Mitsubishi Montero (2002-2004). Manual — part 1024

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-121

7. If the resistance value exceeds the specified value, replace

the HBB master cylinder and hydraulic unit assembly.

8. Connect the HBB connector "B."
9. Erase HBB diagnostic trouble codes (Refer to

P.35A-14

).

HBB MOTOR RELAY CHECK

M1351010600059

Motor Relay A, B

CAUTION

Apply battery voltage according to the table below. Never
confuse the positive and negative battery terminals, or the
diode inside the relay will be damaged.

TESTER
CONNECTION

SPECIFIED
CONDITION

RESISTANCE
VALUE k

Ω

1

− 5

Continuity

Approximately 1

BATTERY CONNECTION TESTER

CONNECTION

SPECIFIED
CONDITION

−

4

− 5

Open circuit

• Connect battery

terminal (+) to terminal
3

• Connect battery

terminal (

−) to terminal

1

4

− 5

Less than 2
ohms

AC204381

4

1

3

5

AC204329

ACX01808

AB

MOTOR
RELAY B

BRAKE FLUID
RESERVOIR

MOTOR
RELAY A

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-122

BRAKE FLUID LEVEL INSPECTION AND BLEEDING

M1351001400295

CAUTION

• Use only brake fluid DOT3 or DOT4. Never mix the specified brake fluid with other brake fluid, as it

will significantly decrease braking performance.

• Depress the brake pedal slowly. If the brake pedal is pressed too quickly, the pump motor will acti-

vate frequently and a large volume of high-pressure brake fluid may flow from the brake caliper
quickly, depleting the HBB reservoir contents and possibly introducing air into the HBB system.

• Depending upon the quantity of brake fluid in the reservoir, if the brake pedal is pressed with the

reservoir cap removed, the brake fluid in the reservoir may overflow.

• Use suitable protection to prevent brake fluid from contacting underhood components and body

paint.

HBB System Bleeding

WARNING

The HBB system bleeding must be done in the follow-
ing cases.

•

If brake fluid is drained after removing or installing
the HBB

•

if there is excessive brake fluid loss during normal
brake system bleeding

•

if you suspect that air has entered the HBB system

NOTE: The HBB brake system bleeding procedure requires
two persons working together.
HBB system bleeding must be done in the following order:

HBB SYSTEM BLEEDING STEPS

1.

FRONT BRAKE LINES (FILLING)

2.

ACCUMULATOR (HBB)

3.

REAR BRAKE LINES (FILLING)

4.

POWER SUPPLY (HBB)

5.

ABS (HBB)

6.

REAR BRAKE LINES (BLEEDING)

7.

FRONT BRAKE LINES (BLEEDING)

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-123

CAUTION

• Keep the brake fluid reservoir level just above the

"MIN" line. Monitor the fluid level during this procedure
to ensure the fluid does not reach below the "MIN" line,
to prevent air from entering the system.

• If a large quantity of brake fluid is drained during the

bleeding procedure, the accumulator pressure will
decrease abnormally. Do not bleed more than 0.1 dm

3

(0.11quart) from each wheel at a time.

• Confirm that the pump motor stops after each air-bleed-

ing step. If not, proceed to the troubleshooting the HBB
System section.

NOTE: The buzzer may sound during this procedure due to low
pressure in the system. The buzzer will stop when normal HBB
pressure is restored.

Required Special Tool:

• MB991502: Scan Tool (MUT-II)

1. Fill the front brake system with brake fluid as follows (RH

first, LH second):

(1) Attach a clear hose to the RH caliper bleeder valve. This

helps to monitor air/fluid flow.

(2) Be sure the fluid level is between the "MIN" and "MAX"

lines.

(3) Turn the ignition switch to the "LOCK" (OFF) position.

Pump the brake pedal 3

− 4 times and hold it depressed.

(4) Open the RH caliper bleeder valve 1/4 turn.
(5) With the bleeder valve still open, pump the brake pedal

repeatedly to fill the line with fluid until no obvious air
bubbles are seen. When no more obvious air bubbles are
seen, and while the brake pedal is still being pumped,
close the bleeder valve.

(6) Repeat steps (1)

− (5) for the LH caliper.

(7) Release the brake pedal when both sides are filled.

2. Fill the pump motor as follows:

(1) Turn the ignition switch to the "ON" position to operate

the pump motor.
a. If the pump motor operates normally (normal operation

sound), go to step 3.

b. If the pump motor operation sound is dry and high-

pitched, depress the brake pedal 3 or 4 times to
introduce fluid into the pump motor. Then go to step 3.

3. Fill the accumulator system with brake fluid as follows:

(1) Wait for the pump motor to stop from step 2.
(2) Depress the brake pedal slowly 3 or 4 times with the

ignition switch at the "ON" position. Observe the condition
of the brake fluid in the reservoir.
a. If the fluid is cloudy, leave it for 2 or 3 minutes until it

becomes clear.

b. Repeat the above procedure (a) until no bubbles

appear while pumping the brake pedal.

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-124

NOTE: OK to fill the reservoir to the "MAX" line during this
process. Brake fluid level around the "MIN" line may cause
bubbles to appear from the jet flow of brake fluid while
pumping the brake pedal.

4. Fill the rear brake system with brake fluid as follows (RH

first, LH second):

CAUTION

• If a large quantity of brake fluid is drained during the

bleeding procedure, the accumulator pressure will
decrease abnormally. Do not bleed more than 0.1 dm

3

(0.11quart) from each wheel at a time.

• Confirm that the pump motor stops after each air-bleed-

ing step.

NOTE: A high-pressure hydraulic noise (hissing) is normal
during this procedure.

(1) Attach a clear hose to the RH caliper bleeder valve. This

helps to monitor air/fluid flow.

(2) Be sure the fluid level is between the "MIN" and "MAX"

lines.

(3) Turn the ignition switch to the "LOCK" (OFF) position.

Pump the brake pedal 3

− 4 times and hold it depressed.

(4) Open the RH caliper bleeder valve 1/4 turn.
(5) With the bleeder valve still open, pump the brake pedal

repeatedly to fill the line with fluid until no obvious air
bubbles are seen. When no more obvious air bubbles are
seen, and while the brake pedal is still being pumped,
close the bleeder valve.

(6) Repeat steps (1)

− (5) for the LH caliper.

(7) Release the brake pedal when both sides are filled.

5. Supply brake fluid into the power supply system as follows:

CAUTION

Keep the brake fluid reservoir level just above the "MIN"
line at this time. Monitor the fluid level during this proce-
dure to ensure it does not reach below the "MIN" line.

(1) To release the pressure in the HBB power supply system,

turn the ignition switch to the "LOCK" (OFF) position and
depress the brake pedal repeatedly until its depressing
force suddenly feels heavy (no pedal travel).

(2) Turn the ignition switch to the "ON" position and at the

same time quickly depress the brake pedal approximately
20 times. Then confirm that the pump motor has stopped.
This can take up to 2 minutes.

(3) Turn the ignition switch to the "LOCK" (OFF) position and

depress the brake pedal repeatedly until its depressing
force suddenly feels heavy (no pedal travel).

(4) Turn the ignition switch to the "ON" position to operate

the pump motor. Confirm that the pump motor stops
within 25 seconds. If the pump motor does not stop,
repeat steps (1) through (3) above.

6. Supply fluid into the ABS system as follows: