Mitsubishi Montero (2004+). Manual - part 1032

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-127

b. Repeat the above procedure (a) until no bubbles 

appear while pumping the brake pedal.

NOTE: OK to fill the reservoir to the "MAX" line during this 
process. Brake fluid level around the "MIN" line may cause 
bubbles to appear from the jet flow of brake fluid while 
pumping the brake pedal.

4. Fill the rear brake system with brake fluid as follows (RH 

first, LH second):

CAUTION

• 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.

NOTE: A high-pressure hydraulic noise (hissing) is normal 
during this procedure.

(1) Attach a clear hose to the RH caliper bleeder valve. This 

helps to monitor air/fluid flow.

(2) Be sure the fluid level is between the "MIN" and "MAX" 

lines.

(3) Turn the ignition switch to the "LOCK" (OFF) position. 

Pump the brake pedal 3 

− 4 times and hold it depressed.

(4) Open the RH caliper bleeder valve 1/4 turn.
(5) With the bleeder valve still open, pump the brake pedal 

repeatedly to fill the line with fluid until no obvious air 
bubbles are seen. When no more obvious air bubbles are 
seen, and while the brake pedal is still being pumped, 
close the bleeder valve.

(6) Repeat steps (1) 

− (5) for the LH caliper.

(7) Release the brake pedal when both sides are filled.

5. Supply brake fluid into the power supply system as follows:

CAUTION

Keep the brake fluid reservoir level just above the "MIN" 
line at this time. Monitor the fluid level during this proce-
dure to ensure it does not reach below the "MIN" line.

(1) To release the pressure in the HBB power supply system, 

turn the ignition switch to the "LOCK" (OFF) position and 
depress the brake pedal repeatedly until its depressing 
force suddenly feels heavy (no pedal travel).

(2) Turn the ignition switch to the "ON" position and at the 

same time quickly depress the brake pedal approximately 
20 times. Then confirm that the pump motor has stopped. 
This can take up to 2 minutes.

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

depress the brake pedal repeatedly until its depressing 
force suddenly feels heavy (no pedal travel).

(4) Turn the ignition switch to the "ON" position to operate 

the pump motor. Confirm that the pump motor stops 
within 25 seconds. If the pump motor does not stop, 
repeat steps (1) through (3) above.

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-128

6. Supply fluid into the ABS system as follows:

CAUTION

To prevent damage to scan tool MB991958, always turn the 
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting scan tool MB991958.

(1) Ensure that the ignition switch is at the "LOCK" (OFF) 

position.

(2) Start up the personal computer.
(3) Connect special tool MB991827 to special tool 

MB991824 and the personal computer.

(4) Connect special tool MB991911 to special tool 

MB991824.

(5) Connect special tool MB991911 to the data link 

connector.

(6) Turn the power switch of special tool MB991824 to the 

"ON" position.
NOTE: When special tool MB991824 is energized, spe-
cial tool MB991824 indicator light will be illuminated in a 
green color.

(7) Start the MUT-III system on the personal computer.
(8) Turn the ignition switch to the "ON" position. Select from 

scan tool menu screen as follows:
[SYSTEM SELECT 

→ ABS → ACTUATOR TEST → AIR 

BLEED]

(9) Depress and hold the brake pedal.
(10)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).

(11)Depress and hold the brake pedal.
(12)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.

AC307591 AC

MB991911

MB991824

MB991827

AC307591

DATA LINK

CONNECTOR

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-129

(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):

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.

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-130

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.

(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.

ACX00664 AC

MAX

MIN