Mitsubishi Outlander XL. Manual — part 604

AC000871

ZC5012370000

When engine
is stopped

When engine
is started

AC000872

ZC5012380000

Good

No good

When one or more of the above check results are "No Good,"
then the check valve, vacuum hose, or brake booster is
suspected faulty.

INSPECTION USING SIMPLIFIED TESTER

1.

Before starting this inspection, remove the brake booster
check valve from the vehicle and check its operation (Refer
to P.35A-14).

ZC6018380000

Pressure gauge

Vacuum
gauge

Vacuum hose

Check valve

MB992146

Pedal depression
gauge

2.

After checking, install the check valve to the vacuum hose and
connect it to the vacuum gauge. Install the booster test
adapter (Special tool: MB992146) to the brake booster and
connect it to the vacuum gauge. Connect the pressure gauge
and pedal depression gauge as shown in the figure. Bleed the
pressure gauge and then perform the following tests:

(1)

Airtightness test with no load
Start the engine, and stop it when the vacuum gauge
indicator has reached approximately -67 kPa (-9.7 psi).
The result is judged as "Good" when the drop of the
vacuum approximately 15 seconds after the engine was
stopped is within -3.3 kPa (-0.5 psi).

(2)

Airtightness test with load
Start the engine and depress the brake pedal with 200 N.
Stop the engine when the vacuum gauge indicator reached
approximately -67 kPa (-9.7 psi). The result is judged as
"Good" when the drop of the vacuum approximately 15
seconds after the engine was stopped is within -3.3 kPa
(-0.5 psi).
When one or more of the above check results are judged
as "No Good," the vacuum hose or brake booster is
suspected faulty.

(3)

Brake booster characteristics test

BASIC BRAKE SYSTEM

35A-17

ON-VEHICLE SERVICE

Perform this test after the above (1) and (2) were performed.

a.

Non-servo effect test
With the engine stopped, make sure that the vacuum
gauge reading is 0 kPa (0 psi). Depress the brake pedal
with 100 N and 300 N, and measure the fluid pressure
generated.

Standard value:

Item

Pedal depression force
100 N

300 N

Generated fluid
pressure

kPa

(psi)

200 (29) or
more

1,800 (261) or
more

b.

Servo effect test
Start the engine. Depress the brake pedal with 100 N and
300 N when the vacuum gauge indicator reached
approximately -67 kPa (-9.7 psi), and measure the fluid
pressure generated.

Standard value:

Item

Pedal depression force
100 N

300 N

Generated fluid
pressure

kPa

(psi)

6,050 - 7,950
(877 - 1,153)

10,720 (1,554)
or more

CHECK VALVE OPERATION CHECK

M13501000090USA0000010000

1.

Remove the check valve.(Refer to P.35A-18.)

ZC601004

Valve

Spring

Intake
manifold
side

Booster side

(1)

(2)

0000

Replace the check valve when it is faulty.

2.

Using a vacuum pump, check operation of the check valve.

Vacuum

pump

connection

Normal condition

When connected to the
booster side (1)

Vacuum is generated
and maintained.

When connected to the
engine side (2)

No vacuum is generated.

BLEEDING

M13501000014USA0000010000

Be sure to use the specified brand and type of brake fluid.
Avoid mixing with other type of brake fluid.

Brake fluid:
Mitsubishi Genuine Diamond Queen Brake Fluid Super
4

35A-18

BASIC BRAKE SYSTEM

ON-VEHICLE SERVICE

BLEEDING OF MASTER CYLINDER
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.

ZC6018390000

Master cylinder

Outlet

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.

BLEEDING OF BRAKE PIPELINE

ZC6010090000

1

2

3

4

Front of
vehicle

1.

Perform the bleeding in the order shown in the figure.

BRAKE FLUID LEVEL SWITCH CHECK

M13501000091USA0000010000

ZC6010100000

The brake fluid level switch is normal when the following
conditions are met: When the brake fluid level is above "MIN,"
continuity is detected; and when the level is below "MIN," no
continuity is detected.

BASIC BRAKE SYSTEM

35A-19

ON-VEHICLE SERVICE

DISC BRAKE PAD CHECK AND REPLACEMENT

M13501000023USA0000010000

ZC6010120000

<Front>

ZC6010130000

<Rear>

1.

Visually check the thickness of brake pad from the inspection
hole of the caliper body.

Standard value: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)

2.

When the thickness is lower than the limit value, replace both
brake pads (right and left) as a set.

ZC6010140000

<Front>

Guide pin

ZC6010150000

<Rear>

Lock pin

3.

Remove the parts indicated in the figure, swivel the caliper
assembly upward and retain it with a wire or similar tool.

35A-20

BASIC BRAKE SYSTEM

ON-VEHICLE SERVICE