Mitsubishi L200. Manual - part 414

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY

BASIC BRAKE

35A-20

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER 

ASSEMBLY

REMOVAL AND INSTALLATION <LHD>

M1351003702663

MASTER CYLINDER AND BRAKE BOOSTER

Pre-removal Operation
Brake fluid draining

Post-installation Operation
• Brake fluid supplying and air bleeding (Refer to 

P.35A-

10

).

• Brake pedal adjustment (Refer to 

P.35A-7

).

AC805356AB

5

6

<Vehicles without ABS>

14 ± 3 N·m

1

13 ± 2 N·m

7

2

15 ± 2 N·m

2

2

3

4

8

9

11

10

N

Removal steps 

1.

Brake fluid level switch connector 
connection

2.

Master cylinder and brake pipe 
connection

>>

C

<<

•

Bleeding of master cylinder 
assembly (only at installation)

3.

Master cylinder mounting nut

4.

Master cylinder assembly

>>

B

<<

•

Push rod protrusion amount check 
and adjustment (only at installation)

>>

A

<<

5.

Vacuum hose connection (with 
built-in check valve)

6.

Hose clip

7.

Snap pin

8.

Pin assembly

9.

Brake booster mounting nut

10. Brake booster assembly
11. Sealer

Removal steps (Continued)

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY

BASIC BRAKE

35A-21

VACUUM HOSE AND VACUUM PIPE

AC805357AB

1

2

2

3

4

5

7

6

8

Removal steps 

>>

A

<<

1.

Vacuum hose (with built-in check 
valve)

2.

Hose clip

3.

Vacuum hose

4.

Hose clip

5.

Vacuum pipe

6.

Vacuum hose

7.

Hose clip

8.

Vacuum pipe

INSTALLATION SERVICE POINTS

>>A<< VACUUM HOSE INSTALLATION

AC508346AB

Vacuum hose
(with built-in
check valve)

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

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>

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY

BASIC BRAKE

35A-22

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-23

REMOVAL AND INSTALLATION <RHD>

M1351003702674

MASTER CYLINDER AND BRAKE BOOSTER

Pre-removal Operation
Brake Fluid Draining

Post-installation Operation
• Brake Fluid Supplying and Air Bleeding (Refer to 

P.35A-

10

).

• Brake Pedal Adjustment (Refer to 

P.35A-7

).

AC805358AB

14 ± 3 N·m

1

13 ± 2 N·m

9

2

2

3

2

4

5

6

7

8

10

11

13

12

N

<Vehicles without ABS>

2

15 ± 2 N·m

Removal steps 

1.

Brake fluid level switch connector 
connection

2.

Master cylinder and brake pipe 
connection

3.

Hydraulic unit assembly and brake 
pipe connection <vehicles with 
ABS>

4.

Brake pipe assembly <vehicles with 
ABS>

>>

C

<<

•

Bleeding of master cylinder 
assembly (only at installation)

5.

Master cylinder mounting nut

6.

Master cylinder assembly

>>

B

<<

•

Push rod protrusion amount check 
and adjustment (only at installation)

>>

A

<<

7.

Vacuum hose connection (with 
built-in check valve)

8.

Hose clip

9.

Snap pin

10. Pin assembly
11. Brake booster mounting nut
12. Brake booster assembly
13. Sealer

Removal steps (Continued)