MITSUBISHI GALANT 1989 Service Repair Manual

35-80SERVICE BRAKES - Brake Pedal
INSPECTION
M35GcAJ
l Check the bushing for wear.
l Check the brake pedal for bend or twisting.
l Check the brake pedal return spring for damage.
STOP LIGHT SWITCH
14L0142
No continuity Continuity
mm (.16

in.)
14L0171
control system>
3
Connect a circuit tester to the stop light switch, and check
whether or not there is continuity when the plunger of the stop light switch is pushed in and when it is released.
The stop light switch is in good condition if there is no continuity when the plunger is pushed in to a depth of within 4mm
(.16 in.) from the outer case edge surface, and if there is
continuity when it is released.
For vehicles with the auto-cruise control system, the check for
continuity should be made at connectors “a” and “b” of the
stop light switch.
/*-Br\ake pedal return springI14AO234
SERVICE POINTS OF INSTALLATIONM25GOBF
7. INSTALLATION OF RETURN SPRING
Install the return spring in the direction indicated in the
illustration.
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SERVICE BRAKES - Master Cylinder35-81
MASTER CYLINDER
REMOVAL AND
INSTALLATION
Pre-removal OperationeDrainIng of Brake FluidPost-installation Operationl Supplying Brake Fluid*Bleeding (Refer to P.3557.)@Adjustment of Brake Pedal(Refer to P.35-53.)
8-l: Nm6-9
ft.lbs. M351A-
Removal steps
I. Fluid level sensor connector
2. Brake tubes
3. Reservoir hoses.
4. Master cylinder
5. Reservoir
6. Bracket
l 4Adjustment of clearance between brakebooster push rod and primary piston
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35-82SERVICE BRAKES - Master Cylinder
14110065
14w573
SERVICE POINTS OF INSTALLATIONM35lDAOa
. ADJUSTMENT OF CLEARANCE BETWEEN BRAKE
BOOSTER PUSH ROD AND PRIMARY PISTON
Adjust the clearance (A) between the brake booster pushrod and primary piston as follows:
(1) Measure the dimension (B) between the .master
cylinder
end face and piston.
NOTE
To obtain (B), first take measurement with a square placed
on the master cylinder end face. Then, subtract the
thickness of the square to arrive at
(B).
(2) Obtain the dimension (C) between the brake booster mounting surface on the master cylinder and the end face.
(3) Measure the dimension (D) between the master cylinder mounting surface on brake booster and the push rod end.
NOTE
To obtain (D), first take measurement with a square placed
on the brake booster. Then, subtract the thickness of the
square to arrive at
(D).
(4) Using the measured values obtained in (1) through (3).
obtain the clearance (A) between the brake booster push
rod and primary piston.
Standard value: [A (A= B-C-D)] 9 inch brake booster
0.8-1.0 mm (.031-.039
in.)
7+8 inch brake booster
0.5-0.7 mm (.020-.028
in.)
8+9 inch brake booster 0.6-O-8
mm (.024-.031
in.)
(5) If the clearance is not within the standard value range, adjust by changing the push rod length by turning the
adjustable end of the push rod.
Caution
Improper clearance may cause excessive brake drag.
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SERVICE BRAKES - Master Cvlinder35-83
DISASSEMBLY AND REASSEMBLY
L1.5-3.0
Nm
1-2 ft.lbs./
-11m
-?
1‘5. 1.5-3.0
Nm
l-2 ft.lbs.
10
(up to 1990.5 models)>
IBrake master cylinder kit
3rake fluid: Conforming to DOT3 or DOT4
14Ao!575
Disassembly steps
1. Reservoir cap assembly
2. Diaphragm
3. Reservoir cap
4. Filter ;: FELte fluid level sensor
7. Reservoir
I)+8.Nipples9.Reservoir seals4*10.Piston stopper bolt
11.Gasketl *12. Piston stopper ringI 3. Primary piston assemblya*14. Secondary piston assembly15. Master cylinder body
CautionDo not disassemble the primary and secondary pistonassembly.
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35-84SERVICE BRAKES - Master Cylinder
14AO237
i
SERVICE POINTS OF DISASSEMBLYhl25HBAAa
10. DISASSEMBLY OF PISTON STOPPER BOLT
Remove the piston stopper bolt, while depressing the
piston.
12. DISASSEMBLY OF PISTON STOPPER RING
Remove the piston stopper ring, while
depressing the
piston.
14. DISASSEMBLY OF SECONDARY PISTON ASSEMBLY
NOTE
If it is hard to remove the secondary piston from the
cylinder, gradually apply compressed air from the outlet
port on the secondary end of the master cylinder.
INSPECTION
M2.5HDAC
l Check the inner surface of master cylinder body for rust or
pitting.
l Check the primary and secondary pistons for rust, scoring,
wear, damage or wear.
l Check the diaphragm for cracks and wear.
SERVICE POINTS OF REASSEMBLY
MJSHCAK
8. INSTALLATION OF NIPPLE Be sure that the primary side nipple and secondary
side
nipple are not mistaken one for the other when installed.
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SERVICE BRAKES - Brake Booster35-85
BRAKE BOOSTER
REMOVAL AND INSTALLATION
MJSJA--
Pre-removal Operation
12@Draining of Brake Fluid
-!3\
Cl989 models> 6-9 ft.lbs. A 1
Post-installation Operation6upplying Brake Fulid*Bleeding (Refer to P.35-57.)l Adjustment of Brake Pedal(Refer to P.35-53.)15-18

Nrh ‘7II-13 ftlbs. :From
1990 models>
15-18 Nm 7II-13 ft.lbs.
Removal steps
1. Brake fluid level sensor connector
2. Brake tube
3. Master cylinder, hose, reservoir assembly +*
l +4. Vacuum hose5. Check valve
+* l +6. Vacuum hose with check valve7. Fitting
8. Cotter pin
9. Washer 10.
Clevis pi
n
11. Sealer
c*
12. Proportioning valve installation bolt
13. Brake tube (front left) installation bolt
14. Brake booster
14A05360
.a
QI1 II ;‘,:
4%14u0050
14Y626
Sealant: 3M ATD Part No.8663or equivalent
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35-86SERVICE BRAKES - Brake Booster
SERVICE POINTS OF REMOVALM35JBAK
4. REMOVAL OF VACUUM HOSETo remove the vacuum hose from the brake booster, pull itstraight upward.
Caution
Prying off the vacuum hose could damage the check
valve installed in the brake booster.
Vacuum hose
14AO394
Vacuum hose
mm (in.)
14A0395
Vacuum hose
i4043 mm (1.57-1.69 in.)
I I__/
Chec/k valve ’ Clip
14LOZ15
6. REMOVAL OF VACUUM HOSE WITH CHECK VALVE
NOTE
Since the check valve is fit to the vacuum hose, replace the
check valve as an assembly unit together with the vacuum
hose if the check valve is defective.
14. REMOVAL OF BRAKE BOOSTER
Caution
Be careful not to damage the body or bend the
air-conditioner’s high-pressure hose.
SERVICE POINTS OF INSTALLATIONM35JDBB
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.
4. CONNECTION OF VACUUM HOSE (1) The vacuum hose at the brake booster should be connected for the distance shown in the illustration,
and should be secured by
the.hose clip so that there is
no contact with the check valve.
(2) The vacuum hose at the engine should be securel
y
connected until it contacts the hexagonal edge of the
fitting, and then should be secured by the hose clip.
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SERVICE BRAKES - Brake Line35-87
BRAKE LINE
REMOVAL AND INSTALLATION
Vehicles without A.B.S.
78
I
Pre-removal Operationl Draining of Brake Fluid
Post-installation Operationasupplying Brake Fluid
l Bleeding (Refer to P.35-57.)
17-26 12-19
+e l 41. Front brake hose2. Strut brake tube
2
i :16.
17.
:: l 4 :;:23. Front brake tube
(R.H.)Front brake tube (L.H.)Brake tube (A)
Brake tube(B)
Main brake tube (R.H.)Main brake tube (L.H.)Proportioning valveRear brake hose
Rear brake tube

23
23
I
2225-35 19-26
d
12-19 ft.lbs.
17-26 NmAWD
Nm ftlbs.
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35-88SERVICE BRAKES - Brake Line
WD-A.B.S.
Pre-removal Operationl Draining of Brake Fluidl Bleeding (Refer to P.35-57.)
,wfl@ -19 \ ,&$ 6li?-‘,V \\\ \-iW/
l a 1. Front brake hose2. Strut brake tube
3. Front brake tube
(R.H.14. Front brake tube (L.H.)5. Brake tube (A)6. Brake tube (B)9. Front brake hose (L.H.110. Front brake hose (R.H.111. Brake tube12. Connector (2 way type)w+ 13. Rear brake tube (R.H.)l * 14. Rear brake tube (L.H.)+a 15. Hydraulic unit 16. Main brake tube (R.H.)17. Main brake tube (L.H.)18. Connector (6 way type)19. Proportioning valve20. Rear brake tube (R.H.)21. Rear brake tube (L.H.)l * 22. Rear brake hose
23. Rear brake tube
24. Delay valve
25. Brake tube bracket26. Brake hose bracket
6
25-35 Nm19-25 ft.lbs.
JA- 2414AO620
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SERVICE BRAKES - Brake Line
MID-A.B.S.

Pre-removal Operation eDraining
of Brake Fluid17
l Bleeding (Refer to P.35-57.)
4*+4 1. Front brake hose2. Strut brake tube3. Front brake tube (R H.)4. Front brake tube (L.H.)5. Brake tube (A)6. Brake tube (B)11. Brake tube12. Connector (2 way type)l 4 13. Rear brake tube (R.H.)l * 14. Rear brake tube (L.H.)l a 15. Hydraulic unit16. Mam brake tube (R.H.)17. Main brake tube (L.H.)4*19. Proportioning valve+**4 22. Rear brake hose23. Rear brake tube
Connection part ofhydraulic unit
6
5 14AO693
25-35 Nm
,19- 25 ft.lbs.
25-35 Nm
17-26
F’-12- 19f...,.
L---
IT-26/Nm12- 19 ft.ibs.14A0694
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