) Output pressure begins to drop relative to inpl
pressure (split point).
Standard value:
<PWD>
3.95-4.45 MPa (561-633 psi
<AWD>
3.45-3.95 MPa (491-561 ps
(2) Output fluid pressure when input fluid pressure are a
follows.
Standard value:
<PWD>
5.15-5.65 MPa (732-804 ps
[at 8.2 MPa (1,163 psi))
<AWD>
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,
‘I
- .~ j, Z’:. ~. jl
2;:‘,.
Y .‘.:
./ ‘:” ‘: ,, . 8,
, . .;$y; ii; :: 1 . . i;, d

BRAKES - Service Adjustment Procedures
5-51
2
3
14A0454
When new When worn
14G0017
1
14 LO169
check the sliding co
WsTm~
3
..“.W% ,Y :
sleeve and guide pin
-~
I .
_. ;;
:i ‘.
(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
decrease and the braking performance will be
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.
(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.
1. Check brake pad thickness through caliper body check
port.
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

5-52
14LO291
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
14N0284
P-piston type
\
14AO400
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.
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.

gui
isur
dd
lght
clidc
Pad assembly
luter shim
nner shim
43l a
14FOO97
14A0399
Apply repair kit grease to both sides of the inner shims.
Specified grease: Brake grease SAE 5310,
NLGI No.1
Caution
1. Make sure that the friction surfaces of pads and
brake discs and free of grease and other contami-
nants.
2. The grease should never squeeze out from around
the shim.
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
(2) Turn brake disc forward 10 tie&.
engine.
(3) Use a spring balance to meastiie fh-e rotation Sliding re-
sistance of the hub in the forward direction.
(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.
FRONT DISC BRAKE ROTOR INSPECTION
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
and wear
lIf the vehicle is not driven for a certain period, the sections of the discs
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
be inappropriate contact between the disc and the lining
(pad).
Run-out or drift
Ehange in thickness (parallelism)
Excessive run-out or drift of the discs will increase the pedal depression
resistance due to piston knock-back.
If the thickness of the disc changes, this will cause pedal pulsation, shud-
dering and surging.

14A0391
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.
(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.
2.
(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.
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).’
.,
“, . . . -..

: : :.. t
,:...!b
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$,m;,
i theouter’edge of the disc.
‘I
+ Brbke.Disc Thickness
..!+@Card value: 24 mm (94 in.)
i
,,~~~:-~4!-~~~t;:22.4 mm (.882 in.)
: ,aThrckness Variation (At least 8 position)
_ The ‘*difference between any thickness. measure-
ments should not be more than 0.015 mm (.0006:
in.).
,,
7.9’-,... .J .
: .A12fi: If~thei;di& is beyond t& Jim@ for thickneT.%, ‘ie’mdv
.,.
one. If thickness variation exceeds the
ace the:disc”or turn. rotor with on the.
(MAD, DL-87OOPF or equivalent).
-
;
_:.j ::
!
‘_, I
i
..;, ‘I
t&;&C BRAKE PAD CHECK AND
., . .:L”” cn:
,., 1. ~:“ch&ii -brake pad thickness through, caliper body$%ck.~
:?;{&:?p., d ii,; ,i..i
; I&+# ~4: ‘ ” :’
/I..: “j.
. .
~~Tl$$$‘~&b mm (08 cn.)
-.‘-‘: (~~#&q
,,I,.
:: y;.
/.
C&&ion”
,- ‘-, -, iii,,, I.“‘?
,t
--. +-When the limit is exceeded, replace the pad&at-:
,--both&sides, and also the brake pads for the wheels
onth-e opposite side at the same time.
&.Jf,tb@re is a signjfjcant difference in the thicknesses
of the pads on the left and right sides, check the
A .J. :%!idi,~g!~ondStion.of the piston, ‘lock p,in sleeve ;a,$$
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,
DO r$$v$e off. the stiecial!.grease. that’ is on the &ck
pi” cii’@!fow it to..c,ontait;inate tl;<jock pin.
j
4. Remove. the- following parts from caliper support.
,,
f :.
,3-
:: ” ,, ” -
_.__ _, .“_,.
/
‘7
,
.< :$, ~
. . 6

BRAKES -
Brake Booster
Vacuum hose
14AO394
14u0050
Semidrvina sealant
141626
Vacuum hose
I
Chevk valve
mm (in.)
14AO395
SERVICE PO@JTS OF REMOVAL
Nocm
6. REM&AL OF VACUUM HOSE WITH CHECK VA+
NOTE
Since the check valve is fit to the vacuum hose, replace th
check valve as an assembly unit together with the vacuur
hose if the check valve is defective.
SERVICE POINTS OF INSTALLATION
10. APPLDJTION OF GREASE TO CLEVIS PIN/g. WASHEI
After applying the specified grease to the clevis pin an
washer, insert the cievis pin and bend the cotter pin tightly
Grease: MOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent
7. APPLICATION OF SEALANT TO FITTING
When installing the vacuum hose fitting, apply semi-cfryin!
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.

N0sJa
4LVI
:e the
cuu<
‘=JD4\
;HER
and
!htly.
Wg
CK
3a
nd
3ly
he
P.
BRAKES - Brake Line
BRAKE LINE
REMOVAL AND INSTALLATION
NOSKA--
1. Front brake hose
2. Strut brake tube
3. Front brake tube (R.H.)
4. Front brake tube (L.H.)
5. Brake tube (A)
6. Brake tube (B)
11. Main brake tube (R.H.)
12. Main brake tube (L.H.)
13. Proportioning valve
14. Rear brake hose
15. Rear axle brake tube
._-
Ill
n
25-35 Nm
I 111-7G f-t Ihr
:lared brake line nuts
13-17 Nm
9-12 ftlbs.
vehicles without ABS Pre-removal Operation
*Draining of Brake Fluid
1425-35 Nm
18-25 ft.lbs.
17-26 Nm
12-19 ft.lbs.
+ 16
16. Bracket

a-.
i
.-J
5-74
BRAKES - Brake tine
Vehicles with ABS
Pre-removal Operation
*Draining of Brake Fluid
,“i
Post-installation Operation
A
@Supplying Brake Fluid
1
l Bleeding (Refer to P.5-50.)
-
Connecting part of
14AO572
I. Front brake hose
2. Strut brake tube
- -
25-35 Nm
Ibs.
12-19 ft.lbs.
Flared brake line ns
13-17 Nm
9-12 ftlbs.
15. Bracket
3. f-ront brake tube (R.H.)
4. Front brake tube (L.H.)
5. Brake tube (A)
6. Brake tube (B)
7. Rear brake tube (R.H.)
8. Rear brake tube (L.H.)
I)+ 9. Hydraulic unit
10. Main brake tube (R.H.)
11. Main brake tube (L.H.)
::
12. Proportioning valve
13. Rear brake hose
14. Rear axle brake tube
14AO585 ;

SERVICE POINTS OF REMOVAL
14w593
Brake hose woo07
s 4
6
1. REMOVAL OF FRONT BRAKE HOSE/13. REAR BRAKE
HOSE
(1) Holding the lock nut on the brake hose side, loosen the
flared brake line nut.
(2) Pull off the brake hose clip and remove the brake hose
from the bracket.
12. REMOVAL OF PROPORTIONING VALVE
Do not disassemble the proportioning valve because its
performance depends on the set load of the spring.
INSPECTION
No6KcM
l Check the brake tubes for cracks, crimps and corrosion.
l Check the brake hoses for cracks, damade and leakage.
l Check the flared brake line nuts for damage and leakage.
SERVICE POINTS OF INSTALLATION
NOSKOAJ
9. CONNECTION OF TUBE TO HYDRAULIC UNIT
Connect the tubes to the hydraulic ‘unit as shown in the
illustration.
i 2
14AO568
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)

! -;-
596
FRONT DISC BRAKE
Bf?Al$ES - Front.:,Diw Brake
REMOVAL AND INSTALLATION
N=U.
3U- IL l-LIDS.
Y-i A
14N0140
14A0420
Pre-removal Operation
eDraining of Brake Fluid
Removal steps
+e l 1. Connection for the brake hose and the
brake tube
NOTE
l + 2. Front brake assembly
(1) Reverse the removal procedures to reinstall.
3. Brake disc
(2) ++ : Refer to “Service Points of Removal”.
(3) l + : Refer to “Service Points of Installation”.
SERVICE POINTS OF REMOVAL
No5LsAF
1. DISCONNECTION OF BRAKE HOSE
Holding the nut on the brake hose side. Loosen the flared
brake line nut.
INSPECTION
NNiLCID
INSPECTION OF BRAKE DISC
l Check disc for wear. (Refer to P.5-55, Thickness Check.)
l Check disc for runout. (Refer to P.5-54, Run-out Check.)
l Check disc for damage.

-
3AF
:d
SERVICE POINTS OF INSTALLATION
NOBLDAG
2. INSTILLATION OF FRONT BRAKE ASSEMBLY
14AO399
Measure the disc brake drag force after installation of the
brake assembly by the following procedure.
(1) With the brake assembly removed, use a spring bal-
ance to measure the rotation sliding resistance of the
hub in the forward direction.
NOTE
Tighten 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.
(3) Start the engine, and after depressing the brake pedal
hard two or three times, stop the engine.
(4) Turn brake disc forward 10 times.
(5) Use a spring balance to measure the rotation sliding re-
sistance of the hub in the forward direction.
(6) Calculate the drag torque of the disc brake (difference
between measured values in 5 and 1).
Standard value: 70 N (15.4 Ibs.) or less
(7) If the disc brake drag force exceeds the standard value,
disassemble piston and’clean the piston. Check for cor-
rosion or worn piston seal.

-.
t
5-78
BRAKES - Front Disc Bra&.
i
DISASSEMBLY AND REASSEMBLY
NO51
< 1 -piston type>
64-86
46-62
64-86
46-62
16
/
w”! 14N0284
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
*+ 3. Bushing
4. Caliper support (Pad, clip, shim)
13. Pad and wear indicator assembly
14. Pad assembly
++ 15. Outer shim
16. Clip
e+ 17. Inner shim
NOTE
(1) Reverse the disassembly procedures to reassemble.
(2) ~~ : Refer to “Service Points of Disassembly”.
(3) l + : Refer to “Service Points of Reassembly”.
(4) m : Non-reusable parts
1
i
14AO537
Brake caliper kit
Pad repair kit Seal and boots
repair kit
10 6
5’ 8 7
-.I.
14AD54(