BRAKE SYSTEM

1993 Mitsubishi Diamante

1993 BRAKES
Mitsubishi - Brake System

Diamante

INTRODUCTION
This article contains information on repair and service of
basic hydraulic brake system. If vehicle is equipped with anti-lock
brakes, also see ANTI-LOCK BRAKE SYSTEM article in the BRAKES section.

DESCRIPTION
Brake system consists of a master cylinder, vacuum power
brake unit, proportioning valve and self-adjusting assembly. Diamante
is equipped with front disc brakes and either rear disc or drum
brakes. Parking brake assembly activates rear brakes.

BLEEDING BRAKE SYSTEM

BLEEDING PROCEDURES
Bleed brakes whenever hydraulic lines are opened or pedal
feels spongy. Bleed system in appropriate sequence. See BRAKE LINE
BLEEDING SEQUENCE table. Bleed system with engine running.

BRAKE LINE BLEEDING SEQUENCE TABLE

Application Sequence

Diamante .................................. RR, LF, LR, RF

ADJUSTMENTS

BRAKE PEDAL HEIGHT & FREE PLAY

1) Separate connector from stoplight switch, and loosen lock
nut. Position switch so it does not contact brake pedal arm. Adjust
brake pedal height by rotating master cylinder push rod (yoke, if
equipped) until distance from top of brake pedal, with pedal released,
is within specification. See BRAKE PEDAL SPECIFICATIONS table.
2) DO NOT depress push rod. Tighten lock nut, and ensure
brake pedal height is within specification. Start engine to evacuate
brake booster chamber. Stop engine, and apply brake several times to
remove vacuum from brake booster.
3) Using hand pressure, depress brake pedal to measure free
play before resistance is felt. Free play distance is .12-.31" (3.0-7.
9 mm). If distance is not within specification, bleed system and check
for misadjusted brakes.

BRAKE PEDAL SPECIFICATIONS TABLE

Pedal Height
Application In. (mm)

Diamante ............................... 6.9-7.1 (175-180)



MASTER CYLINDER PUSH ROD

Check and adjust clearance between back of master cylinder
piston and master cylinder push rod. See Fig. 1. See PUSH ROD
CLEARANCE SPECIFICATIONS table. After adjusting push rod clearance,
adjust pedal height and bleed brake system.

Fig. 1: Adjusting Push Rod Clearance

Courtesy of Mitsubishi Motor Sales of America.

PUSH ROD CLEARANCE SPECIFICATIONS TABLE

Application In. (mm)

Diamante ........................... .026-.033 (0.66-0.84)

PARKING/EMERGENCY BRAKE
NOTE: Adjust service brake before adjusting parking brake.

Start engine, and apply brake pedal. Pull parking brake lever
with a force of 44-45 lbs. (20.0-20.4 kg). Parking brake lever should
move up 3-5 notches. If adjustment is necessary, turn adjusting nut
located under console or at end of cable rod. See Fig. 2.

Fig. 2: Adjusting Parking/Emergency Brake (Typical)

Courtesy of Mitsubishi Motor Sales of America.

REAR BRAKE SHOES

To facilitate adjustment of brake shoe clearance, set
adjustment assembly so brake shoes lightly contact brake drum. With
brake drum installed, fully release parking brake and depress brake
pedal several times to center shoes and adjust brake shoe clearance.
Adjust parking brake, and check pedal travel. Rotate brake drum to
verify free movement.

STOPLIGHT SWITCH
Loosen lock nut, and adjust switch-to-pedal arm clearance to
.02-.04" (0.5-1.0 mm). Tighten lock nut. DO NOT depress master
cylinder push rod during stoplight switch adjustment.

TESTING

POWER BRAKE UNIT

Check Valve Inspection
 Remove vacuum hose from power brake unit. Using a vacuum
pump, ensure airflow is in direction of intake manifold only.

System Check
1) Run engine for 2 minutes. Shut engine off, and depress
brake pedal several times with normal pressure. If pedal height
gradually becomes higher with successive applications, power brake
unit is okay. If pedal height remains steady, power brake unit is
faulty.
2) With engine stopped, depress brake pedal repeatedly until
pedal height no longer falls. Hold brake pedal down, and start engine.
If pedal moves downward slightly, power brake unit is okay. If pedal
height does not change, power brake unit is faulty.
3) With engine running, press and hold brake pedal. Shut off
engine. Hold brake pedal for 30 seconds. Brake pedal height should not
change. If pedal height falls, power brake unit is faulty.

PROPORTIONING VALVE (NON-LOAD-SENSING)

Pressure Test
1) Connect pressure gauges to input and output ports of
proportioning valve. See Fig. 3. Bleed brake system. See BLEEDING
BRAKE SYSTEM.
2) Slowly depress brake pedal. Check readings on pressure
gauges. Ensure output pressure begins to drop relative to input
pressure at specified pressure range (split point). See SPLIT POINT
PRESSURE SPECIFICATIONS table.
3) Continue depressing brake pedal, and check readings on
pressure gauges. See PROPORTIONING VALVE PRESSURE SPECIFICATIONS
table. If fluid pressures or split point are not within specification,
replace proportioning valve.

Fig. 3: Connecting Pressure Gauges To Proportioning Valve (Typical)

Courtesy of Mitsubishi Motor Sales of America.

SPLIT POINT PRESSURE SPECIFICATIONS TABLE

 
Application psi (kg/cm )

Diamante ................................. 533-604 (38-43)

PROPORTIONING VALVE PRESSURE SPECIFICATIONS TABLE





























































Inlet Pressure 
(1) Outlet Pressure
Application psi (kg/cm ) psi (kg/cm )

Diamante .............. 1138 (80) ...... 676-747 (48-53)


(1) - Maximum side-to-side pressure differential
is 57 psi (4kg/cm ).

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS

CAUTION: DO NOT remove or contaminate special grease coating on lock
pins.

Removal
1) Raise and support vehicle. Remove front wheel(s). Remove
lower lock pin or sleeve bolt. See Fig. 4. Lift caliper body upward.

Fig. 4: Exploded View Of Front Disc Brake Assembly (Typical

Single Piston)
Courtesy of Mitsubishi Motor Sales of America.

2) Support caliper aside. Remove shim(s), shim holder (if

equipped), anti-squeak shim and pad assembly from support mounting.
Remove pad clips.

Installation
If installing new pads, compress piston to bottom of bore.
Install retaining clips, pad assembly, shim(s), shim holder (if
equipped) and anti-squeak shim onto support mounting. Start engine.
Depress brake pedal several times to expand caliper piston. Check
brake fluid level.

FRONT BRAKE CALIPER

Removal
1) Raise and support vehicle. Remove front wheel(s). Separate
rubber flexhose from hydraulic line at brake hose mount, located on
strut housing. Secure end of hydraulic line to prevent spillage of
brake fluid.
2) Remove hose clip from brake hose mount. Disconnect brake
hose from caliper. Remove upper and lower caliper-to-steering knuckle
bolts. Lift caliper body upward. Remove caliper.

Installation
To install, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS. Bleed brake system. See
BLEEDING BRAKE SYSTEM.

FRONT BRAKE ROTOR

Removal & Installation
Raise vehicle, and remove wheel(s). Remove caliper, and slide
rotor off hub. To install, reverse removal procedure.

PARKING BRAKE SHOES

Removal
1) Raise and support vehicle. Remove rear wheel(s).
Disconnect rear speed sensor. Remove rear disc brake calipers and
rotors. Remove hub cap, flange nut and washer. See Fig. 5.
2) Remove rear hub/bearing assembly. Remove adjusting wheel
spring. Remove shoe hold-down cup, spring and pin. Note how shoe-to-
anchor spring is installed, and then remove adjuster and shoe-to-
anchor spring. Remove strut and return spring. Remove clip and shoe
and lining assembly.

Fig. 5: Exploded View Of Parking Brake Assembly (FWD)

Courtesy of Mitsubishi Motor Sales of America.

CAUTION: Shoe-to-anchor spring must be installed correctly for

 proper functioning of parking brakes.

Installation
1) To install, reverse removal procedure. When installing
shoe-to-anchor spring, ensure spring is installed correctly. When
installing adjuster, install left adjuster with adjusting bolt facing
vehicle front and right adjuster with adjusting bolt facing vehicle
rear.
2) After tightening flange nut, align spindle indentation and
crimp nut. After installing speed sensor, ensure gap between rotor
teeth and sensor pole piece is .008-.028" (0.20-0.71 mm).

REAR DISC BRAKE PADS

NOTE: Replace inner and outer pads at same time.

Removal
Raise and support vehicle. Remove rear wheel(s), and
disconnect parking brake cable. Remove lower lock pin bolt. Lift
caliper body upward. Using a wire, support caliper from underbody.
Remove inner shim(s), anti-squeak shim and pad assembly from support
mounting. Remove pad clips.

Installation
Rotate piston to align notches in piston projection on back
of pads (if equipped). Install retaining clips, pad assembly, inner
shim(s) and anti-squeak shim onto support mounting. Lower caliper
body, and install lock pin.

REAR BRAKE CALIPER

Removal
Raise and support vehicle. Remove rear wheel(s). Disconnect
parking brake cable connection. Disconnect brake hose from caliper.
Secure end of hydraulic line to prevent spillage of brake fluid.
Remove upper and lower caliper mounting bolts. Lift caliper body
upward. Remove caliper.

Installation
To install, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS. Bleed brake system. See
BLEEDING BRAKE SYSTEM.

REAR BRAKE ROTOR

Removal & Installation
Raise and support vehicle. Remove rear caliper and rotor. To
install, reverse removal procedure.

WHEEL CYLINDERS
Removal & Installation
Raise and support vehicle. Remove rear brake drum and shoes.
See REAR BRAKE DRUM & SHOES. Remove wheel cylinder and seal assembly.
To install, reverse removal procedure. Bleed brakes. See BLEEDING
BRAKE SYSTEM.

MASTER CYLINDER
Removal
Drain brake fluid from master cylinder. Remove sensor
connector (if equipped). Disconnect brakelines from master cylinder,
and install plugs to prevent brake fluid spillage. Remove master
cylinder from booster unit, and separate reservoirs from housing (if
necessary).

Installation
To install, reverse removal procedure. Before installation,
check and adjust clearance between back of master cylinder piston and
power brake push rod. See MASTER CYLINDER PUSH ROD under ADJUSTMENTS.
After installation, adjust pedal height. See BRAKE PEDAL HEIGHT & FREE
PLAY under ADJUSTMENTS. Bleed brake system.

POWER BRAKE UNIT

Removal
Remove brake master cylinder. See MASTER CYLINDER. Disconnect
vacuum hose from power brake unit. Disconnect clevis pin attaching
brake pedal to power brake unit push rod. From inside vehicle, remove
4 nuts attaching power brake unit to firewall. Remove power brake
unit.

Installation
To install, reverse removal procedure. Install master
cylinder. Bleed brake system if necessary.

POWER BRAKE UNIT CHECK VALVE

NOTE: To test check valve before removal, stop engine and apply
service brake to ensure air flows toward intake manifold
only.

Removal & Installation

Remove vacuum hose with check valve from power brake unit.
Coat end(s) of check valve with sealant before installation. Install
valve with arrow (identification mark) pointing toward intake
manifold. Install and secure hose clamp(s).

WHEEL BEARING NUT SPECIFICATIONS TABLE

Application Ft. Lbs. (N.m)

Diamante ....................................... 166 (225)

OVERHAUL
NOTE: For exploded views of front disc brake calipers,
see Figs. 4 & 6.
For exploded views of rear brake calipers, see Fig. 8
For exploded view of master cylinder, see Fig. 7.
Fig. 6: Exploded View Of Front Disc Brake Assembly (Typical Single
Piston)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 7: Exploded View Of Front Disc Brake Caliper (Typical Dual
Piston)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 8: Exploded View Of Master Cylinder (Typical)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 9: Exploded View Of Rear Disc Brake Caliper Assembly

Courtesy of Mitsubishi Motor Sales of America.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE




























































Application Ft. Lbs. (N.m)

Caliper Guide Or Lock Pin Bolt

Front ......................................... 54 (73)
Rear .......................................... 20 (27)
Guide Pin Bolt ............................. 29-36 (39-49)
Lock Pin Bolt .............................. 23-30 (31-41)
Caliper Mounting Bolts
Front .................................... 58-72 (79-98)
Rear ..................................... 36-43 (49-58)
Front Wheel Bearing Nut
FWD .................................. 144-188 (195-254)
Locking or Full-Time Hub Bolt .............. 36-43 (49-60)
Rear Wheel Bearing Nut ......................... 166 (225)
Rotor-To-Hub Bolts Or Nuts ................. 36-43 (49-60)
Wheel Lug Nut ............................. 65-80 (88-108)

INCH Lbs. (N.m)

Master Cylinder-To-Power Brake Unit Nut .......... 84 (10)

DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS TABLE




























































Application In. (mm)

Disc Diameter
Front ....................................... 10.9 (277)
Rear ........................................ 10.5 (267)
Lateral Runout ................................ .003 (.08)
Parallelism .......................................... (1)
Original Thickness
Front ......................................... .94 (24)
Rear ....................................... .71 (18.0)
Master Cylinder Diameter ................... 1.000 (25.40)
Minimum Refinish Thickness
Front ....................................... .88 (22.4)
Rear ........................................ .65 (16.5)
Discard Thickness ................................... (1)

(1) - Information is not available from manufacturer.