Procedure

Before starting this campaign procedure, CHECK ON THE WARRANTY SUPERSCREEN to verify that the vehicle is an affected VIN for this campaign and that this campaign procedure has not already been completed.

1. Record the customer's audio system settings.

2. V6 MODELS ONLY: Remove the air cleaner resonator.

3. V6 MODELS ONLY: Remove the strut bar from the rear of the engine compartment.

IMPORTANT:
Be sure both doors are closed and both windows are in the FULLY CLOSED position. If any window is not fully closed (all the way up) when the battery is disconnected Ihe short stroke mechanism loses its memory and must be reinitialized as follows:

1) Close the door.
2) Use the power window switch to fully close the window.
3) Release the power window switch.
4) Pull up the power window switch again and hold it for a few seconds until a soft "click" is heard.

4. Remove the battery and battery tray.





5. Remove the vacuum hose from the brake booster.





6. M/T MODELS ONLY:

Install a clamp to the clutch master cylinder hose. Then remove the hose from the clutch master cylinder.

CAUTION
Use care to prevent damaging the nipple on the clutch master cylinder during hose removal.





7. Carefully pry the top two metal brake lines from the white plastic clips attached to the bulkhead. Use a small flat blade screwdriver to gently lift the plastic tab. Then remove the brake line from the clip.





8. Remove the master cylinder from the brake booster.

IMPORTANT:
Do not disconnect the brake lines from the master cylinder.

NOTE:
If your replacement part already has a master cylinder installed, remove the master cylinder from the assembly and discard. Use the original master cylinder, so that brake system bleeding is not necessary.

9. Inside the vehicle, under the instrument panel:

a. Remove the C-clip and pivot pin securing the brake booster push rod to the brake pedal.

b. Remove the four 12 mm nuts from the brake booster mounting studs.





10. In the engine compartment, move the master cylinder away from the brake booster.

IMPORTANT:
Do not dislodge the master cylinder plunger sleeve or 0-ring.

11. Carefully remove the brake booster from the bulkhead. Do not damage the brake booster body seal.





12. Replace the brake booster, using the parts listed in the PARTS INFORMATION section of this bulletin.

Torque the mounting nuts to 13 +/- 2 Nm (104 +/- 25 in/lb).

13. Reinstall the C-clip and pivot pin to secure the booster push rod to the brake pedal.

14. V6 MODELS ONLY: Reinstall the strut bar. Torque to 12 +/- 2 Nm (102 +/- 22 in/lb).





15. Reattach the brake lines to the plastic clip at the bulkhead.

16. Reinstall the master cylinder. Torque the 13 mm nuts to 22 +/- 5 Nm (17 +/- 4 ft/lbs).

17. Reinstall the vacuum hose to the brake booster.

18. Reinstall the battery tray and battery.

19. M/T MODELS ONLY: Perform clutch bleeding as follows:

a. Connect a hose with a bottle to the bleeder screw.

b. Open the bleed nipple.

c. Depress the clutch pedal slowly. Open the bleeder screw to let air and brake fluid out. Then close the bleeder screw. Release the clutch pedal. Repeat until only brake fluid and no air comes out.

d. Check that the brake fluid reservoir level stays between the "MAX" and "MIN" marks throughout the clutch bleeding process.

e. Replenish the fluid as necessary. Use Mitsubishi Brake Fluid p/n MZ311987.

20. V6 MODELS ONLY: Reinstall the air cleaner resonator.

21. Reset the customer's audio system settings.

22. Confirm proper brake, clutch (M/T models), and window operation.