Mitsubishi Outlander XL. Manual — part 600

GROUP 35A

BASIC BRAKE SYSTEM

CONTENTS

GENERAL INFORMATION. . .

35A-3

GENERAL SPECIFICATIONS. . .

35A-3

SERVICE SPECIFICATIONS. . .

35A-4

LUBRICANTS. . . . . .

35A-5

BASIC BRAKE SYSTEM DIAGNOSIS
. . . . . . . ...

35A-5

INTRODUCTION TO BASIC BRAKE SYSTEM
DIAGNOSIS. . . . . ..

35A-5

BASIC BRAKE SYSTEM DIAGNOSTIC
TROUBLESHOOTING STRATEGY. ...

35A-5

SYMPTOM CHART. . . . ..

35A-5

SYMPTOM PROCEDURES. . .

.35A

-6

INSPECTION PROCEDURE 1: Vehicle Pulls
to One Side when Brakes are Applied
. . . . . . . . .

35A-6

INSPECTION PROCEDURE 2: Insufficient
Braking Power. . . . .

35A-7

INSPECTION PROCEDURE 3: Increased
Pedal Stroke (Reduced Pedal-to-Floor
Board Clearance). . . . .

35A-7

INSPECTION PROCEDURE 4: Brake Drag
. . . . . . . . .

35A-8

INSPECTION PROCEDURE 5: Scraping or
Grinding Noise when Brakes are Applied
. . . . . . . . .

35A-9

INSPECTION PROCEDURE 6: Squealing,
Groaning or Chattering Noise when
Brakes are Applied. . . ..

35A-10

INSPECTION PROCEDURE 7: Squealing
Noise when Brakes are not Applied
. . . . . . . .

35A-11

INSPECTION PROCEDURE 8: Groaning,
Clicking or Rattling Noise when Brakes
are not Applied. . . . .

35A-12

SPECIAL TOOL. . . . ..

35A-14

ON-VEHICLE SERVICE. . .

35A-14

BRAKE PEDAL CHECK. . . .

35A-14

BRAKE BOOSTER OPERATION CHECK
. . . . . . . ..

35A-16

CHECK VALVE OPERATION CHECK
. . . . . . . ..

35A-18

BLEEDING. . . . . ..

35A-18

BRAKE FLUID LEVEL SWITCH CHECK
. . . . . . . ..

35A-19

DISC BRAKE PAD CHECK AND REPLACEMENT
. . . . . . . ..

35A-20

BRAKE DISC THICKNESS CHECK. . . .

35A-21

BRAKE DISC RUNOUT INSPECTION AND
CORRECTION. . . . ....

35A-21

MASTER CYLINDER FUNCTION CHECK
. . . . . . . ..

35A-22

BRAKE PEDAL. . . . ...

35A-22

REMOVAL AND INSTALLATION. ..

35A-22

BRAKE PEDAL INSPECTION. ....

35A-24

CHECK THE STOPLIGHT SWITCH CONTINUITY.
. . . . . . . .

35A-24

35A-1

Continued on next page

BRAKE PEDAL DISTORTION CHECK.

35A-25

MASTER CYLINDER ASSEMBLY AND BRAKE
BOOSTER. . . . . ...

35A-25

REMOVAL AND INSTALLATION. ..

35A-25

FRONT DISC BRAKE ASSEMBLY. .

35A-28

REMOVAL AND INSTALLATION. ..

35A-28

DISASSEMBLY AND ASSEMBLY. ..

35A-30

FRONT DISC BRAKE ASSEMBLY INSPECTION
. . . . . . . ..

35A-32

REAR DISC BRAKE ASSEMBLY. ..

35A-33

REMOVAL AND INSTALLATION. ..

35A-33

DISASSEMBLY AND ASSEMBLY. ..

35A-35

REAR DISC BRAKE ASSEMBLY INSPECTION
. . . . . . . ..

35A-37

35A-2

GENERAL INFORMATION

M13501000001USA0000010001

Brake systems with higher reliability and durability
have achieved distinguished braking performance.

FEATURES

IMPROVEMENT OF BRAKING PERFORMANCE

｠

In addition to the 10-inch single brake booster, the
small and long stroke-type master cylinder is used
to achieve the downsizing and secure the assist
force.

｠

The installation of 16-inch ventilated disc brake on
the front axle and 16-inch solid disc brake on the
rear axle achieves the secure braking force and
direct braking feeling.

IMPROVEMENT IN SAFETY

｠

The 4-wheel anti-lock brake system (4ABS) has
been installed to prevent slippage resulting from the
wheel lock and assure stable vehicle posture and
driveability.

｠

Electronic control braking force distribution system
(EBD) has been adopted to assure the maximum
braking force independently of the passenger'
position in the vehicle.

｠

X-type piping of brake lines have been adopted for
the front and rear wheels.

｠

Audible wear indicator has been adopted to the
front and rear brake pads to warn the driver of the
wear limit.

SERVICE QUALITY IMPROVEMENTS

｠

Diagnostic function has been adopted to ABS for
easier inspection.

｠

Brake fluid reservoir, master cylinder, and brake
booster have been integrated for downsizing and
better serviceability.

ZC6016900001

Brake booster

Master cylinder

Hydraulic unit

Front disc brake

Rear disc brake

Reserve tank

GENERAL SPECIFICATIONS

M13501000002USA0000010001

Item

Specifications

Master cylinder

Type

Tandem type

BASIC BRAKE SYSTEM

35A-3

GENERAL INFORMATION

Item

Specifications

I.D. mm (in)

20.6 (0.81)

Brake booster

Type

Vacuum type, single

Effective dia. of power cylinder mm
(in)

255 (10.0)

Boosting ratio

8.5 (Pedal pressure: 160N)

Rear wheel hydraulic control method

Electronic

control

braking

force

distribution system (EBD)

Front brake

Type

Floating caliper 1 piston ventilated disc
(V6-S57)

Disc effective dia × thickness mm
(in)

294 × 26 (11.6 × 1.02)

Wheel cylinder I.D. mm (in)

57.1 (2.25)

Pad thickness mm (in)

10.0 (0.39)

Clearance adjustment

Automatic adjustment

Rear brake

Type

Floating caliper 1 piston solid disc (S6-
S38)

Disc effective dia × thickness mm
(in)

302 × 10 (11.9 × 0.39)

Wheel cylinder I.D. mm (in)

38.1 (1.50)

Pad thickness mm (in)

10.0 (0.39)

Clearance adjustment

Automatic adjustment

SERVICE SPECIFICATIONS

M13501000003USA0000010000

Item

Standard value

Limit

Brake pedal height mm (in)

221.8 - 227.8
(8.7 - 9.0)

-

Dimension from the brake booster stud bolt end to the clevis hole
center mm (in)

75.8 - 80.2
(2.98 - 3.16)

-

Brake pedal play mm (in)

3 - 8 (0.12 - 0.31)

-

Pedal-to-floor clearance when brake pedal is depressed mm (in)
[Pedal depression force: approx. 500 N]

80 (3.15) or more

-

Fluid pressure generated by
brake booster non-servo effect
test kPa (psi)

Pedal depression force: 100 N 200 (29) or more

-

Pedal depression force: 300 N 1,800 (261) or more -

Fluid pressure generated by
brake booster servo effect test
kPa (psi)

Pedal depression force: 100 N 6,050 - 7,950

(877 - 1,153)

-

Pedal depression force: 300 N 10,720 (1,554) or

more

-

Front disc brake

Pad thickness mm (in)

10.0 (0.39)

Minimum 2.0 (0.08)

Brake disc thickness mm (in)

26.0 (1.02)

Minimum 24.4 (0.96)

Brake disc runout mm (in)

-

0.06 (0.0024)

35A-4

BASIC BRAKE SYSTEM

SERVICE SPECIFICATIONS