Mitsubishi Outlander GS45X. Manual - part 1547

 

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Mitsubishi Outlander GS45X. Manual - part 1547

 

 

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE

35A-17

BRAKE PEDAL PLAY CHECK AND ADJUSTMENT

1. With the engine stopped, depress the brake pedal 2 or 3 

times to relieve 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 (B): 3 

 8 mm (0.12  0.31 inch)

2. When the brake pedal 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 stoplight 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.
2. Start the engine and depress the brake pedal with 

approximately 500 N (112 pounds), and measure clearance 
between the brake pedal and the floor panel.

Standard value (C): 80 mm (3.15 inch) 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

M1351001001256

.

INSPECTION WITHOUT USING TESTER

1. Carry out the simplified brake booster operation check in the 

following procedure:

(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."

AC505506AC

B

AC505506AI

C

AC000870AC

Good

No good

Once

Second

Third

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE

35A-18

(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.

(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.

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-30

.)

2. After checking, install the check valve to the vacuum hose 

and connect it to the vacuum gauge. Install the booster test 
adapter (Special tool: 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 (−9.7 psi). 

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 (−0.5 psi). 

(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 (−9.7 psi). 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 (−0.5 psi). 

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

AC000871AC

When engine
is stopped

When engine
is started

AC000872 AC

Good

No good

AC610136

Pressure gauge

Vacuum
gauge

Vacuum hose

Checkvalve 

MB992146

Pedal depression
gauge

AB

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE

35A-19

(3) Brake booster characteristics test

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

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

Standard value:

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 (−9.7 psi), and measure the 

fluid pressure generated.

Standard value:

CHECK VALVE OPERATION CHECK

M1351009000837

1. Remove the check valve (Refer to 

P.35A-30

).

CAUTION

Replace the check valve when it is faulty.
2. Using a vacuum pump, check operation of the check valve. 

Item

Pedal depression force

100 N

300 N

Generated fluid 
pressure kPa (psi)

− 600  

(0 

− 87.0)

1,030 

− 2,220  

(149.4 

− 322.0)

Item

Pedal depression force

100 N

300 N

Generated fluid 
pressure kPa (psi)

6,030 

− 7,780 

(874.5 

− 

1,128.4)

10,370 

− 

11,560 
(1,504.0 

− 

1,676.6)

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.

AC508114

Valve

Spring

Intake 
manifold
side

Booster side

(1)

(2)

AB

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE

35A-20

BLEEDING

M1351001401049

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 

Perform the bleeding in the order shown in the figure.

BRAKE FLUID LEVEL SWITCH CHECK

M1351009100834

The brake fluid level switch is normal when the following condi-
tions are met: When the brake fluid level is above "MIN," conti-
nuity is detected; and when the level is below "MIN," no 
continuity is detected.

AC507892AB

1

2

3

4

Front of
vehicle

AC505508AB

 

 

 

 

 

 

 

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