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Mitsubishi Colt Ralliart. Manual - part 215

SPECIAL TOOLS

BASIC BRAKE SYSTEM

35A-6

SPECIAL TOOLS

M1351000600650

Tool

Number

Name

Use

B991922

MB991922

Brake fluid filling
tool

Brake line air-bleeding

B991008

MB991008

piston cup Installer

Installation of the drum brake
wheel cylinder piston cup

MB990652

MB990652

Rear disc brake
piston driver

Removal and installation of the
rear disc brake piston <VR-X>

MB990652

MB996049

Rear disc brake
piston driver

Removal and installation of the
rear disc brake piston <RALLIART
Version-R>

MB991041

MB991041

Snap ring pliers

Removal and installation of the
rear disc brake snap ring

MB991042

MB991042

Claw

MB990964

MB990964
A: MB990520

Brake tool set
A: Disc brake piston
expander

Pushing-in of the disc brake
piston

Main

Index

Group

TOC

ON-VEHICLE SERVICE

BASIC BRAKE SYSTEM

35A-7

ON-VEHICLE SERVICE

BRAKE PEDAL CHECK AND
ADJUSTMENT

M1351000900866

BRAKE PEDAL HEIGHT <EXCEPT FOR
RALLIART VERSION-R>

1. Turn up the carpet, etc. under the brake pedal.

AC208048

Stop lamp switch

2. Measure the brake pedal height as illustrated.

Standard value (A):

142.9

− 145.9 mm <CVT>

143.2

− 146.2 mm <M/T>

(From the surface of floor board to the face of

pedal pad)

3. If the brake pedal height is not within the standard

value, follow the procedure below.
(1) Disconnect the stop lamp switch connector.
(2) Loosen the stop lamp switch anticlockwise

approximately 1/4 turns.

AC208050AB

Brake booster

Clevis

Brake pedal
assembly

Stop lamp
switch

(3) Remove the brake pedal support member

assembly (Refer to

P.35A-20

(4) Adjust the brake pedal height by turning the

brake booster clevis.

NOTE:

AC602118AB

Brake booster
push rod

Clevis

•

When the clevis is turned 180

, the pedal

height is changed approximately 1.5 mm.

•

The extending side can be adjusted to the
position where the thread section of the
pushrod end does not get into the clevis.

(5) Install the brake pedal support member

assembly (Refer to

P.35A-20

AC208051AB

Stopper

0.5 - 1.5 mm

Stop lamp switch

(6) Push the stop lamp switch until its thread

touches the stopper. Then secure the switch
by turning it clockwise approximately 1/4 turns.
During this work, pull the brake pedal towards
you to hold.

(7) Measure the brake pedal height, and ensure

that the measured value is within the standard
value. When it is out of the standard value,
repeat Step (3) - (6).

(8) Check that the clearance between the stop

lamp switch and the stopper is as shown.

CAUTION

Check that the stop lamp does not illuminate
when the brake pedal is not depressed.

(9) Connect the connector at the stop lamp

switch.

4. Check the key interlock and shift lock

mechanisms (Refer to GROUP 23A, On-vehicle
Service

P.23A-144

5. Return the carpet, etc.

Main

Index

Group

TOC

ON-VEHICLE SERVICE

BASIC BRAKE SYSTEM

35A-8

BRAKE PEDAL HEIGHT <RALLIART
VERSION-R>

1. Turn up the carpet, etc. under the brake pedal.

AC208048

Stop lamp switch

2. Measure the brake pedal height as illustrated.

Standard value (A): 143.2

− 146.2 mm

(From the surface of floor board to the face
of pedal pad)

3. When the brake pedal height is not within the

standard value, adjust the brake pedal in the
following procedure.
(1) Disconnect the stop lamp switch connector.
(2) Rotate the stop lamp switch anti-clockwise

and remove it.

AC601385AC

Brake booster

Clevis

Brake pedal
assembly

Stop lamp
switch

(3) Disconnect the brake pedal and clevis

connection and remove the brake pedal
assembly. (Refer to

P.35A-21

(4) Rotate the brake booster clevis to adjust the

brake pedal height.

NOTE:

AC602118AB

Brake booster
push rod

Clevis

•

When the clevis is turned 180

, the pedal

height is changed approximately 1.5 mm.

•

The extending side can be adjusted to the
position where the thread section of the
pushrod end does not get into the clevis.

(5) Install the brake pedal assembly and connect

the brake pedal and the clevis. (Refer to

P.35A-21

(6) Measure the brake pedal height, and make

sure that it is within the standard value. If not
within the standard value, perform the steps
(3) to (5) again.

CAUTION

Pulling out the plunger section too frequently
may damage the automatic adjustment mecha-
nism section of the stop lamp switch because it
is made of plastics. If the plunger section is
pulled out at least 2 or 3 times, replace the stop
lamp switch.

AC404940

Stop lamp switch

Plunger

Approx. 24 mm

(7) Pull out the plunger section of the stop lamp

switch to the maximum length (approx. 24
mm).

NOTE: The stop lamp switch incorporates the
automatic adjustment mechanism for the
plunger section.

(8) Hold the brake pedal to prevent it from

moving, and press in the stop lamp switch to
the bracket of the brake pedal assembly.
Then, turn the stop lamp switch clockwise to
install it.

Main

Index

Group

TOC

ON-VEHICLE SERVICE

BASIC BRAKE SYSTEM

35A-9

NOTE: By installing the stop lamp switch as
described above, the plunger section is
adjusted to the standard value automatically.

CAUTION

Check that the stop lamp does not illuminate
when the brake pedal is not depressed.

(9) Connect the connector at the stop lamp

switch.

4. Return the carpet, etc.

BRAKE PEDAL FREE PLAY

AC208053AB

1. Turn the ignition switch to the "LOCK" (OFF)

position, depress the brake pedal two or three
times. After eliminating the vacuum in the brake
booster, press the pedal down by hand, and
confirm that the amount of movement before
resistance is met (free play) is within the standard
value range.

Standard value: 3

− 8 mm

2. If the brake pedal play is not within the standard

value, check the following, and adjust or replace if
necessary:

• Excessive play between the brake pedal and the

clevis pin, or between the clevis pin and the
brake booster operating rod

• Brake pedal height

• Installation position of the stop lamp switch, etc.

CLEARANCE BETWEEN BRAKE PEDAL
AND FLOOR BOARD

1. Turn up the carpet, etc. under the brake pedal.

AC208054

2. Start the engine, depress the brake pedal with

approximately 500 N of force, and measure the
clearance between the brake pedal and the floor
board.

Standard value (C): 70 mm or more
(From the surface of floor board to the face
of pedal pad)

3. If the clearance between the brake pedal and the

floor is not within the standard value, check the
brake lines for air-lock, the disc brake pad
thickness or the drum brake lining thickness, and
the parking brake for dragging. Adjust or replace
defective part(s) if necessary.

4. Return the carpet etc. to its original position.

BRAKE BOOSTER OPERATING TEST

M1351001000479

1. For simple checking of the brake booster

operation, carry out the following tests:

AC000870

Good

No good

(1) Run the engine for one or two minutes, and

then stop it. If the pedal depresses fully the
first time but gradually becomes higher when
depressed succeeding times, the booster is
operating properly. If the pedal height remains
unchanged, the booster is defective. Go to
step 2.

Main

Index

Group

TOC

Content .. 213 214 215 216 ..