Basic Brake System - Lancer: Component Locations Mitsubishi Lancer X

SPECIAL TOOL

SPECIAL TOOL DESCRIPTION Tool Number Name Use MB992146 Booster test adapter Inspection using a simplified tester MB990964 A: MB990520 B: MB990619 Brake tool set A: Piston expander B: Installer Disc brake piston pushing back Installation of the drum brake wheel cylinder piston cup

Scheme 93

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Scheme 95

1. Turn up the floor carpet under the brake pedal.
2. Remove the stop lamp switch (Refer to «BRAKE PEDAL»(ref-291270-S17112925442008072500000) ).
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 2 and 3 (brake pedal height) is within the standard value. Standard value (A+B): 219.8 - 227.8 mm (8.7 - 9.0 inch)
6. When the brake pedal height is not within the standard value, inspect the brake pedal in the following procedure. Remove the brake pedal assembly (Refer to «BRAKE PEDAL»(ref-291270-S17112925442008072500000) ). Check the removed brake pedal assembly for distortion, and replace it when deformed (Refer to «BRAKE PEDAL DISTORTION CHECK»(ref-291270-S09202787552008072500000) ). Install the brake pedal assembly (Refer to «BRAKE PEDAL»(ref-291270-S17112925442008072500000) ). NOTE: When installing, compress the dash panel pad. 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 center), and make sure it is within the standard value (C). Standard value (C): 75.8 - 80.2 mm (2.98 - 3.16 inch) When the measured value is not within the standard value (C), replace the brake booster (Refer to «MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER»(ref-291270-S12386058562008072500000) ).
7. After checking the brake pedal height, install the stop lamp switch in the following procedure: 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. 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. Connect the stop lamp switch connector.
8. Check the key interlock mechanism and the shift lock mechanism (Refer to «SHIFT LOCK MECHANISM CHECK»(ref-291267-S30768561922008072500000) ).
9. Recover the floor carpet under the brake pedal.

Scheme 96

1. With the engine stopped, depress the brake pedal 2 or 3 times to release 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 stop lamp switch position, and adjust or replace as necessary.

Scheme 97

1. Turn up the floor carpet under the brake pedal.
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 (C): 85 mm (3.35 inch) or more
3. When the clearance is not within the standard value, check for 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.

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1. Carry out the simplified brake booster operation check in the following procedure: 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". 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 move down. 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.

Scheme 101

1. Before starting this inspection, remove the brake booster check valve from the vehicle and check its operation.(Refer to «MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER»(ref-291270-S12386058562008072500000) .)
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: 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). 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. Brake booster characteristics test Perform this test after the above (1) and (2) were performed.

1. Non-servo effect test With the engine stopped, make sure that the vacuum gauge reading is 0 kPa (0 psi). Depress the brake pedal with 100 N (22.5 lb) and 300 N (67.4 lb), and measure the fluid pressure generated. Standard value: < Vehicles without ABS> FLUID PRESSURE SPECIFICATION (VEHICLES WITHOUT ABS) Item Pedal depression force 100 N (22.5 lb) 300 N (67.4 lb) Generated fluid pressure kPa (psi) 0 - 600 (0 - 87) 1,380 - 2,220 (200 - 322) FLUID PRESSURE SPECIFICATION (VEHICLES WITH ABS) Item Pedal depression force 100 N (22.5 lb) 300 N (67.4 lb) Generated fluid pressure kPa (psi) 0 - 590 (0 - 85) 1,360 - 2,180 (197 - 316)
2. Servo effect test Start the engine. Depress the brake pedal with 100 N (22.5 lb) and 300 N (67.4 lb) when the vacuum gauge indicator reached approximately -67 kPa (-9.7 psi), and measure the fluid pressure generated.

Standard value

< Vehicles without ABS>

FLUID PRESSURE SPECIFICATION (VEHICLES WITHOUT ABS)

FLUID PRESSURE SPECIFICATION (VEHICLES WITH ABS)

Scheme 102

1. Remove the check valve (Refer to «REMOVAL AND INSTALLATION»(ref-291270-S29161652782008072500000) ). CAUTION: Replace the check valve when it is faulty.
2. Using a vacuum pump, check operation of the check valve.

VACUUM PUMP CONNECTION REFERENCE