BASIC BRAKE

SYSTEM
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35A-2

BASIC BRAKE
SYSTEM
CONTENTS

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GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 Brake Fluid Level Sensor Check . . . . . . . . . . . . . 10
Disc Brake Pad Check and Replacement . . . . . . 11
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 4
Disc Brake Rotor Check . . . . . . . . . . . . . . . . . . . . . 12
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Brake Disc Thickness Check . . . . . . . . . . . . . . . . . 12
Brake Disc Run-out Check and Correction . . . . 13
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MASTER CYLINDER AND BRAKE
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6 BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Brake Pedal Check and Adjustment . . . . . . . . . . . . 6 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Brake Booster Operating Test . . . . . . . . . . . . . . . . . . 7
FRONT DISC BRAKE . . . . . . . . . . . . . . . . . . . . . 20
Check Valve Operation Check . . . . . . . . . . . . . . . . . 8
Load Sensing Spring Length Check and REAR DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . 25
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Load Sensing Proportioning Valve Function LOAD SENSING PROPORTIONING
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BASIC BRAKE SYSTEM – General Information 35A-3
GENERAL INFORMATION
The brake system offers high dependability and durability along with improved braking performance and
brake sensitivity.

Items Specifications

Master cylinder Type Tandem type

I.D. mm 22.2

Brake booster Type Vacuum type, single

Effective dia. of power cylinder mm 230

Boosting ratio 4.5

Load sensing proportioning Type Dual type

valve
valve
Decompression ratio 0.25

Front disc brakes Type Floating caliper, 1-piston, ventilated disc

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Disc effective dia. × thickness mm 236 × 22

Wheel cylinder I.D. mm 57.2

Pad thickness mm 10.0

Clearance adjustment Automatic

Rear disc brakes Type Floating caliper,1-piston, solid disc

Disc effective dia. × thickness 222 × 9.4

Wheel cylinder I.D. mm 34.93

Pad thickness mm 10.0

Clearance adjustment Automatic

Brake fluid DOT3 or DOT4

CONSTRUCTION DIAGRAM

Load sensing
proportioning
valve
Hydraulic unit

Brake booster
Master cylinder
35A-4 BASIC BRAKE SYSTEM – Service Specifications

SERVICE SPECIFICATIONS
Items Standard value Limit

Brake pedal height mm L.H. drive vehicles 201 – 204 –

R.H. drive vehicles 201.7 – 204.7 –

Brake pedal play mm 3 –8 –

Brake pedal to floorboard clearance when the brake pedal is depressed mm 105 or more –

Brake booster push rod protrusion amount mm L.H. drive vehicles with ABS 22.7 – 22.9 –

L.H. drive vehicles without 23.93 – 24.18 –

ABS and R.H. drive vehicles

Load sensing proportion- When load sensing spring length is 199 mm (when 4.2 – 6.0 (9.8) –
ing valve output fluid unladen)
pressure
pressure (I
(Innpu
putt fluid
fluid pres-
pres-
sure) MPa When load sensing spring length is 217 mm (when 9.7 – 10.5 (9.8) –
laden)
laden)
14.5 – 16.3 (16.7) –

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Output fluid pressure difference between left and right – 0.39
MPa

Load sensing spring length <Distance between spring ends> mm 194 – 198 –

Front disc brake Pad thickness mm 10.0 2.0

Disc
Di sc thickness
thickness mm 22.0 20.4

Disc runout mm – 0.06

Drag force N 69 –

Rear disc brake Pad thickness mm 10.0 2.0

Disc thickness mm 9.4 7.8

Disc runout mm – 0.08

Drag force N 34 –

Front hub end play mm – 0.2

Rear hub end play mm – 0.025

BASIC BRAKE SYSTEM – Lubricants/Sealant/Special Tools 35A-5
LUBRICANTS
Items Specified Lubricant Quantity

Brake fluid DOT3 or DOT4 As required

Vacuum sensor grommet Silicone grease

Brake booster seal

Piston boot, piston seal Repair kit grease

Guide pin, lock pin

Piston, wheel cylinder body DOT3 or DOT4

SEALANT
Items Specified sealant Remarks

Fitting 3M ATD Part No. 8661 or equivalent Semi-drying sealant

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SPECIAL TOOLS
Tool Number Name Use

A MB990964 Brake tool set Pushing-in of the disc brake piston

A: MB990520

A: MB990998 A: Front hub re- When bearing provisional holding

B: MB991000 mover and installer MB991000, which belongs to MB990998,
B: Spacer should be used as a spacer.
A
B

MB991568 Push rod adjusting Adjustment of the brake booster push rod
socket protrusion amount
35A-6 BASIC BRAKE SYSTEM – On-vehicle Service

ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
Operating rod
BRAKE PEDAL HEIGHT
Stop lamp switch
1. Turn up the carpet, etc. under the brake pedal.
Operating 2. Measure the brake pedal height as illustrated.
rod lock nut
Standard value (A):
A <L.H. drive vehicles> 201 – 204 mm
<R.H. drive vehicles> 201.7 – 204.7 mm
3. If the brake pedal height is not within the standard value,
follow the procedure below.
(1) Disconnect the stop lamp switch connector.
(2) Loosen the stop lamp switch by turning it approx.
1/4 turns anticlockwise.
(3) Remove the pin, and then adjust so that the brake
pedal height meets the standard value by turning the
clevis.
NOTE
When the clevis is turned 180°, the pedal height is

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changed approximately 2.3 mm.

(4) Screw in the stop lamp switch until it touches the

Stopper
stopper. At this time, support the brake pedal to the
highest position by hand.
(5) Lock the stop lamp switch by turning it approx. 1/4
turns clockwise, and confirm that the clearance
between the switch plunger and the stopper is as
shown.
(6) Connect the connector at the stop lamp switch.
Caution
0.5 – 1.0 mm
Check that the stop lamp does not illuminate when
the brake pedal is not depressed.
4. For A/T, check the key interlock and shift lock mechanisms.
(Refer to GROUP 23 – On-vehicle Service.)
5. Return the carpet, etc.

BRAKE PEDAL FREE PLAY

1. With the engine stopped, depress the brake pedal two
or three times. After eliminating the vacuum in the power
brake booster, press the pedal down by hand, and confirm
that the amount of movement before resistance is met
(the free play) is within the standard value range.
Standard value (B): 3 – 8 mm
B
BASIC BRAKE SYSTEM – On-vehicle Service 35A-7
2. If the brake pedal play is not within the standard value,
check the following, and adjust or replace if necessary:
D Excessive play between the brake pedal and the clevis
pin, or between the clevis pin and the brake booster
operating rod
D Brake pedal height
D Installation position of the stop lamp switch, etc.

CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR

BOARD
1. Turn up the carpet etc. under the brake pedal.
2. Start the engine, depress the brake pedal with
approximately 490 N of force, and measure the clearance
between the brake pedal and the floorboard.
Standard value (C): 105 mm or more
3. If the clearance is outside the standard value, check for

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air trapped in the brake line, thickness of the disc brake
pad or the drum brake lining and dragging in the parking
brake.
Adjust and replace defective parts as required.
4. Return the carpet, etc.

Good No good
BRAKE BOOSTER OPERATING TEST
For simple checking of the brake booster operation, carry
out the following tests:
1. Run the engine for one or two minutes, and then stop
it.
If the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the
booster is operating properly. If the pedal height remains
unchanged, the booster is defective.

2. With the engine stopped, step on the brake pedal several

When engine is When engine is
stopped started times.
Then start the engine while the brake pedal is stepped
on.
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is
defective.
35A-8 BASIC BRAKE SYSTEM – On-vehicle Service

Good No good 3. With the engine running, step on the brake pedal and
then stop the engine.
Hold the pedal depressed for 30 seconds. If the pedal
height does not change, the booster is in good condition.
If the pedal rises, the booster is defective.
If the above three tests are okay, the booster performance
can be determined as good.
If one of the above three tests is not okay at least, the check
valve, vacuum hose, or booster will be defective.

CHECK VALVE OPERATION CHECK

1. Remove the vacuum hose. (Refer to P.35A-15, 16.)
Caution
The check valve should not be disassembled from
the vacuum hose as they are united as one part.
2. Check the operation of the check valve by using a vacuum
pump.

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Vacuum pump Accept/reject criteria
connection
Connection at the brake A negative pressure (vacuum) is
Valve Spring booster side (A) created and held.
Connection at the intake A negative pressure (vacuum) is
Booster A B Intake manifold side (B) not created.
side manifold
side Caution
If the check valve is defective, always replace it as
an assembly unit together with the vacuum hose.

LOAD SENSING SPRING LENGTH CHECK

AND ADJUSTMENT
1. Park the vehicle on a level ground. The vehicle should
be unloaded and supported only by wheels.
Caution
Never support the vehicle with jacks or other similar
means.

2. With the lever pressed all the way to the load sensing
Load sensing spring proportioning valve side, check whether or not the length
Spring support (shown in the figure) of the spring (the length between
Lever its ends) is the standard value.
Standard value (A): 194 – 198 mm
A 3. If the spring length is not within the standard value, loosen
the bolt attaching the support and adjust the distance by
moving the support.
BASIC BRAKE SYSTEM – On-vehicle Service 35A-9
Pressure gauge LOAD SENSING PROPORTIONING VALVE
FUNCTION TEST
1. Connect pressure gauges to the input and output ports
of the load sensing proportioning valve.
2. Bleed the system. (Refer to P.35A-10.)
3. Disconnect the spring at the support side.

Load sensing pro-

portioning valve

Load sensing pro- 4. Place the spring so that it is in parallel with the load sensing
portioning valve Load sensing spring proportioning valve, and then pull in the direction indicated
A by arrow A so that its length H shown in the figure (the
Parallel
length between its ends) is as noted below.
NOTE
At this time the lever is pressed all the way to the load
sensing proportioning valve side.

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Lever

5. Check at this time whether or not the output fluid’s pressure,

relative to the load sensing proportioning valve’s input fluid
pressure, is within the standard value.
Standard value:
Spring length Input fluid Output fluid pressure
H mm pressure MPa MPa
199*1 9.8 4.2 – 6.0
217*2 9.8 9.7 – 10.5
16.7 14.5 – 16.3
NOTE
*1 and *2 indicate the applicable lengths for unladen
and laden vehicles respectively.
6. Measure each output fluid pressure at both valves, and
check that the difference between the two is at the limit
value or less.
Limit: 0.39 MPa
7. After making the check, install the spring. Disconnect the
pressure gauges from the load sensing proportioning valve
and bleed air.
35A-10 BASIC BRAKE SYSTEM – On-vehicle Service

BLEEDING
Caution
Specified brake fluid: DOT3 or DOT4
Always use the specified brake fluid. Avoid using a mixture
of the specified brake fluid and other fluid.

MASTER CYLINDER BLEEDING

The master cylinder used has no check valve, so if bleeding
is carried out by the following procedure, bleeding of air from
the brake pipeline will become easier. (When brake fluid is
not contained in the master cylinder.)
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylinder outlet with
a finger.

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4. With the outlet still closed, release the brake pedal.
5. Repeat steps 2 – 4 three or four times to fill the inside
of the master cylinder with brake fluid.

BRAKE PIPE LINE BLEEDING

4 (2) Bleed the air in the sequence shown in the figure.
1 (3)

2 (4) 3 (1)
( ): R.H. drive vehicles

BRAKE FLUID LEVEL SENSOR CHECK

The brake fluid level sensor is in good condition if there is
no continuity when the float surface is above “MIN” and if
MAX there is continuity when the float surface is below “MIN”.
MIN
BASIC BRAKE SYSTEM – On-vehicle Service 35A-11
DISC BRAKE PAD CHECK AND REPLACEMENT
NOTE
The brake pads have wear indicators that contact the brake
disc when the brake pad thickness reaches approximately
2 mm and emit a squealing sound to warn the driver.

FRONT REAR 1. Check the brake pad thickness through the caliper body
check port.
Standard value: 10.0 mm
Limit: 2.0 mm
2. When the thickness is less than the limit, always replace
the pads at an axle set.

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3. Remove the guide lock pin bolt. Pivot the caliper assembly
and hold it with wires.

FRONT REAR 4. Remove the following parts from the caliper support.
3 3 1. Pad and wear indicator assembly
2. Pad assembly
2 1
2
3. Clip
4
5
4 4. Inner shim
5 5. Outer shim
1

3 3

5. In order to measure the brake drag force after pad

installation, measure the rotary-sliding resistance of the
hub with the pads removed. (Refer to P.35A-20, 25.)
6. Install the pads and caliper assembly, and then check
the brake drag force. (Refer to P.35A-21, 26.)
35A-12 BASIC BRAKE SYSTEM – On-vehicle Service

DISC BRAKE ROTOR CHECK

Caution
When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within
the allowable service values in order to maintain normal brake operation.
Before re-finishing or re-processing the brake disc surface, the following conditions should be checked.

Inspection items Remarks

Scratches, rust, saturated lining materials D If the vehicle is not driven for a certain period, the sections of
and wear the discs that are not in contact with lining will become rusty, causing
noise and shuddering.
D If grooves resulting from excessive disc wear and scratches are
not removed prior to installing a new pad assembly, there will
momentarily be inappropriate contact between the disc and the
lining (pad).

Run-out or drift Excessive run-out or drift of the discs will increase the pedal depression
resistance due to piston knock-back.

Change in thickness (parallelism) If the thickness of the disc changes, this will cause pedal pulsation,
shuddering and surging.

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Inset or warping (flatness) Overheating and improper handling while servicing will cause inset or
warping.

BRAKE DISC THICKNESS CHECK

1. Using a micrometer, measure disc thickness at eight
positions, approximately 45_ apart and 10 mm in from
the outer edge of the disc.
Brake disc thickness
Item Standard value Limit
Front 22.0 20.4
Rear 9.4 7.8

Thickness variation (at least 8 positions)

The difference between any thickness measurements
should not be more than 0.015 mm.
2. If the disc is beyond the limits for thickness, remove it
and install a new one. If thickness variation exceeds the
specification, replace the brake disc or grind it with
on-the-car type brake lathe (“MAD, DL-8700PF” or
equivalent).
BASIC BRAKE SYSTEM – On-vehicle Service 35A-13
BRAKE DISC RUN-OUT CHECK AND
CORRECTION
1. Remove the brake assembly, and then hold it with wire.
2. Place a dial gauge approximately 5 mm from the outer
circumference of the brake disc, and measure the run-out
of the disc.
Limit: <Front> 0.06 mm or less,
<Rear> 0.08 mm or less
3. If the brake disc run-out exceeds the limit, correct it as
follows:
(1) Chalk phase marks on the wheel stud and the brake
Chalk marks
disc, which run-out is excessive as shown.

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(2) Remove the brake disc. Then place a dial gauge as
shown, and measure the end play by pushing and
pulling the wheel hub.
Limit: <Front> 0.2 mm, <Rear> 0.025 mm
(3) If the end play exceeds the limit, disassemble the
hub and knuckle assembly to check each part.
(4) If the end play does not exceed the limit, dephase
the brake disc and secure it. Then recheck the brake
disc run-out.

4. If the run-out cannot be corrected by changing the phase

of the brake disc, replace the brake disc or grind it with
the on-the-car type brake lathe (”MAD, DL-8700PF” or
equivalent).
35A-14 BASIC BRAKE SYSTEM – Brake Pedal

BRAKE PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
Brake Pedal Adjustment (Refer to P.35A-6.)

14 Nm

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10

3 2 1

4
7 8 9
12 Nm

Removal steps
1. Harness connector 7. Split pin <A/T>
2. Stop lamp switch 8. Shift lock cable connection <A/T>
3. Adjuster 9. Pedal pad
4. Pedal stopper 10. Brake pedal and pedal support
5. Snap pin member
6. Pin assembly

INSPECTION
STOP LAMP SWITCH CHECK
1. Connect an ohmmeter between the stop lamp switch
connector terminals.
No continuity Continuity 2. There should be no continuity between the terminals when
the plunger is pushed in as shown. There should be
continuity when it is released.

4 mm
BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster 35A-15
MASTER CYLINDER AND BRAKE BOOSTER
REMOVAL AND INSTALLATION
<L.H. drive vehicles with ABS>
Pre-removal Operation Post-installation Operation
Brake Fluid Draining D Brake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)
D Brake Pedal Adjustment (Refer to P.35A-6.)

6 10
12
14 11

14.7 – 17.7 Nm 14

Specified Sealant: 3M ATD Grease: Silicone grease

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Part No.8661 or equivalent

9
15 Nm

10
1 4 11
12 Nm
8
5
7
13

2 14 Nm
15 Nm

12
3 Silicon grease
35A-16 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster

<L.H. drive vehicles without ABS and R.H. drive vehicles>

Pre-removal Operation Post-installation Operation
Brake Fluid Draining D Brake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)
D Brake Pedal Adjustment (Refer to P.35A-6.)

10

11 12

14 4 12

Grease: Silicone grease Specified Sealant: 3M ATD Grease: Silicone grease

Part No.8661 or equivalent

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10
15 Nm 11

1 2

8
5 13
12 Nm 7
1
4
14 Nm
15 Nm

12
3

<L.H. drive vehicles> <R.H. drive vehicles>

6 6

14.7 – 17.7 Nm 14

14 14.7 – 17.7 Nm
BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster 35A-17
Master cylinder removal steps
1. Brake pipe connection "AA 6. Vacuum hose
2. Brake fluid level sensor connector (With built-in check valve)
3. Bracket <L.H. drive vehicles> 7. Snap pin
4. Master cylinder 8. Pin assembly
"CA 5. Seal 9. Vacuum sensor connector
Brake booster removal steps 10. Vacuum sensor
11. Grommet
1. Brake pipe connection 12. Brake booster
2. Brake fluid level sensor connector 13. Sealer
3. Bracket <L.H. drive vehicles>
4. Master cylinder Fitting removal
"CA 5. Seal 14. Fitting
"BA D Push rod protrusion amount check and
adjustment

INSTALLATION SERVICE POINTS

"AA VACUUM HOSE CONNECTION
Insert the vacuum hose to the fitting with its paint mark facing
forward <L.H. drive vehicles>/upward <R.H. drive vehicles>
until the hose end reaches the edge of the hexagonal part
of the fitting, and then secure the hose by using the hose
clip.

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"BA PUSH ROD PROTRUSION AMOUNT CHECK AND
ADJUSTMENT
1. Measure dimension (A).
Standard value (A) :
<L.H. drive vehicles with ABS> 22.7 – 22.9 mm
A <L.H. drive vehicles without ABS and R.H. drive
vehicles> 23.93 – 24.18 mm
NOTE
When a negative pressure of 66.7 kPa is applied to the
brake booster, the push rod should protrude 22.2 – 22.4
mm <L.H. drive vehicles with ABS>/23.48 – 23.73 mm
Measuring distance A <L.H. drive vehicles without ABS and R.H. drive vehicles>.

Block gauge
35A-18 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster

2. If the protrusion amount is not within the standard value

range, adjust the push rod length by turning the push
rod. Use the special tool to turn the push rod while holding
the rod spline with angle-nose pliers.

Angle-nose pliers

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MB991568

<L.H. drive vehicles with ABS> "CA SEAL INSTALLATION

Master cylinder 1. Apply silicone grease to the seal.
2. Install the seal to the master cylinder as shown.

Seal

<L.H. drive vehicles without ABS and R.H.

drive vehicles>
Master cylinder

Seal

INSPECTION
VACUUM SENSOR CHECK
Refer to GROUP 13A – Troubleshooting.
NOTE
The vacuum sensor is monitored by the engine-ECU. Diagnosis
code is output when the vacuum sensor has a malfunction.
BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster 35A-19
MASTER CYLINDER <L.H. drive vehicles without ABS and R.H. drive vehicles>
DISASSEMBLY AND REASSEMBLY

4 8 6
9

5
7
10
5 11

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12

12

10
11 10
6
9 8 7
11
12 Brake fluid: DOT3 or DOT4
Master cylinder kit

Disassembly steps
1. Reservoir cap 7. Piston guide
2. Pin 8. Cylinder cup
3. Reservoir tank 9. Plate
4. Brake fluid level sensor 10. Primary piston assembly
5. Reservoir seal 11. Secondary piston assembly
AA" 6. Stopper ring 12. Master cylinder body

DISASSEMBLY SERVICE POINT

AA" STOPPER RING REMOVAL
Push the primary piston assembly and remove the stopper
ring.
35A-20 BASIC BRAKE SYSTEM – Front Disc Brake

FRONT DISC BRAKE

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Brake Fluid Draining Brake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)

49 Nm
90 – 110 Nm
2
1

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3

Removal steps
1. Brake hose connection
2. Gasket
"AA 3. Disc brake assembly
4. Brake disc

MB991000 INSTALLATION SERVICE POINT

(MB990998) "AA DISC BRAKE ASSEMBLY INSTALLATION
1. In order to measure the brake drag force after pad
installation, measure the rotary-sliding resistance of the
hub by the following procedure with the pads removed.
Bolt
(1) Withdraw the drive shaft. (Refer to GROUP 26 – Front
Axle.)
(2) Attach the special tool to the front hub assembly as
shown in the illustration, and tighten it to the specified
torque.
Tightening torque: 196 – 255 Nm
(3) Use a spring balance to measure the rotary-sliding
resistance of the hub in the forward direction.
2. Install the caliper support to the knuckle, and then assemble
the pad clip and the pad to the caliper support.
Caution
Do not contaminate the friction surfaces of the pads
and brake discs by any oil or grease.
BASIC BRAKE SYSTEM – Front Disc Brake 35A-21
3. Clean the piston and insert it into the cylinder with the
special tool.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin to the caliper.
5. Start the engine, and then depress the brake pedal two
or three times strongly. Then stop the engine.
6. Turn the brake disc forward 10 times.
MB990520

7. Use a spring balance to measure the rotary-sliding

resistance of the hub.
8. Calculate the drag force of the disc brake [difference
between the values measured at steps 1 and 7].
Standard value: 69 N
9. If that drag force exceeds the standard value, disassemble
the piston assembly. Then check the piston for
contamination or rust, and confirm if the piston or the
piston seal is deteriorated, and if the lock pin and the

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guide pin slide smoothly.
35A-22 BASIC BRAKE SYSTEM – Front Disc Brake

DISASSEMBLY AND REASSEMBLY

15 15

13 12
26 Nm

1
11 15
2
Clip kit
3 15
26 Nm
9 14
8
7
10
6

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2

3
5
4

1 2
3 11 13 9
9 3
8 7
10 7 6

2
3
5 14 5
4 12 4

Brake caliper kit Pad set Shim kit Seal and boot kit

Disassembly steps
1. Guide pin lock bolt AA" 8. Piston
2. Guide pin AB" 9. Piston seal
3. Boot 10. Caliper body
4. Bushing 11. Pad and wear indicator assembly
5. Bushing retainer 12. Pad assembly
6. Caliper support (including pad, clip, 13. Inner shim
and shim) 14. Outer shim
AA" 7. Piston boot 15. Clip
BASIC BRAKE SYSTEM – Front Disc Brake 35A-23
LUBRICATION POINTS

Piston seal Grease: Repair kit grease

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Caution
The piston seal inside the
seal and boot kit is coated
with special grease, so do
not wipe this grease off.

Brake fluid: DOT3 or DOT4

Grease: Repair kit grease

Grease: Repair kit grease
35A-24 BASIC BRAKE SYSTEM – Front Disc Brake

DISASSEMBLY SERVICE POINTS

AA" PISTON BOOT/PISTON REMOVAL
Use a piece of wood to protect the caliper body outer side,
and then apply compressed air through the brake hose
connection hole to withdraw the piston and piston boot.
Caution
If air is blown into the caliper body suddenly, the piston
will pop out, causing damage to the caliper body. Be sure
to apply compressed air gradually.

AB" PISTON SEAL REMOVAL

1. Remove the piston seal with finger tip.
Caution
Do not use a flat-tipped screwdriver or other tool to
prevent damage to inner cylinder.
2. Clean piston surface and inner bore with trichloroethylene,
alcohol or the specified brake fluid.
Specified brake fluid: DOT3 or DOT4

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INSPECTION
D Check the cylinder for wear, damage or rust.
D Check the piston surface for wear, damage or rust.
D Check the caliper body or sleeve for wear.
D Check pad for damage or adhesion of grease, check the
backing metal for damage.

PAD WEAR CHECK

Measure thickness at the thinnest and worn area of the pad.
Replace the pad assembly if the pad thickness is less than
the limit value.
Standard value: 10 mm
Limit: 2.0 mm
Caution
1. Always replace the brake pads as an axle set.
2. If an excessive difference is found in the thickness
between the right and left brake pads, check moving
parts.
BASIC BRAKE SYSTEM – Rear Disc Brake 35A-25
REAR DISC BRAKE
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Brake Fluid Draining D Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-10.)

55 – 65 Nm
1

15 Nm
2

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3

Removal steps
1. Brake hose connection
"AA 2. Disc brake assembly
3. Brake disc

INSTALLATION SERVICE POINT

"AA DISC BRAKE ASSEMBLY INSTALLATION
1. In order to measure the brake drag force after pad
installation, use a spring balance to measure the
rotary-sliding resistance of the hub with the pads removed.
2. Install the caliper support to the backing plate, and then
assemble the pad clip and the pad to the caliper support.
Caution
Do not contaminate the friction surfaces of the pads
and brake discs by any oil or grease.
35A-26 BASIC BRAKE SYSTEM – Rear Disc Brake

3. Clean the piston and insert it into the cylinder with the
special tool.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin to the caliper.
5. Start the engine, and then depress the brake pedal two
or three times strongly. Then stop the engine.
6. Turn the brake disc forward 10 times.
MB990520

7. Use a spring balance to measure the rotary-sliding

resistance of the hub.
8. Calculate the drag force of the disc brake [difference
between the values measured at steps 1 and 7].
Standard value: 34 N
9. If that drag force exceeds the standard value, disassemble
the piston assembly. Then check the piston for
contamination or rust, and confirm if the piston or the
piston seal is deteriorated, and if the lock pin and the

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guide pin slide smoothly.
BASIC BRAKE SYSTEM – Rear Disc Brake 35A-27
DISASSEMBLY AND REASSEMBLY

15
43 Nm 1 15

8 Nm 11
12
13
5 14

15

Clip set
9 8
7
6
2 15
4
3
10
5

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5
1
9 11 14
10 7 5
9
3
2
3
5 8
7 13 6
6 12 Grease 5

Brake caliper kit Pad set Shim set Seal and boots kit

Disassembly steps
"AA 1. Guide pin AB" 9. Piston seal
"AA 2. Lock pin 10. Caliper body
3. Bushing 11. Pad and wear indicator assembly
4. Caliper support (pad, clip, shim) 12. Pad assembly
5. Pin boot 13. Inner shim
6. Boot ring 14. Outer shim
AA" 7. Piston boot 15. Clip
AA" 8. Piston
35A-28 BASIC BRAKE SYSTEM – Rear Disc Brake

LUBRICATION POINTS

Piston
seal

Grease: Repair kit grease

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Caution
The piston seal inside the seal
and boot kit is coated with
special grease, so do not wipe
this grease off.

Brake fluid: DOT3 or DOT4

Grease: Repair kit grease

Grease: Repair kit grease
BASIC BRAKE SYSTEM – Rear Disc Brake 35A-29
DISASSEMBLY SERVICE POINTS
AA" PISTON BOOT/PISTON REMOVAL
Use a piece of wood to protect the caliper body outer side,
and then apply compressed air through the brake hose
connection hole to withdraw the piston and piston boot.
Caution
If air is blown into the caliper body suddenly, the piston
will pop out, causing damage to the caliper body. Be sure
to apply compressed air gradually.

AB" PISTON SEAL REMOVAL

1. Remove the piston seal with finger tip.
Caution
Do not use a flat-tipped screwdriver or other tool to
prevent damage to inner cylinder.
2. Clean piston surface and inner bore with trichloroethylene,
alcohol or the specified brake fluid.
Specified brake fluid: DOT3 or DOT4

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REASSEMBLY SERVICE POINT
Lock pin
"AA LOCK PIN/GUIDE PIN INSTALLATION
“L”
Install the guide pin and lock pin as illustrated that each head
mark of the guide pin and the lock pin matches the indication
Front mark (“G” or “L”) located on the caliper body.

Guide pin
“G”

INSPECTION
D Check the cylinder for wear, damage or rust.
D Check the piston surface for wear, damage or rust.
D Check the caliper body or sleeve for wear.
D Check pad for damage or adhesion of grease, check the
backing metal for damage.
35A-30 BASIC BRAKE SYSTEM – Rear Disc Brake

PAD WEAR CHECK

Measure thickness at the thinnest and worn area of the pad.
Replace the pad assembly if the pad thickness is less than
the limit value.
Standard value: 10 mm
Limit: 2.0 mm
Caution
1. Always replace the brake pads as an axle set.
2. If an excessive difference is found in the thickness
between the right and left brake pads, check moving
parts.

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BASIC BRAKE SYSTEM – Load Sensing Proportioning Valve 35A-31
LOAD SENSING PROPORTIONING VALVE
REMOVAL AND INSTALLATION
Caution
Do not disassemble the load sensing proportioning valve.

Pre-removal Operation Post-installation Operation

Brake Fluid Draining D Brake Fluid Supplying
D Brake Line Bleeding (Refer to P.35A-10.)

2
5
1

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15 Nm 3

15 Nm

3 4

Removal steps
"AA 1. Spring support 4. Load sensing proportioning valve
2. Load sensing spring 5. Bracket
3. Brake pipe connection

INSTALLATION SERVICE POINT

Load sensing spring
"AA SPRING SUPPORT INSTALLATION
Spring
Lever support 1. Install the load sensing spring, and then tighten the spring
support to the axle assembly temporarily.
2. Insert the lever of the load sensing proportioning valve
fully into the valve side and hold it. Then adjust the spring
support so that the spring length (the distance between
the two ends of the spring) is at the standard value.
Standard value (A): 194 – 198 mm
NOTES

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35A-1

BASIC BRAKE
SYSTEM
CONTENTS

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GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE <1800-MPI> . . . . . . . . . 3
Outline of Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Brake Lining Thickness Check . . . . . . . . . . . . . . . . . 3
Brake Drum Inside Diameter Check . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2
Brake Lining and Brake Drum Contact Check . . . 3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
MASTER CYLINDER AND BRAKE
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 BOOSTER <1800-MPI> . . . . . . . . . . . . . . . . . . . . . 4

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 6

General/General Information/
35A-2 BASIC BRAKE SYSTEM – Service Specifications/Lubricants/Special Tool

GENERAL
OUTLINE OF CHANGE
The following service procedures have been established due to the adoption of the rear drum brake.
<1800-MPI>

GENERAL INFORMATION
Items 1800-MPI

Rear drum brakes Type Leading trailing

Drum I.D. mm 228

Wheel cylinder I.D. mm 22.2

Lining thickness mm 4.9

Clearance adjustment Automatic

SERVICE SPECIFICATIONS

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Items Standard value Limit

Rear drum brake Lining thickness mm 4.9 1.0

Drum inside diameter mm 228.6 230.6

LUBRICANTS
Items Specified Lubricant Quantity

Backing plate Brake grease SAE J310, NLGI No.1 As required

Shoe and lining assembly

Automatic adjuster assembly

SPECIAL TOOL
Tool Number Name Use

A MB990964 Brake tool set D Pushing-in of the disc brake piston

A: MB990520 D Installation of drum brake wheel cylinder
B piston cup
B: MB990619
BASIC BRAKE SYSTEM – On-vehicle Service <1800-MPI> 35A-3
ON-VEHICLE SERVICE <1800-MPI>
BRAKE LINING THICKNESS CHECK
1. Remove the brake drum.
2. Measure the thickness of the brake lining at the place
A worn the most.
Standard value (A): 4.9 mm
Limit (A): 1.0 mm
3. Replace the shoe and lining assembly as an axle set
if brake lining thickness is less than the limit. For information
concerning the procedures for installation of the shoe and
lining assembly, refer to P.35A-26.
Caution
If there is a significant difference in the thickness
of the shoe and lining assemblies on the left and right
sides, check the sliding condition of the piston.

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BRAKE DRUM INSIDE DIAMETER CHECK
1. Remove the brake drum.
2. Measure the inside diameter of the brake drum at two
A or more locations.
Standard value (A) : 228.6 mm
Limit (A) : 230.6 mm
3. Replace the brake drum when the inside diameter exceeds
the limit value or the brake drum is worn unevenly.

BRAKE LINING AND BRAKE DRUM CONTACT

CHECK
1. Remove the shoe and lining assembly. (Refer to P.35A-6.)
2. Chalk inner surface of brake drum and rub with shoe and
lining assembly.
3. Replace shoe and lining assembly or brake drums if there
are any irregular contact area.
4. Clean off chalk after check.
35A-4 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster <1800-MPI>

MASTER CYLINDER AND BRAKE BOOSTER <1800-MPI>

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Brake Fluid Draining D Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-11.)*
D Brake Pedal Adjustment (Refer to P.35A-7.)*

11 5 9

Specified Sealant: 3M ATD Grease: Silicone grease

Part No.8661 or equivalent

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1

15 ± 1 N·m 2

8
5 10
9.8 ± 2.0 N·m
1 7
4
14 ± 2 N·m
15 ± 1 N·m

9
3

<L.H. drive vehicles> <R.H. drive vehicles>

6
6
16 ± 1 N·m
16 ± 1 N·m 11
11
BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster <1800-MPI> 35A-5
Master cylinder removal steps
1. Brake pipe connection "BA D Push rod protrusion amount check and
2. Brake fluid level sensor connector adjustment
3. Bracket <L.H. drive vehicles> "AA 6. Vacuum hose
4. Master cylinder (With built-in check valve)
"CA 5. Seal 7. Snap pin
Brake booster removal steps 8. Pin assembly
9. Brake booster
1. Brake pipe connection 10. Sealer
2. Brake fluid level sensor connector
3. Bracket <L.H. drive vehicles> Fitting removal
4. Master cylinder 11. Fitting
"CA 5. Seal

NOTE
(1) *: Refer to PAJERO PININ ’00 Workshop Manual
(Pub. No. CKRE00E1).
(2) The installation service points are the same as before.

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35A-6 BASIC BRAKE SYSTEM – Rear Drum Brake

REAR DRUM BRAKE

REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Loosening the Parking Brake Cable Adjusting Nut. D Parking Brake Lever Stroke Adjustment
(Refer to GROUP 36 – On-vehicle Service) (Refer to GROUP 36 – On-vehicle Service)
D Brake Fluid Draining D Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-11.)*

9.8 ± 1.9 N·m

11
18 2 4 3 15
14
13
19 12

8
15 ± 1 N·m 16 7
6

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17

10 9 1
8
7
6 5

4
3 17
17 14 4

Specified grease: Brake grease SAE J310, NLGI No.1

Removal steps AA" "BA 12. Retainer

1. Brake drum "AA 13. Wave washer
2. Shoe-to-shoe spring 14. Parking lever
3. Adjuster lever 15. Shoe and lining assembly
4. Auto-adjuster assembly 16. Shoe hold-down pin
5. Retainer spring 17. Backing plate (Refer to GROUP 27
6. Shoe hold-down cup – Rear Axle Shaft.)
7. Shoe hold-down spring Wheel cylinder removal steps
8. Shoe hold-down cup 1. Brake drum
9. Shoe-to-shoe spring 18. Brake pipe connection
10. Shoe and lining assembly 19. Wheel cylinder assembly
11. Shoe and lever assembly

NOTE
*: Refer to PAJERO PININ ’00 Workshop Manual
(Pub. No. CKRE00E1).
BASIC BRAKE SYSTEM – Rear Drum Brake 35A-7
REMOVAL SERVICE POINT
Pin of shoe and lining assembly
AA" RETAINER REMOVAL
Use a flat-tipped screwdriver or the like to open up the retainer
joint, and remove the retainer.

Retainer

INSTALLATION SERVICE POINTS

"AA WAVE WASHER INSTALLATION
Wave washer Shoe and lining
assembly Install the wave washer in the direction shown in the illustration.

Pin

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Parking lever

"BA RETAINER INSTALLATION

Pin of shoe and lining assembly
Use pliers or the like to crimp the retainer or the pin positively.

Retainer

INSPECTION
BRAKE LINING THICKNESS CHECK
Refer to P.35A-3.
BRAKE DRUM INSIDE DIAMETER CHECK
Refer to P.35A-3.
BRAKE LINING AND BRAKE DRUM CONTACT CHECK
Refer to P.35A-3.
35A-8 BASIC BRAKE SYSTEM – Rear Drum Brake

WHEEL CYLINDER
DISASSEMBLY AND REASSEMBLY

1 4 4 1
Grease
7
6
2
2

Brake fluid: DOT3 or DOT4 Grease: Repair kit grease Wheel cylinder repair kit

5 7.9 ± 0.9 N·m

2
6
4 3 1
1

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3 4
2

Disassembly steps
1. Boots "AA 4. Piston cups
2. Piston assembly 5. Spring
"AA 3. Pistons 6. Wheel cylinder body

REASSEMBLY SERVICE POINT

"AA PISTON CUPS/PISTONS REASSEMBLY
MB990619
1. Use trichloroethylene, alcohol or the specified brake fluid
to clean the piston.
Specified brake fluid: DOT3 or DOT4
2. Apply the specified brake fluid to the piston cups and
the outer circumference of the special tool.
3. Set the piston cup on the special tool with the lip of the
cup facing up, fit the cup onto the special tool.
4. Slide the piston cup down the outside of the tool into
the piston groove carefully, making sure that the piston
cup is twisted or slanted.
INSPECTION
Check the piston and wheel cylinder walls for rust or damage,
Piston
and if there is any abnormality, replace the entire wheel cylinder
assembly.

Have the lip facing

upwards.
SERVICE BULLETIN
PUBLICATION GROUP, AFTER SALES SERVICE DEP.
MITSUBISHI MOTOR SALES EUROPE BV

SERVICE BULLETIN No.: ESB-01E35-001

Date: 2001-07-03 <Model> <M/Y>

Subject: REPLACEMENT AND CLEANING FOR BRAKE (EC)CARISMA 98-10
BOOSTER VACUUM NIPPLE ON 4G93 GDI (EC)SPACE STAR
EQUIPPED VEHICLES (EC)PAJERO PININ
Group: SERVICE BRAKE draftno.: 01AL005

INFORMATION
O. Kai - E.V.P. & G.M.
After Sales Service Dept.

1. Description:
On 4G93-GDI engine-equipped vehicles for Europe, the vacuum nipple of the brake booster must

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be replaced and cleaned periodically. This Service Bulletin covers the replacement and cleaning
procedures which should be added in On-Vehicle Service as shown below.

2. Applicable Manuals:
Manual Pub. No. Language Page(s)
’98 CARISMA GDI PWDE9502-C (English) 35A-1
Workshop Manual chassis PWDS9503-C (Spanish) 35A-1
PWDF9504-C (French) 35A-1
PWDG9505-C (German) 35A-1
PWDD9505-C (Dutch) 35A-1
PWDW9506-C (Swedish) 35A-1
PWDI96E1-C (Italian) 35A-1
’99 SPACE STAR CMXE99E1 (English) 35A-14
Workshop Manual chassis CMXS99E1 (Spanish) 35A-14
CMXF99E1 (French) 35A-14
CMXG99E1 (German) 35A-14
CMXD99E1 (Dutch) 35A-14
CMXW99E1 (Swedish) 35A-14
CMXI99E1 (Italian) 35A-14
’00 PAJERO PININ CKRE00E1 (English) 35A-13
Workshop Manual chassis
’00 MONTERO io CKRS00E1 (Spanish) 35A-13
Workshop Manual chassis
’00 PAJERO PININ CKRF00E1 (French) 35A-13
Workshop Manual chassis CKRG00E1 (German) 35A-13
CKRD00E1 (Dutch) 35A-13
CKRW00E1 (Swedish) 35A-13
CKRI00E1 (Italian) 35A-13
3. Details: ’98 CARISMA GDI Workshop Manual chassis
35A-1 BASIC BRAKE SYSTEM - General /On-vehicle Service <Added>

GROUP 35A
BASIC BRAKE SYSTEM
GENERAL
OUTLINE OF CHANGES
The following maintenance service points have been established to correspond to the addition of a pressure
sensor. Maintenance service procedures not listed below are the same as before.

<Added>

Intake manifold Brake ON-VEHICLE SERVICE

booster
hose
BRAKE BOOSTER VACUUM NIPPLE
REPLACEMENT
Nipple 1. Remove the brake booster hose from the intake manifold.
2. Replace the nipple with a new one, using a sealing agent

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and tighten to 15 – 18 N.m

AY0140BY Specified sealant:

3M ATD Part No.8661 or equivalent

Caution
Take care when applying the thread sealant as too
much could block the nipple.

3. After replacement, re-install the brake booster hose.

2
3. Details: ’99 SPACE STAR Workshop Manual chassis
35A-14 BASIC BRAKE SYSTEM - On-vehicle Service

BRAKE LINING THICKNESS CHECK 35100300241

1. Remove the brake drum.

2. Measure the wear of the brake lining at the place worn
the most.
Standard value: 4.38 mm
Limit: 1.0 mm
Replace the shoe and lining assembly if brake lining
thickness is less than the limit if it is not worn evenly.
For information concerning the procedures for installation
14W0096
of the shoe and lining assembly, refer to P.35A-22.
Caution
(1) Whenever the shoe and lining assembly is
replaced, replace both RH and LH assemblies as a
set to prevent car from pulling to one side when
braking.
(2) If there is a significant difference in the thickness
of the shoe and lining assemblies on the left and
right sides, check the sliding condition of the
piston.

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BRAKE DRUM INSIDE DIAMETER CHECK 35100320049

1. Remove the brake drum.

2. Measure the inside diameter of the brake drum at two or
more locations
Standard value: 203 mm
14X0366
Limit: 205 mm
3. Replace brake drums, shoe and lining assembly when
wear exceeds the limit value or is badly imbalanced.

BRAKE LINING AND BRAKE DRUM

CONNECTION CHECK 35100310053

1. Remove the brake drum.

2. Remove the shoe and lining assembly.
(Refer to P.35A-22.)
3. Chalk inner surface of brake drum and rub with shoe and
lining assembly.
4. Replace shoe and lining assembly or brake drums if there
14U007
are any irregular contact area.
NOTE
Clean off chalk after check.
<Added>
Intake manifold
BRAKE BOOSTER VACUUM NIPPLE
Brake booster hose REPLACEMENT
1. Remove the brake booster hose from the intake manifold.
2. Replace the nipple with a new one, using a sealing agent
Nipple and tighten to 15 – 18 N.m
Specified sealant:
3M ATD Part No.8661 or equivalent.
Caution
Take care when applying the thread sealant as too
AY0141BY
much could block the nipple.
3. After replacement, re-install the brake booster hose.

3
3. Details: ’00 PAJERO PININ Workshop Manual chassis
BASIC BRAKE SYSTEM - On-vehicle Service 35A-13
BRAKE DISC RUN-OUT CHECK AND CORRECTION
1. Remove the brake assembly, and then hold it with wire.
2. Place a dial gauge approximately 5 mm from the outer circumference
of the brake disc, and measure the run-out of the disc.
Limit: <Front> 0.06 mm or less,
<Rear> 0.08 mm or less
3. If the brake disc run-out exceeds the limit, correct it as follows:

14F812
(1) Chalk phase marks on the wheel stud and the brake disc, which
run-out is excessive as show

Chalk marks

A14A0398

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(2) Remove the brake disc. Then place a dial gauge as shown, and
measure the end play by pushing and pulling the wheel hub.
Limit: <Front> 0.2 mm, <Rear> 0.025 mm
(3) If the end play exceeds the limit, disassemble the hub and knuckle
assembly to check each part.
(4) If the end play does not exceed the limit, dephase the brake disc
and secure it. Then recheck the brake disc run-out.

14H0052
4. If the run-out cannot be corrected by changing the phase of the brake
disc, replace the brake disc or grind it with the on-the-car type brake
lathe (”MAD, DL-8700PF” or equivalent.
<Added>
BRAKE BOOSTER VACUUM NIPPLE
Intake minifold REPLACEMENT <SCREW TYPE NIPPLE>
1. Remove the brake booster hose from the intake manifold.
Brake booster hose 2. Replace the nipple with a new one, using a sealing agent and
tighten to 15 – 18 N.m.
Nipple Specified sealant:
3M ATD Part No.8661 or equivalent
Caution
AY0142BY
Take care when applying the thread sealant as too much
could block the nipple.
3. After replacement, re-install the brake booster hose.

Brake booster hose MB991876 BRAKE BOOSTER VACUUM NIPPLE CLEANING

<PRESS FIT TYPE NIPPLE>
1. Remove the brake booster hose from the intake manifold.
2. Insert special tool into the nipple and remove the carbon deposit
Nipple by rotating and reciprocating of the special tool.
Caution
The special tool should be inserted more than 50 mm and
AY0143BY confirm that it goes through into the intake manifold.
3. Make sure that no parts of the special tool remain in the manifold.
4. After cleaning, re-install the brake booster hose.