Mitsubishi Montero (2002-2004). Manual — part 1025
ON-VEHICLE SERVICE
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BASIC BRAKE SYSTEM
35A-125
CAUTION
When connecting or disconnecting the scan tool, ensure
that the ignition switch is at the "LOCK" (OFF) position.
(1) Turn the ignition switch to the "LOCK" (OFF) position and
connect scan tool MB991502 to the data link connector.
(2) Turn the ignition switch to the "ON" position. Select from
scan tool menu screen as follows:
[SYSTEM SELECT
→ ABS → ACTUATOR TEST → AIR
BLEED]
(3) Depress and hold the brake pedal.
(4) Activate the actuator test [AIR BLEED (1)]. When the
scan tool flashes confirmation that the AIR BLEED (1)
operation is completed, proceed with AIR BLEED (2).
(5) Depress and hold the brake pedal.
(6) Select and activate [AIR BLEED (2)] on the scan tool
screen. When the scan tool flashes confirmation that the
AIR BLEED (2) operation is completed, go to step 7.
7. Bleed the rear brake system as follows (RH first, LH
second):
CAUTION
• Keep the brake fluid reservoir level just above the
"MIN" line at this time. Monitor the fluid level during
this procedure to ensure it does not reach below the
"MIN" line.
• 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.
(1) Attach the clear hose to the RH caliper to monitor air/fluid
flow.
(2) Turn the ignition switch to the "ON" position.
(3) Open bleeder valve 1/4 turn.
(4) With the bleeder valve open, pump the brake pedal 3
times and hold.
(5) Close the bleeder valve.
(6) Pump the brake pedal 3 times and hold.
(7) Open the bleeder valve 1/8 turn briefly to allow any
remaining air to escape, then close the bleeder valve.
(8) Repeat steps (6) and (7) as many times as necessary to
eliminate all air in the line.
(9) Repeat steps (1)
− (8) at the LH caliper.
8. Bleed the front brake system as follows (RH first, LH
second):
ACX01539
16-PIN
MB991502
AC
ON-VEHICLE SERVICE
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BASIC BRAKE SYSTEM
35A-126
CAUTION
• Keep the brake fluid reservoir level just above the
"MIN" line at this time. Monitor the fluid level during
this procedure to ensure it does not reach below the
"MIN" line.
• 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.
(1) Attach the clear hose to the RH caliper to monitor air/fluid
flow.
(2) Turn the ignition switch to the "ON" position.
(3) Open bleeder valve 1/4 turn.
(4) With the bleeder valve open, pump the brake pedal 3
times and hold.
(5) Close the bleeder valve.
(6) Pump the brake pedal 3 times and hold.
(7) Open the bleeder valve 1/8 turn briefly to allow any
remaining air to escape, then close the bleeder valve.
(8) Repeat steps (6) and (7) as many times as necessary to
eliminate all air in the line.
(9) Repeat steps (1)
− (8) at the LH caliper.
9. Adjust the brake fluid level as follows:
(1) Turn the ignition switch to the "LOCK" (OFF) position.
(2) Depress the brake pedal repeatedly (up to 40 times or
more) until its depressing force suddenly feels very heavy
(no pedal travel).
(3) Release the brake pedal.
(4) Adjust the brake fluid level between the "MIN" and "MAX"
lines on the reservoir.
Normal Brake System Air Bleeding
If the brake fluid level in the HBB reservoir is
between the "MIN" and "MAX" lines after any brake
servicing at the wheels (such as calipers, rotors,
etc.), perform the following steps:
1. Bleed the rear brake system as follows (RH first,
LH second):
CAUTION
• Keep the brake fluid reservoir level just above
the "MIN" line at this time. Monitor the fluid
level during this procedure to ensure it does
not reach below the "MIN" line.
• If a large quantity of brake fluid is drained
during the bleeding procedure, the accumula-
tor 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-bleeding step.
(1) Attach the clear hose to the RH caliper to
monitor air/fluid flow.
(2) Turn the ignition switch to the "ON" position.
(3) Open bleeder valve 1/4 turn.
(4) With the bleeder valve open, pump the brake
pedal 3 times and hold.
ON-VEHICLE SERVICE
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BASIC BRAKE SYSTEM
35A-127
(5) Close the bleeder valve.
(6) Pump the brake pedal 3 times and hold.
(7) Open the bleeder valve 1/8 turn briefly to allow
any remaining air to escape, then close the
bleeder valve.
(8) Repeat steps (6) and (7) as many times as
necessary to eliminate all air in the line.
(9) Repeat steps (1)
− (8) at the LH caliper.
2. Bleed the front brake system as follows (RH first,
LH second):
CAUTION
• Keep the brake fluid reservoir level just above
the "MIN" line at this time. Monitor the fluid
level during this procedure to ensure it does
not reach below the "MIN" line.
• If a large quantity of brake fluid is drained
during the bleeding procedure, the accumula-
tor 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-bleeding step.
(1) Attach the clear hose to the RH caliper to
monitor air/fluid flow.
(2) Turn the ignition switch to the "ON" position.
(3) Open bleeder valve 1/4 turn.
(4) With the bleeder valve open, pump the brake
pedal 3 times and hold.
(5) Close the bleeder valve.
(6) Pump the brake pedal 3 times and hold.
(7) Open the bleeder valve 1/8 turn briefly to allow
any remaining air to escape, then close the
bleeder valve.
(8) Repeat steps (6) and (7) as many times as
necessary to eliminate all air in the line.
(9) Repeat steps (1)
− (8) at the LH caliper.
3. Adjust the brake fluid level as follows:
(1) Turn the ignition switch to the "LOCK" (OFF)
position.
(2) Depress the brake pedal repeatedly (up to 40
times or more) until its depressing force
suddenly feels very heavy (no pedal travel).
(3) Release the brake pedal.
(4) Adjust the brake fluid level between the "MIN"
and "MAX" lines on the reservoir.
BRAKE FLUID LEVEL SWITCH CHECK
M1351009100254
The brake fluid level switch is in good condition if there is no
continuity when the float surface is above the "MIN" line and if
there is continuity when the float surface is below the "MIN"
line.
DISC BRAKE PAD CHECK AND REPLACEMENT
M1351002300246
NOTE: The brake pads 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.
ACX00664 AC
MAX
MIN
ON-VEHICLE SERVICE
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BASIC BRAKE SYSTEM
35A-128
CAUTION
• Whenever a pad must be replaced, replace both LH and
RH wheel pads as a set to prevent the vehicle from pull-
ing to one side when braking.
CAUTION
If there is a significant difference in the thicknesses of the
pads on the left and right sides, check the sliding condi-
tion of the piston, lock pin and guide pin.
1. Check the brake pad thickness through the caliper body
check port.
Standard value: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)
2. Remove the guide pin lock bolt. Lift the caliper assembly
and secure it with a wire.
3. Remove the following parts from caliper support.
(1) Pad and wear indicator assembly <FRONT>
Pad and clip assembly <REAR>
(2) Pad assembly
(3) Clip
(4) Shim
(5) Shim B <REAR>
(6) Shim A <REAR>
4. Measure the hub torque before and after pad installation.
Follow the procedure:
• FRONT: Refer to
.
.
ACX00665
AB
FRONT
REAR
ACX00705
AC204544AB
FRONT
REAR
3
3
3
3
1
1
2
2
4
4
6
5
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