ABS MITSUBISHI MONTERO 2000 Service User Guide

U
PPER ARM ASSEM BLY
R EM OVA L AND IN STA LLA TIO N
C au tio n
* : To pre ven t bush in gs fr o m bre akag e, th e parts in dic ate d by *sh ould be te m pora rily tig hte n ed ,
a n d th en fu lly tig hte n ed wit h th e veh ic le on th e gro und in th e unla d en co ndit io n. 3
2 15
6
71
47 ±
10 N×
m * 3
0 ±
4 N×
m
R em oval ste p s
1 . Fro nt wheel sp eed se nso r bra cke t
m ountin g bolt <V ehic le s wit h ABS>
2 . C lip
3 . B ra ke hose
A A"
4. U ppera rm asse m bly and kn uckle co n-
n ectio n 5
. U pper arm asse m bly and fr o nt fr a m e
c o nnectio n
6 . U pper arm asse m bly
7 . U pper arm ball jo in t asse m bly
w
ww.W ork sh opM an uals .c o .u k
P urc h ased f r o m w ww.W ork sh opM an uals .c o .u k

S
H O CK ABSO RBER ASSEM BLY
R EM OVA L AND IN STA LLA TIO N
C au tio n
* : To pre ven t bush in gs fr o m bre akag e, th e parts in dic ate d by *sh ould be te m pora rily tig hte n ed ,
a n d th en fu lly tig hte n ed wit h th e veh ic le on th e gro und in th e unla d en co ndit io n. 2
1

3
21
5
6
78
9
1
0 1
1 4
D is assem bly ste p s
A A" "
CA
1. S elf - lo ckin g nut
2 . S eat
3 . C olla r
4 . U pper bush
" BA
5. S prin g bra cke t asse m bly
6 . S prin g upper pad 7
. C up asse m bly
8 . H elp er ru bber
" AA
9. C oil sp rin g
" AA
10. S prin g lo w er pad
1 1 . S hock abso rb er asse m bly
D IS A SSEM BLY SER VIC E PO IN T
A A"
SELF-L O CKIN G NUT REM OVA L
1 . Use th e sp ecia l to ols to co m pre ss th e co il sp rin g.
C au tio n
( 1 ) Do not tig hte n th e sp ecia l to ol bolt to o tig ht. T he
s p ecia l to ol will be bro ken if th e allo w ab le
t ig hte n in g to rq ue of 74 N×
m is exceed .
( 2 ) In sta ll th e sp ecia l to ols even ly , an d so th at th e
m axim um le n gth will be atta in ed wit h in th e
i n sta lla tio n ra n ge.
( 3 ) Do not use an im pact w re n ch as it w ill cau se th e
b olt of th e sp ecia l to ol to be seiz e d .
2 . To pre ve nt th e pis to n ro d fr o m tu rn in g and unscre w th e
s e lf - lo ckin g nut.
C au tio n
T o pre ven t th e pis to n ro d lo ck nut in sid e th e str u t
f r o m lo osen in g, do not use an im pact w re n ch when
t h e lo ckin g nuts are lo osen ed . M
B991237

S
prin g lo w er
p ad C
oil s p rin g end S
prin g upper
b ra cke t
a sse m bly V
ie w A A
S
hock abso rb er
w
ww.W ork sh opM an uals .c o .u k
P urc h ased f r o m w ww.W ork sh opM an uals .c o .u k

L
O W ER ARM ASSEM BLY
R EM OVA L AND IN STA LLA TIO N
C au tio n
* : To pre ven t bush in gs fr o m bre akag e, th e parts in dic ate d by *sh ould be te m pora rily tig hte n ed ,
a n d th en fu lly tig hte n ed wit h th e veh ic le on th e gro und in th e unla d en co ndit io n. 7
4
2
5
±4
N
×m 1
0 5 6
2 5
R em oval ste p s
1 . S plit pin
2 . Low er arm ball jo in t and kn uckle as-
s e m bly co nnectio n
A A"
3. Tie ro d end and kn uckle co nnectio n
4 . U pper arm and upper arm ball jo in t
c o nnectio n
A A"
5. Low er arm ball jo in t
6 . H ub and kn uckle asse m bly 7
. S hock abso rb era nd lo w era rm asse m -
b ly co nnectio n
8 . B um p sto pper
9 . Low er arm asse m bly and sta biliz e r
l in k co nnectio n
A B"
10. Low er arm mountin g bolt
1 1 . Low er arm asse m bly
w
ww.W ork sh opM an uals .c o .u k
P urc h ased f r o m w ww.W ork sh opM an uals .c o .u k

34-1
REAR
SUSPENSION
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 3.................
SPECIAL TOOLS 3..........................
ON-VEHICLE SERVICE 4.....................
Wheel Alignment Check and Adjustment 4.......
Ball Joint Dust Cover Check 5..................
UPPER ARM ASSEMBLY 6...................SHOCK ABSORBER/COIL SPRING/LOWER
ARM ASSEMBLY 9...........................
STABILIZER BAR 11.........................
TOE CONTROL ARM ASSEMBLY/TOE
CONTROL TOWER BAR 13..................
TRAILING ARM ASSEMBLY 16..............


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

S
H O CK ABSO RBER /C O IL SPR IN G /L O W ER ARM ASSEM BLY
R EM OVA L AND IN STA LLA TIO N
C au tio n
* : To pre ven t bush in gs fr o m bre akag e, th e parts in dic ate d by *sh ould be te m pora rily tig hte n ed ,
a n d th en fu lly tig hte n ed wit h th e veh ic le on th e gro und in th e unla d en co ndit io n. 15
1
52 ±
25 N×
m * 9
48
7
S hock ab so rb er re m oval ste p s
1 . S hock abso rb er m ountin g nut
2 . S hock abso rb er m ountin g bolt
3 . S hock abso rb er
C oil sp rin g re m oval ste p s
2 . S hock abso rb er m ountin g bolt
A A"
"
AA
4. Low er arm mountin g bolt
" AA
5. C oil sp rin g
6 . S prin g upper pad
7 . S prin g lo w er pad L
ow er arm re m oval ste p s
2 . S hock abso rb er m ountin g bolt
A A"
"
AA
4. Low er arm mountin g bolt
" AA
5. C oil sp rin g
6 . S prin g upper pad
7 . S prin g lo w er pad
A B"
8. B olt a sse m bly (fo rca m bera dju stm ent)
9 . Low er arm
w
ww.W ork sh opM an uals .c o .u k
P urc h ased f r o m w ww.W ork sh opM an uals .c o .u k

35A-2
BASIC BRAKE
SYSTEM
CONTENTS
GENERAL INFORMATION 3..................
SERVICE SPECIFICATIONS 5.................
LUBRICANTS 6..............................
SPECIAL TOOLS 6..........................
TROUBLESHOOTING
<Vehicles with ABS> 7......................
ON-VEHICLE SERVICE 19...................
Brake Pedal Check and Adjustment 19..........
Hydraulic Brake Booster (HBB) Operation Check
<Vehicles with ABS> 20........................
HBB Check <Vehicles with ABS> 23............
HBB Motor Relay Continuity Check
<Vehicles with ABS> 24........................
Brake Booster Operating Test
<Vehicles without ABS> 24.....................
Check Valve Operation Check
<Vehicles without ABS> 25.....................
Load Sensing Spring Length Check and
Adjustment <Vehicles without ABS> 25.........
Load Sensing Proportioning Valve Function
Test <Vehicles without ABS> 26................
Bleeding <Vehicles with ABS> 27...............Bleeding <Vehicles without ABS> 29.............
Brake Fluid Level Sensor Check 30.............
Brake Booster Vacuum Switch Check
<Vehicles with 4D5 engine> 30..................
Disc Brake Pad Check and Replacement 31.....
Disc Brake Rotor Check 32.....................
Brake Disc Thickness Check 32.................
Brake Disc Run-out Check and Correction 33....
BRAKE PEDAL 34..........................
HYDRAULIC BRAKE BOOSTER (HBB)
<Vehicles with ABS> 36....................
HBB BUZZER <Vehicles with ABS> 40......
MASTER CYLINDER AND BRAKE
BOOSTER <Vehicles without ABS> 41......
Master Cylinder 43.............................
FRONT DISC BRAKE 44....................
REAR DISC BRAKE 49......................
LOAD SENSING PROPORTIONING
VALVE <Vehicles without ABS> 54..........


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

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


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

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-


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk