Mitsubishi Lancer Evolution IX. Manual — part 490
BRAKE PEDAL
SERVICE BRAKES
35A-15
INSTALLATION SERVICE POINT
>>A<< BRAKE PEDAL ASSEMBLY
INSTALLATION
AC006234 AB
A
A
B
B
Tighten the brake booster mounting nuts (A), and
then the brake pedal assembly mounting bolts (B).
NOTE: The brake pedal assembly cannot be posi-
tioned correctly if the brake pedal assembly mount-
ing bolts (B) are tightened first, as their holes are
oblong holes.
INSPECTION
M1351003500254
STOPLAMP SWITCH CHECK
AC006235AB
4 mm
No continuity
Continuity
1. Connect an ohmmeter between the stop lamp
switch connector terminals.
2. There should be no continuity between the
terminals when the plunger is pushed in as
shown. There should be continuity when it is
released.
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
SERVICE BRAKES
35A-16
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
REMOVAL AND INSTALLATION
M1351003700537
Pre-removal Operation
• Brake Fluid Draining
• Air Intake Hose and Air Cleaner Removal (Refer to
GROUP 15, Air Cleaner
).
• Strut Tower Bar Removal (Refer to GROUP 42, Strut
Tower Bar
Post-installation Operation
• Brake Pedal Adjustment (Refer to
• Air Intake Hose and Air Cleaner Installation (Refer to
GROUP 15, Air Cleaner
).
• Strut Tower Bar Removal (Refer to GROUP 42, Strut
Tower Bar
• Brake Fluid Supplying and Air Bleeding (Refer to
).
AC310837
3M ATD part No. 8661 or equivalent
AB
13
16 ± 1 N·m
13
8
15 ± 2 N·m
10 ± 2 N·m
15 ± 2 N·m
22 ± 3 N·m
14 ± 3 N·m
7
9
11
10
7
6
2
4
1
12
5
5
3
7
13
16 ± 1 N·m
Master cylinder removal steps
1.
Clutch hose connection
2.
Brake fluid level indicator switch
connector
3.
Brake fluid reservoir cap
4.
Brake fluid level indicator switch
5.
Brake tube connection
6.
Brake master cylinder assembly
Brake booster removal steps
1.
Clutch hose connection
2.
Brake fluid level indicator switch
connector
5.
Brake tube connection
6.
Brake master cylinder assembly
>>
B
•
Push rod protrusion amount check
and adjustment
>>
A
7.
Brake booster vacuum hose
(With built-in check valve)
8.
Brake booster pin
9.
Brake booster pin assembly
10. Clevis
•
Remove A/C liquid pipe B from the
retaining clip (Refer to GROUP 55,
Refrigerant Line
11. Brake booster assembly
12. Brake booster body seal
Brake booster removal steps
Fitting removal steps
>>
A
<<
7.
Brake booster vacuum hose
(With built-in check valve)
13. Brake booster vacuum hose fitting
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
SERVICE BRAKES
35A-17
INSTALLATION SERVICE POINTS
>>A<< BRAKE BOOSTER VACUUM HOSE
CONNECTION
Insert the brake booster vacuum hose to the brake
booster assembly with its paint mark facing upward,
and then secure the hose by using the hose clip.
>>B<< PUSH ROD PROTRUSION
AMOUNT CHECK AND ADJUSTMENT
AC006237AB
A
Measuring distance A
Block gauge
1. Measure dimension (A).
Standard value (A): 8.98
− 9.23 mm
NOTE: When a negative pressure of 66.7 kPa is
applied to the brake booster, the push rod should
protrude 10.27 - 10.53 mm.
AC006238AB
MB991568
Angle-nose pliers
Rod spline
2. If the protrusion amount is not within the standard
value range, adjust the push rod length by turning
the push rod. Use special tool push rod adjusting
socket (MB991568) to turn the push rod while
holding the rod spline with angle-nose pliers.
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
SERVICE BRAKES
35A-18
MASTER CYLINDER
M1351004200449
DISASSEMBLY AND REASSEMBLY
AC006239
2
3
1
4
6
7
5
10
N
9
N
8
N
10
9
8
Master cylinder kit
9
Brake fluid: DOT 3 or DOT 4
3
7
8
AB
Disassembly steps
1. Brake fluid reservoir cap
2. Brake fluid reservoir filter
3. Brake master cylinder pin
4. Brake fluid reservoir
5. Brake master cylinder to reservoir
seal
6. Brake master cylinder pin
7. Piston retainer
8. Primary piston assembly
9. Secondary piston assembly
10. Master cylinder body
INSPECTION
M1351004300338
• 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.
Disassembly steps (Continued)
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