Mitsubishi MOTORS Laser 1993 Service Manual
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Mitsubishi MOTORS Laser 1993 Service Manual

Mitsubishi MOTORS Laser 1993 Service Manual

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Summary of Contents for Mitsubishi MOTORS Laser 1993

  • Page 2 Service Manual Introduction and Master Troubleshooting ....i Lubrication and Maintenance ..Front Suspension ......A . . Rear Axle .

  • Page 3: Table Of Contents

    SERVICE AND PARKING CONTENTS ANTI-LOCK BRAKING SYSTEM Front Disc Brake Pad Check and Replacement ........TROUBLESHOOTING ......Front Disc Brake Rotor Inspection ..BRAKE BOOSTER ......Inspection of Hydraulic Unit ....BRAKE LINE ........Measurement of Wheel Speed Sensor Output Voltage ........ BRAKE PEDAL ........

  • Page 4: Brake Booster

    BRAKES - Specifications GENERAL SPECIFICATIONS <Non-Turbo> Vehicles without ABS Vehicles with ABS Items Master cylinder Tandem type Tandem type (with level sensor) (with level sensor) I.D. mm (in.) 22.2 (78) 23.8 P5/1d Brake booster Vacuum type Vacuum type Effective dia. of power cylinder mm (in.) Front side: 180 (7.0) 230 (9.0)
  • Page 5 <Turbo> Items Master cylinder Tandem type Tandem type (with level sensor) (with level sensor) mm (in.) 25.4 (1) 25.4 (1) I.D. Brake booster 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]...
  • Page 6 BRAKES - Specifications SERVICE SPECIFICATIONS Specifications Items Standard value mm (in.) Brake pedal height 3 - 8 (.l-.3) Brake pedal free play mm (in.) mm (in.) 80 (3.1) or more Brake pedal to floorboard clearance 5-7 notches Parking brake lever stroke. Output pressure proportioning valve Split point 3.95-4.45 (561-633)
  • Page 7 BRAKES - Specifications Master cylinder to brake booster 8 - 1 2 6 - 9 Piston stopper bolt installation screw Brake booster installation nuts Fitting Brake hose bracket installation bolts 17-26 12-19 58-72 Lock pin (front) 64-86 4 6 - 6 2 Guide pin (front) 64-86 46-62...
  • Page 8 BRAKES 2. Check the operation of the check valve by using a vacuul Brake Vacuum pump connection Accept/reject criteria booster side at the brake A negative pressure (vacuum) Connection Spring booster side @ created and held. Connection at the -intake A negative pressure (vacuum) is not Valve created.

  • Page 9: Service Adjustment Procedures

    BRAKES (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.
  • Page 10 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. Remove the following parts from caliper support. P-piston type 1 -piston type 4.

  • Page 11: Front Disc Brake Rotor Inspection

    Apply repair kit grease to both sides of the inner shims. Pad assembly Specified grease: Brake grease SAE 5310, g u i Caution 1. Make sure that the friction surfaces of pads and brake discs and free of grease and other contami- nants.

  • Page 12: Run-Out Check

    RUN-OUT CHECK 1. Remove the caliper support; then raise the caliper ass 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.
  • Page 13 , .‘i 45” apart and 10 mm (.39 in.) in f,r$,m;, ments should not be more than 0.015 mm (.0006: in.). one. If thickness variation exceeds the ace the:disc”or turn. rotor with on the. (MAD, DL-87OOPF or equivalent). 1. ~:“ch&ii -brake pad thickness through, caliper body$%ck.~ of the pads on the left and right sides, check the .
  • Page 14 Brake Booster BRAKES - SERVICE PO@JTS OF REMOVAL Vacuum hose 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.
  • Page 15 BRAKES INSTALLATION Pre-removal Operation *Draining of Brake Fluid 13-17 Nm 9-12 ftlbs. 25-35 Nm 25-35 Nm 18-25 ft.lbs. 17-26 Nm 12-19 ft.lbs. 1. Front brake hose 2. Strut brake tube 3. Front brake tube (R.H.) 4. Front brake tube (L.H.) 5.
  • Page 16 BRAKES - Brake tine Vehicles with ABS Pre-removal Operation Post-installation Operation *Draining of Brake Fluid @Supplying Brake Fluid Bleeding (Refer to P.5-50.) brake line ns Flared 13-17 Nm 9-12 ftlbs. 25-35 Nm Connecting part of 12-19 ft.lbs. 3. f-ront brake tube (R.H.) 4.
  • Page 17 SERVICE POINTS OF REMOVAL 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.
  • Page 18 FRONT DISC BRAKE Pre-removal Operation Removal steps 1. Connection for the brake hose and the NOTE brake tube + 2. Front brake assembly 3. Brake disc + : Refer to “Service Points of Installation”. SERVICE POINTS OF REMOVAL 1. DISCONNECTION OF BRAKE HOSE Holding the nut on the brake hose side.
  • Page 19 SERVICE POINTS OF INSTALLATION 2. INSTILLATION OF FRONT BRAKE ASSEMBLY 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.
  • Page 20 BRAKES DISASSEMBLY AND REASSEMBLY 64-86 46-62 64-86 46-62 Brake caliper kit Caliper assembly disassembly steps l + 2. Lock pin l + 3. Bushing 4. Caliper support (Pad, clip, shim) l + 5. Guide pin boot Lock pin boot Boot ring 8.
  • Page 21 POINTS OF DISASSEMBLY SERVICE When disassembling the front disc brakes, disassemble both and right) as a set. sides (left 7. REMOVAL OF BOOT RING Remove boot ring with flat tip (-1 screwdriver. 1460054 8. REMOVAL OF PISTON BOOT/g. PISTON Protect caliper body with cloth. Blow compressed air through brake hose to remove piston boot and piston.
  • Page 22 BRAKES - Front Disc Brake SERVICE POINTS OF REASSEMBLY Pad and wear Pad assembly indicator assembly 17. INSTALLATION OF INNER SHIM/15. OUTER SHIM Coat the mounting surfaces of the pad and inner shim ant the mounting surface of the inner shim and outer shin with repair kit grease, and assemble them.
  • Page 23 Disc Brake BRAKES - Front 2. INSTALLATION OF LOCK PIN/ 1. GUIDE PIN Install the guide pin and lock pin so the identification mark on the caliper body and head mark on the guide pin and lock pin are aligned.
  • Page 24 BRAKES DISASSEMBLY AND REASSEMBLY 54 ft.lbs. 6 ft.lbs. Nm / 54 ft.lbs. Brake caliper kit Caliper assembly disassembly steps + 1. Guide pin 3. Bushing 4. Caliper support (pad, clip, shim) 6. Boot ring 7. Piston boot + 9. Piston seal +I 0.
  • Page 25 BRAKES When disassembling the rear disc brakes, disassemble both sides (left and right) as a set. 7. REMOVAL OF PISTON BOOT/8. PISTON Pump in compressed air through the brake hose installa- tion hole and remove the pistons and piston boot. Caution When removing the pistons, be sure to use the handle of a plastic hammer and adjust the height of the two...
  • Page 26 BRAKES - Front Disc Brake Pad and wear indicator assembly Pad assembly 7. INSTALLATION OF INNER SHIM/13. OUTER SHIM Inner Coat the mounting surfaces of the pad and inner shim a shim Inner shim the mounting surface of the inner shim and outer shim vv repair kit grease, and assemble them.
  • Page 27 BRAKES 2. INSTALLATION~OF LOCK PIN/l. GUIDE PIN Install the guide pin and lock pin so the identification mark on the caliper body and head mark on the guide pin and lock pin are aligned. REMOVAL AND INSTALLATION Post-installation Operation Pre-removal Operation *Supplying Brake Fluid Draining of Brake Fluid Bleeding...
  • Page 28 BRAKES - Rear Disc Btike 36-43 ft.lbs. 9-14 Nm 55-65 Nm Pre-removal Operation *Draining of Brake Fluid Removal steps Post-installation Operation 1. Parking brake cable connection 2. Brake hose connection 3. Rear brake assembly (Refer to P.5-50.) Adjustment of Parking Brake Lever 4.

  • Page 29: Thickness Check

    BRAKES - Rear Disc Brake SERVICE POINTS OF -REMOVAL t u b e 2. DISCONNECTION OF BRAKE HOSE Holding the lock nut on the brake hose side, loosen the flared brake line nut. 10. REMOVAL OF SELF LOCKING NUT Using end yoke holder, secure and hold the rear axle shaft, and remove the self locking nut.
  • Page 30 axle shaft, shaft. Using special tool; r Thickness Check.) Run-out Check.) Check disc for damage.
  • Page 31 Aluminium type 140 Nm 01 ft.lbs. Removal steps 2. Center cover <Vehicles with center cover> l + 3. Wheel nuts 4. Center cap <Vehicles with center cap> 5. Spring 6. Ornament 7. Balance weight 8. Tire 9. Wheel NOTE (1) Reverse the removal procedures to reinstall. 4 : Refer to “Service Points of Installation”.
  • Page 32 INSTRUCTIONS INSTRUCTIONS FOR ALUMINUM TIRE WHEELS space in the luggage compartment, washing detergent has been used, or salt from lighter weight makes it easier to use if sea water or road chemicals has adhered, wash occurs. the vehicle as soon as possible. After washing compact spare .,z, -- I The following instructions for the...

  • Page 33: Special Tools

    BODY CONTENTS QUARTER WINDOW GLASS....i .. 59 REAR BUMPER ........41 SEAT BELT ..........94 DOOR GLASS AND REGULATOR ....64 SERVICE ADJUSTMENT PROCEDURES..30 DOOR HANDLE AND LATCH ..... 67 Door Adjustment ........31 DOOR MIRROR........Door Glass Adjustment ......
  • Page 34 BODY - Hood 1 7 - 2 6 N m 1 2 - 1 9 ftlbs. 9 - 1 4 N m Hood lock release cable removal steps Removal 1. Bumper 12. Front fascia bracket 2. Hood weatherstrip 13. CllP 3.
  • Page 35 BODY - Hood SERVICE HOOD LATCH/l 1. HOOD LOCK RELEASE HAN LE ’ Apply multipurpose grease to all moving parts. Grease: MOPAR Multipurpose Grease Part No 2932524 or equivalent 6. INSTALLATION OF BUMPER Install the bumper so that the amount of projection from the front end @per bar is as shown in the illustration.
  • Page 36 B O D Y - Liftgate 1 1 - 1 6 Nm 9 - 1 4 N m Scuff plate (driver’s side) 1. Bumper (Refer to P.23-85.) 2. Llftgate damper (upper) 13 Release handle cover 3. Liftgate outer weatherstrip * 14. Liftgate lock release handle 4.
  • Page 37 nk Filler Door SERVICE POINTS OF REMOVAL 17. REMOVAL OF LIFTGATE STOPPER Caution 1. Never try to disassemble the liigate gas spring cr bum it. 2. Always bore a hole in the gas spring to release the interior gas before the spring is discarded. SERVICE POINTS OF INSTALLATION LEASE HANDLE/ 10.
  • Page 38 - - .__.,_.. .__ <EAGLE Talon> 3 5 - 5 5 Front bumper fascia removal Steps Front. bumper assembly removal steps 1. Splash shield mounting clip 1. Splash shield mounting clip 2. Front combination light 2. Front combrnation light 3. Headlight 3.
  • Page 39 BODY - Front Bum$i Front bumper fascia removal StePS Front bumper assembly removal steps 2. Front combination light 3. Headlight 3. Headlight 4. Fog light 4. Fog light 5. Center upper plate 5. Center upper plate 6. Front fascia bracket 6.
  • Page 40 BODY <EAGLE Talon> Disassembly steps NOTE Lower plate 3. Front bumper reinforcement 4. Front bumper fascia SERVICE POINTS OF DISASSEMBLY 1. REMOVAL OF BUMPER ABSORBER Caution 1. Do not attempt to repair a bumper absorber that has been compressed in an accident; replace it with a new one.
  • Page 41 BODY - Front Buripr <PLYMOUTH Laser> 1 7 - 2 6 Disassembly steps NOTE 2. Lower plate 3. Front bumper reinforcement + : Refer to “Service Points of Reassembly”. 4. Front bumper fascia SERVICE POINTS OF DISASSEMBLY 1. REMOVAL OF BUMPER ABSORBER Caution 1.
  • Page 42 BODY - Rear Burn-r REMOVAL AND INSTALLATION <EAGLE Talon> Pre-removal Operation *Removal of Rear End Trim (Refer to P.23.85.) lnstallatron of Rear End Trim Rear bumper fascia removal steps Rear bumper assembly removal steps 1. Splash shield mounting clip 1. Splash shield mounting clip 2.
  • Page 43 <PLYMOUTH Laser> 35-55 Nni Rear bumper assembly removal steps Rear bumper fascia removal steps 1. Splash shield mounting clip 2. Rear panel garnish 2. Rear panel garnish 3. Rear combination light 3. Rear combinatjon light 4. Connectron for license plate light wiring 6.
  • Page 44 BODY <EAGLE Talon> Disassembly steps NOTE 1 Bumper absorber to reassemble. of Disassembly”. 2 R e a r b u m p e r r e i n f o r c e m e n t SERVICE POINTS OF DISASSEMBLY 1.
  • Page 45 <PLYMOUTH Laser> 1 7 - 2 6 Nm Disassembly steps 1. License plate light 2. Back-up light 3. License plate light wiring harness 4. Bumper absorber 5. Rear bumper reinforcement 6. License plate bracket 7. Rear bumper fascia SERVICE POINTS OF DISASSEMBLY 4.
  • Page 46 BODY - Garnishes <EAGLE Talon> <PLYMOUTH Laser> ,,-..,.,- Front deck garnish removal steps (Refer to GROUP 8 -Windshield Wiper.) Rear panel garnish removal steps Rear end trim (Refer to P.23-85.) 2. Cover 3. Back up light 4. Rear panel garnish NOTE Reverse the removal procedures to relnstall.
  • Page 47 23-46 BODY MOULDING REMOVAL AND INSTALLATION 1. Drip moulding 2. Windshield upper moulding 3. Quarter window moulding lower 4. Quarter window moulding upper 5. Quarter window moulding front 6. Liftgate moulding lower 7. Liftgate moulding upper 8. Liftgate moulding side NOTE + : Refer to “Service Pdints of Installation”.
  • Page 48 BODY 3. REMOVAL OF QUARTER WINDOW MOULDING LOWER/ 4. QUARTER WINDOW MOULDING UPPER/B. QUARTER WINDOW MOULDING FRONT Refer to P.23-59. 6. REMOVAL OF LIFTGATE MOULDING LOWER17. LIFT- GATE MOULDING UPPER/8. LIFTGATE MOULDING SIDE Refer to P.23-60. 9. REMOVAL OF SIDE PROTECT MOULDING FENDER/ 10.
  • Page 49 23-48 BODY - Moulding (3) Remove backrng paper from adhesive tape, and apply specified adhesive tape as shown in the illustration, Specified adhesive tape: (4) Apply specrfred sealant to the places shown in the Specified sealant: 3M Super Fast Urethane Primer Part No.
  • Page 50 Post-installation Operation Pm-removal Operation (Refer to P.23-72.) (Refer to P.23.45.) Bezel and Front Combination Light (Refer to GROUP 8-Headlight) (Refer to GROUP 8-Front Combi- nation Light) Light and Front Combination Light (Refer to GROUP 8-Front Combi- (Refer to GROUP 8-Headlights) nation Light) Removal of Side Air Dam (Refer to P.23.72 )
  • Page 51 BODY - Fender 2. Al’PLlCATlON OF ADHESIVE TO SPLASH SHIELD- . _ When installing the splash shield, apply specified adhesive to the flange part of the fender. SECT. A-A Specified adhesive: MOPAR Silicone Rubber Sealer Front fender Part No.402zWiO oket;F Glass panel Adhesive .
  • Page 52 BODY - Loose Panel /&OVAL AND INSTALLATION 9 - 1 4 Nm crossmember Deck crossmember sta Headlight support Inter cooler duct Headlight support Hood lock support 4 - 6 Nm 3 - 4 ft.lbs. <EAGLE Talon> Laser>...
  • Page 53 BODY - Aero Parts 23-72 AERO PARTS REMOVAL AND INSTALLATION <EAGLE Talon> <PLYMOUTH Laser> Side air dam removal steps <PLYMOUTH Laser> <EAGLE Talon> 2. Front side air dam Quarter trim (Refer to P.23-85.) 1. Door side garnish 2. Front side air dam 3.
  • Page 54 BODY - Aero Parts <EAGLE Talon> Rear air spoiler removal steps Rear air spoiler assembly (center) removal steps <EAGLE Talon> Rear wiper High mounted stop light (Refer to GROUP 8 - Rear Wiper.) System.) (Refer to GROUP 8 - Lighting High mounted stop light Rear air spoiler assembly (side) removal steps <EAGLE Talon>...
  • Page 55 BODY - Aero Parts SERVICE POINTS OF REMOVAL 1. REMOVAL OF SIDE AIR DAM (DOOR)/4. SIDE AIR (1) After the mounting screws are removed, apply the plastic trim tool to the bonding and clipped areas to remove the side air dam. tool.
  • Page 56 BODY - Aero P&s body painted surface and the side air dam. Heating temperature Body painted surface..25-55OC (77- 131 OFI Side air dam ....25-40°C (77-104OF) Door side garnish adhesive and sealant at the places shown in the figure, and attach to the body adhesive surface.
  • Page 57 BODY - Aero Parts Side air dam positions <EAGLE Talon> 1 SA0940 Section A-A Section B-B Front door 0 7- 1.7 1 3 - 2 . 3 (.05-.09) Front fender panel Front door <PLYMOUTH Laser> 1 SAOS40 Section A-A Section B-B Front fender panel 1 SAOS43...

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Talon 1993

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