brake fluid MITSUBISHI ENDEAVOR 2004 Service Repair Manual

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 < FRONT>
, Rear: refer to
DISASSEMBLY AND ASSEMBLY < REAR> ). Then go to Step 5 .
STEP 3. Check brake disc(s) for run out.
Refer to DISC BRAKE ROTOR CHECK
.
Q: Is runout outside of specifications?
YES: Repair or replace the brake disc(s) as necessary. Then go to Step 5 .
NO: Go to Step 4.
STEP 4. Check brake discs for correct thickness.
Refer to DISC BRAKE ROTOR CHECK .
Q: Is the thickness outside of specifications?
YES: Repair or replace the brake disc(s) as necessary. Then go to Step 5.
NO: Carry out the brake line bleeding. Then go to Step 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
.
INSPECTION PROCEDURE 2: INSUFFICIENT BRAKING POWER DIAGNOSIS
STEP 1. Check that the specified brake fluid is used, its level is correct,

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

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 PROPORTIONING VALVE
FUNCTION TEST < Vehicles without ABS>
). Then go to Step 7 .
NO: Go to Step 2.
STEP 2. Check for spongy (not firm brakes).
1. With engine not running, depress the brake pedal rapidly several times to
deplete booster vacuum reserve.
2. With the brake pedal fully released, depress the brake pedal slowly until it
stops.
3. 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
PROPORTIONING VALVE FUNCTION TEST < Vehicles without
ABS>
). Then go to Step 7 .
NO: Go to Step 3.
STEP 3. Check the brake booster function.
Refer to BRAKE PEDAL FREE PLAY
.
Q: Is there a fault?
YES: Replace the brake booster. Then go to Step 7 .
NO: Go to Step 4.
STEP 4. Check for pinched or restricted brake tube or hose.
Q: Is there a pinched or restricted brake tube or hose?
YES: Replace that complete section of brake tube or brake hose. Then go

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

2. With the brake pedal fully released, depress the brake pedal slowly until it
stops.
3. 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
PROPORTIONING VALVE FUNCTION TEST < Vehicles without
ABS>
). Then go to Step 7 .
NO: Go to Step 2.
STEP 2. Check the pad for wear.
Refer to DISC BRAKE PAD CHECK AND REPLACEMENT
.
Q: Is the pad thickness outside of specifications?
YES: Replace the part. Then go to Step 7 .
NO: Go to Step 3.
STEP 3. Check the vacuum hose and check valve for damage.
Refer to CHECK VALVE OPERATION CHECK
.
Q: Is there a damage?
YES: Replace the part. Then go to Step 7 .
NO: Go to Step 4.
STEP 4. Check the master cylinder function.
Refer to MASTER CYLINDER FUNCTION CHECK
.
Q: Is there a fault?
YES: Repair it. Then go to Step 7 .
NO: Go to Step 5.
STEP 5. Check for brake fluid leaks
.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 24: Connecting Pressure Gauges To Output Port Of Master Cylinder And Proportioning Valve

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Bleed the brake line and the pressure gauges (Refer to PROPORTIONING
VALVE FUNCTION TEST < Vehicles without ABS>
).
3. Depress the brake pedal gradually. Then check that the split point, where the
output fluid pressure begins to drop in proportion to the output fluid pressure,
is at the standard value.
Standard value: 3.19 - 3.67 MPa (463 - 532 psi)
4. Depress the brake pedal more strongly than at the above step. Then check that
the output fluid pressure is at the standard value when the input fluid pressure
is 7.35 MPa (1,066 psi).
Standard value: 4.17 - 4.66 MPa (605 - 676 psi)
5. Measure each out
put fluid
pressure at both valves
, and check that the

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

difference between the two is at the limit value or less.
Limit: 0.5 MPa (73 psi)
Fig. 25: Checking Split Point

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
6. If the measured pressure exceeds the limit, replace the proportioning valve.
BLEEDING MASTER CYLINDER BLEEDING
CAUTION: Use only brake fluid DOT 3 or DOT 4. Never mix the
specified brake fluid with other fluid as it will
influence the braking performance significantly.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

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.
Fig. 26: Identifying Master Cylinder Outlet

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

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 LINE BLEEDING Start the en
gine and bleed the air in the se
quence shown in the fi
gure.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 27: Identifying Brake Line Bleeding Sequence

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
BRAKE FLUID LEVEL SENSOR CHECK
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

The brake fluid level sensor is in good condition if there is no continuity when the
float surface is above &#34;MIN&#34; and if there is continuity when the float surface is
below &#34;MIN&#34;.
Fig. 28: Checking Brake Fluid Level Sensor

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
DISC BRAKE PAD CHECK AND REPLACEMENT NOTE: The brake pads (LH wheel) have indicators that contact the
brake disc when the brake pad thickness becomes 2 mm
(0.08 inch), and emit a squealing sound to warn the driver.
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

5. 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 (&#34;MAD,
DL-8700PF&#34; or equivalent). MASTER CYLINDER FUNCTION CHECK 1. Remove the reservoir cap.
2. While watching the open reservoir from a distance of 50 cm (20 inches), have
an assistant depress the brake pedal. If there was a stream of brake fluid rising
from the reservoir, proceed to Step 3. If there was no stream of brake fluid
rising from the reservoir, repair or replace the master cylinder.
3. While watching the open reservoir from a distance of 50 cm (20 inches), have
the assistant release the brake pedal. If there was a small amount of air bubbles
rising through the brake fluid, master cylinder function is normal. If there were
no bubbles rising through the brake fluid, repair or replace the master cylinder. BRAKE PEDAL REMOVAL AND INSTALLATION
Fig. 42: Identifying M12 Flat Washer

Courtes
y of MITSUBISHI MOTOR SALES OF
A
Grind the brake disc with all wheel nuts dia
gon
equall
y tightened to the specified torque 100
N
lb). When all numbers of wheel nuts are not u
s
the ti
ghtenin
g torque is excessive or not equa
brake disc rotor or drum ma
y be deformed, re
s
judder.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor