MITSUBISHI MONTERO 2000 Service Repair Manual

BASIC BRAKE SYSTEM -General Information35A-3
GENERAL INFORMATION
The brake system offers high dependability and durability along with improved braking performance and
brake sensitivity.
ItemsSpecifications
Hydraulic brake boosterMaster cylinder typeSingle type (with center valve)
(HBB) <Vehicles with ABS>Master cylinder I.D. mm22.22
Boosting ratio5.4 <Pedal depressing force: 274 N>
Master cylinderTypeTandem type
<Vehicles without ABS>I.D. mm23.81
Brake boosterTypeVacuum type, tandem
<Vehicles without ABS>Effective dia. of power cylinder mm216 + 217
Boosting ratio6.5 <Pedal depressing force: 240 N>
Rear wheel hydraulic pressure control type <Vehicles with ABS>Electronic brake-force distribution (EBD)
Load sensing proportioning
valve<Vehicles without ABS>Decompression ratio0.3
Front brakesTypeFloating caliper, 2 piston, ventilated disc
Disc effective dia.¢
thickness mm241¢
26
Wheel cylinder I.D. mm45.4
Pad thickness mm10.0
Clearance adjustmentAutomatic
Rear brakesTypeFloating caliper, 1 piston, ventilated disc
Disc effective dia.¢
thickness mm256¢
22
Wheel cylinder I.D. mm44.5
Pad thickness mm10.0
Clearance adjustmentAutomatic
Brake fluidDOT3 or DOT4


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BASIC BRAKE SYSTEM -Service Specifications35A-5
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Brake pedal heightL.H. drive vehicles192 - 195-
mm
R.H. drive vehicles187 - 190-
Brake pedal play mm3-8-
Brake pedal to floorboard clearance when the brake pedal is depressed mm90 or more-
Hydraulic brake
booster (HBB)Pump motor
operation timeWhen power supply system brake fluid
pressure is not applied20 - 80-
<Vehicles with ABS>second
When power supply system brake fluid
pressure is applied2-11-
Hydraulic pressurePedal depressionFront0.6 or more-
during no vacuum
operation testforce: 100 N
Rear0-
MPa
Pedal depressionFront4.5 or more-
force: 500 N
Rear0-
Hydraulic pressurePedal depressionFront3.0 - 4.0-
during vacuum op-
eration test
MPa
force: 100 N
Rear3.3 - 4.3-
Pedal depressionFront8.0 - 10.0-
force: 200 N
Rear8.0 - 10.0-
Pedal depressionFront14.0 - 18.0-
force: 400 N
Rear14.0 - 18.0-
Pedal depressionFront15.0 - 19.0-
force: 500 N
Rear15.0 - 19.0-
Clearance between brake booster push rod and primary piston6G70.5 - 0.9-
mm <Vehicles without ABS>
4D5, 4M40.8 - 1.2-
Load sensing propor-When load sensing spring length is 133Short wheelbase4.9 - 5.9 (9.8)-
tioning valve output
fluid pressure (Inputmm (when unladen)
Long wheelbase5.9 - 6.9 (9.8)-
fluid pressure) MPa
<Vehicles withoutWhen load sensing spring length is 149Short wheelbase7.5 - 8.5 (9.8)-
ABS>mm (when laden)
9.0 - 11.0
(16.7)-
Long wheelbase9.3 - 10.3 (9.8)-
11.4 - 13.4
(16.7)-
Load sensing spring length <Distance between spring ends> mm
<Vehicles without ABS>135 - 139-


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F
ro nt dis c bra ke P
ad th ic kn ess mm 1
0.0 2
.0 D
is c th ic kn ess mm 2
6.0 2
4.4 D
is c ru nout mm - 0
.0 6 D
ra g fo rc e N 5
5 -
R
ear dis c bra ke P
ad th ic kn ess mm 1
0.0 2
.0 D
is c th ic kn ess mm 2
2.0 2
0.4 D
is c ru nout mm - 0
.0 6 D
ra g fo rc e N 5
5 -
F
ro nt hub end pla y mm - 0
R
ear hub end pla y mm - 0
S
pecif ie d Lubric a nt Q
uantit y B
ra ke flu id D
O T3 or D O T4 A
s re quir e d P
is to n boot, pis to n se al R
epair kit gre ase G
uid e pin ,lo ck pin P
is to n, w heelcylin der body D
O T3 or D O T4 N
um ber N
am e U
se M
B991502 M
UT-II su b
a sse m bly M
B991529 D
ia gnosis co de
c h eck harn ess M
B991620 V
alv e sp rin g
c o m pre sso r adapte r H
old in g hyd ra ulic bra ke booste r (H BB)

M
B991568 P
ush ro d adju stin g
s o cke t A
dju stm ent of th e bra ke booste r push ro d
p ro tr u sio n am ount B
ra ke to ols e t
A : Dis c bra ke pis -
t o n exp ander P
ush in g-in of th e dis c bra ke pis to n B
ra ke warn in g
l a m p I
llu m in ate d A
ppro x. 3 s A
ppro x. 3 s I
g nit io n
s w it c h S
TA R T O
N A
C C, L
O CK B
ra ke warn in g la m p
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2
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th 5
th 6
th 7
th 8
th 9
th 1
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s e co nd W
it h in
1
s e co nd W
it h in
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s e co nd W
it h in
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s e co nd W
it h in
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s e co nd W
it h in
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s e co nd W
it h in
1
s e co nd W
it h in
1
s e co nd W
it h in
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s e co nd O
N L
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to p la m p sw it c h O
N O
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BS warn in g la m p O
N O
FF A
BS-E C U mem ory W
it h in 3
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ra sin g of
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d ia gnosis
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c o m ple te .

BASIC BRAKE SYSTEM -Troubleshooting35A-9
INSPECTION CHART FOR DIAGNOSIS CODES
Diagnosis
code No.Diagnosis itemsReference page
16*ABS-ECU power supply (Abnormal voltage decrease or increase)35A-9
17, 18ABS-ECU power supply (Open circuit or short circuit)
53Motor relay system (open circuit, short circuit or motor relay coil failure)35A-10
55Pump motor system (Pump motor seized or abnormal ABS-ECU current
detection circuit)35A-11
63ABS-ECU systemReplace ABS-ECU
(Refer to 35B.)
78Accumulator system (Motor has been energized abnormally for long time
or abnormal low-pressure accumulator)35A-12
79Pressure switch system (open circuit or short circuit)35A-13
NOTE
*: Code No. 16 is erased by turning the ignition switch OFF.
INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code No.16 ABB-ECU power supply system (abnormal
voltage increase or decrease)Probable cause
Code No.17, 18 ABS-ECU power supply system (open or
short circuit)
Code No.16 is output if the ABS-ECU power supply voltage is increased or decreased
than the specified.
Code No.17, 18 is output if the ABS-ECU power supply circuit isopen orshort, or
the ABS-ECU internal circuit is defective.
In addition, code No. 16 is erased by turning the ignition switch OFF.DMalfunction of the battery
DMalfunction of connector or harness
DMalfunction of the ABS-ECU
Caution
If the battery voltage is decreased or increased during the test, code No. 16 is output as a present
malfunction, disabling a correct diagnosis. Check the battery and fully charge it if necessary before
carrying out the following tests.
NG
NG
OK
NG
Replace the ABS-ECU. (Refer to GROUP 35B.)
OK
Check trouble symptom.
NG
Repair
NG
Check the harness wire, and repair if necessary.
DBetween the ignition switch and the ABS-ECU
OK
Check trouble symptom.
Measure at the ABS-ECU connector E-107.
DDisconnect the connector, and measure at the harness side.
DStart theengine and then measure the voltage between terminal
31 and the body earth.
OK:System voltageNGCheck the following connectors:E-13, E-107
Repair
OK
Check the following connectors:E-106, E-107
NG
Check the harness wire, and repair if necessary.
DBetween the ignition switch and the ABS-ECU
OK
Check trouble symptom.
Measure at the ABS-ECU connector E-106.
DDisconnect the connector, and measure at the harness side.
DStart theengine and then measure the voltage between terminal
13 and the body earth.
OK:System voltageNG
Check the following connectors:D-32 <R.H. drive vehicles>,
D-128, D-208, D-210 <R.H. drive vehicles>, D-213 <L.H.drive
vehicles>, E-08 <Diesel-powered vehicles>, E-13, E-106
Repair


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BASIC BRAKE SYSTEM -Troubleshooting35A-10
Code No.53 Motor relay system (open circuit, short circuit
or a defective motor relay coil)Probable cause
This code is output if the motor relay circuit is short or open, ABS-ECU internal circuit
is defective, or the hydraulic brake booster (HBB) master cylinder and hydraulic unit
assembly is defective.DMalfunction of connector or harness
DMalfunction of the motor relay
DMalfunction of the ABS-ECU
DMalfunction of the HBB (master cylinder and
hydraulic unit assembly)
NG
Replace the ABS-ECU. (Refer to GROUP 35B.)NG
Repair
NG
OK
Check trouble symptom.
Repair NGNG
OK
Check trouble symptom.
Replace
OK
Check the following connectors:
B-17, B-18, B-19X, B-20X,
D-32 <R.H. drive vehicles>, D-128, D-208, D-210 <R.H. drive
vehicles>, D-213 <L.H. drive vehicles>, E-13, E-106, E-107
Check the harness wire:
DBetween the ignition switch and the motor relay
DBetween fusible link No.9 and the motor relay
DBetween the motor relay and HBB
DBetween the motor relay and the ABS-ECU
DBetween the HBB and the ABS-ECU
Check trouble symptom.
NG
NG
Replace
OK
Check the motor relay. (Refer to P.35A-24.)
Check the hydraulic brake booster (HBB).
(Refer to P.35A-23.)


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BASIC BRAKE SYSTEM -Troubleshooting35A-11
Code No.55 Pump motor system (pump motor seized or
abnormal ABS-ECU current detection circuit)Probable cause
This code is output if the motor relay drive circuit is short or open, the motor relay
or the ABS-ECU internal circuit is defective, or the hydraulic brake booster (HBB)
pump motor ormaster cylinder and hydraulic unit assembly is defective.DMalfunction of connector or harness
DMalfunction of the motor relay
DMalfunction of the ABS-ECU
DMalfunction of the HBB (pump motor or master
cylinder and hydraulic unit assembly)
NG
Repair
NG
OK
Check trouble symptom.
Repair NGNG
OK
Check trouble symptom.
Replace
OK
Check the following connectors:
B-17, B-18, B-19X, B-20X,
E-107
Check the harness wire:
DBetween fusible link No.9 and the motor relay
DBetween the motor relay and HBB
DBetween the HBB and the ABS-ECU
DBetween the HBB and the earthNG
Check the motor relay. (Refer to P.35A-24.)
NG
Replace the ABS-ECU. (Refer to GROUP 35B.)
Check trouble symptom.
NG
OKCheck the hydraulic brake booster (HBB).
(Refer to P.35A-23.)Replace NG
Replace
OKCheck the continuity and resistance of thepump motor.(Refer
to P.35A-23.)


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BASIC BRAKE SYSTEM -Troubleshooting35A-12
Code No. 78 Accumulator system (Motor has
been energized abnormally for long time or
abnormal low-pressure accumulator)Probable cause
This code is output under the following cases:
DPump motor is operated for consecutive 300 seconds
DBrake fluid pressure is decreased, the HBB buzzer sounds due
to the operation of the pressure switch (for low pressure
warning), and then the brake warninglamp illuminates.DBrake fluid leaks inside the hydraulic brake booster (HBB)
DMalfunction of the HB motor relay
DMalfunction of connector or harness
DMalfunction of the ABS-ECU
DMalfunction of HBB (accumulator, pressure switch,pump motor or
master cylinder and hydraulic unit assembly)
NG
Repair
NG
OK
Check trouble symptom.
Repair NGNG
OK
Check trouble symptom.
Replace
OK
Check the following connectors:
B-17, B-18, B-19X, B-20X,
E-106, E-107
Check the harness wire:
DBetween fusible link No.9 and the motor relay
DBetween the motor relay and HBB
DBetween the HBB and the ABS-ECU
DBetween the HBB and the earthNG
Check the motor relay. (Refer to P.35A-24.)
NG
Replace the ABS-ECU. (Refer to GROUP 35B.)
Check trouble symptom.
NG
OKCheck the pressure switch. (Refer to P.35A-23.)NG
Replace
OKCheck the continuity and resistance of thepump motor.(Refer
to P.35A-23.)NG
Replace
OKVisually check the accumulator
Replace the master cylinder and hydraulic unit assembly.


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