Mitsubishi Montero (2002-2004). Manual — part 1027
HYDRAULIC BRAKE BOOSTER (HBB)
TSB Revision
BASIC BRAKE SYSTEM
35A-133
HYDRAULIC BRAKE BOOSTER (HBB)
REMOVAL AND INSTALLATION
M1351010700056
CAUTION
To prevent damaging the HBB pump motor, do not turn the ignition switch to the "ON" position until
installation is completed and brake fluid is replenished.
Pre-removal Operation
• Bleeding of the brake fluid power supply system (Depress
the brake pedal repeatedly more than 40 times with the
ignition switch at the LOCK (OFF) position.)
• Brake Fluid Draining
Post-installation Operation
• Brake Pedal Adjustment (Refer to
• Brake Fluid Supplying
• Brake Line Bleeding (Refer to
• HBB Operating Check (Refer to
ACX00672 AB
2
2
6
4
3
7
7
8
5
1
14 ± 3 N
·
m
124 ± 26 in-lb
15 ± 2 N
·
m
11 ± 2 ft-lb
N
N
REMOVAL STEPS
•
BATTERY
1.
HARNESS CONNECTORS
2.
BRAKE TUBE CONNECTION
3.
SNAP PIN
4.
CLEVIS PIN
5.
HBB MOUNTING NUT
<<A>> >>A<<
6.
HBB
7.
SEAL
8.
SPACER
REMOVAL STEPS (Continued)
HYDRAULIC BRAKE BOOSTER (HBB)
TSB Revision
BASIC BRAKE SYSTEM
35A-134
REMOVAL SEVICE POINT
.
<<A>> HBB REMOVAL
CAUTION
Since high-pressure is applied to the tube shown in the
illustration, do not bend it.
INSTALLATION SEVICE POINT
.
>>A<< HBB INSTALLATION
CAUTION
Since high-pressure is applied to the tube shown in the
illustration, do not bend it.
ACCUMULATOR REPLACEMENT
M1351015800014
Required Special Tool:
• MB991926: Accumulator Wrench
1. Depress the brake pedal repeatedly more than 40 times until
the pedal depressing force feels heavy with the ignition
switch at the "LOCK" (OFF) position to release the pressure
of the HBB power supply system.
CAUTION
To prevent damaging the pump motor, do not turn the igni-
tion switch to the "ON" position until brake fluid is replen-
ished.
2. Drain the brake fluid.
AC204332
AC204332
HYDRAULIC BRAKE BOOSTER (HBB)
TSB Revision
BASIC BRAKE SYSTEM
35A-135
3. Using special tool MB991926, remove the accumulator.
4. Remove the o-ring installed between the accumulator and
the HBB.
5. Install a new o-ring to a new accumulator.
6. Using special tool MB991926, install the new accumulator to
the HBB. The tightening torque of the accumulator is 54
± 5
N
⋅m (40 ± 4 ft-lb).
7. Fill the HBB brake system with brake fluid and bleed the
HBB brake system (Refer to
8. Carry out the function and operation check of power supply
system (Refer to
).
9. Erase HBB diagnostic trouble code (Refer to
10.Dispose of the removed accumulator (Refer to
ACCUMULATOR DISPOSAL
M1351015900011
WARNING
Do not disassemble, throw into fire, cut, weld, drop,
or shock the accumulator without purging filled gas.
1. Fix the accumulator on a vice as illustrated.
2. Punch in the area shown in the illustration to fix the drilling
position.
3. Set a drill [diameter
φ 4 mm (φ 0.16 in)] on the drill motor.
AC204060
AB
MB991926
ACCUMULATOR
AC204540
AC204541AB
Φ
50 mm
Φ
2.0 in
HYDRAULIC BRAKE BOOSTER (HBB)
TSB Revision
BASIC BRAKE SYSTEM
35A-136
WARNING
Wear protective glasses during drilling to protect you
from scattered chips caused by spouting gas.
4. Using a drill motor, drill a hole on the accumulator to purge
filled gas.
NOTE:
.
•
There is no danger of accumulator burst due to drilling
work.
•
You can hear purging sound of gas as soon as a hole is
made on the accumulator.
•
The filled gas is nitrogen, which is colorless, odorless
and harmless.
5. Dispose of the accumulator in compliance with Federal,
state, and local laws.
DISASSEMBLY AND ASSEMBLY
M1351010800064
AC204539
AC204377 AC
1
2
1.7 ± 0.3 N
•
m
15 ± 2.6 in-lb
25.5 ± 5.1 N
•
m
19 ± 3 ft-lb
19
21
20
22
23
3
4
BRAKE FLUID: DOT3 OR DOT4
24
5
6
7
8
9
15
15.2 ± 3 N
•
m
11 ± 2 ft-lb
3.0 ± 0.5 N
•
m
26 ± 4 in-lb
1.7 ± 0.1 N
•
m
15 ± 1 in-lb
14
13
12
11
18
17
16
10
7.8 ± 1.5 N
•
m
69 ± 13 in-lb
7.8 ± 1.5 N
•
m
69 ± 13 in-lb
1.7 ± 0.3 N
•
m
15 ± 2.6 in-lb
54 ± 5 N
•
m
40 ± 4 ft-lb
N
N
N
N
11.8 ± 2.3 N
•
m
104 ± 20 in-lb
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