sensor MITSUBISHI ECLIPSE 1991 User Guide

BRAKES
SERVICE AND PARKING
CONTENTS
ANTI-LOCK BRAKING SYSTEM
TROUBLESHOOTING
......................................
9
BRAKEBOOSTER...........................................
60BRAKE LINE
....................................................
62
BRAKE PEDAL.................................................
53ELECTRONIC CONTROL UNIT
ABS>...............................87
- FRONT DISC BRAKE......................................
65G-SENSOR
..............................86
HYDRAULIC UNIT
ABS>...............................
77
MASTERCYLINDER
........................................56
PARKING BRAKES
..........................................88
REAR
DISC BRAKE.........................................70SERVICE ADJUSTMENT PROCEDURES..
.....41
ABSPowerRelayCheck.............................52
Bleeding........................................................
45Brake Booster Operating
Inspection...........43
BrakeFluidLevelSensor Check.................
42Brake Pedal Inspection and Adjustment
.....41Check Valve
OperationCheck.....................
44
FlatBattery
Remedy....................................52
FrontBrakeDiscRun-out Check................47Front Brake Disc Run-out Correction
..........48Front Brake
Disc Thickness Check
.............47Front Disc Brake Pad Check and
Replacement.................................................46
Parking
BrakeLever Stroke Check.............42
Parking
BrakeSwitchCheck.......................43
Proportioning
ValveFunctionTest...............44Rear Brake
DiscRun-out Check.................50Rear Brake Disc Run-out Correction
...........50Rear Brake
Disc Thickness
Check..............49Rear Disc Brake Pad Check and
Replacement.................................................48Observation of Wheel Speed Sensor
Output Voltage Variations
with
ABS>..................................51
SPECIAL TOOLS.............................................6
SPECIFICATIONS.............................................
2General Specifications
..................................2
Lubricants
......................................................5
Service
Specifications...................................4
Torque
Specifications...................................4
TROUBLESHOOTING......................................7WHEEL SPEED SENSOR
...............................80
_ 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 duringservice operations. Breathing dust which contains asbestos fibers can cause serious bodily harm.

5-2BRAKES - SDecifications
SPECIFICATIONS
GENERAL SPECIFICATIONS

NO!iCA-- -
ItemsItems
NNVehicles without ABS Vehicles without ABSVehicles with ABS Vehicles with ABS
BIBI
PlPl
Fr Frlaster cylinder
TypeTandem typeTandem type
(with level sensor)(with level sensor)
I.D.mm (in.) 22.2 (7/8)23.8 (‘%6)rake booster
TypeVacuum typeVacuum 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.)]5.5 [at 220 N (48 Ibs.)]
.oportioning valve
TypeDual typeDual type
Split point
kPa (psi) 4,200 (597)
4,200 (597)
Decompression ratio
0.3
0.3ont brakes
TypeFloating caliper, single-piston,ventilated disc (M-R44V)Floating caliper, single-piston,ventilated disc (M-R44V)Disc O.D.
mm (in.) 256 (10.1)256 (10.1)
Disc thickness
mm (in.) 24
(.94)24 (.94)Pad thicknessmm (in.) 16.0 (63)
16.0
(.63)Wheel cylinder I.D.
mm (in.) 53.9 (2
l/8)53.9 (2%)
Clearance adjustmentAutomaticAutomatic
3ar disc brakes
TypeFloating caliper, single-piston,Floating caliper, single-piston,ventilated disc (AD30P)ventilated disc (AD30P)Disc
O.D.mm (in.) 265 (10.4)265 (10.4)
Disc thickness
mm (in.)
10 (39)10 i.39)Pad thickness
mm (in.) 14.5 (57)
14.5 (57)
Wheel cylinder I.D.
mm (in.) 30.1
(1 3/16)30.1 (1 346)Clearance adjustment
AutomaticAutomatic
)tor teeth
Front wheel side
-47Rear wheel side
-47
leed sensor-Magnet coil type
rking brakes
TypeMechanical brake actingMechanical brake acting
on rear wheelson rear wheels
Brake lever type
Lever type
Lever type
Cable arrangement
V-type
V-type
Rc Rc
SP SP
Pa Pa

-.
BRAKES - Specifications5-3
ItemsFWDAWDMaster cylinder
TypeTandem type
(with level sensor)Tandem type
(with level sensor)
I.D.mm (in.) 23.8 (‘%a)25.4 (1)Brake booster
TypeVacuum type
Vacuum type
Effective dia. of power cylinder
mm (in.) Front side: 180 (7.0)
Front side: 180 (7.0)
Rear side: 205 (8.0)
Rear side: 205 (8.0)
Boosting ratio [Brake pedal depressing force]
5.5 [at 220
N (48 Ibs.)]5.5 [at 220 N (48 Ibs.)]Proportioning valve
TypeDual typeDual type
Split point
kPa (psi) 4,200 (597)
3,700 (526)
Decompression ratio
0.30.3Front brakes
TypeFloating caliper, single-piston,Floating caliper, single-piston,ventilated disc (M-R44V)ventilated disc (M-R46V)Disc O.D.
mm (in.) 256 (10.1)256 (10.1)
Disc thickness
mm (in.) 24
(.94)24 (.94)Pad thickness
mm (in.) 16.0
(.63)16.0 (.63)Wheel cylinder I.D.
mm (in.)
53.9 (2 ‘16)60.3 (23%3)Clearance adjustment
AutomaticAutomatic
Rear disc brakes
TypeFloating 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 thicknessmm (in.) 10
(.39)10 f.39)Pad thicknessmm (in.) 14.5
(.57)14.5 (.57)Wheel cylinder I.D.mm (in.) 30.1 (1
3/16)34.9 (1 3h)Clearance adjustmentAutomaticAutomatic
qotor teeth*
Front wheel side
4747Rear wheel side
4747
speed sensor*Magnet coil typeMagnet coil type‘arking brakes
TypeMechanical brake actingMechanical brake acting
on rear wheelson rear wheels
Brake lever typeLever typeLever type
Cable arrangementV-typeV-type
NOTEThe *symbol indicates vehicles with ABS.

5-4BRAKES - Specifications
SERVICE SPECIFICATIONS
NO5CB-
ItemsSpecifications
Standard value
Brake pedal heightmm (in.) 176-181 (6.9-7.1)
Brake pedal free playmm (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)
3.45-3.95 (491-561)
Output pressure [input pressure]
5.15-5.65 (732-804) [8.2 (1 ,I 63)l
4.65-5.15 (661-732) (7.7 (1,095)1Disc brake dragging force at hub bolt
N (Ibs.) [Nm (ftlbs.)]70 (15) or less [4 (3) or less1Booster push rod to master cylinder piston clearance
mm (in.)
9 inch brake booster
0.8-l .O (.031-,039)
7
+8 inch brake booster0.5-0.7 (.020-.028)
Speed sensor’s internal resistance
kQ 0.8-l .2*
Clearance between the speed pole piece and
the toothed rotor
mm (in.)
0.3-0.9 (.012-,035)”Limit
Left/right proportioning valve out pressure difference
MPa (psi)0.4 (57)
Disc brake pad thickness
mm (in.) 2.0 (08)
Front disc thickness
mm (in.) 22.4 (882)
Rear disc thickness
mm (in.) 8.4
(.331)Disc
runoutmm (in.) 0.08 (.0031)Hub end play
mm (in.) 0.008
(.00031)
NOTE
*: Vehicles with ABS
TORQUE SPECIFICATIONS
ItemsNmft.lbs.
Pedal support bracket installation bolts
8-12
6-9
Pedal support bracket installation nut
IO-157-11
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
IO-157-l 1‘Clutch master cylinder installation nuts
10-157-11
Clutch pedal installation nut
20-2514-18
Lever assembly (A) installation nut
20-2514-18
Lever assembly
(B) installation nut20-2514-18

BRAKES - Specifications5-5Items
Nmftlbs.Master cylinder to brake booster
8-126-9
Piston stopper bolt
1.5-3.0l-2Nipple installation screw
1.5-3.0l-2Brake booster installation nuts
11-178-12
Fitting15-1811-13
Flared brake line nuts
13-179-12
Brake hose bracket installation bolts
17-2612-19
Front disc brake assembly installation bolts
80-10058-72
Lock pin (front)
64-8646-62
Guide pin (front)
64-8646-62
Bleeder screw
7-95-7
Wheel bearing nut
200-260144-188
Dust shield to axle beam
9-14
7-10Rear disc brake assembly installation bolts
50-6036-43
Drive shaft to companion flange
55-6539-47
companion flange to rear axle shaft160-200116-159
Brake hose to caliper body (rear)
25-35
18-25Lock
pin (rear)
22-3216-23
Guide pin (rear)
22-32
16-23Spindle lever to parking brake lever
40-5529-40
3ear speed sensor installation bolt
9-147-10Speed sensor bracket installation bolt
9-14
7-10
3otor to front hub
7-115-8
3otor to rear hub
9-147-10
LUBRICANTSNO5CP-
ItemsBrake fluidSpecified lubricant
MOPAR Brake
Fluid/Conforming to
DOT3Brake pedal bushing inner surface
Clevis pin and washer
Parking brake lever sliding parts
Bushing inner surfaceMOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent

BRAKES - Anti-lock Braking System Troubleshooting5-14
./
No.Trouble conditionMajor causesRemedyAfter the ignition key is turned to the
l Break in harness for ECU warningCheck, usinflow
“ON” position, it blinks once and then
light drive circuit
chart D. (Re er to9illuminates when it is turned to the
l Malfunction of ECUP.5-18.)“START” position. When the key is
4returned to the “ON” position, the light
blinks again. (Blinking with the ignition
key in the “ON” position is synchronized
with operation noise of the valve relay.)
ABSwarninglighto:-
Ignition
keyACC. LCi+-
14*0593CONTINUED FROM PREVIOUS PAGE
Does the ABS warning light illuminate
when starting to drive the car?
Yes~ Trouble with the motor re-lay, solenoid valve [due toL Check, following trouble
source check charts E-l -self test when driving above
E-6.6 km/h (4 mph)] or malfunc-
NoIs there one-sided braking, insufficient
braking force or malfunction of ABS
operation?
YesTrouble condition
Major causes
One-sided braking
Insufficient braking forcel Mechanical lock of HU solenoid valve
l Hydraulic line in HU is clogged.
Decline in ABS function
(Wheels easily lock when there is sud-
den braking.)
ABS sometimes functions even when
there is no sudden braking. (ABS opera-
tion vibration is transmitted.)
1 tion of wheel speed sensor 1
NoNormall Malfunction in HU solenoid valve op-
erationl Hydraulic line in HU is clogged.
l Insufficient wheel speed sensor out-
put voltage (sensor malfunction, too
large a gap between sensor rotor,
missing rotor teeth or temporarily
broken wire in sensor harness)
l Malfunction of ABS ECU
RemedyCheck HU operation and, if
necessary, replace HU.
If HU is normal, check
structural parts for normal
braking. (Refer to
P.5-7.)Check wheel speed sensor
(Refer to
P.5-82.) and, ifnecessary,replace sensor,
adjust gap or replace rotor.
If tests indicate that there are
no mechanical or electrical
failures, replace the ECU.

BRAKES - Anti-lock Braking System Troubleshooting549
E-lInput abnormality of wheel speed sensorI-[Explanation][Hint]The ABS ECU detects breaks in the wheel speed
In addition to a broken wire/short circuit in the wheelsensor wire. The warning light lights up if the wheel
speed sensor, also check whether the sensor gap isspeed sensor signal is not input (or short circuited)
too large, rotor teeth are missing, sensor harness
or if its output is low when starting to drive or while
wire is temporarily broken, or sensor harness and
driving.body connector are not properly inserted.
I IE-2Output abnormality of wheel speed sensorI
[Explanation]The warning light lights up when there is an
abnormality (other than broken wire or short circuit)
in the wheel speed sensor output signal while
driving.
[Hint]
The following can be considered as the cause of thewheel speed sensor output abnormality.
l Distortion of rotor, teeth missing
lLow frequency noise interference when sensor
harness wire is broken
l Noise interference in sensor signall When the sensor output signal is below the
standard value or when amplitude modulation is
over the standard value, using an oscilloscope tomeasure the wave shape of the wheel speed
sensor output signal is very effective.
l Loose wheel bearing
l Temporarily broken wire in sensor harness
l Sensor harness and body connector are not
properly inserted.
NOTE
If contact is poor, check the sensor cable by bendingand lightly stretching it.
SPEED SENSOR
FRONTREAR(LEFT SIDE) (RIGHT SIDE) (LEFT SIDE) (RIGHT SIDE)
Km
I-.IIGND
III24I
FRONT SIDE
I
ABSECU
REVERSE SIDE
SELF-DIAGNOSIS
CHECK CONNECTOR
14AO601

5-20 _BRAKES - Anti-lock Braking System TroubleshootingCheck flow connected with wheel speed
sensorNOTE:When checking with an oscilloscope, first measure voltage
variations in the wheel speed sensor output. (Refer to
P.5-51.)
Is the resistance value of the wheelNo c Malfunction of wheel speedReplace wheel speed
speed sensor part, which the displayedsensor
sensor.trouble code indicates, normal?
Standard value:
0.8-l .2 kQ
I YesIs the resistance value with the ECU
No c Harness wire for wheel -Repair harness.connector normal?
speed
sensorcircuit is
Ibroken.
II1
1
Is the standard value for the
gap between the wheel
speed sensor and rotor,
which the output trouble
code indicates, within the
range?
Standard value:
h
%Z~Pf!;!~~~e~no missing or damaged
teeth?
1 Yes
1Check the output of each
wheel speed sensor with an
oscilloscope, including the
waveform. (Refer to
measurement ofwheel
speed sensor output voltage
variations on
P.5-51 .I Is the
output voltage for each
wheel speed sensor over
the standard value and is thewave form normal?
Yes
Canthe abnormality beNoRepair harness.foundeven if the sensorIharness and connection be-
tween sensor harness and
body harness are bent and
estretched?
Yes

5-26BRAKES - Anti-lock Braking System Troubleshooting
No.Trouble conditionMajor causesRemedyAfter the ignition key is turned to the
l Break in harness for ECU warningCheck, using flow“ON” position, it blinks once and thenlight drive circuitchart D. (Refer to P.5-illuminates when it is turned to the
l Malfunction of ECU33.)“START” position. When the key is
returned to the “ON” position, the light
4blinks again. (Blinking with the ignition
key in the “ON” position is synchronized
with operation noise of the valve relay.)
ABSwarning
light
0:~
Ignition
keyACC. iv-
14A0593CONTINUED FROM
PREVIOU? PAGE
I ,
Does the ABS warning light illuminateYes* Check, following trouble
when starting to drive the car?L Trouble with the motor re-lay, solenoid valve [due to
self test when driving above
6 km/h (4 mph)] or malfunc-source check charts E-l -E-7.
Notion of wheel speed sensor
Normal
YesTrouble condition
Major causes
RemedyOne-sided brakingl Mechanical lock of HU solenoid valveCheck HU operation and, if
Insufficient braking forcel Hydraulic line in HU is clogged.
necessary, replace HU.
If HU is normal, check
Decline in ABS functionl Malfunction in HU solenoid valve op- structural parts for normal
(Wheels easily lock when there is
sud-
erationbraking. (Refer to P.5-2.)den braking.)l Hydraulic line in HU is clogged.
ABS sometimes functions even whenl Insufficient wheel speed sensor
out-Check wheel speed sensor
there is no sudden braking. (ABS opera-put voltage (sensor malfunction, too (Refer to P.5-82.) and, if
tion vibration is transmitted.)
large a gap between sensor rotor, necessary, replace sensor,
missing rotor teeth or temporarily adjust gap or replace rotor.
broken wire in sensor harness)
If tests indicate that there are
l Malfunction of ABS ECU
no mechanical or electrical
failures, replace the ECU.

5-34BRAKES -Anti-lock Braking System Troubleshooting
E-lInput abnormality of wheel speed sensorI.
[Explanation][Hint]s”rThe ABS ECU detects breaks in the wheel speed
In addition to a broken wire/short circuit in the wheel--sensor wire. The warning light lights up if the wheel
speed sensor, also check whether the sensor gap isspeed sensor signal RL is not input (or shorttoo large, rotor teeth are missing, sensor- harness
circuited) or if its output is low when starting to drivewire is temporarily broken, or sensor harness and
or while driving.body connector are not properly inserted.
E-2Output abnormality of wheel speed sensor
[Explanation]The warning light lights up when there is an
abnormality (other than broken wire or short circuit)
in the wheel speed sensor output signal while
driving.
[Hinti
The following can be considered as the cause of thewheel speed sensor output abnormality.
l Distortion of rotor, teeth missing
lLow frequency noise interference when sensor
harness wire is broken
l Noise interference
in sensor signall When the sensor output signal is below the
standard value or when amplitude modulation is
over the standard value, using an oscilloscope tomeasure the wave shape of the wheel speed
sensor output signal is very effective.
l Loose wheel bearing
l Temporarily broken wire in sensor harness
l Sensor harness and body connector are not
properly inserted.
NOTE
If contact is poor, check the sensor cable by bendingand lightly stretching it.
SPEED SENSOR
FRONTREARP%(LEFT SIDE)
(RIGHT SIDE)(LEFT SIDE)(RIGHT SIDE),’
1
FRONT SIDE
SELF-DIAGNOSISCHECK CONNECTOR14AO608