Mitsubishi Colt Ralliart. Manual - part 216

AC000871AE

When engine
is stopped

When engine
is started

ON-VEHICLE SERVICE

BASIC BRAKE SYSTEM

35A-10

(2) With the engine stopped, step on the brake 

pedal several times. Then step on the brake 
pedal and start the engine. If the pedal moves 
downward slightly, the booster is in good 
condition. If there is no change, the booster is 
defective. Go to step 3.

AC000872

Good

No good

AE

(3) With the engine running, step on the brake 

pedal and then stop the engine. Hold the 
pedal depressed for 30 seconds. If the pedal 
height does not change, the booster is in good 
condition, if the pedal rises, the booster is 
defective.

2. If the above three tests are okay, the booster 

performance can be determined as good. If one of 
the above three tests is not okay, the check valve, 
vacuum hose, or booster is defective. Check the 
check valve (Refer to 

P.35A-10

), vacuum hose for 

leaks, high volume engine vacuum applied to 
booster. Repair or replace as necessary. If these 
are okay, replace the booster and repeat this test 
starting at Step 1.

CHECK VALVE OPERATION CHECK

M1351009000495

CAUTION

The check valve should not be removed from the 
vacuum hose.
1. Remove the vacuum hose (Refer to 

P.35A-23

).

CAUTION

If the check valve is defective, replace it as an 
assembly unit together with the vacuum hose.

AC314141AB

A

B

Engine side
(does not
hold)

Booster
side
(holds)

Vacuum hose
assembly

2. Check the operation of the check valve by using a 

vacuum pump.

Vacuum pump 
connection

Accept/reject criteria

Connection at the brake 
booster side (A)

A negative pressure 
(vacuum) is created and 
held.

Connection at the intake 
manifold side (B)

A negative pressure 
(vacuum) is not created.

BLEEDING

M1351001400842

CAUTION

Use only brake fluid DOT 3 or DOT 4. Never mix 
the specified brake fluid with other fluid as it will 
influence the braking performance significantly.

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TOC

ON-VEHICLE SERVICE

BASIC BRAKE SYSTEM

35A-11

MASTER CYLINDER BLEEDING

The master cylinder used has no check valve, so if 
bleeding is carried out by the following procedure, 
bleeding of air from the brake pipeline will become 
easier (When brake fluid is not contained in the mas-
ter cylinder).
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.

AC601749AB

Master cylinder

3. Have another person cover the master cylinder 

outlet with a finger.

4. With the outlet still closed, release the brake 

pedal.

5. Repeat steps 2 

− 4 three or four times to fill the 

inside of the master cylinder with brake fluid.

BRAKE LINE BLEEDING

AC207973AC

MB991922

Reservoir assembly

1. Install the special tool brake fluid filling tool 

(MB991922) as shown. Carry out air-bleeding 
while brake fluid is being added.

AC102356

1

AF

4

3

2

2. Start the engine and bleed the air in the sequence 

shown in the figure.

BRAKE FLUID LEVEL SENSOR CHECK

M1351009100663

AC509656

The brake fluid level sensor is in good condition if 
there is no continuity when the float surface is above 
"MIN" and if there is continuity when the float surface 
is below "MIN".

DISC BRAKE PAD CHECK AND 
REPLACEMENT <EXCEPT FOR 
RALLIART VERSION-R>

M1351002300848

<FRONT>

NOTE: 

AC000879

When new

When worn

AD

Pad

Wear indicator

Brake
disc

The brake pads have indicators that contact the 
brake disc when the brake pad thickness becomes 2 
mm, and emit a squealing sound to warn the driver.

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ON-VEHICLE SERVICE

BASIC BRAKE SYSTEM

35A-12

CAUTION

• Whenever a pad must be replaced, replace 

both LH and RH wheel pads as a set to pre-
vent the vehicle from pulling to one side when 
braking.

• If there is a significant difference in the thick-

ness of the pads on the left and right sides, 
check the sliding condition of the piston and 
slide pins.

AC403292 AB

<14-inch>

<15-inch>

1. Check the brake pad thickness through the caliper 

body check port.
Standard value: 10.0 mm
Minimum limit: 2.0 mm

AC403291AB

<14-inch>

<15-inch>

Guide pin

Slide pin 
bolt (sub)

2. Remove the guide pin or slide pin bolt (sub).Pivot 

the caliper assembly and hold it with wires.

AC602357AB

1

4

3

5

1

5

1

1

4

2

5

5

<14-inch>

<15-inch>

3. Remove the following parts from caliper 

assembly.
(1) Shim
(2) Outer pad <14-inch>
(3) Pad assembly <15-inch>
(4) Pad assembly <RH> or Pad and wear 

indicator assembly <LH>

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ON-VEHICLE SERVICE

BASIC BRAKE SYSTEM

35A-13

(5) Pad clip

4. In order to measure the brake drag force after pad 

installation, measure the rotary-sliding resistance 
of the hub with the pads removed <Refer to 

P.35A-26

 (14-inch) or 

P.35A-29

 (15-inch)>.

5. Install the pads and caliper assembly, and then 

check the brake drag force <Refer to 

P.35A-26

 

(14-inch) or 

P.35A-29

 (15-inch)>.

<Rear>

AC402247AB

1. Visually check the thickness of brake pad from the 

inspection hole of the caliper body.
Standard value: 9.5 mm
Limit value: 2.0 mm

2. When the thickness is lower than the limit value, 

replace the both brake pads (right and left) as a 
set.

3. Disengage the connection between the rear brake 

caliper and rear parking brake cable.

AC402247AC

4. Remove the bolt, and swivel the caliper assembly 

upward to retain with a wire or other similar 
material.

AC402334

AB

1

2

3

4

1

4

5. Remove the following parts from the caliper 

assembly.
(1) Shim
(2) Outer pad
(3) Pad assembly <RH> or Pad and wear 

indicator assembly <LH>

(4) Pad clip

6. In order to measure the brake drag force after pad 

installation, measure the hub sliding torque with 
no pad attached (Refer to 

P.35A-41

).

CAUTION

Keep grease or other fouling off the pad and 
brake disc friction surface. 

AC402607AB

MB990652

7. Clean the piston, and press the piston into the 

cylinder using the special tool, rear disc brake 
piston driver (MB990652).

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