Mitsubishi L200. Manual — part 411

AC803009AB

0.5 - 1.5 mm

ON-VEHICLE SERVICE

BASIC BRAKE

35A-8

(3) Screw in the stop lamp switch until its thread

contacts the stopper, and fix the stop lamp
switch by turning it approximately one eighth
of a turn clockwise.

(4) 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.

(5) Connect the connector at the stop lamp

switch.

6. Return the carpet, etc.

BRAKE PEDAL FREE PLAY

AC502988AB

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 DASH PANEL

1. Turn up the carpet, etc. under the brake pedal.

AC502998

B

Silencer

A

AC

Dash panel

Melting sheets

2. Pierce a needle or similar material to the silencer

and melting sheets, and measure the thickness of
"A" shown in the figure.

3. Start the engine, depress the brake pedal with

approximately 490 N of force, and measure the
distance "B" between the silencer and brake
pedal shown in the figure.

4. Check that the total value of "A" and "B"

measured in the previous items 2 and 3 is within
the standard value.

ON-VEHICLE SERVICE

BASIC BRAKE

35A-9

Standard value (A + B): 75 mm or more
[From the surface of dash panel to the face
of pedal pad]

5. 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.

6. Return the carpet etc. to its original position.

BRAKE BOOSTER OPERATING TEST

M1351001000576

1. For simple checking of the brake booster

operation, carry out the following tests:

AC000870

Good

No good

AE

(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.

AC000871AE

When engine
is stopped

When engine
is started

(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.

AC000872

Good

No good

AE

(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 OK, the booster is OK.

If one of the above three tests is not OK, the
check valve, vacuum hose, or booster is
defective. Check the check valve (Refer to

P.35A-

9

), vacuum hose for leaks, high volume engine

vacuum applied to booster. Repair or replace as
necessary. If these are OK, replace booster and
repeat this test starting at Step 1.

CHECK VALVE OPERATION CHECK

M1351009000893

CAUTION

The check valve should not be removed from the
vacuum hose.
1. Remove the vacuum hose (Refer to

P.35A-20

<LHD> or

P.35A-23

<RHD>).

CAUTION

If the check valve is defective, replace it as an
assembly unit together with the vacuum hose.

AC314141AB

A

B

Engine side
(does not
hold)

Booster
side
(holds)

Vacuum hose
assembly

2. Check the operation of the check valve by using a

vacuum pump.

Vacuum pump
connection

Normal condition

When connected to the
booster side (A)

Vacuum is generated
and maintained.

When connected to the
engine side (B)

No vacuum is generated.

ON-VEHICLE SERVICE

BASIC BRAKE

35A-10

BLEEDING

M1351001400734

CAUTION

Use only brake fluid DOT 3 or DOT 4. Never mix
the specified brake fluid with other fluid as it will
influence the braking performance significantly.
BRAKE LINE BLEEDING

AC508341AB

1

3

3

1

4

Vehicles with ABS

Vehicles without ABS

2

4

2

Start the engine and bleed the air in the sequence
shown in the figure.

BRAKE FLUID LEVEL SENSOR CHECK

M1351009100588

AC102357

The brake fluid level sensor is in good condition if
there is no continuity when the float surface is above
"MIN" and if there is continuity when the float surface
is below "MIN".

LOAD SENSING SPRING LENGTH
CHECK AND ADJUSTMENT <Vehicles
without ABS>

M1351001200161

CAUTION

• Perform without any parcels placed in the

vehicle (in the state of delivery).

• Do not raise the vehicle using a jack or similar

device.

1. Park the vehicle on a level surface.

AC503665AB

Load sensing proportioning valve

Spring

Lever

A

2. While pushing the lever in the arrowed direction

fully, measure the length A (the length between
the both ends of the spring) shown in the figure.

Standard value (A):

188

− 192 mm <2WD (except High rider)>

165

− 169 mm <2WD (High rider), 4WD (Vehi-

cles with rear body)>

161

− 165 mm <2WD (High rider), 4WD (Vehi-

cles without rear body)>

3. If the value is not within the standard value in the

item 2, loosen the spring support and adjust to set
within the standard value.

ON-VEHICLE SERVICE

BASIC BRAKE

35A-11

LOAD-SENSING PROPORTIONING
VALVE FUNCTION TEST <Vehicles
without ABS>

M1351001300191

1. Load sensing spring length check (Refer to

P.35A-10

).

AC503753AB

<Front>

<Rear>

Pressure gauge

Pressure
gauge

2. Remove the bleeder from the front disk brake

calliper and rear drum brake cylinder, and connect
a pres
sure gauge.

3. Air bleeding (Refer to

P.35A-10

).

4. Unhook the spring support side.

CAUTION

The lever should be fully compressed toward the
load sensing proportioning valve side.

AC505287AB

Load sensing proportioning valve

Spring

Lever

A

Parallel

H

5. Pull the spring toward the "A" direction in parallel

with the load sensing proportioning valve. Adjust
the length "H" as shown in the illustration to the
specified dimension. At this time, check that the
front disc brake caliper output fluid pressure and
rear drum brake cylinder output fluid pressure are
within the standard value.

Standard value:

Item

Length
H mm

Front disc
brake
caliper
output fluid
pressure
MPa

Rear drum
brake
cylinder
output fluid
pressure
MPa

2WD
(except High
rider)

193.2

8.12

4.98

17.64

6.25

− 7.53

223.0

13.52

10.38

2WD (High
rider)

168.8

5.72

2.58

17.64

4.33

− 5.61

213.5

12.02

8.88

2WD (High
rider)-Heavy
duty rear
suspension

169.0

4.96

1.82

17.64

3.72

− 5.00

194.1

11.52

8.38

4WD

168.2

5.92

2.78

17.64

4.49

− 5.77

213.6

12.32

9.18

BRAKE PAD CHECK

M1351017300587

CAUTION

If there is a significant difference in thickness
between the brake pads at right and left, check
the sliding area and the run-out of the brake disc
(Refer to

P.35A-14

).

AC503003

AF

<2WD (except High rider)>

<2WD (High rider), 4WD>