Mitsubishi Outlander GS45X. Manual — part 1550

BRAKE PEDAL

TSB Revision

BASIC BRAKE

35A-29

INSPECTION

STOPLIGHT SWITCH CHECK

M1351008900633

CAUTION

Do not apply grease or lubricant to the switch and the
switch installation section to avoid malfunction of the
switch. In addition, do not use gloves which have grease
on them.
Check for continuity between the terminals of the switch.

BRAKE PEDAL DISTORTION CHECK

M1351016300205

1. Place the brake pedal assembly on a level surface as shown

in the figure, and set the distance from the centre of the pin
assembly mounting hole to the level surface to 97 mm (3.82
inch). Make sure that the dimension A in the figure (distance
from the pedal pad surface to the level surface) is within the
standard value.

Standard value (A): 250

− 254 mm (9.8 − 10.0 inch)

2. When dimension A is not within the standard value, replace

the brake pedal assembly.

Check
condition

Terminal
connector of
tester

Normal
condition

At free position 1

− 2 (for

stoplight switch)

Continuity
exists

(2

Ω or less)

3

− 4 (for cruise

control)

No continuity

Press the
plunger from the
edge of the
outer case by
the dimension
shown in the
figure.

1

− 2 (for

stoplight switch)

No continuity

3

− 4 (for cruise

control)

Continuity
exists

(2

Ω or less)

AC900541AB

No continuity

For stoplight switch

For cruise control

Continuity

Continuity

No continuity

6.0 ± 0.5 mm
(0.24 ± 0.01 in)

3.6 ± 0.4 mm
(0.14 ± 0.01 in)

AC507986AB

97mm
(3.82 inch)

A

Brake pedal assembly

Pin assembly
center hole

Pedal pad center part

Flat surface

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY

TSB Revision

BASIC BRAKE

35A-30

MASTER CYLINDER ASSEMBLY AND

BRAKE BOOSTER ASSEMBLY

REMOVAL AND INSTALLATION

M1351003701659

CAUTION

Do not touch the push rod in the brake booster
because it is already adjusted.

Pre-removal operation
• Brake Fluid Draining

• Bottom Cover Assembly (driver's seat) Removal (Refer to

GROUP 52A

− Instrument Panel Assembly

P.52A-2

).

• Air Cleaner Body Removal (Refer to GROUP 15 − Air

Cleaner

P.15-4

<2.4L Engine> or

P.15-5

<3.0L Engine>).

Post-installation operation
• Air Cleaner Body Installation (Refer to GROUP 15 − Air

Cleaner

P.15-4

<2.4L Engine> or

P.15-5

<3.0L Engine>).

• Brake Fluid Refilling and Air Bleeding (Refer to

P.35A-20

).

• Bottom Cover Assembly (driver's seat) Installation (Refer

to GROUP 52A

− Instrument Panel Assembly

P.52A-2

).

AC709978

14

N

N

1

3

3

2

7

8

10

11

12

5

6

9

13

15

17

16

AB

25 ± 4 N·m
18 ± 3 ft-lb

N

4

14 ± 3 N·m
11 ± 2 ft-lb

16 ± 3 N·m
12 ± 2 ft-lb

Master cylinder removal steps

1.

Brake fluid level switch connector
connection

2.

Reservoir cap

3.

Brake pipe connection

>>

B

<< •

Bleeding of master cylinder
assembly (only at installation)

4.

Master cylinder mounting nuts

5.

Reservoir assembly and master
cylinder assembly

6.

Torx bolt

7.

Reservoir assembly

8.

O-ring

9.

Master cylinder assembly

Brake booster removal steps

1.

Brake fluid level switch connector
connection

3.

Brake pipe connection

>>

B

<< •

Bleeding of master cylinder
assembly (only at installation)

4.

Master cylinder mounting nuts

5.

Reservoir assembly and master
cylinder assembly

>>

A

<< 10. Vacuum hose connection

11. Hose clip
12. Check valve
13. Snap pin
14. Pin assembly
15. Brake booster mounting nut
•

Strut tower bar (Refer to GROUP
42A, Strut Tower Bar

P.42A-12

.)

16. Brake booster assembly
17. Seal

Brake booster removal steps

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY

TSB Revision

BASIC BRAKE

35A-31

<VACUUM HOSE AND VACUUM PIPE>

AC709979

<3.0L Engine>

3

4

6

1

2

2

2

1

2

7

4

5

5

<2.4L Engine>

13 ± 2 N·m
111 ± 22 in-lb

11 ± 1 N·m
98 ± 4 in-lb

AB

Removal steps

>>

A

<< 1.

Vacuum hose

2.

Hose clip

>>

A

<< 3.

Vacuum hose <2.4L Engine>

4.

Hose clip <2.4L Engine>

5.

Emission vacuum hose connection
<2.4L Engine>

6.

Vacuum pipe assembly <2.4L
Engine>

7.

Clamp <3.0L Engine>

Removal steps (Continued)

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY

TSB Revision

BASIC BRAKE

35A-32

INSTALLATION SERVICE POINTS

.

>>A<< VACUUM HOSE INSTALLATION

Align the mark as shown in the figure to assemble the vacuum
hose.

.

>>B<< BLEEDING OF MASTER CYLINDER
ASSEMBLY

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 cyl-
inder).
1. Fill the brake fluid reservoir with the brake fluid.
2. Depress and hold the brake pedal.

AC613196

AH

<2.4L Engine>

A

B

C

View A

View B

D

Paint mark

View C

Paint mark

Paint mark

Paint mark

View D

AC607649

Vacuum hose

AF

<3.0L Engine>

Paint mark

Paint mark