Mitsubishi Montero (2002-2004). Manual - part 1025

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-125

CAUTION

When connecting or disconnecting the scan tool, ensure 
that the ignition switch is at the "LOCK" (OFF) position.

(1) Turn the ignition switch to the "LOCK" (OFF) position and 

connect scan tool MB991502 to the data link connector.

(2) Turn the ignition switch to the "ON" position. Select from 

scan tool menu screen as follows:
[SYSTEM SELECT 

→ ABS → ACTUATOR TEST → AIR 

BLEED]

(3) Depress and hold the brake pedal.
(4) Activate the actuator test [AIR BLEED (1)]. When the 

scan tool flashes confirmation that the AIR BLEED (1) 
operation is completed, proceed with AIR BLEED (2).

(5) Depress and hold the brake pedal.
(6) Select and activate [AIR BLEED (2)] on the scan tool 

screen. When the scan tool flashes confirmation that the 
AIR BLEED (2) operation is completed, go to step 7.

7. Bleed the rear brake system as follows (RH first, LH 

second):

CAUTION

• Keep the brake fluid reservoir level just above the 

"MIN" line at this time. Monitor the fluid level during 
this procedure to ensure it does not reach below the 
"MIN" line.

• If a large quantity of brake fluid is drained during the 

bleeding procedure, the accumulator pressure will 
decrease abnormally. Do not bleed more than 0.1 dm

3

 

(0.11quart) from each wheel at a time.

• Confirm that the pump motor stops after each air-bleed-

ing step.

(1) Attach the clear hose to the RH caliper to monitor air/fluid 

flow.

(2) Turn the ignition switch to the "ON" position.
(3) Open bleeder valve 1/4 turn.
(4) With the bleeder valve open, pump the brake pedal 3 

times and hold.

(5) Close the bleeder valve.
(6) Pump the brake pedal 3 times and hold.
(7) Open the bleeder valve 1/8 turn briefly to allow any 

remaining air to escape, then close the bleeder valve.

(8) Repeat steps (6) and (7) as many times as necessary to 

eliminate all air in the line.

(9) Repeat steps (1) 

− (8) at the LH caliper.

8. Bleed the front brake system as follows (RH first, LH 

second):

ACX01539

16-PIN

MB991502

AC

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-126

CAUTION

• Keep the brake fluid reservoir level just above the 

"MIN" line at this time. Monitor the fluid level during 
this procedure to ensure it does not reach below the 
"MIN" line.

• If a large quantity of brake fluid is drained during the 

bleeding procedure, the accumulator pressure will 
decrease abnormally. Do not bleed more than 0.1 dm

3

 

(0.11quart) from each wheel at a time.

• Confirm that the pump motor stops after each air-bleed-

ing step.

(1) Attach the clear hose to the RH caliper to monitor air/fluid 

flow.

(2) Turn the ignition switch to the "ON" position.
(3) Open bleeder valve 1/4 turn.
(4) With the bleeder valve open, pump the brake pedal 3 

times and hold.

(5) Close the bleeder valve.
(6) Pump the brake pedal 3 times and hold.
(7) Open the bleeder valve 1/8 turn briefly to allow any 

remaining air to escape, then close the bleeder valve.

(8) Repeat steps (6) and (7) as many times as necessary to 

eliminate all air in the line.

(9) Repeat steps (1) 

− (8) at the LH caliper.

9. Adjust the brake fluid level as follows:

(1) Turn the ignition switch to the "LOCK" (OFF) position.
(2) Depress the brake pedal repeatedly (up to 40 times or 

more) until its depressing force suddenly feels very heavy 
(no pedal travel).

(3) Release the brake pedal.
(4) Adjust the brake fluid level between the "MIN" and "MAX" 

lines on the reservoir.

Normal Brake System Air Bleeding

If the brake fluid level in the HBB reservoir is 
between the "MIN" and "MAX" lines after any brake 
servicing at the wheels (such as calipers, rotors, 
etc.), perform the following steps:
1. Bleed the rear brake system as follows (RH first, 

LH second):

CAUTION

• Keep the brake fluid reservoir level just above 

the "MIN" line at this time. Monitor the fluid 
level during this procedure to ensure it does 
not reach below the "MIN" line.

• If a large quantity of brake fluid is drained 

during the bleeding procedure, the accumula-
tor pressure will decrease abnormally. Do not 
bleed more than 0.1 dm

3

 (0.11quart) from 

each wheel at a time.

• Confirm that the pump motor stops after each 

air-bleeding step.

(1) Attach the clear hose to the RH caliper to 

monitor air/fluid flow.

(2) Turn the ignition switch to the "ON" position.
(3) Open bleeder valve 1/4 turn.
(4) With the bleeder valve open, pump the brake 

pedal 3 times and hold.

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-127

(5) Close the bleeder valve.
(6) Pump the brake pedal 3 times and hold.
(7) Open the bleeder valve 1/8 turn briefly to allow 

any remaining air to escape, then close the 
bleeder valve.

(8) Repeat steps (6) and (7) as many times as 

necessary to eliminate all air in the line.

(9) Repeat steps (1) 

− (8) at the LH caliper.

2. Bleed the front brake system as follows (RH first, 

LH second):

CAUTION

• Keep the brake fluid reservoir level just above 

the "MIN" line at this time. Monitor the fluid 
level during this procedure to ensure it does 
not reach below the "MIN" line.

• If a large quantity of brake fluid is drained 

during the bleeding procedure, the accumula-
tor pressure will decrease abnormally. Do not 
bleed more than 0.1 dm

3

 (0.11quart) from 

each wheel at a time.

• Confirm that the pump motor stops after each 

air-bleeding step.

(1) Attach the clear hose to the RH caliper to 

monitor air/fluid flow.

(2) Turn the ignition switch to the "ON" position.
(3) Open bleeder valve 1/4 turn.
(4) With the bleeder valve open, pump the brake 

pedal 3 times and hold.

(5) Close the bleeder valve.
(6) Pump the brake pedal 3 times and hold.
(7) Open the bleeder valve 1/8 turn briefly to allow 

any remaining air to escape, then close the 
bleeder valve.

(8) Repeat steps (6) and (7) as many times as 

necessary to eliminate all air in the line.

(9) Repeat steps (1) 

− (8) at the LH caliper.

3. Adjust the brake fluid level as follows:

(1) Turn the ignition switch to the "LOCK" (OFF) 

position.

(2) Depress the brake pedal repeatedly (up to 40 

times or more) until its depressing force 
suddenly feels very heavy (no pedal travel).

(3) Release the brake pedal.
(4) Adjust the brake fluid level between the "MIN" 

and "MAX" lines on the reservoir.

BRAKE FLUID LEVEL SWITCH CHECK

M1351009100254

The brake fluid level switch is in good condition if there is no 
continuity when the float surface is above the "MIN" line and if 
there is continuity when the float surface is below the "MIN" 
line.

DISC BRAKE PAD CHECK AND REPLACEMENT

M1351002300246

NOTE: The brake pads have indicators that contact the brake 
disc when the brake pad thickness becomes 2 mm (0.08 inch), 
and emit a squealing sound to warn the driver.

ACX00664 AC

MAX

MIN

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-128

CAUTION

• Whenever a pad must be replaced, replace both LH and 

RH wheel pads as a set to prevent the vehicle from pull-
ing to one side when braking.

CAUTION

If there is a significant difference in the thicknesses of the 
pads on the left and right sides, check the sliding condi-
tion of the piston, lock pin and guide pin.
1. Check the brake pad thickness through the caliper body 

check port.

Standard value: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)

2. Remove the guide pin lock bolt. Lift the caliper assembly 

and secure it with a wire.

3. Remove the following parts from caliper support.

(1) Pad and wear indicator assembly <FRONT>

Pad and clip assembly <REAR>

(2) Pad assembly
(3) Clip
(4) Shim
(5) Shim B <REAR>
(6) Shim A <REAR>

4. Measure the hub torque before and after pad installation. 

Follow the procedure: 

• FRONT: Refer to 

P.35A-140

.

• REAR: Refer to 

P.35A-146

.

ACX00665

AB

FRONT

REAR

ACX00705

AC204544AB

FRONT

REAR

3

3

3

3

1

1

2

2

4

4

6

5