Mitsubishi Outlander (2013+). Manual - part 435

ON-VEHICLE SERVICE

BASIC BRAKE

35A-7

CAUTION

Replace the check valve when it is faulty.

ACC00529

Intake 
manifold
side

Booster side

(1)

(2)

AB

2. Using a vacuum pump, check operation of the 

check valve. 

Vacuum pump 
connection

Normal condition

When connected to the 
booster side (1)

Vacuum is generated 
and maintained.

When connected to the 
engine side (2)

No vacuum is generated.

BLEEDING

M1351001401362

CAUTION

Be sure to use the specified brand and type of 
brake fluid. Avoid mixing with other type of brake 
fluid.

Brake fluid: DOT3 or DOT4

BLEEDING OF BRAKE PIPELINE 

AC607427AD

Front of
vehicle

3

4

1

2

1. Perform the bleeding in the order shown in the 

figure.

BRAKE FLUID LEVEL SWITCH CHECK

M1351009100986

AC505508AB

The brake fluid level switch is normal when the fol-
lowing conditions are met: When the brake fluid level 
is above "MIN," continuity is detected; and when the 
level is below "MIN," no continuity is detected.

BRAKE PAD CHECK

M1351017300703

CAUTION

If there is a significant difference in thickness 
between the brake pads at right and left, check 
the sliding area and the run-out of the brake disc 
(Refer to 

P.35A-9

).

ACB05917

<Front>

AB

ACB05918

<Rear>

AB

1. Visually check the thickness of brake pad from the 

inspection hole of the caliper body.

Standard value: 10.0 mm <Front>, 9.0 mm 
<Rear>
Limit: 2.0 mm <Front>, 1.5 mm <Rear>

2. If the brake pad thickness is less than the limit 

value, replace the brake pad (Refer to 

P.35A-8

).

ON-VEHICLE SERVICE

BASIC BRAKE

35A-8

BRAKE PAD REPLACEMENT

M1351017400915

<FRONT>

CAUTION

When replacing, replace both brake pads (right 
and left) as a set.

AC505542AH

<Front>

Guide pin

1. Remove the parts indicated in the figure, swivel 

the caliper body upward and retain it with a wire or 
similar tool.

ACB06047

3

3

1

Vehicle 
out side

2

1

AB

2. Remove the following parts from the caliper 

support.
(1) Shim
(2) Brake pad assembly
(3) Clip

CAUTION

Keep grease or other soiling off the pad and 
brake disc friction surfaces.

AC706162AB

MB990520

Piston

Caliper body

3. Clean the piston part, and press the piston into 

the cylinder using the special tool piston expander 
(MB990520).

AC505542AH

<Front>

Guide pin

4. Assemble the shim, brake pad assembly and clip 

to the caliper support, and tighten the lock pin to 
the specified torque.

Tightening torque: 44 

± 5 N⋅m

NOTE: Install the brake pad assembly (with wear 
indicator) to the inner side of the brake disc, mak-
ing sure that the wear indicator is located on the 
top.

LUBRICATION POINTS

AC808474

Grease: Repair kit grease (Colour: Translucent red),
              Niglube RX-2 or equivalent

AB

<REAR>

CAUTION

When replacing, replace both brake pads (right 
and left) as a set.
1. Remove the parking brake rear cable mounting 

bolts and nut (at the cable clamp) to loosen the 
cable. (Refer to GROUP 36 

− Parking Brake ).

ACC00566

<Rear>

Guide pin

AB

ON-VEHICLE SERVICE

BASIC BRAKE

35A-9

2. Remove the parts indicated in the figure, swivel 

the caliper body upward and retain it with a wire or 
similar tool.

ACC00403

3

2

3

1

AB

Vehicle out side

1

3. Remove the following parts from the caliper 

support.
(1) Shim
(2) Brake pad assembly
(3) Clip

CAUTION

Keep grease or other soiling off the pad and 
brake disc friction surfaces.

ACB05961

MB991621

AB

Extension

4. Clean the piston part, and press the piston into 

the cylinder using the special tool piston expander 
(MB991621).

ACC00566

<Rear>

Guide pin

AB

5. Assemble the brake pad assembly to the caliper 

support, and tighten the guide pin to the specified 
torque.

Tightening torque: 44 

± 5 N⋅m

NOTE: Install the brake pad assembly (with wear 
indicator) to the inner side of the brake disc, mak-
ing sure that the wear indicator is located on the 
bottom.

6. Connect the parking brake rear cable.(Refer to 

GROUP 36 

− Parking Brake ).

LUBRICATION POINT

ACC00404AB

Grease: Repair kit grease, Niglube RX-2 or 
              equivalent

ACC00405AB

Grease: Repair kit grease, AS880N or 
              equivalent

BRAKE DISC CHECK

M1351018600365

BRAKE DISC THICKNESS CHECK

1. Remove contaminants or corrosion from the brake 

disc surface.

ACX00668AH

Approx. 10 mm

ON-VEHICLE SERVICE

BASIC BRAKE

35A-10

2. Use a micrometer to measure the brake disc 

thickness at minimum eight points which are 10 
mm inward from its circumference.

Standard value:

26.0 mm <Front>
10.0 mm <Rear>

Limit:

24.4 mm <Front>
8.4 mm <Rear>

3. If the brake disc thickness is worn beyond the limit 

value at more than one point, replace the brake 
disc and check its run-out.

BRAKE DISC THICKNESS UNEVENNESS 
CHECK AND CORRECTION

1. Remove contaminants or corrosion from the brake 

disc surface.

ACX00668AH

Approx. 10 mm

2. Use a micrometer to measure the brake disc 

thickness at minimum eight points which are 10 
mm inward from its circumference. Then record 
the measurements.

3. If the brake disc thickness unevenness (the 

difference between the maximum and minimum 
values measured above) is 0.015 mm or less, it is 
within the standard value.

4. If the brake disc thickness unevenness exceeds 

the standard value, grind it according to the 
procedure below while it is mounted on the 
vehicle.

NOTE: If it is suspected that the brake disc thick-
ness will become less than the limit value after the 
grinding, replace the brake disc and check its 
run-out.
(1) Check for wheel bearing looseness in the axial 

direction (Refer to GROUP 26 

− On-vehicle 

Service, Wheel bearing axial play check  
<Front>, GROUP 27A 

− On-vehicle Service, 

Wheel bearing axial play check  <Rear 
(2WD)> or GROUP 27B 

− On-vehicle Service, 

Wheel bearing axial play check  <Rear 
(4WD)>).

CAUTION

•

AC006226 AE

M12 Flat washer

M12 Flat washer

Insert M12 plain washer and then install the 

adapter as shown before grinding. Failure to 
use the M12 plain washer will cause the brake 
disc to be deformed and earth incorrectly.

• To grind the brake disc, ensure that all the 

nuts (M12 X 1.5) are tightened evenly and in a 
diagonal sequence to the specified torque 
(100 N

⋅m). Failure to use all the nuts 

(M12

×1.5), excessive or uneven tightening 

torque will cause the brake disc to deform or 
judder.

(2) Correct the brake disc uneven thickness by 

grinding it while in place on the vehicle.