Mitsubishi Montero (2002-2004). Manual — part 994
35A-1
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .
BASIC BRAKE SYSTEM DIAGNOSIS
INTRODUCTION. . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TROUBLESHOOTING
STRATEGY. . . . . . . . . . . . . . . . . . . . . . . . .
SYMPTOM CHART. . . . . . . . . . . . . . . . . . .
SYMPTOM PROCEDURES . . . . . . . . . . . .
HYDRAULIC BRAKE BOOSTER (HBB)
DIAGNOSIS . . . . . . . . . . . . . . . . . . . .
INTRODUCTION. . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TROUBLESHOOTING
STRATEGY. . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE WARNING LIGHT CHECK . . . . . .
TROUBLE CODE DIAGNOSIS. . . . . . . . . .
DIAGNOSTIC TROUBLE CODE CHART . .
HBB DIAGNOSTIC TROUBLE CODE
PROCEDURES. . . . . . . . . . . . . . . . . . . . . .
SYMPTOM CHART. . . . . . . . . . . . . . . . . . .
HBB SYMPTOM PROCEDURES . . . . . . . .
DATA LIST REFERENCE TABLE . . . . . . .
ACTUATOR TEST REFERENCE TABLE. .
CHECK AT M-ASTC-ECU . . . . . . . . . . . . .
SPECIAL TOOLS. . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE. . . . . . . . . . .
BRAKE PEDAL CHECK AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .
STOPLIGHT SWITCH CHECK . . . . . . . . . .
HBB OPERATING CHECK . . . . . . . . . . . . .
HBB CHECK . . . . . . . . . . . . . . . . . . . . . . . .
HBB MOTOR RELAY CHECK . . . . . . . . . .
BRAKE FLUID LEVEL INSPECTION AND
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE FLUID LEVEL SWITCH CHECK . .
DISC BRAKE PAD CHECK AND
REPLACEMENT . . . . . . . . . . . . . . . . . . . . .
DISC BRAKE ROTOR CHECK . . . . . . . . . .
BRAKE DISC THICKNESS CHECK . . . . . .
BRAKE DISC RUN-OUT CHECK AND
CORRECTION . . . . . . . . . . . . . . . . . . . . . .
BRAKE PEDAL. . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
HYDRAULIC BRAKE BOOSTER
(HBB) . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
ACCUMULATOR REPLACEMENT . . . . . . .
ACCUMULATOR DISPOSAL . . . . . . . . . . .
DISASSEMBLY AND ASSEMBLY . . . . . . .
BUZZER . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
BUZZER CHECK. . . . . . . . . . . . . . . . . . . . .
FRONT DISC BRAKE ASSEMBLY . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY AND ASSEMBLY . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
Continued on next page
35A-2
REAR DISC BRAKE ASSEMBLY . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY AND ASSEMBLY . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . .
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . .
GENERAL SPECIFICATIONS . . . . . . . . . .
SERVICE SPECIFICATIONS . . . . . . . . . . .
GENERAL DESCRIPTION
TSB Revision
BASIC BRAKE SYSTEM
35A-3
.
GENERAL DESCRIPTION
M1351000100235
The brake system has been designed to give greater
reliability and durability and to provide excellent brak-
ing performance.
.
FEATURES
Improved Braking Performance
• Adoption of a hydraulic brake booster (HBB)
which maintains a high brake-assisting force
even in high deceleration ranges.
• 16-inch ventilated disc brakes have been
adopted to provide stable braking force and
improved braking feel.
.
Improved Stability
• Adoption of an electronic brake-force distribution
(EBD) which makes it possible to maintain the
maximum amount of braking force even when the
vehicle's load is unevenly distributed.
• Adoption of independent front and rear wheel
brake lines (H piping).
• Ventilated discs have been adopted for front
wheel and rear wheel in order to improve anti-
fading performance.
.
Improved Serviceability
• A diagnosis function has been adopted for the
HBB system in order to make inspection easier.
• For the front and rear disc brakes, an outer disc
method separated hub and rotor has been
adopted to make removal and installation easier.
• The HBB reservoir tank cap has been colored
white to make identification easier.
CONFIGURATION DIAGRAM
ACX01742 AB
HYDRAULIC BRAKE
BOOSTER (HBB)
FRONT DISC BRAKE
PARKING BRAKE
REAR DISC BRAKE
GENERAL DESCRIPTION
TSB Revision
BASIC BRAKE SYSTEM
35A-4
HYDRAULIC BRAKE BOOSTER (HBB)
The master cylinder hydraulic pressure for the front
brakes is assisted by a brake booster which utilizes
accumulator pressure; the hydraulic pressure gener-
ated by the accumulator is introduced directly to the
rear brakes.
AC000675
ACCUMULATOR
CHECK VALVE
PUMP
MOTOR
PRESSURE
SWITCH
RELIEF VALVE
RESERVOIR (BUILT-IN BRAKE
FLUID LEVEL WARNING SWITCH)
MASTER CYLINDER PISTON
BOOSTER
CHAMBER
POWER PISTON
REACTION DISC
OPERATING ROD
MASTER CYLINDER AND
BRAKE BOOSTER
SELECT SOLENOID VALVE
CONTROL SOLENOID VALVE
REACTION
ROD
SPOOL
VALVE
REGULATOR PISTON
HYDRAULIC UNIT
IN IN IN IN
OUT OUT OUT OUT
REAR-LEFT
REAR-RIGHT
FRONT-LEFT
FRONT-RIGHT
AB
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