Mitsubishi L200. Manual — part 415
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY
BASIC BRAKE
35A-24
VACUUM HOSE AND VACUUM PIPE
AC805359AB
1
4
3
5
2
6
Removal steps
>>
A
<<
1.
Vacuum hose (with built-in check
valve)
2.
Hose clip
>>
A
<<
3.
Vacuum hose
4.
Hose clip
5.
Vacuum pipe
6.
Clamp
INSTALLATION SERVICE POINTS
>>A<< VACUUM HOSE INSTALLATION
AC502302AC
Vacuum hose
(with built-in
check valve)
AC505445AC
Vacuum hose
B
A
View A
View B
Paint mark
Paint mark
Install the vacuum hose and the clip so that the paint
mark on the vacuum hose and the clip are in the
position shown in the figure.
>>B<< PUSH ROD PROTRUSION AMOUNT
CHECK AND ADJUSTMENT
AC903695AB
A
A
Measuring distance A
<Vehicles without ASTC>
<Vehicles with ASTC>
Block gauge
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY
BASIC BRAKE
35A-25
1. Use the vacuum pump to measure dimension "A"
applying a negative pressure of 66.7 kPa to the
brake booster.
Standard value (A):
10.0
− 10.1 mm <Vehicles without ASTC>
6.6
− 6.9 mm <Vehicles with ASTC>
NOTE: When a negative pressure of 66.7 kPa is
not applied to the brake booster, the push rod pro-
trusion amount (A) should be 9.0
−
9.1 mm <Vehi-
cles without ASTC> , 7.7
−
7.9 mm <Vehicles with
ASTC>.
AC903696
AB
MB991568
Angle-nose pliers
Rod spline
Rod spline
<Vehicles without ASTC>
<Vehicles with ASTC>
2. If the protrusion amount is not within the standard
value range, adjust the push rod length by turning
the push rod. Use the special tool push rod
adjusting socket (MB991568) to turn the push rod
while holding the rod spline with angle-nose
pliers.
>>C<< BLEEDING OF MASTER CYLINDER
ASSEMBLY
CAUTION
Be sure to use the specified brand and type of
brake fluid. Avoid mixing with other type of brake
fluid.
Brake fluid: DOT3 or DOT4
When removed the master cylinder assembly, bleed
the master cylinder in the following procedure to
make bleeding of the brake pipeline easier (When no
brake fluid is in the master cylinder).
1. Fill the brake fluid reservoir with the brake fluid.
2. Depress and hold the brake pedal.
AC000876
3. Another operator closes the master cylinder
outlets with his fingers.
4. In this condition, release the brake pedal.
5. Repeat Steps 2 to 4 for 3 or 4 times to fill the
master cylinder with the brake fluid.
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY
BASIC BRAKE
35A-26
MASTER CYLINDER
M1351004200580
DISASSEMBLY AND REASSEMBLY
<Vehicles without ASC>
AC503739AB
2
1
4
7
8
6
N
N
N
10
Master cylinder kit
Brake fluid: DOT 3 or DOT 4
3
5
N
5
9
N
10
7
8
9
Disassembly steps
1. Reservoir cap
2. Diaphragm
3. pin
4. Reservoir
5. Reservoir seal
6. Brake fluid level switch
7. Piston retainer
8. Primary piston assembly
9. Secondary piston assembly
10. Master cylinder body
Disassembly steps (Continued)
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY
BASIC BRAKE
35A-27
<Vehicles with ASC>
AC508347AB
2
1
4
7
8
6
N
N
N
10
Master cylinder kit
Brake fluid: DOT 3 or DOT 4
3
5
N
5
9
N
10
7
8
9
Disassembly steps
1. Reservoir cap
2. Diaphragm
3. pin
4. Reservoir
5. Reservoir seal
6. Brake fluid level switch
7. Piston retainer
8. Primary piston assembly
9. Secondary piston assembly
10. Master cylinder body
INSPECTION
M1351004300413
• Check the inner surface of master cylinder body
for rust or pitting.
• Check the primary and secondary pistons for
rust, scoring, wear or damage.
• Check the diaphragm for cracks and wear.
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