Mitsubishi Montero (2004+). Manual — part 1001
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
AC206001AC
HYDRAULIC BRAKE
BOOSTER (HBB)
FRONT DISC BRAKE
PARKING BRAKE
REAR DISC BRAKE
GENERAL DESCRIPTION
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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
GENERAL DESCRIPTION
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BASIC BRAKE SYSTEM
35A-5
HYDRAULIC BRAKE BOOSTER (HBB)
OPERATION
1. When the pedal operating force is transmitted in
turn by the operating rod, the power piston and
the master cylinder piston, the regulator piston
and the spool valve move to the left.
2. When the spool valve opens line A and closes line
B, the accumulator pressure is supplied to the
rear brakes. This pressure is introduced to the
booster chamber and provides power assistance
to move the master cylinder piston to the left.
3. Then, when the pressure in the booster chamber
increases, the pressure which is applied to the
rear (left side) of the reaction disc also increases,
and the reaction disc starts to change shape. The
reaction disc contacts the reaction rod, and the
reaction rod in turn contacts the spool valve, so
that the master cylinder pressure being applied
towards the left and the booster pressure being
applied to the right are brought into balance by the
reaction disc. This allows the power-assist
hydraulic pressure generated by the pedal
operating force to be kept at an equilibrium.
.
<When booster is not operating>
.
<When booster is operating>
.
AC000676
AC000676 AB
ACCUMULATOR
RESERVOIR
CHECK
VALVE
PUMP
MOTOR
PRESSURE
SWITCH
LINE B (OPEN)
LINE A (CLOSED)
RETURN SPRING
REACTION DISC
REACTION ROD
SPOOL
VALVE
REAR
FRONT
REGULATOR PISTON
MASTER CYLINDER RETURN SPRING
MASTER CYLINDER PISTON
POWER PISTON
BOOSTER CHAMBER
OPERATING ROD
MASTER CYLINDER
MECHANISM
AC000677AB
ACCUMULATOR
PRESSURE
LINE B
(CLOSED)
LINE A
(OPEN)
SPOOL
VALVE
ASSIST
FORCE
BOOSTER
CHAMBER
OPERATING ROD
REACTION ROD
REACTION
DISC
REAR
FRONT
POWER PISTON
BASIC BRAKE SYSTEM DIAGNOSIS
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BASIC BRAKE SYSTEM
35A-6
<When a loss of accumulator pressure occurs>
If a loss of accumulator pressure occurs because of
a problem such as a pump motor problem, the power
assist force and rear brake pressure cannot increase
in response to the input from the brake pedal.
Accordingly, the front brakes can be operated
directly by depressing the brake pedal, but the rear
brakes do not operate at all.
BASIC BRAKE SYSTEM DIAGNOSIS
INTRODUCTION
M1351009700223
The hydraulic brake system consists of the brake
pedal, the hydraulic brake booster (HBB), and the
disc brakes. Insufficient braking power or noise may
occur due to wear, damage or incorrect adjustment
of these parts.
DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1351009800220
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find a
basic brake system fault.
1. Gather information from the customer.
2. Verify that the condition described by the
customer exists.
3. Find the malfunction by following the symptom
chart.
4. Verify malfunction is eliminated.
SYMPTOM CHART
M1351009900238
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Vehicle Pulls to One Side when Brakes are Applied
DIAGNOSIS
STEP 1. Check for oil, water, etc., on the pad
contact surface of all brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES :
Replace the pads on both left and right
wheels as a set and determine the
source/cause of foreign material. Then go to
Step 5.
NO :
Go to Step 2.
SYMPTOM
INSPECTION
PROCEDURE
REFERENCE
PAGE
Vehicle pulls to one side when brakes are applied
1
Insufficient braking power
2
Increased pedal stroke (Reduced pedal-to-floor board clearance) 3
Brake drag
4
Scraping or grinding noise when brake are applied
5
Squealing, groaning or chattering noise when brake are applied
6
Squealing noise when brakes are not applied
7
Groaning, clicking or rattling noise when brakes are not applied
8
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