Mitsubishi Pajero Pinin. Manual - part 237

BASIC BRAKE SYSTEM – 

Master Cylinder and Brake Booster

35A-16

<L.H. drive vehicles without ABS and R.H. drive vehicles>

Pre-removal Operation
Brake Fluid Draining

Post-installation Operation

D

Brake Fluid Supplying and Air Bleeding 
(Refer to P.35A-10.)

D

Brake Pedal Adjustment (Refer to P.35A-6.)

Specified Sealant: 3M ATD
Part No.8661 or equivalent

Grease: Silicone grease

11

4

7

8

14

9

10

1

2

12

12 Nm

15 Nm

14 Nm

15 Nm

1

3

11

6

14

14.7 – 17.7 Nm

12

10

5

13

<L.H. drive vehicles>

14

<R.H. drive vehicles>

14.7 – 17.7 Nm

6

Grease: Silicone grease

12

4

BASIC BRAKE SYSTEM – 

Master Cylinder and Brake Booster

35A-17

Master cylinder removal steps

1. Brake pipe connection
2. Brake fluid level sensor connector
3. Bracket <L.H. drive vehicles>
4. Master cylinder

"

C

A

5. Seal

Brake booster removal steps

1. Brake pipe connection
2. Brake fluid level sensor connector
3. Bracket <L.H. drive vehicles>
4. Master cylinder

"

C

A

5. Seal

"

B

A D

Push rod protrusion amount check and
adjustment

"

A

A

6. Vacuum hose 

(With built-in check valve)

7. Snap pin
8. Pin assembly
9. Vacuum sensor connector

10. Vacuum sensor

11. Grommet

12. Brake booster
13. Sealer

Fitting removal

14. Fitting

INSTALLATION SERVICE POINTS

"

A

A

VACUUM HOSE CONNECTION

Insert the vacuum hose to the fitting with its paint mark facing
forward <L.H. drive vehicles>/upward <R.H. drive vehicles>
until the hose end reaches the edge of the hexagonal part
of the fitting, and then secure the hose by using the hose
clip.

"

B

A

PUSH ROD PROTRUSION AMOUNT CHECK AND
ADJUSTMENT

1.

Measure dimension (A).

Standard value (A) : 

<L.H. drive vehicles with ABS> 22.7 – 22.9 mm
<L.H. drive vehicles without ABS and R.H. drive
vehicles> 23.93 – 24.18 mm

NOTE
When a negative pressure of 66.7 kPa is applied to the
brake booster, the push rod should protrude 22.2 – 22.4
mm <L.H. drive vehicles with ABS>/23.48 – 23.73 mm
<L.H. drive vehicles without ABS and R.H. drive vehicles>.

Block gauge

Measuring distance A

A

BASIC BRAKE SYSTEM – 

Master Cylinder and Brake Booster

35A-18

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 to turn the push rod while holding
the rod spline with angle-nose pliers.

"

C

A

SEAL INSTALLATION

1.

Apply silicone grease to the seal.

2.

Install the seal to the master cylinder as shown.

INSPECTION

VACUUM SENSOR CHECK

Refer to GROUP 13A – Troubleshooting.

NOTE
The vacuum sensor is monitored by the engine-ECU. Diagnosis
code is output when the vacuum sensor has a malfunction.

Angle-nose pliers

MB991568

Seal

Master cylinder

<L.H. drive vehicles with ABS>

<L.H. drive vehicles without ABS and R.H.
drive vehicles>

Master cylinder

Seal

BASIC BRAKE SYSTEM – 

Master Cylinder and Brake Booster

35A-19

MASTER CYLINDER <L.H. drive vehicles without ABS and R.H. drive vehicles>
DISASSEMBLY AND REASSEMBLY

1

2

3

8

6

8

Brake fluid: DOT3 or DOT4

7

7

5

Master cylinder kit

4

5

9

6

12

11

10

9

10

11

12

11

12

10

Disassembly steps

1. Reservoir cap
2. Pin
3. Reservoir tank
4. Brake fluid level sensor
5. Reservoir seal

A

A

"

6. Stopper ring

7. Piston guide
8. Cylinder cup
9. Plate

10. Primary piston assembly

11. Secondary piston assembly

12. Master cylinder body

DISASSEMBLY SERVICE POINT

A

A

"

STOPPER RING REMOVAL

Push the primary piston assembly and remove the stopper
ring.