Mitsubishi Pajero Pinin. Manual - part 243

BASIC BRAKE SYSTEM – 

Rear Drum Brake

35A-8

WHEEL CYLINDER
DISASSEMBLY AND REASSEMBLY

3

Brake fluid: DOT3 or DOT4

Grease: Repair kit grease

Grease

Wheel cylinder repair kit

2

4

2

1

4

1

4

1

6

2

6

7

5

4

2

3

1

7.9 

±

 0.9 N·m

Disassembly steps

1. Boots
2. Piston assembly

"

A

A

3. Pistons

"

A

A

4. Piston cups
5. Spring
6. Wheel cylinder body

REASSEMBLY SERVICE POINT

"

A

A

PISTON CUPS/PISTONS REASSEMBLY

1.

Use trichloroethylene, alcohol or the specified brake fluid
to clean the piston.

Specified brake fluid: DOT3 or DOT4

2.

Apply the specified brake fluid to the piston cups and
the outer circumference of the special tool.

3.

Set the piston cup on the special tool with the lip of the
cup facing up, fit the cup onto the special tool.

4.

Slide the piston cup down the outside of the tool into
the piston groove carefully, making sure that the piston
cup is twisted or slanted.

INSPECTION

Check the piston and wheel cylinder walls for rust or damage,
and if there is any abnormality, replace the entire wheel cylinder
assembly.

MB990619

Piston

Have the lip facing
upwards.

SERVICE BULLETIN

PUBLICATION GROUP, AFTER SALES SERVICE DEP.

MITSUBISHI MOTOR SALES EUROPE BV

SERVICE BULLETIN

No.: ESB-01E35-001

Date

:

 2001-07-03

<Model>

<M/Y>

Subject:

REPLACEMENT AND CLEANING FOR BRAKE
BOOSTER VACUUM NIPPLE ON 4G93 GDI
EQUIPPED VEHICLES

(EC)CARISMA
(EC)SPACE STAR
(EC)PAJERO PININ

98-10

Group:

SERVICE BRAKE

draftno.: 01AL005

INFORMATION

O. Kai - E.V.P. & G.M.
After Sales Service Dept.

1. Description:

On 4G93-GDI engine-equipped vehicles for Europe, the vacuum nipple of the brake booster must
be replaced and cleaned periodically. This Service Bulletin covers the replacement and cleaning
procedures which should be added in On-Vehicle Service as shown below.

2. Applicable Manuals:

Manual

Pub. No.

Language

Page(s)

’98 CARISMA GDI

PWDE9502-C

(English) 35A-1

Workshop Manual chassis

PWDS9503-C

(Spanish) 35A-1

PWDF9504-C

(French) 35A-1

PWDG9505-C

(German) 35A-1

PWDD9505-C

(Dutch) 35A-1

PWDW9506-C

(Swedish) 35A-1

PWDI96E1-C

(Italian) 35A-1

’99 SPACE STAR

CMXE99E1

(English) 35A-14

Workshop Manual chassis

CMXS99E1

(Spanish) 35A-14

CMXF99E1

(French) 35A-14

CMXG99E1

(German) 35A-14

CMXD99E1

(Dutch) 35A-14

CMXW99E1

(Swedish) 35A-14

CMXI99E1

(Italian) 35A-14

’00 PAJERO PININ
Workshop Manual chassis

CKRE00E1

(English) 35A-13

’00 MONTERO io
Workshop Manual chassis

CKRS00E1

(Spanish) 35A-13

’00 PAJERO PININ

CKRF00E1

(French) 35A-13

Workshop Manual chassis

CKRG00E1

(German) 35A-13

CKRD00E1

(Dutch) 35A-13

CKRW00E1

(Swedish) 35A-13

CKRI00E1

(Italian) 35A-13

2

GROUP 35A

BASIC BRAKE SYSTEM

GENERAL

OUTLINE OF CHANGES
The following maintenance service points have been established to correspond to the addition of a pressure
sensor. Maintenance service procedures not listed below are the same as before.

ON-VEHICLE SERVICE

BRAKE BOOSTER VACUUM NIPPLE
REPLACEMENT

1.  Remove the brake booster hose from the intake manifold.
2.  Replace the nipple with a new one, using a sealing agent

and tighten to 15 – 18 N.m

Specified sealant:

3M ATD Part No.8661 or equivalent

Caution
Take care when applying the thread sealant as too
much could block the nipple.

3.  After replacement, re-install the brake booster hose.

3. Details: ’98 CARISMA GDI Workshop Manual chassis

35A-1

BASIC BRAKE SYSTEM - General /On-vehicle Service

<Added>

Intake manifold

Brake
booster
hose

AY0140BY

Nipple

<Added>

3

BRAKE LINING THICKNESS CHECK

35100300241

1.  Remove the brake drum.
2.  Measure the wear of the brake lining at the place worn

the most.
Standard value: 4.38 mm
Limit: 1.0 mm
Replace the shoe and lining assembly if brake lining
thickness is less than the limit if it is not worn evenly.
For information concerning the procedures for installation
of the shoe and lining assembly, refer to P.35A-22.
Caution
(1)  Whenever the shoe and lining assembly is

replaced, replace both RH and LH assemblies as a
set to prevent car from pulling to one side when
braking.

(2)  If there is a significant difference in the thickness

of the shoe and lining assemblies on the left and
right sides, check the sliding condition of the
piston.

BRAKE DRUM INSIDE DIAMETER CHECK 

35100320049

1.  Remove the brake drum.
2.  Measure the inside diameter of the brake drum at two or

more locations
Standard value: 203 mm
Limit: 205 mm

3.  Replace brake drums, shoe and lining assembly when

wear exceeds the limit value or is badly imbalanced.

BRAKE LINING AND BRAKE DRUM
CONNECTION CHECK

35100310053

1.  Remove the brake drum.
2.  Remove the shoe and lining assembly.

(Refer to P.35A-22.)

3.  Chalk inner surface of brake drum and rub with shoe and

lining assembly.

4.  Replace shoe and lining assembly or brake drums if there

are any irregular contact area.
NOTE
Clean off chalk after check.

BRAKE BOOSTER VACUUM NIPPLE
REPLACEMENT

1.  Remove the brake booster hose from the intake manifold.
2.  Replace the nipple with a new one, using a sealing agent

and tighten to 15 – 18 N.m
Specified sealant:

3M ATD Part No.8661 or equivalent.

Caution
Take care when applying the thread sealant as too
much could block the nipple.

3.  After replacement, re-install the brake booster hose.

3. Details: ’99 SPACE STAR Workshop Manual chassis

35A-14

BASIC BRAKE SYSTEM - On-vehicle Service

14W0096

14X0366

14U007

AY0141BY

Intake manifold

Brake booster hose

Nipple

<Added>