Mitsubishi Outlander (2013+). Manual - part 434

SPECIAL TOOLS

BASIC BRAKE

35A-3

SPECIAL TOOLS

M1352000601872

Tool

Number

Name

Use

MB992146

MB992146

Booster test 
adapter

Inspection using a simplified tester

MB990964

A

B

a

MB990964
a: MB990520

Brake tool set
a: Piston expander

Disc brake piston pushing back <Front 
disc brake>

MB991621

MB991621

Piston driver

Disc brake piston pushing back <Rear 
disc brake>

ON-VEHICLE SERVICE

BRAKE PEDAL CHECK

M1351003501042

CAUTION

Do not apply grease or lubricant to the switch 
and the switch installation section to avoid mal-
function of the switch. In addition, do not use 
gloves which have grease on them.

BRAKE PEDAL HEIGHT CHECK

1. Turn up the floor carpet under the brake pedal.

2. Remove the stop lamp switch (Refer to 

P.35A-13

).

AC505506AE

B

A

Dash panel

Dash panel pad

Stop lamp
switch

3. Use a needle or similar tool to measure the 

dimension A in the figure (distance from the dash 
panel pad surface to the dash panel).

4. Measure the dimension B in the figure (distance 

from the pedal pad surface to the dash panel pad 
surface).

5. Make sure that the total of the dimensions A and 

B measured in Steps 3 and 4 (brake pedal height) 
is within the standard value.

Standard value (A+B): 221.8 

− 227.8 mm

6. When the brake pedal height is not within the 

standard value, inspect the brake pedal in the 
following procedure.
(1) Remove the brake pedal assembly (Refer to 

P.35A-13

).

(2) Check the removed brake pedal assembly for 

distortion, and replace it when deformed 
(Refer to 

P.35A-14

).

(3) Install the brake pedal assembly (Refer to 

P.35A-13

).

NOTE: When installing, compress the dash 
panel pad.

AC508163AB

C

Clevis

Stud bolt

ON-VEHICLE SERVICE

BASIC BRAKE

35A-4

(4) Measure the brake pedal height again, and 

make sure that it is within the standard value 
(A+B).

 

When the measured value is not within the 
standard value, measure the dimension C in 
the figure (distance from the stud bolt end to 
the clevis hole centre), and make sure it is 
within the standard value (C).

Standard value (C): 75.8 

− 80.2 mm

(5) When the measured value is not within the 

standard value (C), replace the brake booster 
(Refer to 

P.35A-15

).

AC309282 AF

0.5 to 1.5 mm

Stop lamp switch

Pedal stopper

Pedal stopper

7. After checking the brake pedal height, install the 

stop lamp switch in the following procedure:
(1) Screw in the stop lamp switch until its thread 

contacts the pedal stopper, then turn the 
switch approximately one eighth of a 
clockwise turn to fix it. While doing this, pull 
and hold the brake pedal by hand.

(2) Check that the clearance between the stop 

lamp switch and the pedal stopper is as shown 
in the figure.

CAUTION

Make sure that the stop lamp is not illuminated 
when the brake pedal is not depressed.

(3) Connect the stop lamp switch connector.

8. Recover the floor carpet under the brake pedal.

BRAKE PEDAL FREE PLAY CHECK AND 
ADJUSTMENT

AC505506AH

D

ON-VEHICLE SERVICE

BASIC BRAKE

35A-5

1. With the engine stopped, depress the brake pedal 

2 or 3 times to relief the vacuum in the brake 
booster. Then, press the brake pedal with your 
finger and check if the pedal stroke until the pedal 
becomes heavy (play) is within the standard 
value.

Standard value (D): 3 

− 8 mm

2. When the brake pedal free play is not within the 

standard value, check the brake pedal-to-clevis 
pin looseness, clevis pin-to-booster operating rod 
looseness, brake pedal height, and stop lamp 
switch position, and adjust or replace as 
necessary.

BRAKE PEDAL-TO-FLOOR PANEL 
CLEARANCE CHECK AND ADJUSTMENT

1. Turn up the floor carpet under the brake pedal.

AC505506AL

E

2. Start the engine and depress the brake pedal with 

approximately 500 N, and measure clearance 
between the brake pedal and the floor panel.

Standard value (E): 80 mm or more

3. When the clearance is not within the standard 

value, check for the air in the brake line and 
thickness of the disc brake pad, and correct or 
replace as necessary.

4. Recover the floor carpet under the brake pedal.

BRAKE BOOSTER OPERATION CHECK

M1351001001331

INSPECTION WITHOUT USING TESTER

1. Carry out the simplified brake booster operation 

check in the following procedure:

AC000870AC

Good

No good

Once

Second

Third

(1) Run the engine for 1 to 2 minutes, and then 

stop. Depress the brake pedal with normal 
depression force. The result is judged as 
"Good" when the pedal stroke is great at the 
first depression, and becomes smaller as you 
repeat depressing the pedal. If the pedal 
stroke does not change, the result is judged as 
"No Good."

AC000871AC

When engine
is stopped

When engine
is started

(2) With the engine stopped, depress the brake 

pedal several times. Keep the brake pedal 
depressed and start the engine. At this time, 
when the pedal moves down slightly, the result 
is judged as "Good." The result is judged as 
"No Good" if the pedal does not moves down.

AC000872 AC

Good

No good

(3) With the engine running, depress the brake 

pedal. Stop the engine in this condition. The 
result is judged as "Good" when the pedal 
height does not change for approximately 30 
seconds. The result is judged as "No Good" if 
the pedal moves up.

ON-VEHICLE SERVICE

BASIC BRAKE

35A-6

2. The brake booster is judged as normal when the 

results of all the above checks are "Good."

When one or more of the above check results are 
"No Good," then the check valve, vacuum hose, 
or brake booster is suspected faulty.

INSPECTION USING SIMPLIFIED TESTER

1. Before starting this inspection, remove the brake 

booster check valve from the vehicle and check its 
operation (Refer to 

P.35A-15

).

AC610136

Pressure gauge

Vacuum
gauge

Vacuum hose

Checkvalve 

MB992146

Pedal depression
gauge

AB

2. After checking, install the check valve to the 

vacuum hose and connect it to the vacuum 
gauge. Install special tool booster test adapter 
(MB992146) to the brake booster and connect it 
to the vacuum gauge. Connect the pressure 
gauge and pedal depression gauge as shown in 
the figure. Bleed the pressure gauge and then 
perform the following tests:
(1) Airtightness test with no load

Start the engine, and stop it when the vacuum 
gauge indicator has reached approximately 
−67 kPa. The result is judged as "Good" when 
the drop of the vacuum approximately 15 
seconds after the engine was stopped is within 
−3.3 kPa.

(2) Airtightness test with load 

Start the engine and depress the brake pedal 
with 200 N. Stop the engine when the vacuum 
gauge indicator reached approximately 

−67 

kPa. The result is judged as "Good" when the 
drop of the vacuum approximately 15 seconds 
after the engine was stopped is within 

−3.3 

kPa.
When one or more of the above check results 
are judged as "No Good," the vacuum hose or 
brake booster is suspected faulty.

(3) Brake booster characteristics test

Perform this test after the above (1) and (2) 
were performed.
a. Non-servo effect test

With the engine stopped, make sure that 
the vacuum gauge reading is 0 kPa. 
Depress the brake pedal with 100 N and 
300 N, and measure the fluid pressure 
generated.

Standard value:

Item

Pedal depression force

100 N

300 N

Generated fluid pressure  
kPa

0 

− 600

1,030 

− 

2,220

b. Servo effect test

Start the engine. Depress the brake pedal 
with 100 N and 300 N when the vacuum 
gauge indicator reached approximately 

−67 

kPa, and measure the fluid pressure 
generated.

Standard value:

Item

Pedal depression force

100 N

300 N

Generated fluid pressure  
kPa

6,570 

− 

8,330

10,370 

− 

11,560

CHECK VALVE OPERATION CHECK

M1351009001197

1. Remove the check valve (Refer to 

P.35A-15

).