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Mitsubishi Outlander (2003+). Manual - part 258

SERVICE SPECIFICATIONS

BASIC BRAKE SYSTEM

35A-3

SERVICE SPECIFICATIONS

M1351000300530

LUBRICANTS

M1351000400377

SEALANT

M1351000500385

Item

Standard value

Limit

Brake pedal height mm

L.H. drive vehicles 150

−

153

−

R.H. drive vehicles 176.2

−

179.2

−

Brake pedal free play mm

−

Brake pedal to floor board clearance mm

100 or more

−

Disc brake pad thickness mm

10.0

2.0

Disc brake disc thickness mm

Front

24.0

22.4

Rear

10.0

8.4

Disc brake disc run-out mm

Front

−

0.04

Rear

−

0.05

Disc brake drag force N

Front/Rear

68 or less

−

Wheel bearing axial play mm

Front/Rear

−

0.05

Brake booster push rod protruding length mm (When applying
negative pressure of 66.7 kPa to the brake booster)

10.15

−

10.40

−

Item

Specified lubricant

Brake fluid

DOT3 or DOT4

Guide pin

Repair kit grease

Lock pin
Guide pin boot inner surface
Lock pin boot inner surface
Piston boot mounting grooves
Brake piston boot inner surface
Guide pin bush inner surface

Item

Specified sealant

Remark

Fitting thread part

3M ATD Part No.8661 or equivalent

Semi-drying sealant

SPECIAL TOOLS

BASIC BRAKE SYSTEM

35A-4

SPECIAL TOOLS

M1351000600326

ON-VEHICLE SERVICE

BRAKE PEDAL CHECK AND
ADJUSTMENT

M1351000900479

BRAKE PEDAL HEIGHT

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

2. Measure the brake pedal height as illustrated.

Standard value (A):
150

−

153 mm <L.H. drive vehicles>

176.2

−

179.2 mm <R.H. drive vehicles>

[From the surface of dash panel 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) Remove the brake booster (Refer to

P.35A-15

NOTE: With the master cylinder and brake
pipe connected, remove the brake booster
only.

(3) Adjust the brake pedal height by turning the

clevis.

NOTE: When the clevis is turned 180

, the

pedal height is changed approximately 2.4
mm.

(4) Install the brake booster (Refer to

P.35A-15

(5) 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 (2) - (5).

Tool

Number

Name

Use

MB991568

Push rod adjusting
socket

Adjustment of the brake booster
push rod protrusion amount

MB990964
A: MB990520

Brake tool set
A: Disc brake
piston expander

Pushing-in of the disc brake
piston

MB990964

AC200515

AC006217AD

Clevis

ON-VEHICLE SERVICE

BASIC BRAKE SYSTEM

35A-5

(6) Screw in the stop lamp switch until its thread

contacts the stopper, and fix the stop lamp
switch by turning it approximately one quarter
of a turn clockwise.

(7) 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.

(8) Connect the connector at the stop lamp

switch.

4. Return the carpet, etc.

BRAKE PEDAL FREE PLAY

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.

2. Start the engine, depress the brake pedal with

approximately 490 N of force, and measure the
clearance between the brake pedal and the floor
board.

Standard value (C): 100 mm or more
[From the surface of floor board to the face
of pedal pad]

3. If the clearance is outside the standard value,

check for air trapped in the brake line, thickness of
the disc brake pad, clearance between the lining
and the drum and dragging in the parking brake.
And then adjust and replace defective parts as
required.

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

AC309282 AC

1.0 - 1.5 mm

Stopper

AC200011

AC107452

ON-VEHICLE SERVICE

BASIC BRAKE SYSTEM

35A-6

BRAKE BOOSTER OPERATING TEST

M1351001000327

1. For simple checking of the brake booster

operation, carry out the following tests:

(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.

(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.

(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 is

OK. 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-6

), vacuum hose for leaks, high volume

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

CHECK VALVE OPERATION CHECK

M1351009000321

CAUTION

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

P.35A-15

CAUTION

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

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

vacuum pump.

AC000870

Good

No good

AC000871AE

When engine
is stopped

When engine
is started

AC000872

Good

No good

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.

AC000873AE

Valve

Spring

Intake manifold
side
(does not hold)

Booster side
(holds)

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