Mitsubishi Outlander (2003+). Manual — part 258
SERVICE SPECIFICATIONS
BASIC BRAKE SYSTEM
35A-3
SERVICE SPECIFICATIONS
M1351000300530
LUBRICANTS
M1351000400377
SEALANT
M1351000500385
Item
Standard value
Limit
Brake pedal height mm
L.H. drive vehicles 150
−
153
−
R.H. drive vehicles 176.2
−
179.2
−
Brake pedal free play mm
3
−
8
−
Brake pedal to floor board clearance mm
100 or more
−
Disc brake pad thickness mm
10.0
2.0
Disc brake disc thickness mm
Front
24.0
22.4
Rear
10.0
8.4
Disc brake disc run-out mm
Front
−
0.04
Rear
−
0.05
Disc brake drag force N
Front/Rear
68 or less
−
Wheel bearing axial play mm
Front/Rear
−
0.05
Brake booster push rod protruding length mm (When applying
negative pressure of 66.7 kPa to the brake booster)
10.15
−
10.40
−
Item
Specified lubricant
Brake fluid
DOT3 or DOT4
Guide pin
Repair kit grease
Lock pin
Guide pin boot inner surface
Lock pin boot inner surface
Piston boot mounting grooves
Brake piston boot inner surface
Guide pin bush inner surface
Item
Specified sealant
Remark
Fitting thread part
3M ATD Part No.8661 or equivalent
Semi-drying sealant
SPECIAL TOOLS
BASIC BRAKE SYSTEM
35A-4
SPECIAL TOOLS
M1351000600326
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND
ADJUSTMENT
M1351000900479
BRAKE PEDAL HEIGHT
1. Turn up the carpet, etc. under the brake pedal.
2. Measure the brake pedal height as illustrated.
Standard value (A):
150
−
153 mm <L.H. drive vehicles>
176.2
−
179.2 mm <R.H. drive vehicles>
[From the surface of dash panel to the face
of pedal pad]
3. If the brake pedal height is not within the standard
value, follow the procedure below.
(1) Disconnect the stop lamp switch connector.
(2) Remove the brake booster (Refer to
).
NOTE: With the master cylinder and brake
pipe connected, remove the brake booster
only.
(3) Adjust the brake pedal height by turning the
clevis.
NOTE: When the clevis is turned 180
°
, the
pedal height is changed approximately 2.4
mm.
(4) Install the brake booster (Refer to
).
(5) Measure the brake pedal height, and ensure
that the measured value is within the standard
value. When it is out of the standard value,
repeat Step (2) - (5).
Tool
Number
Name
Use
MB991568
Push rod adjusting
socket
Adjustment of the brake booster
push rod protrusion amount
MB990964
A: MB990520
Brake tool set
A: Disc brake
piston expander
Pushing-in of the disc brake
piston
MB990964
A
B
AC200515
A
AC
AC006217AD
Clevis
ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM
35A-5
(6) Screw in the stop lamp switch until its thread
contacts the stopper, and fix the stop lamp
switch by turning it approximately one quarter
of a turn clockwise.
(7) Check that the clearance between the stop
lamp switch and the stopper is as shown.
CAUTION
Check that the stop lamp does not illuminate
when the brake pedal is not depressed.
(8) Connect the connector at the stop lamp
switch.
4. Return the carpet, etc.
BRAKE PEDAL FREE PLAY
1. Turn the ignition switch to the "LOCK" (OFF)
position, depress the brake pedal two or three
times. After eliminating the vacuum in the brake
booster, press the pedal down by hand, and
confirm that the amount of movement before
resistance is met (free play) is within the standard
value range.
Standard value: 3
−
8 mm
2. If the brake pedal play is not within the standard
value, check the following, and adjust or replace if
necessary:
•
Excessive play between the brake pedal and the
clevis pin, or between the clevis pin and the
brake booster operating rod
•
Brake pedal height
•
Installation position of the stop lamp switch, etc.
CLEARANCE BETWEEN BRAKE PEDAL
AND FLOOR BOARD
1. Turn up the carpet, etc. under the brake pedal.
2. Start the engine, depress the brake pedal with
approximately 490 N of force, and measure the
clearance between the brake pedal and the floor
board.
Standard value (C): 100 mm or more
[From the surface of floor board to the face
of pedal pad]
3. If the clearance is outside the standard value,
check for air trapped in the brake line, thickness of
the disc brake pad, clearance between the lining
and the drum and dragging in the parking brake.
And then adjust and replace defective parts as
required.
4. Return the carpet etc. to its original position.
AC309282 AC
1.0 - 1.5 mm
Stopper
Stopper
AC200011
B
AC
AC107452
AC
C
ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM
35A-6
BRAKE BOOSTER OPERATING TEST
M1351001000327
1. For simple checking of the brake booster
operation, carry out the following tests:
(1) Run the engine for one or two minutes, and
then stop it. If the pedal depresses fully the
first time but gradually becomes higher when
depressed succeeding times, the booster is
operating properly. If the pedal height remains
unchanged, the booster is defective. Go to
step 2.
(2) With the engine stopped, step on the brake
pedal several times. Then step on the brake
pedal and start the engine. If the pedal moves
downward slightly, the booster is in good
condition. If there is no change, the booster is
defective. Go to step 3.
(3) With the engine running, step on the brake
pedal and then stop the engine. Hold the
pedal depressed for 30 seconds. If the pedal
height does not change, the booster is in good
condition, if the pedal rises, the booster is
defective.
2. If the above three tests are okay, the booster is
OK. If one of the above three tests is not okay, the
check valve, vacuum hose, or booster is
defective. Check the check valve (Refer to
), vacuum hose for leaks, high volume
engine vacuum applied to booster. Repair or
replace as necessary. If these are OK, replace the
booster and repeat this test starting at Step 1.
CHECK VALVE OPERATION CHECK
M1351009000321
CAUTION
The check valve should not be removed from the
vacuum hose.
1. Remove the vacuum hose (Refer to
CAUTION
If the check valve is defective, replace it as an
assembly unit together with the vacuum hose.
2. Check the operation of the check valve by using a
vacuum pump.
AC000870
Good
No good
AE
AC000871AE
When engine
is stopped
When engine
is started
AC000872
Good
No good
AE
Vacuum pump
connection
Accept/reject criteria
Connection at the brake
booster side (A)
A negative pressure
(vacuum) is created and
held.
Connection at the intake
manifold side (B)
A negative pressure
(vacuum) is not created.
AC000873AE
A
B
Valve
Spring
Intake manifold
side
(does not hold)
Booster side
(holds)
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