ignition MITSUBISHI MONTERO 2000 Service Repair Manual

BASIC BRAKE SYSTEM -On-vehicle ServiceBASIC BRAKE SYSTEM -On-vehicle Service35A-27
BLEEDING
Caution
Specified brake fluid: DOT3 or DOT4
1. Always use the specified brake fluid. Avoid using
a mixture of the specified brake fluid and other fluid.
2. Maintain the fluid reservoir level between the MIN
and MAX marks during the air bleeding.
3. Do not depress the brake pedal hard during the air
bleeding (normal air bleeding) to prevent the pump
motor from operating frequently.
4. After the air bleeding, check that the brake dragging
does not become stronger.
5. If the pedal is depressed with the reservoir cap
removed, the brake fluid may overflow. Do not depress
the brake pedal while the fluid is being added.
NORMAL AIR BLEEDING
After the front brake or the rear brake is removed and installed,
some fluid may remain in the hydraulic brake booster (HBB)
reservoir. In this case, bleed air from the brake caliper.
HBB SYSTEM AIR BLEEDING
If all the brake fluid inside the reservoir is drained due to
the removal and installation of the HBB, bleed air as follows:
Air bleeding from front brake system
1. Turn the ignition switch to the LOCK (OFF) position. Bleed
air from the front brake calipers (right and left) by pumping
the brake pedal.
Pump motor operation
2. Turn the ignition switch ON, and operate the pump motor.
If the pump motor is running free, supply the brake fluid
into the pump motor by depressing the brake pedal three
or four times.
Air bleeding from accumulator system
3. After the pump motor stopped, depress the brake pedal
three or four times with the ignition switch ON. Then
observe the brake fluid in the reservoir. If the brake fluid
looks whitish, wait for a few minutes until it becomes
clear.
4. Repeat step 3 until the brake fluid becomes clear.


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ABS <4WD> -Troubleshooting35B-10
Code No.16 ABS-ECU power supply system (abnormal
voltage increase or decrease)Probable cause
This code is output if the ABS-ECU power supply voltage or valve relay power
supply voltage drops below or rises above a certain level.DMalfunction of battery
DMalfunction of harness or connector
DMalfunction of the ABS-ECU
Caution
If the system voltage drops or rises during inspection, this code will beoutput to indicate a current
problem. And correct problem diagnosis will not be possible. Before carrying out the following
procedure, check the battery and recharge it if necessary.
OKNG
Repair
OK
(1)NGCheck the following connectors:D-32 , D-128,
D-208, D-210 , D-213 , E-08 , E-13,
E-106
NG
Check the harness wire, and repair if necessary.
DBetween the ignition switch and the ABS-ECU (2)NG
OK
Check the trouble symptoms.
NG
Repair
NG
Check the harness wire, and repair if necessary.
DBetween the ignition switch and the ABS-ECU
Check the following connectors:E-13, E-107
Measure at E-106, E-107 ABS-ECU connectors.
DDisconnect the connector and measure at the harness
side.
DIgnition switch: ON
(1) Voltage between terminal 13 and body earth
OK:System voltage
(2) Voltage between terminal 31 and body earth
OK:System voltage
NG (1)NG
Check the ABS valve relay (Refer to P.35B-28).NGReplace the ABS valve relay.
OK
Check the harness wire, and repair if necessary.
DBetween ignition switch and ABS valve relay
OK
Repair
OK
Replace the ABS-ECU.
Check the trouble symptoms.
Check the following connectors:B-21X, D-32 ,
D-128, D-208, D-210 , D-213 , E-13 OK
NG(2)NG
Check the harness wire, and repair if necessary.
DBetween fusible link No. 8 and the ABS valve relay
OK
NG
Repair
NGCheck the trouble symptoms.
Check the following connector:B-21X
OK
NG
OK
NG
Repair
Check the harness wire, and repair if necessary.
DBetween ABS-ECU and ABS valve relayNG
Check the trouble symptoms.
Check the following connectors:E-107, B-21X
OK
OK
NG
RepairCheck the trouble symptoms.
Check the following connectors:B-17, B-18, B-21X, E-107
NG
Repair
Check the harness wire, and repair if necessary.
DBetween ABS valve relay and HBB and ABS-ECU terminal
(48)
Measure at ABS-ECU connector E-107.
DDisconnect the connector and measure at the harness
side.
DIgnition switch: ON
DVoltage between terminal 37 and body earth
OK:System voltage
Measure at ABS valve relay connector B-21X.
DDisconnect the connector and measure at the harness
side.
DIgnition switch: ON
(1) Voltage between 1 and body earth
OK:System voltage
(2) Voltage between terminal 5 and body earth
OK:System voltage
Check the trouble symptoms.


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ABS <4WD> -Troubleshooting35B-11

Code No. 26 Center differential lock switch system
Probable cause
Code No. 27 Rear differential lock switch system
The ABS-ECU is designed to accommodate the fitting of a rear differential lock.
Because of this, for vehicles which are notequippedwith a rear differential lock,
system voltage isapplied to terminal(33) of the ABS-ECU instead of the rear
differential lock switch signal. If there is anopencircuit in the lines by which this
system voltage is applied, the ABS-ECU outputs code Nos. 26 and 27.DMalfunction of harness or connector
DMalfunction of the ABS-ECU
NG
OK
Replace the ABS-ECU.
NG
Check the harness wire, and repair if necessary.
DBetween the ignition switch and the ABS-ECU
OK
NG
Repair
Measure at ABS-ECU connector E-107.
DDisconnect the connector and measure at the harness
side.
DIgnition switch: ON
DVoltage between terminal 33 and body earth
OK:System voltage
Check the trouble symptoms.
Check the following connector:D-32, D-124, D-208, D-210,
E-13, E-107, F-17
OK NG
Repair
NG
Check the trouble symptoms.
Check the following connector:E-107


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ABS <4WD>-Troubleshooting35B-12

Code No.26 Center differential lock detection switch
Probable cause
Code No.27 Rear differential lock detection switch
On vehicles with rear differential lock system, these codes will be set under the
following conditions:
DThe ABS-ECU detects an open-circuit in the center differential lock detection
switch and the rear differential lock detection switch systems, so no signal is
sent.
DThe vehicle hasbeendriven at 20 km/h or more for five minutes or more
while the center differential lock detection switch is off and the rear
differential lock detection switch is on, and then the vehicle speed decreases
to 2 km/h in that condition.DMalfunction of harness or connector
DMalfunction of the
center differential lock detection
switch
DMalfunction of the
rear differential lock detection
switch
DMalfunction of the
rear differential lock-ECU
DMalfunction of the
ABS-ECU
YES
NG OK
Do the both of the center differential lock indicatorlamp and the
rear differential lock indicatorlamp illuminate normally?YESMeasure at the ABS-ECU connector E-107.
DDisconnect the connector, and measure at the harness side
connector.
DIgnition switch: ON
DVoltage between 33 and body earth
OK:System voltage
NG OK
NO
Does the center differential lock indicatorlamp illuminate normally?
NO
Replace the center differ-
ential lock detection
switch.
Check the following
connector:E-107Check the following
connectors:
D-32,
D-124, E-13,
E-107
NG
Repair
Repair
Check the trouble symp-
tom
Check the trouble symp-
tomOKNG
NG
Check the harness wire,
and repair if necessary.
DBetween ABS-ECU
and rear differential
lock-ECU
Check the following
connectors:
C-16, E-107, E-113
NG OK
Repair
Check the trouble symp-
tom
NG
Check the harness wire.
DBetween ABS-ECU and center differential lock detection switch
NG
Repair
OK
Check the trouble symp-
tom
Replace the ABS-ECU.
Rear differential lock detection switch check
(Refer to GROUP 27)
NG
OK
Check the following connectors:
D-26, D-32, D-124, F-17, G-01, G-13
NG
Repair
OK
Check the trouble symptom
NG
Check the harness wire.
DBetween rear differential lock-ECU and rear differential lock
detection switch
NG
Repair
OK
Check the trouble symptom
NG
Replace the rear differential lock-ECU.
NG
Replace the rear differen-
tial lock detection switch.


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ABS <4WD> -Troubleshooting35B-16
Code No. 51 Valve relay system (ON problem)Probable cause
This code is output when the ABS-ECU judges during the initial check when the
ignition switch is turned to the ON position and the valve relay is OFF that there
is a fused relay contact or a short-circuit in the valve relay drive circuit when
power isbeing supplied to the solenoidvalve.DMalfunction of harness or connector
DMalfunction of ABS valve relay
DMalfunction of the ABS-ECU
Repair NG
Check the ABS valve relay (Refer to P.35B-28).NGReplace the ABS valve relay.
OK
Check the harness, and repair if necessary.
DBetween ABS valve relay and ABS-ECU
OKNG
Repair
OK
Replace the ABS-ECU.
Check the trouble
symptoms.
Check the following connectors:E-107, B-21X OK
NG
NG
Check the harness, and repair if necessary.
DBetween ABS valve relay and HBB and ABS-ECU terminal
No.48
DBetween ABS valve relay and body earth
Measure at ABS-ECU connector E-107.
DDisconnect the connector and measure at the harness
side.
DIgnition switch: ON
DVoltage between terminal 37 and body earth
OK:System voltage


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ABS <4WD> -Troubleshooting35B-17
Code No. 52 Valve relay system (OFF problem)Probable cause
This code is output if the ABS-ECU judges that there is a valve relay OFF
problem when the valve relay is on and power is supplied to the solenoid valve.DMalfunction of harness or connector
DMalfunction of ABS valve relay
DMalfunction of the ABS-ECU
NOTE
When reading the diagnosis codes using the ABS warning lamp (Refer to P.35B-5.), the valve relay
connector is disconnected during inspection, with the result that this problem code will be output in addition
to any other problem codes.
After the problem locations indicated by the problem diagnosis codes have been checked and repaired
but the ABS warning lamp remains illuminated and no diagnosis codes other than code No. 52 are displayed,
there is probably a malfunction of the valve relay system. In this case, carry out the following inspection.
NG
Repair (1)NG
Check the ABS valve relay (Refer to P.35B-28).NGReplace the ABS valve relay.
OK
Check the harness wire, and repair if necessary.
DBetween ignition switch and ABS valve relay
OK
Repair
OK
Replace the ABS-ECU.
Check the trouble symptoms.
Check the following connectors:B-21X, D-32 ,
D-128, D-208, D - 210 , D-213 , E - 13 OK
NG
NG
Check the harness wire, and repair if necessary.
DBetween ABS valve relay and HBB and ABS-ECU terminal
No. 48
(2)NG
Measure at ABS valve relay connector B-21X.
DDisconnect the connector and measure at the harness
side.
DIgnition switch: ON
(1) Voltage between 1 and body earth
OK:System voltage
(2) Voltage between terminal 5 and body earth
OK:System voltage
Check the harness wire, and repair if necessary.
DBetween fusible link No. 8 and the ABS valve relay
OK
NG
Repair
NGCheck the trouble symptoms.
Check the following connector: B-21X
OK
NG
Measure at ABS-ECU connector E-107.
DDisconnect the connector and measure at the harness
side.
DIgnition switch: ON
DVoltage between terminal 37 and body earth
OK:System voltage
OK
NG
Repair
Check the harness wire, and repair if necessary.
DBetween ABS-ECU and ABS valve relayNG
Check the trouble symptoms.
Check the following connectors:E-107, B-21X
OK
OK
NG
RepairCheck the trouble symptoms.
Check the following connectors:B-17, B-18, B-21X, E-107


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ABS <4WD> -Troubleshooting35B-18
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble SymptomInspection
procedure
No.Reference
page
Communication with MUT-II is not possible.135B-18
Communication with MUT-II and the ABS-ECU is not possible.235B-19
The ABS warning lamp does not illuminate when the ignition key is turned to ON (engine
stopped).335B-20
The ABS warning lamp remains illuminated after the engine has started.435B-20
The brake warning lamp does not illuminate when the ignition switch is turned ON (engine
stopped).Refer to GROUP 35A.
The brake warning lamp remains illuminated after the engine has started.
Abnormal brake operation535B-21
Caution
(1) Because the ABS may also operate at times when sudden braking is not being carried out,
such as when driving on low frictional coefficient roads, when turning at high speed or during
high - speed overtaking, check with the customer that the problems are not occurring when
driving under conditions such as these.
(2) When the ABS is operating, changes in the brake pedal feel (vibration and difficulty depressing
the pedal) may occur. This happens because the hydraulic pressure inside the brake line is
continually changing in order to stop the wheels from locking up, and is not a malfunction.
INSPECTION PROCEDURES FOR TROUBLE SYMPTOMS
Inspection procedure 1
Communication with MUT-II
is not possible.
Probable cause
The cause is probably a malfunction of the diagnosis connector power supply
circuit or earth circuit.DMalfunction of diagnosis connector
DMalfunction of harness or connector
NGCheck the following connectors:D-23, D-27, D-210, D-211
NG
Repair
OK
Check the trouble symptoms.
NG
Check the harness wire, and repair if necessary.
DBetween battery and diagnosis connector
OK
NG
NG
Repair
OK
Check the trouble symptoms.
NG
Check the harness wire, and repair if necessary.
DBetween diagnosis connector and earth
OK
NG
Replace the MUT-
II.
Measure at diagnosis connecter D-23.
DVoltage between 16 and body earth
OK:System voltage
Check the following connector:D-23
Measure at diagnosis connecter D-23.
DContinuity between terminals 4, 5 and body earth
OK:Continuity
Check the trouble symptoms.


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ABS <4WD> -Troubleshooting35B-19
Inspection procedure 2
Communication with MUT-II
and the ABS-ECU is not
possible.
Probable cause
The cause is probably anopencircuit in the ABS-ECU power supply circuit or
an opencircuit in the diagnosis output circuit.DBlown fuse
DMalfunction of harness or connector
DMalfunction of the ABS-ECU
(1)NG
OK
Check the following connectors:E-13, E-107
NG
Repair
OK
Check the trouble symptoms.
NG
Check the harness wire, and repair if necessary.
DBetween ABS-ECU and diagnosis connector
OK
Check the following connectors:D-32 , D-128,
D-208, D-210 , D-213 , E-08 , E-13,
E-106
NG
Repair OKCheck the trouble symptoms.
NG
Check the harness wire, and repair if necessary.
DBetween the ignition switch and the ABS-ECU
NG
Repair
OK
Check the trouble symptoms.
NG
Check the harness, and repair if necessary.
DBetween the ignition switch and the ABS-ECU
OK
NG
Repair
OK
NG
Replace the ABS-ECU.
Measure at diagnosis connector D-23 and ABS-ECU connector
E-107.
DDisconnect the connectors and measure at the harness
side.
DContinuity between the following terminals:
Between terminals 47 (ABS-ECU side) and 1 (diagnosis
connector side)
Between terminals 36 (ABS-ECU side) and 7 (diagnosis
connector side)
OK:ContinuityNGCheck the following connectors:D-23, D-33, D-128, D-222,
E-13, E-107
Check the trouble
symptoms.
Check the following connectors:E-106, E-107(2)NG
Measure at ABS-ECU connectors E-106, E-107.
DDisconnect the connectors and measure at the harness
side.
DIgnition switch: ON
(1) Voltage between terminal 13 and body earth
OK:System voltage
(2) Voltage between terminal 31 and body earth
OK:System voltage
OK
Check the following connectors:E-106, E-107
Repair
OK
Check the trouble
symptoms.
NG
Check the harness wire, and repair if necessary.
DBetween the ABS-ECU and earthNG NG
Measure at ABS-ECU connectors E-106, E-107.
DDisconnect the connectors and measure at the harness
side.
DContinuity between terminals 12, 25, 26 and 42 and body
earth
OK:Continuity


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ABS <4WD> -Troubleshooting35B-20
Inspection procedure 3
The ABS warning lamp does not illuminate when the
ignition key is turned to ON (engine stopped).
Probable cause
When power is first supplied to the ABS-ECU, the ABS-ECU turns the ABS-ECU
valve relay from off to on, off and back to onagain aspart of its initial check.
Accordingly, if the ABS warninglampdoes not illuminate, the cause is probably
an opencircuit in the ABS warninglamppower supply circuit, a blownlamp bulb
or an opencircuit between the ABS warninglamp and theABS-ECU.DBlown fuse
DBlown ABS warninglamp bulb
DMalfunction of ABS valve relay
DMalfunction of harness or connector
DMalfunction of combination meter
DMalfunction of the ABS-ECU
NG
Replace the combination meter.
NG
Repair
OK
NG
Check for a blown bulb.Replace the ABS
warning lamp bulb.
OK
NG
Repair
OK
Check the trouble symptoms.
Multi - purpose fuse No. 6 checkNGRefer to GROUP 00 – Inspection service Points for Blown
Fuse.
NG
Check the harness wire.
DBetween ignition switch and combination meter
DBetween the combination meter and the ABS-ECU
OK
OK
After replacing the ABS-ECU, carry out the following check.
DCheck the harness wire between the ABS warning lamp,
ABS valve relay and earth.
Check the following connector:E-107
NG
RepairCheck the trouble symptoms.OK
NG
Check the following connectors:D-01, D-208, D-210
, D-213 , E-10, E-107
Measure at the ABS-ECU connector E-107.
DDisconnect the connector and measure at the harness
side.
DIgnition switch: ON
DWarning lamp conditionwhen terminal 50 is shorted to
body earth
OK:Illuminates
Inspection procedure 4
The ABS warning lamp remains illuminated after the
engine has started.
Probable cause
The cause is probably a short-circuit in the ABS warninglamp illuminationcircuit.DMalfunction of combination meter
DMalfunction of harness (short-circuit)
DMalfunction of the ABS-ECU
NOTE
This trouble symptom is limited to cases where communication with the MUT-II is possible(ABS-ECU
power supply is normal) and the diagnosis code is a normal diagnosis code.
When the ABS valve relay connector B-21X and the
ABS-ECU connector E-107 are disconnected and the ignition
switch is turned to the ON position, does the ABS warning
lamp remain illuminated?YES
NO
Replace the ABS-ECU.
Replace the combination meter.
NG
Repair
OK
Check the harness wire.
DBetween the ABS warning lamp, the ABS-ECU and the
ABS valve relay


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ABS <4WD> -Troubleshooting35B-22
DATA LIST REFERENCE TABLE
The following ECU input data items can be read using the MUT-II
.
(1) When system is normal
Item
No.Check itemInspection conditionsNormal condi-
tion
11Front - right wheel
speedWhen vehicle is being drivenSpeedometer
display and
12Front - left wheel
speedMUT-IIdisplay
are identical.
13Rear - right wheel
speed
14Rear - left wheel
speed
16System voltageIgnition switch: ON6.5 - 22.3 V
26Center differential
lock switchIgnition switch: ONTransfer selector lever position:
2H, 4HOFF
Transfer selector lever position:
4HLc, 4LLcON
27Rear differential lock
switchIgnition switch: ONOFF
32G sensorD
Ignition switch: ON
D
When vehicle is stationary (level)2.4 - 2.6 V
When vehicle is being driven1.0 - 4.0 V
33Stop lampIgnition switch: ONWhen brake pedal is depressedON
SwitchWhen brake pedal is releasedOFF
(2) When system is interrupted by the ECU
When the diagnosis function has caused the operation of the ABS-ECU to be stopped, the
MUT-II
display data may be different from the actual condition.
ACTUATOR TEST TABLE
The following actuators can be force-driven using the MUT-II
.
NOTE
(1) Actuator tests cannot be carried out when the operation of the ABS-ECU has been stopped by
the fail-safe function.
(2) Actuator tests can only be carried out while the vehicle is stopped.
ACTUATOR TEST SPECIFICATIONS
Item No.Check itemDrive Contents
01FR wheel solenoid valveHBB select solenoid valves and control solenoid valves for the
02FL wheel solenoid valverespective channel
03RR wheel solenoid valve
04RL wheel solenoid valve
27Air bleeding (1)HBB select solenoid valves and control solenoid valve OUT (FR, FL)
28Air bleeding (2)HBB control solenoid valve OUT (RR, RL)


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