2000 MITSUBISHI MONTERO engine

35A-2
BASIC BRAKE
SYSTEM
CONTENTS
GENERAL INFORMATION 3..................
SERVICE SPECIFICATIONS 5.................
LUBRICANTS 6..............................
SPECIAL TOOLS 6..........................
TROUBLESHOOTING
7......................
ON-VEHICLE SERVICE 19...................
Brake Pedal Check and Adjustment 19..........
Hydraulic Brake Booster (HBB) Operation Check
20........................
HBB Check 23............
HBB Motor Relay Continuity Check
24........................
Brake Booster Operating Test
24.....................
Check Valve Operation Check
25.....................
Load Sensing Spring Length Check and
Adjustment 25.........
Load Sensing Proportioning Valve Function
Test 26................
Bleeding 27...............Bleeding 29.............
Brake Fluid Level Sensor Check 30.............
Brake Booster Vacuum Switch Check
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)
36....................
HBB BUZZER 40......
MASTER CYLINDER AND BRAKE
BOOSTER 41......
Master Cylinder 43.............................
FRONT DISC BRAKE 44....................
REAR DISC BRAKE 49......................
LOAD SENSING PROPORTIONING
VALVE 54..........


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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 ,
D-128, D-208, D-210 , D-213 vehicles>, E-08 , E-13, E-106
Repair


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BASIC BRAKE SYSTEM -Troubleshooting35A-13
Code No.79 Pressure switch system (open or short
circuit)Probable cause
This code is output if the pressure switch circuit is short, ABS-ECU internal circuit
is defective, or the hydraulic brake booster (HBB) pressure switch or master cylinder
and hydraulic unit assembly is defective.DMalfunction of connector or harness
DMalfunction of the ABS-ECU
DMalfunction of the HBB (pressure switch or master
cylinder and hydraulic unit assembly)
NG
Repair
NG
OKRepair NG
OK
Check trouble symptom.
Check the following connectors:
B-17, B-18, E-106, E-107
Check the harness wire:
DBetween the HBB and the ABS-ECU
DBetween the HBB and the earthNG
Check trouble symptom.
Replace the ABS-ECU. (Refer to GROUP 35B.)
NG
OKCheck the pressure switch. (Refer to P.35A-23.)Replace the master cylinder and hydraulic unit assembly.
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomInspection
procedure
No.Reference page
The brake warning lamp does not illuminate when the ignition switch is turned ON
(engine stopped).135A-14
The brake warning lamp remains illuminated after the engine is started.235A-15
The HBB buzzer does not sound when the hydraulic brake booster (HBB) is
defective. (However, the brake warning lamp is illuminated.)335A-15
The HBB buzzer does not stop sounding.435A-16
Communication with MUT-II
is not possible.Refer to GROUP 35B.
Communication with MUT-II
and the ABS-ECU is not possible.


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BASIC BRAKE SYSTEM -Troubleshooting35A-14
Inspection procedure 1
The brake warning lamp does not illuminate when the
ignition switch is turned ON (engine stopped).
Probable cause
The cause may be anopencircuit in thelamppower supply circuit, a blown lamp,
a malfunction of the lampdrive transistor inside the ABS-ECU, anopencircuit between
the ignition switch and brake warninglamp or anshort circuit between the brake
warning lamp and theABS-ECU.DBlown fuse
DBurn out brake warninglamp bulb
DMalfunction of combination meter
DMalfunction of connector or harness
DMalfunction of ABS-ECU (lamp drive transistor)
Repair NG NG
NO
Replace the ABS-ECU. (Refer to GROUP 35B.)
Repair
Repair
NG
OK
Check for blown bulb.Replace the brake warninglamp bulb.
OK
Check the following connectors:
D-01, D-208, D-210 drive vehicles>, D-213
NG
Replace the combination meter. (Refer to GROUP 54.)
OK
Check trouble symptom.
OK
YES
Check multi-purpose fuse No.6.NGRefer to GROUP 00 – Inspection Procedure when a Fuse is blown.
Check the harness wire:
DBetween the ignition switch and the combination meter
Check the harness wire:
DBetween the combination meter and the ABS-ECU
Disconnect the ABS-ECU connector E-107. Does the brake warning
lamp illuminatewhen the ignition switch is turned ON?
NG
OK


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BASIC BRAKE SYSTEM -Troubleshooting35A-15
Inspection procedure 2
The brake warning lamp remains illuminated after the
engine is started.
Probable cause
The cause is probably malfunction of thelampdrive transistor inside the ABS-ECU
or an opencircuit between the brake warninglamp and theABS-ECU.DMalfunction of combination meter
DMalfunction of connector or harness
DMalfunction of ABS-ECU (lamp drive transistor)
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.
Repair NG
Repair
Replace the combination meter. (Refer to GROUP 54.)
OK
YESReplace the ABS-ECU. (Refer to GROUP 35B.)
NO
Disconnect the ABS-ECU connector E-107. Does the brake warning
lamp go outwhen the ignition switch is turned ON and No.39 terminal
is connected to the body earth.
OK
Check the following connectors:
D-01, E-13, E-107
Check trouble symptom.
Check the harness wire:
DBetween the combination meter and the ABS-ECUNG
NG
Inspection procedure 3
The HBB buzzer does not sound when the hydraulic brake
booster (HBB) is defective. (However, thebrake warning
lamp is illuminated.)
Probable cause
The cause is probably anopencircuit in the buzzer power supply circuit, a defective
buzzer, a malfunction of the buzzer drive transistor inside the ABS-ECU or anopen
circuit from the ignition switch through the HBB buzzer to the ABS-ECU.DBlown fuse
DMalfunction of the HBB buzzer
DMalfunction of connector or harness
DMalfunction of ABS-ECU (buzzer drive transistor)
Replace the ABS-ECU. (Refer to GROUP 35B.)
Repair NG
Repair
NG
OK
Check the HBB buzzer. (Refer to P.35A-40.)
OK
Check the following connectors:
D-32 ,
D-128, D-208, D-210 , D-213 vehicles>, E-08, E-13, E-107
NG
OK
Check trouble symptom.
Check multipurpose fuse No.5.NGRefer to GROUP 00 – Inspection Service Points for Blown Fuse.
Check the harnesse wire:
DBetween the ignition switch and the HBB buzzer
DBetween the HBB buzzer and the ABS-ECUNGReplace


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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-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-25
Termi-
nal
No.Normal condition Inspection conditions Check item
37ABS valve relay outputIgnition
switch: ONWhen system abnormality is
detected and relay is offSystem voltage
When relay is on approx. 1
second after engine starts2 V or less
39Brake warning lamp outputIgnitionWhen lamp is switched off2 V or less
switch: ONWhen lamp is illuminatedSystem voltage
40Control solenoid valve OUT (RL)Ignition switch: ONSystem voltage
41Control solenoid valve OUT(FR)Ignition switch: ONSystem voltage
46Center differential lock switch
input Ignition
switch: ONTransfer selector lever position:
2H, 4HSystem voltage
Transfer selector lever position:
4HLc, 4LLc2 V or less
4WD detection switch input
Ignition
switch: ONTransfer selector lever position:
2HSystem voltage
Transfer selector lever position:
4H2 V or less
47Diagnosis select inputWhen the MUT-IIis connected1 V or less
When the MUT-IIis not connectedApprox. 12 V
48Valve relay monitorIgnition switch: ONSystem voltage
50ABS warning lamp outputIgnitionWhen lamp is switched offSystem voltage
switch: ONWhen lamp is illuminated2 V or less
51Control solenoid valve IN (RL)Ignition switch: ONSystem voltage
52Control solenoid valve IN (FR)Ignition switch: ONSystem voltage


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