Mitsubishi Grandis. Manual - part 893

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

BASIC BRAKE SYSTEM

35A-14

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

REMOVAL AND INSTALLATION

M1351003700548

<LH drive vehicles>

Pre-removal Operation
• Air Cleaner Resonator, Air Cleaner Cover, Air Cleaner 

Intake Duct, Air Cleaner Body Assembly Removal (Refer 

to GROUP 15, Air Cleaner

P.15-3

.) <LH drive vehicles>

• Engine Cover and Engine Cover Bracket Removal (Refer 

to GROUP 11A, Camshaft and Valve Stem Seal 

P.11A-16

.) <LH drive vehicles>

• Air Intake Hose Removal (Refer to GROUP 15, Air 

Cleaner

P.15-3

.) <LH drive vehicles>

• Canister removal (Refer to GROUP 17, Evaporative 

Emission Control System 

− Canister 

P.17-64

.) <LH drive 

vehicles>

• Brake Fluid Draining

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

P.35A-6

.)

• Canister Installation (Refer to GROUP 17, Evaporative 

Emission Control System 

− Canister 

P.17-64

.) <LH drive 

vehicles>

• Brake Pedal Adjustment (Refer to 

P.35A-4

.)

• Air Intake Hose Installation (Refer to GROUP 15, Air 

Cleaner

P.15-3

.) <LH drive vehicles>

• Engine Cover and Engine Cover Bracket Installation 

(Refer to GROUP 11A, Camshaft and Valve Stem Seal 

P.11A-16

.) <LH drive vehicles>

• Air Cleaner Resonator, Air Cleaner Cover, Air Cleaner 

Intake Duct, Air Cleaner Body Assembly Installation 

(Refer to GROUP 15, Air Cleaner

P.15-3

.) <LH drive 

vehicles>

AC312193

AB

1

10

12

14

13

15 ± 2 N·m

14 ± 3 N·m

6

11

15

N

8

14.7 ± 2.9 N·m

2

7

5

3

4

13 ± 2 N·m

9

7

Master cylinder removal steps

1.

Brake fluid level switch connector

2.

Hose clip

>>C<<

3.

Reservoir hose

4.

Reservoir assembly

5.

Reservoir cap

6.

Brake fluid level switch

7.

Brake pipe connection

•

Brake pipe [between brake master 
cylinder and hydraulic unit 
(ABS-ECU)] (Refer to GROUP 35B, 
Hydraulic Unit 

P.35B-77

.)

Master cylinder removal steps 

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

BASIC BRAKE SYSTEM

35A-15

<RH drive vehicles>

•

Clip (LH side only) (Refer to  

P.35A-18

.)

8.

Clutch damper bracket

9.

Brake master cylinder

>>B<<

•

Push rod protrusion amount check 
and adjustment
Brake booster removal steps

>>A<<

10. Vacuum hose (with built-in check 

valve)

11. Snap pin
12. Pin
13. Brake booster mounting nut
14. Brake booster assembly
15. Sealer

Master cylinder removal steps 

AC303153 AC

1

8

10

12

14

13

15 ± 2 N·m

14 ± 3 N·m

6

11

15

N

8

14 ± 3 N·m

2

7

5

5 ± 1 N·m

3

4

13 ± 2 N·m

9

Master cylinder removal steps

1.

Heat protector

2.

Brake fluid level switch connector

3.

Hose clip

>>C<<

4.

Reservoir hose

5.

Reservoir assembly

6.

Reservoir cap

7.

Brake fluid level switch

8.

Brake pipe connection

9.

Brake master cylinder

>>B<<

•

Push rod protrusion amount check 
and adjustment

Brake booster removal steps

>>A<<

10. Vacuum hose (with built-in check 

valve)

•

Inlet manifold (Refer to GROUP 15, 
Inlet manifold 

P.15-5

.)

11. Snap pin
12. Pin
13. Brake booster mounting nut
14. Brake booster assembly
15. Sealer

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

BASIC BRAKE SYSTEM

35A-16

INSTALLATION SERVICE POINTS
>>A<< VACUUM HOSE CONNECTION

<LH drive vehicles>

1. Insert the vacuum hose into the vacuum pipe with 

its white marking facing upward.

2. Insert the vacuum hose into the brake booster 

with its brown marking facing forward.

<RH drive vehicles>

1. Insert the vacuum hose into the inlet manifold 

with its white marking facing vehicle right side.

2. Insert the vacuum hose into the brake booster 

with its blue marking facing forward.

>>B<< PUSH ROD PROTRUSION 
AMOUNT CHECK AND ADJUSTMENT

1. Use the vacuum pump to measure dimension "A" 

applying a negative pressure of 66.7 kPa to the 
brake booster. 

Standard value (A): 11.3 

− 11.7 mm

NOTE: When a negative pressure of 66.7 kPa is 
not applied to the brake booster, the push rod 
protrusion amount (A) should be 10.3 - 10.7 mm.

AC311395

Marking

AB

Vacuum hose assembly

Marking

Vacuum pipe

AC301646

AC301647
AC302065 AC

Marking

Inlet manifold

Marking

Vacuum
hose

Vacuum hose assembly

AC102457BD

A

Measuring distance A

Block gauge

AC200306AC

MB991568

Angle-nose pliers

Rod spline

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

BASIC BRAKE SYSTEM

35A-17

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.

>>C<< RESERVOIR HOSE CONNECTION

1. Insert the reservoir hose into the reservoir 

assembly with its paint mark facing upward.

2. Insert the reservoir hose into the master cylinder 

with its paint mark facing upward.

MASTER CYLINDER

M1351004200450

DISASSEMBLY AND REASSEMBLY

AC311389 AB

Master
cylinder

Reservoir
assembly

<LH drive vehicles>

AC301992

AD

Master
cylinder

Reservoir
assembly

<RH drive vehicles>

AC303562

1

3

4

N

9

AC

5

N

6

N

7

N

N

2

8

10

5

6

7

8

9

Master cylinder kit

2.45 ± 0.5 N·m

(Apply fluid to cylinder 
inner)

Disassembly steps    

1. Inner bolt
2. Reservoir union
3. Reservoir seal
4. Stop pin
5. Rod seal

<<A>>

6. Circlip
7. Piston guide assembly
8. Primary piston assembly
9. Secondary piston assembly
10. Master cylinder body

Disassembly steps     (Continued)