Basic Brake System - Lancer: Diagnosis Mitsubishi Lancer X рестайлинг

BASIC BRAKE SYSTEM DIAGNOSTIC TROUBLESHOOTING STRATEGY

Use these steps to plan your diagnostic strategy. If you follow them carefully, you will be sure that you have exhausted most of the possible ways to find a basic brake system fault.

1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find the malfunction by following the «SYMPTOM CHART»(ref-592607-S33120866282014011000000) .
4. Verify malfunction is eliminated.

SYMPTOM CHART

SYMPTOM CHART

DIAGNOSIS

1. STEP 1. Check for oil, water, etc., on the pad contact surface of all brakes. Q: Is oil, water, etc., on the pad contact surface? YES: Replace the part and determine the source/cause of foreign material. Then go to Step 5 . NO: Go to Step 2.
2. STEP 2. Check disc brake pistons for smooth operation. With engine not running, depress the brake pedal rapidly several times to deplete booster vacuum reserves. Test each disc brake assembly one at a time. Remove the lower caliper bolt, then remove caliper from mount. Have an assistant slowly depress the brake pedal. Confirm piston(s) extend slowly and smoothly with no jumpiness. Repeat for each disc brake assembly. Q: Do (does) the piston(s) move correctly? YES: Go to Step 3. NO: Disassemble and inspect the brake assembly (Front: refer to «DISASSEMBLY AND ASSEMBLY < 15-INCH FRONT DISC BRAKE >»(ref-592607-S30322453422014011000000) < 15-inch front disc brake >, «DISASSEMBLY AND ASSEMBLY < 16-INCH FRONT DISC BRAKE (EXCEPT RALLIART) >»(ref-592607-S34549363552014011000000) < 16-inch front disc brake (Except RALLIART) > or «DISASSEMBLY AND ASSEMBLY < 16-INCH FRONT DISC BRAKE (RALLIART) >»(ref-592607-S41101902642014011000000) < 16-inch front disc brake (RALLIART) >, Rear: refer to «DISASSEMBLY AND ASSEMBLY < 14-INCH REAR DISC BRAKE >»(ref-592607-S02543231052014011000000) < 14-inch rear disc brake >, «DISASSEMBLY AND ASSEMBLY < 16-INCH REAR DISC BRAKE (EXCEPT RALLIART) >»(ref-592607-S23106915722014011000000) < 16-inch rear disc brake (Except RALLIART) > or «DISASSEMBLY AND ASSEMBLY < RALLIART >»(ref-592607-S05665472052014011000000) < 16-inch rear disc brake (RALLIART) >}. Then go to Step 5 .
3. STEP 3. Check brake disc(s) for run-out. Refer to «BRAKE DISC CHECK»(ref-592607-S03385931962014011000000) . Q: Is run-out outside of specifications? YES: Repair or replace the brake disc(s) as necessary. Then go to Step 5 . NO: Go to Step 4.
4. STEP 4. Check brake discs for correct thickness. Refer to «BRAKE DISC CHECK»(ref-592607-S03385931962014011000000) . Q: Is the thickness outside of specifications? YES: Repair or replace the brake disc(s) as necessary. Then go to Step 5. NO: Perform the brake line bleeding. Refer to «BLEEDING»(ref-592607-S11953691932014011000000) . Then go to Step 5.
5. STEP 5. Retest the system. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at Step 1 . If a new symptom appears, refer to the appropriate «SYMPTOM CHART»(ref-592607-S33120866282014011000000) .

Scheme 9

1. STEP 1. Check that the specified brake fluid is used, its level is correct, and no contamination is found. Q: Is there a fault? YES: Refill or replace with the specified brake fluid DOT 3 or DOT 4. Bleed the brakes if necessary (Refer to «BLEEDING»(ref-592607-S11953691932014011000000) ). Then go to Step 8 . NO: Go to Step 2.
2. STEP 2. Check for spongy (not firm brakes). With engine not running, depress the brake pedal rapidly several times to deplete booster vacuum reserve. With the brake pedal fully released, depress the brake pedal slowly until it stops. With a measuring stick (ruler, etc.) next to the brake pedal, depress the pedal firmly and measure the distance the pedal traveled. Q: Is the distance greater than 20 mm (0.8 inch)? YES: Bleed the brakes to remove air in the fluid (Refer to «BLEEDING»(ref-592607-S11953691932014011000000) ). Then go to Step 8 . NO: Go to Step 3.
3. STEP 3. Check the lining and brake drum contact. < Vehicles equipped with rear drum brake > If equipped with rear disc brake, go to Step 5 . Put chalk on the inner surface of the brake drum. Rub the lining against the drum inner surface. NOTE: Clean off chalk after check. Q: Does the lining wipe off or smudge the chalk across the full width of the lining? YES: Go to Step 4. NO: Replace the shoe and lining assemblies on both sides. Go to Step 8 .
4. STEP 4. Check the auto adjuster function. < Vehicles equipped with rear drum brake > Refer to «BRAKE LINING AND BRAKE DRUM CONTACT CHECK < VEHICLES WITH REAR DRUM BRAKE >»(ref-592607-S38043468612014011000000) . Q: Is there fault? YES: Repair it. Then go to Step 8 . NO: Go to Step 5.
5. STEP 5. Check the brake booster function. Refer to «BRAKE BOOSTER OPERATION CHECK»(ref-592607-S11451999832014011000000) . Q: Is there fault? YES: Replace the part. Then go to Step 8 . NO: Go to Step 6.
6. STEP 6. Check for pinched or restricted brake tube or hose. Q: Is there pinched or restricted brake tube or hose? YES: Replace that complete section of brake tube or brake hose. Then go to Step 8 . NO: Go to Step 7.
7. STEP 7. Check for oil, water, etc., on the pad or lining contact surfaces of all brakes. Q: Is oil, water, etc., on the pad or lining contact surface? YES: Replace the part and determine and repair source/cause of foreign material. Recheck symptom. Then go to Step 8. NO: The procedure is complete. If condition persists, go to Step 8.
8. STEP 8. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(ref-592607-S33120866282014011000000) .

1. STEP 1. Check for spongy (not firm) brakes. With engine not running, depress the brake pedal rapidly several times to deplete booster vacuum reserve. With the brake pedal fully released, depress the brake pedal slowly until it stops. With a measuring device (ruler, etc.) next to the brake pedal, depress the pedal firmly and measure the distance the pedal traveled. Q: Is the distance greater than 20 mm (0.8 inch)? YES: Bleed the brakes to remove air in the fluid (Refer to «BLEEDING»(ref-592607-S11953691932014011000000) ). Then go to Step 6 . NO: Go to Step 2.
2. STEP 2. Check the pad for wear. Refer to «BRAKE PAD CHECK»(ref-592607-S29231324392014011000000) . Q: Is the pad thickness outside of specifications? YES: Replace the part. Then go to Step 6 . NO: Go to Step 3.
3. STEP 3. Check the vacuum hose and check valve for damage. Refer to «CHECK VALVE OPERATION CHECK»(ref-592607-S22414491842014011000000) . Q: Is there a damage? YES: Replace the part. Then go to Step 6 . NO: Go to Step 4.
4. STEP 4. Check for brake fluid leaks. Q: Is there a leak? YES: Check the connection for looseness, corrosion, etc. Clean and repair as necessary. If leaking in any tube or hose section, replace the complete tube or hose. Then go to Step 6 . NO: Go to Step 5.
5. STEP 5. Check the master cylinder assembly. Remove the master cylinder assembly (Refer to «REMOVAL AND INSTALLATION < EXCEPT RALLIART >»(ref-592607-S33552575352014011000000) < Except RALLIART > or «REMOVAL AND INSTALLATION < RALLIART >»(ref-592607-S17314277122014011000000) < RALLIART >). Check for brake fluid leaks from the master cylinder assembly seal. Q: Is a brake fluid leaking from the master cylinder assembly seal present? YES: Replace the master cylinder assembly and the brake booster assembly (Refer to «REMOVAL AND INSTALLATION < EXCEPT RALLIART >»(ref-592607-S33552575352014011000000) < Except RALLIART > or «REMOVAL AND INSTALLATION < RALLIART >»(ref-592607-S17314277122014011000000) < RALLIART >). Then go to Step 6. NO: Go to Step 6.
6. STEP 6. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(ref-592607-S33120866282014011000000) .

Scheme 10

1. STEP 1. Check the parking brake lever return. Q: Is the operation faulty? YES: Repair it. Then go to Step 7 . NO: Go to Step 2.
2. STEP 2. Check the brake shoe springs for breakage. Q: Are the brake shoe springs broken? YES: Replace the spring. Then go to Step 7 . NO: Go to Step 3.
3. STEP 3. Check the amount of grease at each sliding section. Refer to «PARKING BRAKE LINING AND DRUM»(ref-592606-S04852712922014011000000) < Except RALLIART > or «REMOVAL AND INSTALLATION < RALLIART >»(ref-592606-S23562482922014011000000) < RALLIART >. Q: Is the grease amount low? YES: Apply grease. Then go to Step 7 . NO: Go to Step 4.
4. STEP 4. Check the parking brake pull amount. Refer to «PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT»(ref-592606-S24561166322014011000000) . Q: Is there a fault? YES: Adjust it. Then go to Step 7 . NO: Go to Step 5.
5. STEP 5. Check port for clogging. Q: Is the port clogged? YES: Repair it. Then go to Step 7 . NO: Go to Step 6.
6. STEP 6. Check disc brake pistons for sticking. Depress the brake pedal, then release. Confirm each wheel spins freely. Q: Does any wheel stick? YES: Inspect that brake assembly. Then go to Step 7. NO: Go to Step 7.
7. STEP 7. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(ref-592607-S33120866282014011000000) .

1. STEP 1. Check the front brakes, then rear brakes, for metal-to-metal condition. Q: Is any metal-to-metal contact evident? YES: Repair or replace the components. Then go to Step 6 . NO: Go to Step 2.
2. STEP 2. Check for interference between the caliper and wheel. Q: Is there any interference? YES: Repair or replace the part. Then go to Step 6 . NO: Go to Step 3.
3. STEP 3. Check for interference between the dust shield and brake disc < Front >, interference between the backing plate and brake disc < Rear >. Q: Is there any interference? YES: Repair or replace the part. Then go to Step 6 . NO: Go to Step 4.
4. STEP 4. Check the brake discs for cracks. Q: Are there cracks? YES: Repair or replace the part. Then go to Step 6 . NO: Go to Step 5.
5. STEP 5. Check for bent dust shield or backing plate. Q: Is the dust shield or backing plate bent? YES: Repair or replace the part. Then go to Step 6. NO: Go to Step 6.
6. STEP 6. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(ref-592607-S33120866282014011000000) .

1. STEP 1. Check the brake disc and pads for wear or cutting. Q: Is there wear or cutting? YES: Repair or replace the part. Then go to Step 4 . NO: Go to Step 2.
2. STEP 2. Check the calipers for rust. Q: Is there any rust? YES: Remove the rust. Then go to Step 4 . NO: Go to Step 3.
3. STEP 3. Adjust the brake pedal. Refer to «BRAKE PEDAL CHECK AND ADJUSTMENT»(ref-592607-S01802380522014011000000) . Q: Is the brake pedal adjusted correctly? YES: Go to Step 4. NO: Adjust the brake pedal. Then go to Step 4.
4. STEP 4. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(ref-592607-S33120866282014011000000) .

1. STEP 1. Check whether the backing plate is bent or loose and interfering with the drum. Q: Is there a fault? YES: Replace the part. Then go to Step 8 . NO: Go to Step 2.
2. STEP 2. Check whether the drum is damaged due to interference with the backing plate or shoe. Q: Is there any damage? YES: Replace the part. Then go to Step 8 . NO: Go to Step 3.
3. STEP 3. Check the brake drum for wear and the shoe spring for damage. Q: Is there any wear or damage? YES: Replace the part. Then go to Step 8 . NO: Go to Step 4.
4. STEP 4. Check the brake discs for rust. Q: Are the brake discs rusted? YES: Remove the rust by using sand paper. If still rusted, turn the rotors with an on-the-car brake lathe. Then go to Step 8 . NO: Go to Step 5.
5. STEP 5. Check the brake pads for correct installation. Q: Are the pads installed incorrectly? YES: Install the pads correctly. Then go to Step 8 . NO: Go to Step 6.
6. STEP 6. Check the calipers for correct installation. Q: Are the calipers installed incorrectly? YES: Install the calipers correctly. Then go to Step 8 . NO: Go to Step 7.
7. STEP 7. Check the wheel bearings for end play. Refer to «WHEEL BEARING END PLAY CHECK»(ref-592614-S09378715322014011000000) < Front >, «WHEEL BEARING END PLAY CHECK»(ref-592676-S08833494702014011000000) < Rear (FWD) > or «WHEEL BEARING END PLAY CHECK»(ref-592611-S02323284972014011000000) < Rear (AWD) >. Q: Does the measured end play exceed the limit? YES: Replace the faulty hub assembly (Refer to «FRONT AXLE HUB ASSEMBLY»(ref-592614-S28489955852014011000000) < Front >, «REAR AXLE HUB ASSEMBLY»(ref-592676-S13437749452014011000000) < Rear (FWD) > or «REAR AXLE HUB ASSEMBLY»(ref-592611-S11316468702014011000000) < Rear (AWD) >). Then go to Step 8. NO: Go to Step 8.
8. STEP 8. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(ref-592607-S33120866282014011000000) .

Scheme 11

Scheme 12

1. STEP 1. Check whether foreign material has entered the wheel covers. Q: Is there any foreign material? YES: Remove it. Then go to Step 5 . NO: Go to Step 2.
2. STEP 2. Check for looseness of the wheel nuts. Refer to «WHEEL AND TIRE»(ref-592625-S09072020102014011000000) . Q: Are the wheel nuts loose? YES: Tighten the wheel nuts to the specified torque (Refer to «WHEEL AND TIRE»(ref-592625-S09072020102014011000000) ). Then go to Step 5 . NO: Go to Step 3.
3. STEP 3. Check for looseness of the caliper installation bolts. Refer to «FRONT DISC BRAKE ASSEMBLY»(ref-592607-S21110794362014011000000) < Front >, «REMOVAL AND INSTALLATION < EXCEPT RALLIART >»(ref-592607-S10786360712014011000000) < Rear (Except RALLIART) > or «REMOVAL AND INSTALLATION < RALLIART >»(ref-592607-S07422829772014011000000) < Rear (RALLIART) >. Q: Are the caliper installation bolts loose? YES: Tighten the caliper installation bolts to the specified torque (Refer to «FRONT DISC BRAKE ASSEMBLY»(ref-592607-S21110794362014011000000) < Front >, «REAR DISC BRAKE ASSEMBLY»(ref-592607-S05303196462014011000000) < Rear (Except RALLIART) > or «REMOVAL AND INSTALLATION < RALLIART >»(ref-592607-S07422829772014011000000) < Rear (RALLIART) >. Then go to Step 5 . NO: Go to Step 4.
4. STEP 4. Check the wheel bearings for end play. Refer to «WHEEL BEARING END PLAY CHECK»(ref-592614-S09378715322014011000000) < Front >, «WHEEL BEARING END PLAY CHECK»(ref-592676-S08833494702014011000000) < Rear (FWD) > or «WHEEL BEARING END PLAY CHECK»(ref-592611-S02323284972014011000000) < Rear (AWD) >. Q: Does the measured end play exceed the limit? YES: Replace the faulty hub assembly (Refer to «FRONT AXLE HUB ASSEMBLY»(ref-592614-S28489955852014011000000) < Front >, «REAR AXLE HUB ASSEMBLY»(ref-592676-S13437749452014011000000) < Rear (FWD) > or «REAR AXLE HUB ASSEMBLY»(ref-592611-S11316468702014011000000) < Rear (AWD) >). Then go to Step 5. NO: Go to Step 5.
5. STEP 5. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(ref-592607-S33120866282014011000000) .

INSPECTION USING SIMPLIFIED TESTER

Required Special Tool

1. MB992146: Booster test adapter installer

1. Before starting this inspection, remove the brake booster check valve from the vehicle and check its operation (Refer to «REMOVAL AND INSTALLATION < EXCEPT RALLIART >»(ref-592607-S33552575352014011000000) < Except RALLIART > or «REMOVAL AND INSTALLATION < RALLIART >»(ref-592607-S17314277122014011000000) < RALLIART >).
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 illustration. Bleed the pressure gauge and then perform the following tests

Scheme 13

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.
3. 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: STANDARD VALUE - EXCEPT RALLIART Item Pedal depression force 100 N (22.5 lb) 300 N (67.4 lb) Generated fluid pressure kPa (psi) 0 - 600 (0 - 87) 1, 030 - 2, 220 (149 - 322) STANDARD VALUE - RALLIART Item Pedal depression force 100 N (22.5 lb) 300 N (67.4 lb) Generated fluid pressure kPa (psi) 0 - 520 (0 - 75) 890 - 1, 910 (129 - 277)
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

STANDARD VALUE - EXCEPT RALLIART

STANDARD VALUE - RALLIART

Scheme 14

1. Remove the check valve (Refer to «REMOVAL AND INSTALLATION < EXCEPT RALLIART >»(ref-592607-S33552575352014011000000) < Except RALLIART > or «REMOVAL AND INSTALLATION < RALLIART >»(ref-592607-S17314277122014011000000) < RALLIART >). CAUTION: Replace the check valve when it is faulty.
2. Using a vacuum pump, check operation of the check valve. CHECK VALVE OPERATION 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.

BRAKE PAD WEAR INSPECTION

Measure the brake pad thickness at the most worn area. If the brake pad thickness is less than the limit value, replace the brake pad.

Standard value: 10.0 mm (0.39 inch)

Limit: 2. 0 mm (0.08 inch)

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the bottom.

Scheme 19

Measure the brake pad thickness at the most worn area. If the brake pad thickness is less than the limit value, replace the brake pad.

Standard value: 10.0 mm (0.39 inch)

Limit: 2. 0 mm (0.08 inch)

Scheme 20