Mitsubishi Montero (2004+). Manual — part 1029

HYDRAULIC BRAKE BOOSTER (HBB) DIAGNOSIS

TSB Revision

BASIC BRAKE SYSTEM

35A-115

Resistance and Continuity between Harness
Connector Terminals

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

disconnect the M-ASTC-ECU connectors.

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-116

SPECIAL TOOLS

M1351000600382

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MB991958

A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991914
F: MB991825
G: MB991826

MUT-III Sub Assembly

A: Vehicle communication

interface (V.C.I.)

B: MUT-III USB cable
C: MUT-III main harness A

(Vehicles with CAN
communication system)

D: MUT-III main harness B

(Vehicles without CAN
communication system)

E: MUT-III main harness C

(for Daimler Chrysler
models only)

F: MUT-III measurement

adapter

G: MUT-III trigger harness

MB991824-KIT
NOTE: G:
MB991826 MUT-III
trigger harness is
not necessary
when pushing V.C.I
ENTER key

• For checking of HBB

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

• Air bleeding of ABS system

in HBB system

CAUTION

MUT-III main harness B
(MB991911) should be used.
MUT-III main harness A and C
should not be used for this
vehicle.

MB991529
Diagnostic trouble code
check harness

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

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

MB991910

MB991826

MB991958

MB991911

MB991914

MB991824

MB991827

MB991825

DO NOT USE

A

B

C

D

E

F

G

DO NOT USE

MB991529

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-117

ON-VEHICLE SERVICE

BRAKE PEDAL CHECK AND ADJUSTMENT

M1351000900297

Brake Pedal Height

1. Turn up the carpet etc. under the brake pedal.

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

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MB991223

A

AB

B

C

D

MB991926

MB991620

MB990964

A

B

B

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-118

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.23A-551

).

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)