Mitsubishi Montero (2002-2004). Manual — part 1022

HYDRAULIC BRAKE BOOSTER (HBB) DIAGNOSIS

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BASIC BRAKE SYSTEM

35A-113

2. Measure the resistance between the terminals of the

harness connector (component side). The terminals to be
checked are indicated in the table below.

TERMINAL NO.

SIGNAL

NORMAL
CONDITION

22

− body ground

Ground 1

Less than 2 ohms

4

− body ground

Ground 2

Less than 2 ohms

56

− body ground

Ground 3

Less than 2 ohms

64

− body ground

Ground 4

Less than 2 ohms

AC203901

AC204627AU

M-ASTC-ECU

HARNESS CONNECTORS:

COMPONENT SIDE

SPECIAL TOOLS

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BASIC BRAKE SYSTEM

35A-114

SPECIAL TOOLS

M1351000600230

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MB991502
Scan tool (MUT-II)

MB991496-OD

• For checking of HBB

[Diagnostic trouble code
display when using the scan
tool (MUT-II)]

• Air bleeding of ABS system

in HBB system

MB991529
Diagnostic trouble code
check harness

Tool not necessary
if scan tool (MUT-
II) is available.

For checking of HBB [Diagnostic
trouble code display when using
the brake warning light]

MB991223
Harness set
A: MB991219
Inspection harness

MB991223
MB991709-01

For hydraulic brake booster
(HBB) diagnosis

MB991926
Accumulator wrench

−

Accumulator removal and
installation

MB991620
Valve spring compressor
adapter

−

Fixing of HBB

MB990964
Brake tool set
A: MB990520
Disc brake piston expander

General service
tool

Pushing-in of the disc brake
piston

B991502

MB991529

MB991223

A

AB

B

C

D

MB991926

MB991620

MB990964

A

B

B

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-115

ON-VEHICLE SERVICE

BRAKE PEDAL CHECK AND ADJUSTMENT

M1351000900297

Brake Pedal Height

1. Turn up the carpet etc. under the brake pedal.
2. Measure the brake pedal height as illustrated.

Standard value: 192

− 195 mm (7.6 − 7.7 inches)

3. If the brake pedal height is not within the standard value,

adjust as follows.

(1) Disconnect the stoplight switch connector.
(2) Rotate the stoplight switch 1/4 turn counterclockwise to

loosen.

(3) Loosen the operating rod jam nut. Turn the serrations of

the operation rod with pliers to adjust the brake pedal
height to the standard value.

(4) Turn the stoplight switch until it contacts the stopper.

During this step, secure the pedal by moving it forward by
hand.

(5) Turn the stoplight switch 1/4 turn clockwise to secure,

and confirm that the clearance between the switch
plunger and the stopper is as shown.

(6) Connect the connector of the stoplight switch.
(7) Check to be sure that the stoplight does not illuminate

with the brake pedal released.

4. Check the key interlock and shift lock mechanisms (Refer to

GROUP 23A, On-vehicle Service

− Key Interlock and Shift

Lock Mechanism Check

P.23Aa-24

).

5. Return the carpet etc. to its original position.

Brake Pedal Free Play

1. Turn the ignition switch to the "ON" position, and wait until

the HBB pump motor stops.
NOTE: If the brake fluid inside the accumulator is not pres-
surized to a predetermined value, the pump motor will start
to run. Once the pump motor has stopped, the brake fluid
inside the accumulator is pressurized to the predetermined
value. If the brake fluid inside the accumulator is pressurized
to a predetermined value, the pump motor will not start to
run.

ACX00657AB

OPERATING
ROD LOCK
NUT

STOPLIGHT
SWITCH

OPERATING
ROD

ACX01815AB

JAM NUT

PEDAL UP

PEDAL
DOWN

AC101091AB

STOPPER

0.5 - 1.0 mm
(0.02 - 0.04 in)

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-116

2. Operate the pedal by hand, and check that the pedal stroke

(free play) meets the standard value at the point where
resistance is felt.

Standard value: 3 mm (0.1 inch) or less

3. If the brake pedal play is not within the standard value,

check the following, and adjust or replace if necessary:

• Excessive play between the brake pedal and the clevis pin,

or between the clevis pin and the brake booster operating
rod

• Brake pedal height

• Installation position of the stoplight switch, etc.

Clearance between Brake Pedal and Floorboard

1. Turn up the carpet etc. under the brake pedal.
2. Start the engine, depress the brake pedal with

approximately 500 N (112 pounds) of force, and measure
the clearance between the brake pedal and the floorboard.

Standard value: 90 mm (3.5 inches) or more

3. If the clearance is outside the standard value, check for air

trapped in the brake line and thickness of the disc brake
pad. And then adjust and replace defective parts as
required.

4. Return the carpet etc. to its original position.

STOPLIGHT SWITCH CHECK

M1351008900213

1. Connect an ohmmeter between the stoplight switch

connector terminals.

2. There should be no continuity between the terminals when

the plunger is pushed in as shown. There should be
continuity when it is released.

ACX00659

ACX00660

TESTER
CONNECTION

PLUNGER

SPECIFIED
CONDITION

1

− 2

IN

Open circuit

OUT

Less than 2 ohms

ACX00671AB

NO CONTINUITY CONTINUITY

4 mm

(0.16 in)