E35AA--
SERVICE BRAKES
CONTENTS
| SPECIFICATIONS | 2 |
|---|---|
| General Specifications | 2 |
| Service Specifications | 3 |
| Lubricants | 4 |
| Sealants | 4 |
| SPECIAL TOOLS | 4 |
|
ABS TROUBLESHOOTING
|
5 |
|
ABS TROUBLESHOOTING
|
36-1 |
| SERVICE ADJUSTMENT PROCEDURES | 37 |
| Brake Pedal Inspection and Adjustment | 37 |
| Brake Booster Operating Test | 37 |
| Check Valve Operation Check | 38 |
| Brake Fluid Level Sensor Check | 38 |
| Brake Booster Vacuum Switch Check <25000D, 2800D> | 39 |
|
Load Sensing Spring Length Check
and Adjustment |
39 |
| Load Sensing Proportioning Valve | 20 |
| Bleeding | 11 |
| Disc Brake Pad Check | 42 |
|
Front Disc Brake Pad Replacement and
Brake Drag Check |
42 |
| Front Disc Brake Rotor Inspection | 44 |
| Front Brake Disc Run-out Check | 44 |
| Front Brake Disc Run-out Correction | 44-1 |
| Front Brake Disc Thickness Check | 44-1 |
|
Rear Disc Brake Pad Check and
Replacement |
44-2 |
| Rear Brake Disc Thickness Check 45 |
| Rear Brake Disc Run-out Check 45 |
| Rear Brake Disc Run-out Correction 46 |
| Brake Lining Thickness Check 47 |
| Brake Drum Inside Diameter Check 47 |
|
Brake Lining and Brake Drum
Connection Check 47 |
|
Wheel Speed Sensor Output Voltage
Measurement |
|
Hydraulic Unit Check
|
|
G-sensor Output Voltage Check
|
|
ABS Power Relay Check
|
|
Valve Relay and Motor Relay Check
|
|
ABS Relay Box Check
|
| Solenoid Valve Check < ABS > |
|
Motor Operation Check
|
| ABS Idle-up Solenoid Valve Check < ABS> · · 53-2 |
| BRAKE PEDAL |
| BRAKE BOOSTER |
| BRAKE LINE 61 |
| RONT DISC BRAKE 66 |
| IEAR DISC BRAKE 71 |
|
IYDRAULIC UNIT
|
|
G-SENSOR
|
|
VHEEL SPEED SENSOR
|
|
LECTRONIC CONTROL UNIT
|
E
SPECIFICATIONS
GENERAL SPECIFICATIONS
E35CA--
| Items | 2400, 3000, 3500 | 2500D, 2800D |
|---|---|---|
| Master cylinder | ||
| Туре | Tandem Type (with level sensor) | Tandem type (with level sensor) |
| I.D. mm (in.) | 23.8 (15/16) | 23.8 (15/16) |
| Brake booster | ||
| Туре | Vacuum Type, tandem | Vacuum Type, tandem |
| Effective dia. of power cylinder | 190 - 205 (7 - 9) | |
| Beesting ratio | ||
| 8.0 | ||
| Proportioning valve type | Load sensing proportioning type | Load sensing proporting type |
| Front brakes | ||
| Туре | Floating caliper, double pistons, ventilated disc (M-R57W) | Floating caliper, double pistons, ventilated disc (M-R57W) |
|
Disc effective dia. x thickness
mm (in.) |
228 x 24 (8.98 x 0.94) <2400, 3000>
228 x 27 (8.98 x 1.06) <3500> |
228 × 24 (8.98 × 0.94) |
| Wheel cylinder I.D. mm (in.) | 42.8 (1 11/16) x 2 | 42.8 (1 11/16) x 2 |
| Lining thickness mm (in.) | 10 (0.39) | 10 (0.39) |
| Clearance adjustment | Automatic | Automatic |
| Rear brakes | ||
| Туре | Floating caliper, single piston, solid disc (M-R59S) | Floating caliper, single piston, solid disc (M-R59S) |
| Disc effective dia. x thickness | ||
| mm (in.) | 272 x 18 (10.71 x 0.71) | 272 x 18 (10.71 x 0.71) |
| Wheel cylinder I.D. mm (in.) | ||
| 9 (0.354) | 9 (0.354) | |
| Automatic | Automatic | |
| ABS | ||
| Rotor teeth | ||
|
|
||
| front | ||
| rear | | 110 | 110 |
|
|
||
| front | 4/ | 4/ |
| rear | ||
| Speed sensor type | IVIagnet coil type | iviagnet coll type |
SERVICE SPECIFICATIONS
35-3
| Items | Specifications | |
|---|---|---|
| Standard value | ||
| Brake pedal height | mm (in.) | 186–191 (7.3–7.5) |
| Brake pedal to toeboard clearance | mm (in.) | 100 (3.94) or more |
| Brake pedal free play | mm (in.) | 3-8 (0.12-0.32) |
| Load sensing spring length | mm (in.) | 224–228 (8.8–9.0) |
| Load sensing proportioning valve |
output pressure
MPa (kg/cm², psi) |
|
| 2-door models | ||
|
When load sensing spring le
227.5 mm (9.0 in.) |
ngth is | |
| Input pressure | MPa (kg/cm², psi) | |
| at 10 (100, 1422) | 5.37-6.27 (53.7-62.7, 763.8-891.8) | |
| at 18 (180, 2560) | 7.17–8.47 (71.7–84.7, 1019.8–1204.7) | |
|
When load sensing spring le
255.6 mm (10.1 in.) |
ngth is | |
| Input pressure | MPa (kg/cm², psi) | |
| at 18 (180, 2560) | 10.4–12.4 (104–124, 1479.2–1763.7) | |
| 4-door models | ||
|
When load sensing spring le
226.7 mm (8.9 in.) |
ngth is | |
| Input pressure | MPa (kg/cm², psi) | |
| at 10 (100, 1422) | 6.14-7.04 (61.4-70.4, 873.3-1001.3) | |
| at 18 (180, 2560) | 7.94–9.24 (79.4–92.4, 1129.3–1314.2) | |
|
When load sensing spring le
257.7 mm (10.1 in.) |
ength is | |
| Input pressure | MPa (kg/cm², psi) | |
| at 18 (180, 2560) | 13.1–15.1 (131–151, 1863.3–2147.7) | |
|
Booster push rod to master cyline
clearance |
der piston
mm (in.) |
|
| 7 + 8 inch tandem brake boos | ter | 0.85-1.10 (0.033-0.043) |
| 8 + 9 inch tandem brake boos | ter | 0.65-0.90 (0.026-0.035) |
| Brake dragging force | N (kg, lbs.) | 57 (5.7, 13) or less |
| [Brake dragging torque] | Nm (kgm, ft.lbs.) | [4 (0.4, 3)] or less |
| Pad thickness | mm (in.) | |
| Front | 10.0 (0.39) | |
| Rear | 9.0 (0.35) | |
| Disc thickness | mm (in.) | |
| Front |
24 (0.94)
27 (1.06) <3500> |
|
| Rear | 18 (0.71) | |
| Lining thickness | mm (in.) | 6.5 (0.256) |
| Brake drum inside diameter | mm (in.) | 197 (7.76) |
SERVICE BRAKES - Specifications / Special Tools
| Items | Specifications | |
|---|---|---|
| Limit | ||
| Pad thickness | mm (in.) | 2.0 (0.079) |
| Disc thickness | mm (in.) | |
| Front |
22.4 (0.882)
25.4 (1.0) <3500> |
|
| Rear | 16.4 (0.646) | |
| Brake disc runout | mm (in.) | |
| Front | 0.1 (0.0039) | |
| Rear | 0.08 (0.0031) | |
| Hub axial play | mm (in.) | 0.25 (0.0098) |
| Lining thickness | mm (in.) | 4.5 (0.177) |
| Brake drum inside diameter | mm (in.) | 198 (7.8) |
LUBRICANTS
| Items | Specified lubricant | Quantity | |
|---|---|---|---|
| Brake fluid | DOT3 or DOT4 | As required | |
|
Brake piston boot inner surfaces
Lock pin boot inner surfaces Guide pin boot inner surfaces |
Repair kit grease | As required |
SEALANTS
| ltems | Specified sealants | Remarks |
|---|---|---|
| Thread part of vacuum switch | 3M ATD Part No. 8659 or equivalent | Non-drying sealant |
| Thread part of fitting | 3M ATD Part No. 8663, 8661 or equivalent | Semi-drying sealant |
SPECIAL TOOLS
| Tool | Number | Name | Use |
|---|---|---|---|
|
MB990964
|
Brake tool set |
Pushing-in of the front disc brake
piston MB990520 |
|
| MB991341 |
Multi-use tester
assembly |
Vehicles built up to October, 1993
For checking of A.B.S. |
|
| MB991419 | ROM pack |
35-4
E35CE--
E35DA--
E35CD--
SERVICE BRAKES – Special Tools
| Тооі | Number | Name | Use |
|---|---|---|---|
| E Solo | MB991502 |
MUT-II sub
assembly |
All models
For checking of A.B.S. |
| 16x0607 | ROM pack | ||
| MB991529 |
Diagnosis code
check harness |
For checking of ABS with a voltmeter |
35-4-2
NOTES
ARS TROUBLESHOOTING <Vehicles built up to May, 1994> EDEEA
PARTICULAR PHENOMENA OF THE ANTI-I OCK BRAKE SYSTEM
Models equipped with the anti-lock brake system (A.B.S.) may exhibit one or more of the following phenomena from time to time but none of these are abnormal
- (1) A pulsing feeling in the brake pedal, or vibration of the body or the steering wheel when the anti-lock brake system is activated by sudden braking or by braking on a slippery road surface Actually this phenomenon is an indication that the A B S is functioning normally
- (2) When the vehicle speed reaches approximately 8 km/h (5 mph) after the engine is started and the vehicle starts off (for the first time) a whining motor noise may be heard from the engine compartment if the vehicle is traveling in a quiet place, but this noise is simply the result of a self-check being made of the A.B.S. operation.
TROUBLESHOOTING METHODS
Problems related to the A.B.S. can be classified into two general categories: problems in the electrical system and those in the hydraulic systom
For problems in the electrical system the selfdiagnosis function is built into the electronic control unit (E.C.U.), causing the A.B.S. warning lamp to illuminate as a warning to the driver. In this instance checks can be made by using the multiuse tester and osciloscope.
Problems in the hydraulic system (pcor braking, etc.) can be located in the same way as for ordinary brakes. There is, however, the necessity to check to determine whether the problem is related to ordinary brake components or to the components related to the A.B.S. To make this check, use the multi-use tester.
HOW TO USE THE TROUBLESHOOT. ING FLOW CHART
- (1) Following the flow chart, first refer to the illumination pattern of the ABS warning lamp. and next note the diagnosis code and inspect the brake operation
- (2) Follow the inspection charts listed in the "Remedy" column to carry out an inspection In each inspection chart [Comment] and (Hint) are listed for troubleshooting reference.
ECU: Electronic control unit
35-6 SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994>
Check the trouble symptoms by the following procedure, and inspect according to the instructions.
Before the engine starts, does the ABS warning lamp illuminate?
- (1) With the ignition key in the "ON" position, the ABS-ECU causes the ABS warning lamp to illuminate for approximately 1 second (during this time, the initial check is carried out), and then the lamp switches off.
- (2) With the ignition key in the "START" position, power to the ABS-ECU is cut, and be-
cause the valve relay turns OFF, the ABS
"START" position back to the "ON" posi-
tion, the ABS warning lamp illuminates for
approximately 1 second (during this time,
the initial check is carried out once more).
(3) When the janition key is turned from the
warning lamp remains illuminated.
and then the lamp switches off.
Yes To next page
| No. | Trouble symptom | Main cause | Remedy |
|---|---|---|---|
| 1 |
The ABS warning lamp does not
illuminate at all. ABS Illuminated warning Not illuminated START Ignition key ON ACC, LOCK |
|
Inspect according
to Flow Chart A (Refer to P.35-13). |
| 2 |
When the ignition key is turned to "ON",
the ABS warning lamp remains illuminated. ABS Illuminated warning Not illuminated START Ignition key ON ACC, LOCK |
|
Inspect according
to Flow Chart B (Refer to P.35-16). |
SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994> 35-7
| No. | Trouble symptom | Main cause | Remedy |
|---|---|---|---|
| З |
When the ignition key is turned to
"START", the ABS warning lamp does not illuminate. ABS - Illuminated warning Not lamp illuminated START Ignition key ON ACC, LOCK 14E0055 |
|
Inspect according
to Flow Chart C (Refer to P.35-18). |
| 4 |
After the ignition key is turned to "ON",
the ABS warning lamp blinks twice, and when turned to "START", it illuminates. When returned to "ON", the lamp flashes once, and then switches off. (The blinking when the key is turned to "ON" occurs simultaneously with the operation noise from the valve relay) ABS warning lamp Not illuminated START Ignition key ACC, LOCK |
|
Inspect according
to Flow Chart D (Refer to P.35-19). |
| 14E0058 |
From previous page
| After the vehicle starts to move, does the ABS warning lamp illuminate? | Yes |
Malfunction in the motor relay or solenoid valve (from self diag-
nosis when driving), or the vehicle speed sensor, free wheel engage switch, center differential lock detection switch, or rear differential lock detection switch is defective |
|---|---|---|
|
Is there unequal braking power on both sides, in-
sufficient braking power or defective ABS opera- tion? Yes To next page |
No | To next page |
35-8 SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994>
| From previous page | - | , | |
|---|---|---|---|
| From | previous | page |
| Trouble symptom | Main cause | Remedy | |
|---|---|---|---|
|
Unequal braking
power Insufficient braking power |
|
Follow the hydraulic unit operation
inspection (refer to P.35-50) and replace the hydraulic unit if necessan If the hydraulic unit is normal, inspec |
|
| Decline in ABS function |
|
the components of the normal brake. | |
|
Operation of the idle-up system during ABS operation
when vehicle speed is approx. 24 km/h (15 mph) or more is defective <2500D-M/T> |
Inspect the operation of the idle-up
system (Refer to GROUP 13 – Service Adjustment Procedures <4D56> |
||
|
ABS operates
even when not carrying out sudden braking (ABS operating vibration starts to be felt). |
|
Inspect the wheel speed sensor (refer
to P.35-48), and replace the sensor or adjust the sensor clearance if necessary. If the problem occurs frequently even though the sensor is normal, then replace the ABS-ECU. |
|
not show a malfunction occurring previously also.)
SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994> 35-9
INSPECTION BY SELF-DIAGNOSIS
1. Turn the ignition key to ACC and connect the multi-use tester or MUT-II as shown in the illustration.
Caution
Turn off the ignition switch before disconnecting or connecting MUT or the MUT-II.
- 2. Start the engine, and select the ABS system.
- 3. Read and make a note of the diagnosis output codes. If the ABS-ECU and multi-use tester cannot communicate, inspect the harness between diagnosis connector and the ABS-ECU power circuit or the ABS-ECU.
- 4. Momentarily erase the diagnosis code memory. (Refer to P.35-10.)
If the memory cannot be erased, the function is being stopped by a malfunction that is currently displaying a malfunction code. If the memory can be erased, then the malfunction was only temporary, or it is a malfunction that can only be detected while driving.
If the malfunction code is not erased, or if the ABS function is stopped by a repeated driving test and a malfunction code is output, inspect according to the malfunction code inspection charts (E-1-E-13).
NOTE
The codes below are output as diagnosis codes according to the vehicle's condition, even when the ABS system is normal. These codes are output only for a current malfunction, and if the vehicle's condition returns to normal, malfunction code will be erased automatically.
METHOD OF ERASING THE DIAGNOSIS CODE MEMORY
Caution
When repairs are completed, the diagnosis code memory should be erased. When the ABS-ECU function is stopped, the malfunction code memory cannot be erased, so the function should be continuing while inspection and repair is being carried out.
1. Erase the memory with the multi-use tester or MUT-II. NOTE
After erasing the memory, a command cannot be received from the multi-use tester or MUT-II. When checking diagnosis codes, momentarily stop and restart the engine, and then reactivate the multi-use tester or MUT-II.
2. Check the diagnosis codes to check that the memory has been erased.
|
Diagnosis
code no. |
Name of inspection chart or remedy |
Reference
page |
Diagnosis
code no. |
Name of inspection chart or remedy |
Reference
page |
|---|---|---|---|---|---|
| 11 | 27 | E-7 | P.35-28 | ||
| 12 |
-
|
D 05 00 | 31 | E8 | P.35-29 |
| 13 | 1.33-20 | 32 | E–9 | P.35-30 | |
| 14 | 33 | E-10 | P.35-33 | ||
| 15 | E-2 | P.35-21 | 41 | ||
| 16 | E-4 | P.35-24 | 43 | E–11 | P.35-34 |
| 21 | P.35-22 | 45 | |||
| 22 | – – 2 | 51 | E-12 | P.35-35 | |
| 23 | 53 | E-13 | P.35-36 | ||
| 24 | 63 | Boplace the ABS-ECU | |||
| 25 | E-5 | P.35-25 | 64 | ||
| 26 | E6 | P.35-26 |
DIAGNOSIS CODE REFERENCE TABLE
DIAGNOSIS CODE DISPLAY METHOD
All problem codes that are in memory are displayed.
NOTE
- (1) Diagnosis code no. 16 (abnormally low or abnormally high voltage) is only displayed when there is a current problem. (Past occurrences are not recorded in memory.)
- (2) Even if identical codes are output continuously, the code is only displayed one time.
SERVICE DATA INSPECTION TABLE
The following items can be read by the multi-use tester or MUT-II from the ABC-ECU input data.
| Service data item | Display units | ||
|---|---|---|---|
| No. | ltem | ||
| 11 | Front right wheel speed | km/H | |
| 12 | Front left wheel speed | km/H | |
| 13 | Rear right wheel speed | km/H | |
| 14 | Rear left wheel speed | km/H | |
| 16 | ABS-ECU power voltage | V | |
| 25 | ON/OFF condition of free wheel engage switch | ON/OFF | |
| 26 | ON/OFF condition of centre differential lock detection switch | ON/OFF | |
| 27 | ON/OFF condition of rear differential lock detection switch | ON/OFF | |
| 32 | G sensor output voltage | V | |
| 33 | ON/OFF condition of stop lamp switch | ON/OFF | |
ACTUATOR TEST FUNCTION
By using the multi-use tester or MUT-II, the following force-activation of the actuator can be performed.
By using this function, function checking of the hydraulic unit can be done without the need for special devices such as a hydraulic unit checker (MB991131).
NOTE
- When the ABS-ECU function is stopped, actuator testing cannot be carried out.
- (2) Actuator testing can be carried out only when the vehicle is stopped.
- (3) During actuator testing, if the maximum vehicle wheel speed reaches 10 km/h (6 mph), the test will be cancelled.
- (4) During actuator testing, the ABS warning lamp illuminates, and ABS control is interrupted.
ACTUATOR TEST SPECIFICATIONS
© Mitsubishi Motors Corporation Jun. 1994
35-14 SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994>
SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994> 35-15
NOTE
For inspection sections marked by *, pay attention to the polarity of the diodes. (Refer to the circuit diagram on P.35-13.)
<Vehicles built from November, 1993>
- [Comment] When the lamp does not illuminate at all, there is a strong possibility that there is a malfunction of the ABS warning lamp or the power supply.
- [Comment] When the lamp does not illuminate at (Hint) If other warning lamps also do not ilall, there is a strong possibility that luminate, it is probably a blown fuse.
35-15-3 SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994>
NOTE
For inspection sections marked by *, pay attention to the polarity of the diodes. (Refer to the circuit diagram on P.35-13.)
NOTES
B When the ignition switch is turned to "ON", the ABS warning lamp remains illuminated
<Vehicles built up to October, 1993>
Fusible
[Comment] This symptom occurs when the ABS-ECU is not functioning due to a broken wire, etc., in the ABS-ECU power circuit, when the fail-safe function is operating to isolate the system, or when there is a short in the warning lamp drive circuit.
nition witch (IG1)
(Hint) Check the diagnosis output, and if there is no output voltage, or the multi-use tester and the ABS-ECU cannot communicate, then there is a high possibility that power is not being supplied to the ABS-ECU.
Caution
If no malfunction code is output, there is a high possibility that the fail-safe function is operating. In this case, to check if there is a current problem, the memory should be temporarily erased, and a test run should be carried out.
© Mitsubishi Motors Corporation Jun. 1994
SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994> 35-17
35-17-1 SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994>
<Vehicles built from November, 1993>
- [Comment] This symptom occurs when the ABS-ECU is not functioning due to a broken wire, etc., in the ABS-ECU power circuit, when the fail-safe function is operating to isolate the system, or when there is a short in the warning lamp drive circuit.
- (Hint) Check the diagnosis output, and if there is no output voltage, or the multi-use tester and the ABS-ECU cannot communicate, then there is a high possibility that power is not being supplied to the ABS-ECU.
Caution
If no malfunction code is output, there is a high possibility that the fail-safe function is operating. In this case, to check if there is a current problem, the memory should be temporarily erased, and a test run should be carried out.
SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994> 35-17-2
C When ignition key is turned to "START", ABS warning lamp switches off
<Vehicles built up to October, 1993>
[Comment] The ABS-ECU uses the power to the IG2 which is cut when the ignition switch is turned to "START". The ABS warning lamp uses IG1 power which is not cut even when the ignition switch is turned to "START". Accordingly, because the power to the
ABS-ECU is stopped in "START" position, the valve relay turns OFF. At this time, if the warning lamp does not illuminate, the cause is a problem in the lamp illumination circuit in the valve relay.
<Vehicles built from November, 1993>
[Comment] The ABS-ECU uses the power to the IG2 which is cut when the ignition switch is turned to "START". The ABS warning lamp uses IG1 power which is not cut even when the ignition switch is turned to "START". Accordingly, because the power to
the ABS-ECU is stopped in "START" position, the valve relay turns OFF. At this time, if the warning lamp does not illuminate, the cause is a problem in the lamp illumination circuit in the valve relay.
35-18-2
NOTES
The ABS warning lamp flashes twice after the ignition key is turned to "ON". The lamp D illuminates when the ignition key is turned to "START", and when the key is returned to "ON", it flashes once.
[Comment] The ABS-ECU causes the ABS warning lamp to illuminate during the initial check (approx. 1 second). During the initial check, the valve relay changes from OFF to ON→OFF→ON, and
if there is a broken harness wire between the ABS-ECU and the ABS warning lamp, the lamp will illuminate only when the valve relay is OFF because of a valve relay test, etc.
E-1 When diagnosis code nos. 11, 12, 13, or 14 are displayed
- [Comment] These codes are displayed when there is a broken (+) wire or (-) wire in one of the vehicle speed sensors detected by the ABS-ECU hardware circuit
- (Hint) Apart from a broken wire in a vehicle speed sensor, the cause could also be an intermittent break in a sensor harness or a defective harness connection, so check these also.
<Vehicles built up to October, 1993>
NOTE
- 1. When there is a defective contact, inspect the sensor cable by lightly flexing and stretching it.
- 2. If there is no current problem, a normal value will result even if a problem is detected, so when the malfunction in the sensor circuit indicated cannot be discovered, momentarily turn the ignition switch to OFF, and carry out another driving test. At this time, replace the ABS-ECU only if the same problem code is output. After this, if the code does not reappear, there is a problem with the ABS-ECU interface. (For a problem that is difficult to reproduce, there is a possibility that the code will recur even when the ABS-ECU is replaced.)
© Mitsubishi Motors Corporation Jun. 1994
35-22 SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994>
NOTES
E-3 When diagnosis code no. 21, 22, 23 or 24 is displayed
- [Comment] These malfunction codes are displayed when a broken wire cannot be verified, and when the vehicle speed reaches 8 km/h (5 mph) or more, no pulses are input.
- (Hint) The cause is likely to be either a short between the sensor harnesses, a short between the sensor (+) wire and the body, or an excessive sensor gap.
NOTE
- (1) When there is a defective contact, inspect the sensor cable by lightly flexing and stretching it.
- (2) If there is no current problem, a normal value will result even if a problem is detected, so when the malfunction in the sensor circuit indicated cannot be discovered, momentarily erase the diagnosis code and turn the ignition switch to OFF, and carry out another driving test. At this time, replace the ABS-ECU only if the same malfunction code is output. After this, if the code does not reappear, there is a problem with the ABS-ECU interface. (For a problem that is difficult to reproduce, there is a possibility that the code will recur even when the ABS-ECU is replaced.)
SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994> 35-23
E-4 When diagnosis code no. 16 is displayed
<Vehicles built up to October, 1993>
[Comment] This indicates that the ABS-ECU power voltage or the solenoid valve power voltage is lower than the standard value.
If the voltage returns to standard voltage or above, this malfunction code will not be output.
Caution
If the system voltage drops during inspection, this code will be output as a current problem, and correct diagnosis of the problem cannot be made. Before carrying out the following inspection, check the battery, and charge it if necessary.
<Vehicles built from November, 1993>
-
[Comment] This indicates that the ABS-ECU power voltage or the solenoid valve power voltage is lower than the standard value.
- If the voltage returns to standard voltage or above, this malfunction code will not be output.
Caution
If the system voltage drops during inspection, this code will be output as a current problem, and correct diagnosis of the problem cannot be made. Before carrying out the following inspection, check the battery, and charge it if necessary.
35-24-2
NOTES
E-5 When diagnosis code no. 25 is displayed
- [Comment] This malfunction code is output by the ABS-ECU when there is a broken harness wire or defective 4WD indicator circuit in the free-wheel engage switch (thick wire in centre of circuit diagram).
- (Hint) When this malfunction code is output, and also none of the 4WD indicator lamps (excluding the rear differential lamp) are illuminated, the cause is likely to be the power circuit in the 4WD indicator control unit.
E-6 When diagnosis code no. 26 is displayed
[Comment] This malfunction code is output by the ABS-ECU in the following cases:
- Broken harness wire (thick wire) in the center differential lock detection switch system
- At a vehicle speed of 15 km (9 mph) or higher, the free-wheel engage switch is OFF and the center differential lock switch is ON for a continuous period of 5 seconds or more (Combination switch signal abnormality)
- When the 4WD indicator circuit is defective
- (Hint) 1. A combination switch signal abnormality occurs at the following times: Broken harness wire (thick wire)
<Vehicles built up to October, 1993>
in the free-wheel engage switch system or defective switch (stays OFF)
(Short in harness wire (thick wire) in the center differential lock switch system or defective switch (stays ON)
The above malfunctions are also affected by the 4WD indicator, so it might be the case that the malfunction is caused by a trouble symptom in the 4WD indicator.
2. When this malfunction code is output, and also none of the 4WD indicator lamps (excluding the rear differential lamp) are illuminated, the cause is likely to be the power circuit in the 4WD indicator control unit.
<Vehicles built from November, 1993>
© Mitsubishi Motors Corporation Jun. 1994
SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994> 35-27
| Does the | 4WD indicator operate nor- No | 0 | ||||
|---|---|---|---|---|---|---|
| Yes | ||||||
|
↓
Main cause |
Remedy | |||||
| Even when the transfer shift leven when the transfer shift leven is in the "4H" position, the 4W front wheel indicator lamp does not illuminate. |
ver
/D s |
Broken harness wire betw
4WD indicator ECU and the free-wheel engage switch broken earth wire from the free-wheel engage switch |
ween the
the a, or ne 1. |
Repair the harness | ||
| Free wheel engage switc defective | h is | Replace the switch | ||||
| Even when the transfer shift leven when the transfer shift levens in the "4H" position, the 4W center differential lamp does not |
ver
/D ot |
Broken harness wire betw
4WD indicator ECU and to center differential lock sw |
ween the
the vitch |
Repair the harness | ||
| illuminate. | Broken wire in the 4WD ECU circuit | indicator | Replace the ECU | |||
|
4WD indicator center differentia
lamp illuminates regardless of t position of the transfer shift lev |
al
he ver |
Short in the harness wire
center differential lock de switch circuit |
e in the
etection |
Repair the harness | ||
| Center differential lock de switch is defective | etection | Replace the switch | ||||
| Short inside the ABS-ECU | J circuit | Replace the ABS-ECU | ||||
|
Short inside the 4WD inc
ECU circuit |
dicator | Replace the 4WD indicator ECU | ||||
| No indicator is illuminated | Power circuit in the 4WE ECU is defective | ) indicator | Repair the harness | |||
| 4WD indicator ECU is de | fective | Replace the 4WD indicator ECU | ļ | |||
|
When th
removed, harness-s 107 and t When ce oV When ce system |
NOTE
When checking a short in the Al returns to normal. If it returns to the 4WD indicator ECU will be d be ABS-ECU connector is is the voltage between the ide connector terminal no. the earth normal? Inter differential is locked: Inter differential is free: voltage |
BS-EC
norm lefecti |
CU circuit, remove the AB
hal, the ABS-ECU is defective. |
S-ECU cor |
nector and check if the 4WD indi
ermore, if the ABS-ECU is normal, |
cator
then |
| Yes | ||||||
| ABS | S-ECU is defective |
Broker
center |
harness
differentia |
wire between the ABS-ECU and t
al lock detection switch |
he | |
| ۲~ | ||||||
| Rep | lace the ABS-ECU | Re | pair the harness |
E-7 When diagnosis code no. 27 is displayed
<Vehicles with rear differential lock>
- [Comment] This malfunction code is output by the ABS-ECU when there is a broken harness wire or a defective rear differential lock circuit (thick wire in circuit diagram) in the rear differential lock detection switch system.
- [Hint] When this malfunction code is output, and also none of the 4WD indicator lamps (rear differential lamp) are illuminated, the cause is likely to be the power circuit in the 4WD indicator control unit.
<Vehicles without rear differential lock>
(Vehicles built up to October, 1993)
[Comment] For vehicles without rear differential lock, battery voltage is applied to the ABS-ECU terminal no. 108. This malfunction code is output when this line is interrupted.
(Vehicles built from November, 1993)
[Comment] For vehicles without rear differential lock, battery voltage is applied to the ABS-ECU terminal no. 108. This malfunction code is output when this line is interrupted.
E-8 When diagnosis code no. 31 is displayed
[Comment] This code is displayed when there is an abnormality in the G sensor power voltage (including a short in the G sensor power harness)
(Hint) If there is a short in the G sensor power harness, code no. 32 will be output at the same time as this code.
© Mitsubishi Motors Corporation
SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994> 35-31
35-32 SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994>
<Vehicles built from November, 1993>
- [Comment] This malfunction code is output when there is an abnormality in the G sensor voltage output. This code is also output when there is a broken wire or short in the G sensor power or signal harness or a broken earth wire.
- (Hint) Malfunctions can be distinguished by the G sensor output voltage read by the multiuse tester or MUT-II service data.
| G sensor output voltage (when vehicle is on a horizontal surface) | Main problem location |
|---|---|
| 2.5±0.12V | Normal |
| 0.4V or less | Broken wire or short in the power harness or signal harness |
| 4.6V or more | Broken earth wire |
| Other than the above | G sensor is defective (including defective installation) |
35-32-2 SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994>
Inspection Chart 2
35-32-4
NOTES
E-10 When diagnosis code no. 33 is displayed
<Vehicles built up to October, 1993>
[Comment] This malfunction code is output by the ABS-ECU in the following cases:
- Problem with the stop lamp switch being ON (even though the ABS is not operating, the stop lamp is continuously diagnosed as being ON for a continuous period of 15 minutes or more.)
- Broken harness wire in the stop lamp switch system.
- (Hint) If the stop lamp illuminates and switches off normally, then there is a broken harness wire in the stop lamp switch input circuit, or the ABS-ECU circuit is defective.
35-33-1 SERVICE BRAKES – ABS Troubleshooting <Vehicles built up to May, 1994>
<Vehicles built from November, 1993>
-
[Comment] This malfunction code is output by the ABS-ECU in the following cases:
- Problem with the stop lamp switch being ON (even though the ABS is not operating, the stop lamp is continuously diagnosed as being ON for a continuous period of 15 minutes or more.)
- Broken harness wire in the stop lamp switch system.
- (Hint) If the stop lamp illuminates and switches off normally, then there is a broken harness wire in the stop lamp switch input circuit, or the ABS-ECU circuit is defective.
NOTES
E-11 When diagnosis code nos. 41, 43 or 45 are displayed
<Vehicles built up to October, 1993>
[Comment] The ABS-ECU normally monitors the solenoid valve drive circuit. If there is no current flowing to the solenoid even when the solenoid is ON, or the current continues to flow to the solenoid even when
the solenoid is OFF, the ABS-ECU diagnoses a broken wire or short in the solenoid coil or a broken wire or short in the harness, and this malfunction code is output.
© Mitsubishi Motors Corporation Jun. 1994
<Vehicles built from November, 1993>
[Comment] The ABS-ECU normally monitors the solenoid valve drive circuit. If there is no current flowing to the solenoid even when the solenoid is ON, or the current continues to flow to the solenoid even when the solenoid is
OFF, the ABS-ECU diagnoses a broken wire or short in the solenoid coil or a broken wire or short in the harness, and this malfunction code is output.
© Mitsubishi Motors Corporation Jun. 1994
35-34-2
NOTES
REVISED
<Vehicles built from November, 1993>
[Comment] When the ignition switch is turned to ON, the valve relay is switched ON and OFF during the initial check, and the ABS-ECU compares the signal to the valve relay and the voltage in the valve power monitor line to check if
the valve relay is operating normally. Normally, the valve relay is ON, so if power is not being supplied to the valve power monitor line, this malfunction code is output.
© Mitsubishi Motors Corporation Jun. 1994
NOTES
E-13 When diagnosis code no. 53 is displayed
[Comment] This code is output by the ABS-ECU when the motor relay or motor is as follows:
- Motor relay does not operate
- Motor will not work due to some problem
- Motor will not work because the earth is insufficient
• Motor will not stop
(Hint) Temporarily turn the ignition switch to OFF and after releasing the fail-safe mechanism, carry out an actuator test with the multi-use tester. If the sound of the motor working is heard during the multiuse tester actuator test, there is a broken wire or short in the motor monitor line.
ABS TROUBLESHOOTING <Vehicles built from June, 1994>
INSPECTION SERVICE POINTS FOR A BLOWN FUSE
Remove the fuse and measure the resistance between the load side of the fuse and the earth. Set the switches of all circuits which are connected to this fuse to a condition of continuity. If the resistance is almost 0 Ω at this time, there is a short circuit somewhere between these switches and the load. If the resistance is not 0 Ω, there is no short circuit at the present time, but a momentary short circuit has probably caused the fuse to blow.
The main causes of a short circuit are the following.
- Harness being clamped by the vehicle body
- Damage to the outer, casing of the harness due to wear or heat
- Water getting into the connector or circuitry
- Human error (mistakenly shorting a circuit, etc.)
POINTS TO NOTE FOR INTERMITTENT MALFUNC-TIONS.
Intermittent malfunctions often occur under certain conditions, and if these conditions can be ascertained, determining the cause becomes simple. In order to ascertain the conditions under which an intermittent malfunction occurs, first ask the customer for details about the driving conditions, weather conditions, frequency of occurrence and trouble symptoms, and then try to recreate the trouble symptoms. Next, ascertain whether the reason why the trouble symptom occurred under these conditions is due to vibration, temperature or some other factors. If vibration is thought to be the cause, carry out the following checks with the connectors and components to confirm whether the trouble symptom occurs.
The objects to be checked are connectors and components which are indicated by inspection procedures or given as probable causes (which generate diagnosis codes or trouble symptoms).
- Gently shake the connector up, down and to the left and right.
- Gently shake the wiring harness up, down and to the left and right.
- Gently rock each sensor and relay, etc. by hand.
- Gently shake the wiring harness at suspensions and other moving parts.
NOTE
If determining the cause is difficult, the flight recorder function of the MUT-II can also be used.
PWJE9086-F
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
NOTES WITH REGARD TO DIAGNOSIS
The phenomena listed in the following table are not abnormal.
| Phenomenon | Explanation of phenomenon |
|---|---|
| System check sound | When starting the engine, a thudding sound can sometimes be heard coming from inside the engine compartment. However, the sound doesn't mean any malfunction, but indicates that the system operation check is working. |
| ABS operation sound |
|
|
ABS operation
(Long braking distance) |
For road surfaces such as snow-covered roads and gravel roads, the braking distance for vehicles with ABS can sometimes be longer than that for other vehicles. Accordingly, advise the customer to drive safely on such roads by lowering the vehicle speed and not being too overconfident. |
Diagnosis detection condition depends on a diagnosis code. So, when rechecking a trouble symptom, be sure to satisfy the condition in the listed in the "Comments" column of the inspection procedure for diagnosis codes.
DIAGNOSTIC FUNCTION DIAGNOSIS CODES CHECK With the MUT-II
Connect the MUT-II to the diagnosis connector (16-pin), then check diagnosis codes.
Caution
Turn the ignition switch off before connecting or disconnecting the MUT-II.
Without the MUT-II
- 1. Turn the ignition switch off and then disconnect the valve relay connector.
- 2. Use the special tool to earth diagnosis connector terminal No. 1.
- 2. Use the special tool to earth diagnosis connector terminal No. 1.
- 3. Turn the ignition switch to ON and then take a reading of the diagnosis codes from the flashing of the ABS warning lamp. NOTE
Diagnosis code No. 51 (indicating an open or short circuit in the valve relay) will be always output, because the valve relay connector is disconnected.
All diagnosis code numbers are the same as those when using the MUT-II.
© Mitsubishi Motors Corporation Jun. 1994
Diagnosis
connector
14E0207
Junction
4. Remedy the malfunctions indicated by the diagnosis codes, disconnect the diagnosis code check harness, and then install the valve relay. Then turn the ignition switch to ON again to check the ABS warning lamp. (Refer to P.35-36-16.) If the lamp indicates a malfunction, the valve relay system may be detective. (Refer to P.35-36-14.)
ERASING DIAGNOSIS CODES With the MUT-II
Connect the MUT-II to the diagnosis connector 16-pin), and then erase the diagnosis codes.
Without the MUT-II
Remove the battery cable from the battery (–) terminal for 10 seconds or more, and then reconnect the cable.
INSPECTION CHART FOR DIAGNOSIS CODES
Inspect according to the inspection chart that is appropriate for the diagnosis code.
|
Diagnosis
code no. |
Inspection item | Diagnosis content |
Reference
page |
|---|---|---|---|
| 11 | .Front right wheel speed sensor | ||
| 12 | Front left wheel speed sensor | ||
| 13 | Rear right wheel speed sensor | F.30-30-0 | |
| 14 | Rear left wheel speed sensor | ||
| 15 | Wheel speed sensor | Abnormal output signal | P.35-36-6 |
| 16 | Power supply system | P.35-36-7 | |
| 21 | Front right wheel speed sensor | ||
| 22 | Front left wheel speed sensor | ||
| 23 | Rear right wheel speed sensor | P.35-36-7 | |
| 24 | Rear left wheel speed sensor | ||
| 25 | Free-wheeling engage switch | P.35-36-8 | |
| 26 | Center differential lock detection switch | P.35-36-9 | |
| 27 | Rear differential lock detection switch | Rear differential lock detection switch | |
| 32 | G-sensor system | P.35-36-11 | |
| 33 | Stop lamp switch system | P.35-36-12 | |
| 41 | Front right solenoid valve | ||
| 42 | Front left solenoid valve | P.35-36-13 | |
| 43 | Rear solenoid valve | ||
| 51 | Valve relay | P.35-36-14 | |
| 53 | Motor relay, motor | P.35-36-15 | |
| 63 | Benless the ABS ECU | ||
| 64 | |||
ADDED
INSPECTION PROCEDURE FOR DIAGNOSIS CODES
| Code No. 15 Wheel speed sensor (Abnormal output signal) | Probable cause | |
|---|---|---|
|
[Comment]
A wheel speed sensor outputs an abnormal signal (other than an open or short-circuit). |
|
|
© Mitsubishi Motors Corporation Jun. 1994
| Code No. 16 Power supply system | Probable cause |
|---|---|
|
[Comment]
The voltage of the ABS-ECU power supply drops lower or rises higher than the specified value. If the voltage returns to the specified value, this code is no longer output. |
|
Caution
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to the specified value, this code is no longer output.
Before carrying out the following inspection, check the battery level, and refill it if necessary.
© Mitsubishi Motors Corporation Jun. 1994
PWJE9086-F
ADDED
35-36-8 SERVICE BRAKES – ABS Troubleshooting <Vehicles built from June, 1994>
SERVICE BRAKES – ABS Troubleshooting <Vehicles built from June, 1994> 35-36-9
Continued from previous page
| Trouble symptom | Main causes | Remedy |
| Even when the transfer shift lever is in the "4H" position, the 4WD front wheel indicator lamp does not illuminate. | Broken harness wire between the 4WD indicator ECU and the free-wheel engage switch, or broken earth wire from the free-wheel engage switch. | Repair the harness |
| Free-wheeling engage switch is detective | Replace the switch | |
| Even when the transfer shift lever is in the "4H" position, the 4WD center differential lamp does not illuminate. | Broken harness wire between the 4WD indicator ECU and the center differential lock switch | Repair the harness |
| Broken wire in the 4WD indicator ECU circuit |
4WD indicator ECU inspection
(Refer to GROUP 22 – Service Adjustment Procedures.) |
|
|
4WD indicator center differential lamp
illuminates regardless of the position of the transfer abift lower |
Short in the harness wire in the center differential lock detection switch circuit | Repair the harness |
| Center differential lock detection switch is defective | Replace the switch | |
| Short inside the ABS-ECU circuit | Replace the ABS-ECU | |
| Short inside the 4WD indicator ECU circuit |
4WD indicator ECU inspection
(Refer to GROUP 22 – Service Adjustment Procedures.) |
|
| No indicator is illuminated | Power circuit in the 4WD indicator ECU is defective | Repair the harness |
| 4WD indicator ECU is defective |
4WD indicator ECU inspection
(Refer to GROUP 22 – Service Adjustment Procedures.) |
NOTE
When checking a short in the ABS-ECU circuit, remove the ABS-ECU connector and check if the 4WD indicator returns to normal. If it returns to normal, the ABS-ECU is defective. Furthermore, if the ABS-ECU is normal, then the 4WD indicator ECU will be defective.
35-36-10 SERVICE BRAKES – ABS Troubleshooting <Vehicles built from June, 1994>
© Mitsubishi Motors Corporation Jun. 1994
PWJE9086-F
| Code No. 32 G-sensor system | Probable cause |
|---|---|
|
|
- NOTE (1) *1 indicates vehicles without auto-cruise control system.
- *2 indicates vehicles with auto-cruise control system.
, ок
↓ОК
Check the following
Check trouble symptoms
• E-12 and E-13
NG
► Repair
Replace the ABS-ECU
ADDED
| Code No. 51 Valve relay | Probable cause |
|---|---|
|
[Comment]
When the ignition switch is turned to ON, the ABS-ECU switches the valve relay off and on during the initial check. In that way, the ABS-ECU compares the signals sent to the valve relay with the voltage in the valve power monitor line. That is how to check if the valve relay is operating normally. The ABS-ECU always checks if current flows in the valve power monitor line, too. It determines that there is an open circuit when no current flows. If no current flows in the valve power monitor line, this diagnosis code is output. |
|
NOTE
Whenever reading the diagnosis codes using the ABS warning lamp (P.35-36-16), this diagnosis code will be output. That is not a malfunction but because the valve relay connector is disconnected. After repairing all other malfunctions, connect the valve relay connector again to check the valve relay. Then check that the ABS warning lamp does not illuminate. If it illuminates, the valve relay may be defective. So carry out the following procedure.
| Code No. 53 Motor relay, motor | Probable cause | |
|---|---|---|
|
|
|
Caution
Because force-driving of the motor by means of the actuator test will drain the battery, the engine should be started and left to run for a while after testing is completed.
© Mitsubishi Motors Corporation Jun. 1994
PWJE9086-F
ABS WARNING LAMP INSPECTION
Check that the ABS warning lamp illuminates as follows.
- When the ignition key is turned to "ON", the ABS warning lamp illuminates for approximately 3 seconds and then switches off.
- 2. When the ignition key is turned to "START", the ABS warning lamp remains illuminated.
- 3. When the ignition key is turned from "START" back to "ON", the ABS warning lamp illuminates for approximately 3 seconds and then stays switched off.
- 4. If the illumination is other than the above, check the diagnosis codes.
INSPECTION CHART FOR TROUBLE SYMPTOMS
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
| Trouble symptom |
Inspection
procedure No. |
Reference
page |
|
|---|---|---|---|
| Communication with MUT-II | No communication with any system is possible. | 1 | P.35-36-18 |
| is not possible. | Communication is not possible with ABS only. | 2 | P.35-36-18 |
|
When the ignition key is turne
does not illuminate. |
ed to "ON" (engine stopped), the ABS warning lamp | 3 | P.35-36-19 |
| After the engine starts, the la | mp remains illuminated. | 4 | P.35-36-19 |
| When the ignition key is turned to "START", the ABS warning lamp does not illuminate. | P.35-36-20 | ||
|
After the ignition key is turned
when turned to "START", it il once, and then switches off. |
d on "ON", the ABS warning lamp blinks twice, and luminates. When returned to "ON", the lamp flashes | 6 | P.35-36-20 |
| Faulty ABS operation | Unequal braking power on both sides | 7 | P.35-36-21 |
| Insufficient braking power | |||
| ABS operates under normal braking conditions | |||
| ABS operates before vehicle stops under normal braking conditions | |||
| Large brake pedal vibration (Caution 2.) | _ | - | |
Caution
- 1. If steering movements are made when driving at high speed, or when driving on road surfaces with low frictional resistance, or when passing over bumps, the ABS may operate even though sudden braking is not being applied. Because of this, when getting information from the customer, check if the problem occurred while driving under such conditions as these.
- 2. During ABS operation, changes in the feeling of the brake pedal (vibration may occur or pedal may not be able to be depressed). Such changes are due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is not an abnormality.
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
Inspection Procedure 1
Inspection Procedure 3
| When ignition key is turned to "ON" (engine stopped), ABS warning lamp does not illuminate. | Probable cause |
|---|---|
|
[Comment]
When current flows in the ABS-ECU, the valve relay turns from off to on, off and back to on again as the initial check. So the ABS warning lamp will illuminate twice when the valve relay is off even if there is a problem with the circuit between the ABS warning lamp and the ABS-ECU. Therefore, if the lamp does not illuminate, the cause may be: an open circuit in the lamp power supply circuit, a blow lamp bulb, an open circuit in both the circuit between the ABS warning lamp and the ABS-ECU and in the circuit between the ABS warning lamp and the valve relay |
|
Inspection Procedure 4
| Even after the engine is started, the ABS warning lamp remains illuminated. | Probable cause | ||
|---|---|---|---|
|
[Comment]
The cause is probably a short-circuit in the ABS warning lamp illumination circuit. |
|
||
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.
Inspection Procedure 5
| When ignition key is turned to "START", ABS warning lamp does not illuminate. | Probable cause |
|---|---|
|
[Comment]
Current does not flow in the ABS-ECU when the ignition switch is turned to START. Current flows in the ABS warning lamp even when the ignition switch is turned to START. Therefore, the valve relay, which current is supplied through the ABS-ECU, turns off when the ignition switch is at START. However, the warning lamp circuit of the valve relay must turn on in turn. So the cause must be a defective circuit on valve relay side. |
|
Inspection Procedure 6
| The ABS warning lamp flashes twice after the ignition key is turned to "ON". The lamp illuminates when the ignition key is turned to "START", and when the key is returned to "ON", it flashes once. | Probable cause |
|---|---|
|
[Comment]
The ABS-ECU causes the ABS warning lamp to illuminate during the initial check (approx. 3 seconds). During the initial check, the valve relay turns from off to on, off and back to on again. If there is an open circuit in the harness between the ABS-ECU and the ABS warning lamp, the lamp will illuminate only when the valve relay is OFF during valve relay test, etc. |
|
Inspection Procedure 7
| Brake operation is abnormal | Probable cause |
|---|---|
|
[Comment]
This depends on the driving conditions and the road surface conditions, so problem diagnosis is difficult. However, if a normal diagnosis code is displayed, carry out the following inspection. |
|
DATA LIST REFERENCE TABLE
The following items can be read by the MUT-II from the ABS-ECU input data.
1. When the system is normal
|
ltem
No. |
Check item | Checking Requirements | Normal Value |
|---|---|---|---|
| 11 | Front-right wheel speed sensor | Vehicle speeds | |
| 12 | Front-left wheel speed sensor | displayed on | |
| 13 | Rear-right wheel speed sensor | Do a test run. |
the speedome-
ter and MUT-II |
| 14 | Rear-left wheel speed sensor | are identical. | |
| 16 | ABS-ECU power supply voltage | IG power supply voltage and valve monitor voltage | 9–16V |
| 25 | Free-wheeling engage switch | Engage 4WD. | ON |
| 25 | Engage 2WD. | OFF | |
| 26 | Center differential lock detection | Place the transfer lever at 4HLC. | ON |
| 20 | switch | Place the transfer lever at 4H. | OFF |
| 27 | Rear differential lock detection | Turn on the switch. | ON |
| 27 | switch | Turn off the switch. | OFF |
| Stop the vehicle. | 2.5 ± 0.12∨ | ||
| 32 | G-sensor output voltage | Do a test turn. |
Display value
fluctuates with a mean value of 2.5 V. |
| 33 | Stop Jamp switch | Depress the brake pedal. | ON |
| Release the brake pedal. | OFF |
2. When the ABS-ECU shut off ABS operation.
When the diagnosis system stops the ABS-ECU, the MUT-II display data will be unreliable.
ACTUATOR TEST REFERENCE TABLE
The MUT-II activates the following actuators for testing.
NOTE
1. If the ABS-ECU runs down, actuator testing cannot be carried out.
Actuator testing is only possible when the vehicle is stationary. If the vehicle speed during actuator testing exceeds 10 km/h, forced actuation will cancels.
ACTUATOR TEST SPECIFICATIONS
| No. | Driving objective | Driving pattern | |
|---|---|---|---|
| 01 |
Solenoid valves and
pump motors for each corresponding channel in the bydraulic unit |
Solenoid valve
for front left wheel |
Solenoid Pressure |
| 02 |
Solenoid valve
for front right wheel |
valve Pressure Reduction in pressure 48 ms Pump ON | |
| 03 |
Solenoid valve
for rear wheels |
( OF 14E0048 | |
CHECK AT ABS-ECU TERMINAL VOLTAGE CHECK CHART
120000123
- 1. Measure the voltages between terminals (15), (25) and (42) (earth terminals) and each respective terminal.
- 2. The terminal layouts are shown in the illustrations below.
14W0043
|
ltem
No. |
Signal | Checking Requirements |
Normal
Condition |
|---|---|---|---|
| 1 |
Output to front-left hydraulic
unit solenoid valve (OUT side) |
||
| 2 |
Output to rear hydraulic
unit solenoid valve (OUT side) |
Ignition switch: ON
(When solenoid valve is off approximately 1 second after engine is started) |
System
voltage |
| 3 |
Output to rear hydraulic
unit solenoid valve (IN side) |
||
| 4 | G-sensor signal | Ignition switch: ON |
2.5 ±0.12V
(Horizontal condition) |
| 13 | ABS-ECU power supply | Ignition switch: ON |
System
voltage |
| Ignition switch: START | 0 V |
35-36-24 SERVICE BRAKES – ABS Troubleshooting <Vehicles built from June, 1994>
|
Connector
Terminal No. |
Signal | Checking Re | equirements | Normal Condition | |
| 14 |
Output to front-left hydraulic
unit solenoid valve (IN side) |
lgnition swit
(When soler second afte |
tch: ON
noid valve is off a r engine is starte |
approximately 1
d) |
System
voltage |
| 17 | G-sensor earth | Always | 0 V | ||
| 26 | Output to relay power supply | Ignition swit | tch: ON |
System
voltage |
|
| 32 | Memory power supply | Always |
System
voltage |
||
| 34 | Input from stop lamp switch |
Ignition
switch: |
Stop lamp swit | ch ON |
System
voltage |
| - | ON | Stop lamp swi * | ch OFF | 1 V or less | |
| 0.5 | Input from center differential | Ignition | Ignition Transfer lever position: 4H | System voltage | |
| 35 | lock detection switch |
switch:
ON |
Transfer lever position: 4Lc | 1 V or less | |
| 36 | MUT-II | Connect the MUT-II. |
Serial communica-
tion with MUT-II |
||
| Do not conr | Do not connect the MUT-II. | 1 V or less | |||
| Ignition | Approximately engine is starte |
1 second after
d. The relay is on. |
2 V or less | ||
| 37 | Output to valve relay | ON | The system ru relay is off. | ns down. The | System voltage |
| Ignition swi | tch: ON | Motor is on | 2 V or less | ||
| 38 | after engine | (Approximately 1 second after engine is started) | System voltage | ||
| 39 | Idle-up solenoid valve (-) |
Ignition switch: ON
(When motor is on approximately 1 second after engine is started) |
2 V or less | ||
| 41 |
Output to front-right hydraulic
unit solenoid valve (OUT side) |
Ignition switch: ON
(When solenoid valve is off approximately 1 second after engine is started) |
System voltage | ||
| 43 | Idle-up solenoid valve (+) |
Ignition swi
(When mot after engine |
tch: ON
or is on approxin e is started) |
System voltage | |
RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS
- 1. Turn the ignition switch off and disconnect the ABS-ECU connectors before checking resistance and continuity.
- 2. Check them between the terminals indicated in the table below.
- 3. The terminal layouts are shown in the illustrations below.
| п | |||
|---|---|---|---|
| 4140 | 00000 | 26 26 24 | 2220 21 |
| 141140 | 39 38 37 | 30 35 34 | 333231 |
| E 0 E 1 | 444040 | ||
| 152|51 | 50|49|48 | 47 46 45 | 44 43 42 |
| 1 | |||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Ň | , | l. | |||||||||||
| 13 | 12 | 110 | 9 | 181 | 6 | 5 | 4 | 3 | 2 | ||||
| ** | ÷ | ŤĚ | |||||||||||
| 26 | 25 | 24 | 23 | 22 | 21 | 20 | 19 | 18 | 17 | 16 | 115 | 141 | |
| 20 | 20 | 5 | ± / | 10 | ت شا |
14W0042
SERVICE BRAKES – ABS Troubleshooting <Vehicles built from June, 1994> 35-36-25
|
Connector
Terminal No. |
Signal | Checking Requirements | Normal Condition | ||
|---|---|---|---|---|---|
| 45 | Input from free-wheeling | Ignition | Engage 2WD. | System voltage | |
| 45 | engage switch |
switch:
ON |
Engage 4WD. | 1 V or less | |
| 46*1 | Ignition swi | tch: ON | System voltage | ||
| 40 " | Ignition switch | Ignition swi | tch: START | 0 V | |
| 40*2 | Input from rear differential | Ignition |
Rear different
ON |
ial lock switch: | 0 V |
| 40*** | lock detection switch | ON |
Rear differential lock switch:
OFF |
System voltage | |
| A 7 | Input from diagnosis | Connect the | the MUT-II. | 0 V | |
| 47 | indication selection | Do not con | onnect the MUT-II. | Approx. 12 V | |
| 48 | Input from valve relay monitor | Ignition swi | tch: ON | System voltage | |
| 40 | Ignition switch: ON | Motor is on | System voltage | ||
| 49 | after engine | e is started) | Motor is off | 0.5 V or less | |
| F0 | Ignition | The lamp is sv | witched off | System voltage | |
| 50 | Output to ABS warning lamp |
SWITCH:
ON |
N The lamp illuminates | 0-2 V | |
| 52 |
Output to front-right hydraulic
unit solenoid valve (IN side) |
Ignition switch: ON
(When solenoid valve is off approximately 1 second after engine is started) |
System voltage | ||
NOTE (1) *1: (2) *2:
(1) *1: Vehicles without rear differential lock
(2) *2: Vehicles with rear differential lock
35-36-26 SERVICE BRAKES – ABS Troubleshooting <Vehicles built from June, 1994>
RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS
- 1. Turn the ignition switch off and disconnect the ABS-ECU connectors before checking resistance and continuity.
- 2. Check them between the terminals indicated in the table below.
- 3. The terminal layouts are shown in the illustrations below.
| Connector Terminal No. | Signal | Normal Condition |
|---|---|---|
| 1 – Body earth | Front-left solenoid valve (OUT side) | 4.7 ± 0.25 Ω |
| 2 – Body earth | Rear solenoid valve (OUT side) | 4.7 ± 0.25 Ω |
| 3 – Body earth | Rear solenoid valve (IN side) | 9.0 ± 0.5 Ω |
| 7–20 |
Front-left wheel speed sensor
(+ wire) |
0.9 ± 1.1 Ω |
| 8–21 |
Rear-right wheel speed sensor
(+ wire) |
1.3 ± 2.1 Ω |
| 9–22 |
Rear-left wheel speed sensor
(+ wire) |
1.3 ± 2.1 Ω |
| 10–23 |
Front-right wheel speed sensor
(+ wire) |
0.9 ± 1.1 Ω |
| 14 – Body earth | Front-left solenoid valve (IN side) | 9.0 ± 0.5 Ω |
| 15 – Body earth | ||
| 25 – Body earth | Continuity | |
| 39–43 | ldle-up solenoid valve | 36 – 44 Ω |
| 41 – Body earth | Front-right solenoid valve (OUT side) | 4.7 ± 0.25 Ω |
| 42 – Body earth | ABS-ECU earth | Continuity |
| 48 – Body earth | Valve relay monitor input | Continuity |
| 49 – Body earth | Motor monitor | Continuity |
| 52 – Body earth | Front-right solenoid valve (IN side) | 9.0 ± 0.5 Ω |
ock nu
(0.019-0.039 in )
SERVICE ADJUSTMENT PROCEDURES
BRAKE PEDAL INSPECTION AND ADJUSTMENT
1. Measure the brake pedal height (A) as illustrated.
Standard value (A): 186–191 mm (7.3–7.5 in.)
2. Start the engine, depress the brake pedal with approximately 500N (50 kg, 110 lbs.) of force, and measure the clearance between the brake pedal and the floor-board.
Standard value (C): 100 mm (3.94 in.) or more
3. While the engine is stopped, depress the brake pedal two or three times. After thus eliminating the vacuum in the brake booster, press the pedal down by hand, and confirm that the free play (B) is within the standard value range.
Standard value (B): 3-8 mm (0.12-0.31 in.)
-
4. Adjust the brake pedal height.
- (1) Sufficiently loosen the stop lamp switch by loosening lock nut.
- (2) Adjust the brake pedal height by turning the operating rod with pliers (with lock nut loosened).
- (3) After turning the stop lamp switch until it contacts the pedal stop (until immediately before the brake pedal begins to move), turn the stop lamp switch back 1/2 to 1 revolution and secure with a lock nut.
Caution
Check that the stop lamp is not illuminated when the brake pedal is not depressed.
© Mitsubishi Motors Corporation Feb. 199
BRAKE BOOSTER OPERATING TEST E35FCAA&
For simple checking of the brake booster operation, carry out the following tests:
1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly. If the pedal height remains unchanged, the booster is defective.
25-28
Good
SERVICE BRAKES - Service Adjustment Procedures
No good
2 With the engine stopped step on the brake pedal several times
Then step on the brake pedal and start the engine. If the pedal moves downward slightly the booster is in good condition. If there is no change the booster is defective
3 With the engine running step on the brake pedal and then stop the engine
Hold the pedal depressed for 30 seconds. If the pedal height does not change the booster is in good condition if the pedal rises, the booster is defective
If the above three tests are okay, the booster performance can be determined as good.
If one of the above three tests is not okay at last, the check valve vacuum hose or booster will be defective
CHECK VALVE OPERATION CHECK
E35EEAI When checking the check valve, keep the check valve fit in
1991
1. Remove the vacuum hose.
the vacuum hose
The check valve is press-fit inside the vacuum hose.
2. Check the operation of the check valve by using a vacuum pump.
| Vacuum pump connection | Accept/reject criteria |
|---|---|
| Connection at the brake booster side ① | A negative pressure (vacuum) is created and held. |
| Connection at the engine side ② | A negative pressure (vacuum) is not created. |
Caution
If the check valve is defective, replace it as an assembly unit together with the vacuum hose.
BRAKE FLUID LEVEL SENSOR CHECK E35FBAE
The brake fluid level sensor is in good condition if there is no continuity when the float surface is above "A", and if there is continuity when the float surface is below "A".
PWJE9086
BRAKE BOOSTER VACUUM SWITCH CHECK <2500D> E35FDAAb
- 1. Connect an ohmmeter to the connector of the vacuum switch.
- 2. Start the engine and check for continuity when the vacuum hose is connected and when it is disconnected. The vacuum switch is in good condition if there is no continuity when the vacuum hose is connected, and if there is continuity when it is not connected.
LOAD SENSING SPRING LENGTH CHECK AND ADJUSTMENT
1. Park the vehicle on a level ground. The vehicle should be unloaded and supported only by wheels.
Caution
Never support the vehicle with jacks or other similar means.
2. With the lever pressed all the way to the load-sensing proportioning valve side, check whether or not the length (shown in the figure) of the spring (the length between its ends) is the standard value.
Standard value: 224-228 mm (8.8-9.0 in.)
- 3. If the spring length is not within the standard value, loosen the bolt attaching the support and adjust the distance by moving the support.
© Mitsubishi Motors Corporation Feb. 1991
LOAD SENSING PROPORTIONING VALVE FUNCTION TEST E35FKAK
1. Connect pressure gauges to the input and output ports of the load sensing proportioning valve. Bleed the system.
- 2. Disconnect the spring at the support side.
- Place the spring so that it is in parallel with the loadsensing proportioning valve, and then pull in the direction indicated by arrow A so that its length H shown in the figure (the length between its ends) is as noted below. NOTE
At this time the lever is pressed all the way to the loadsensing proportioning valve side.
Check at this time whether or not the output fluid's pressure, relative to the load-sensing proportioning valve's input fluid pressure, is within the standard value.
Standard value:
| Items |
Spring
length H mm (in.) |
Input fluid
pressure MPa (kg/cm², psi) |
Output fluid
pressure MPa (kg/cm², psi) |
| 2-door models |
227.5
(9.0) |
10 (100, 1422) |
5.37–6.27
(53.7–62.7, 763.8–891.8) |
| 18 (180, 2560) |
7.17–8.47
(71.7–84.7, 1019.8–1204.7) |
||
| 4-door models 2 |
226.7
(8.9) |
10 (100, 1422) |
6.14-7.04
(61.4-70.4, 873.3- 1001.3) |
| 18 (180, 2560) |
7.94–9.24
(79.4–92.4, 1129.3–1314.2) |
4. In the same manner as in step 3., check whether or not the output fluid's pressure, relative to the load-sensing proportioning valve's input fluid pressure, is within the standard valve when the spring's length H is the dimension noted below.
Standard value:
| Items |
Spring
length H mm (in.) |
Input fluid
pressure MPa (kg/cm², psi) |
Output fluid
pressure MPa (kg/cm 2 , psi) |
|---|---|---|---|
| 2-door models |
255.6
(10.1) |
18 (180, 2560) |
13.1–15.1
(131–151, 1863.3–2147.7) |
| 4-door models |
257.7
(10.1) |
18 (180, 2560) |
10.4–12.4
(104–124, 1479.2–1763.7) |
5. After making the check, install the spring. Disconnect the pressure gauges from the load-sensing proportioning valve and bleed the air.
BLEEDING
E35FYAJ
Caution Use the specified brake fluid. Avoid using a mixture of the specified brake fluid and other fluid. Specified brake fluid: DOT3 or DOT4
AIR BLEEDING OF THE MASTER CYLINDER
If there is no brake fluid in the master cylinder, bleed air from the master cylinder by following the steps below.
- (1) Supply brake fluid to the reservoir tank.
- (2) Depress and hold the brake pedal.
- (3) Another person should then plug the outlet of the master cylinder with a finger.
- (4) In the (3) condition, return the brake pedal.
- (5) Repeat steps (2) to (4) three or four times so as to supply brake fluid inside the master cylinder.
AIR BLEEDING OF THE BRAKE PIPE LINE
Bleed the brake system in the sequence shown in the illustration.
Furthermore, for vehicles with ABS, start the engine before bleeding the air.
Caution
When supplying brake fluid for vehicles with ABS, the filter should be installed to the master cylinder reserve tank.
© Mitsubishi Motors Corporation Feb. 1991
© Mitsubishi Motors Corporation Oct. 1991
- 3. In order to measure the dragging force of the disc brakes after installation of the brake pads, use a spring balance to measure the rotational sliding resistance of the hub in the forward direction with the pads removed.
- Securely attach the pad clip to the caliper support. Caution
Do not deposit grease or other dirt on pad or brake disc friction surfaces.
PWJE9086-A
5. Clean piston and insert into cylinder with special tool. Be careful that the piston boot does not become caught, when lowering the caliper assembly and install the lock pin.
- 6. Start the engine and, after strongly depressing the brake pedal 2-3 times, stop the engine.
- 7. Turn brake disc forward 10 times.
- Use a spring balance to measure the rotational sliding resistance of the hub in the forward direction.
- Calculate the dragging force of the disc brakes (the difference between the values measured in steps 8 and 3).
Standard value: 57N (5.7 kg. 13 lbs.) or less
10. If the dragging force of the disc brakes exceeds the standard value, disassemble piston and clean the piston. Check for corrosion or worn piston seal, and check the sliding condition of the lock pin sleeve and guide pin sleeve.
FRONT DISC BRAKE ROTOR INSPECTION
CAUTION
When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within the allowable service values in order to maintain normal brake operation.
Before re-finishing or re-processing the brake disc surface, the following conditions should be checked.
| Inspection items | Remarks | |
|---|---|---|
|
Scratches, rust, saturated lining materi-
als and wear |
|
|
| Run-out or drift | Excessive run-out or drift of the discs will increase the pedal depression resistance due to piston knock-back. | |
| Change in thickness (parallelism) | If the thickness of the disc changes, this will cause pedal pulsation, shuddering and surging. | |
| Inset or warping (flatness) | Overheating and improper handling while servicing will cause inset or warping. | |
1. Remove the caliper support; then raise the caliper assembly upward and secure by using wire.
2. Place a dial gauge approximately 5 mm (.2 in.) from the outer circumference of the brake disc, and measure the run-out of the disc.
Limit: 0.1 mm (0.0039 in.)
If the measurement exceeds the limit, change the relative position of the hub and brake disc, and measure the run-out again. If the result still does not fall within the limit, check the run-out of the hub, and replace either the hub or disc, whichever is appropriate.
© Mitsubishi Motors Corporation July 1992
FRONT BRAKE DISC RUN-OUT CORRECTION
- 1. If the run-out of the brake disc is equivalent to or exceeds the limit specification, change the phase of the disc and hub, and then measure the run-out again. (Refer to P. 35-44)
- If the run-out cannot be corrected by changing the phase of the brake disc, replace the disc or turn rotor with on the car type brake lathe ("MAD, DL–8700PF" or equivalent).
FRONT BRAKE DISC THICKNESS CHECK E35FRAI
- 1. Inspect the disc surface for grooves, cracks, and rust. Clean the disc thoroughly and remove all rust.
- Using a micrometer, measure disc thickness at eight positions, approximately 45° apart and 10 mm (0.39 in.) in from the outer edge of the disc.
| Standard value |
24 mm (0.94 in.)
27 mm (1.01 in.) <3500> |
|||
|---|---|---|---|---|
| Limit: |
22.4 mm (0.882 in.)
25.4 mm (1.0 in.) <3500> |
|||
| The difference | hatwaan any thickness maaguramenta | |||
The difference between any thickness measurements should not be more than 0.015 mm (0.0006 in.)
- 3. Replace the discs and pad assembly for both sides left and right of the vehicle if they are beyond the limits for thickness.
- If thickness variation exceeds the specification, replace the disc or turn rotor with on the car type brake lathe ("MAD, DL-8700PF" or equivalent).
REAR DISC BRAKE PAD CHECK AND REPLACEMENT
1. Check brake pad thickness through caliper body check port. Standard value: 9.0 mm (0.35 in )
Standard value:
9.0 mm (0.35 in.) 2.0 mm (0.079 in.)
Caution
- 1. When the limit is exceeded, replace the pads at both sides, and also the brake pads for the wheels on the opposite side at the same time.
- If there is a significant difference in the thicknesses of the pads on the left and right sides, check the sliding condition of the piston, lock pin sleeve and guide pin sleeve.
- 2. Remove lock pin. Lift caliper assembly and retain with wires.
Caution
Do not wipe off the special grease that is on the lock pin or allow it to contaminate the lock pin.
-
3. Remove the following parts from caliper support.
- (1) Outer shim
- (2) Pad assembly
- (3) Pad and wear indicator assembly
- (4) Clip
450125
4. In order to measure the dragging force of the disc brakes after installation of the brake pads, use a spring balance to measure the rotational sliding resistance of the hub in the forward direction with the pads remove
To secure the disc to the hub, tighten the nuts.
5. Securely attach the pad clip to the caliper support.
Caution
Do not deposit grease or other dirt on pad or brake disc friction surfaces.
SERVICE BRAKES – Service Adjustment Procedures
6. Clean piston and insert into cylinder with special tool. Be careful that the piston boot does not become caught, when lowering the caliper assembly and install the lock pin.
35-45
- 7. Start the engine and, after strongly depressing the brake pedal 2-3 times, stop the engine.
- 8. Turn brake disc forward 10 times.
- 9. Use a spring balance to measure the rotational sliding resistance of the hub in the forward direction.
- 10. Calculate the dragging force of the disc brakes (the difference between the values measured in steps 9 and 4).
Standard value: 57N (5.7 kg. 13 lbs.) or less
11. If the dragging force of the disc brakes exceeds the standard value, disassemble piston and clean the piston. Check for corrosion or worn piston seal, and check the sliding condition of the lock pin sleeve and guide pin sleeve.
REAR BRAKE DISC THICKNESS CHECK E35FVAB
- 1. Remove dirt and rust from brake disc surface.
-
2. Measure disc thickness at 4 locations or more.
- Standard value: 18.0 mm (0.71 in.) Limit: 16.4 mm (0.646 in.)
Replace the discs and pad assembly for both sides left and right of the vehicle if they are worn beyond the specified limit.
REAR BRAKE DISC RUN-OUT CHECK E35PWA
1. Remove the caliper support, raise the caliper assembly, and secure it by using a wire, etc.
© Mitsubishi Motors Corporation Oct. 1991
PWJE9086-A
35-46
SERVICE BRAKES - Service Adjustment Procedures
2. Place a dial gauge approximately 5 mm (0.2 in.) from the outer circumference of the brake disc, and measure the run-out of the disc.
Limit: 0.08 mm (0.0031 in.) NOTE To secure the disc to the hub, tighten the nuts.
REAR BRAKE DISC RUN-OUT CORRECTION
-
If the run-out of the brake disc is equivalent to or exceeds the limit specification, change the phase of the disc and axle shaft and then measure the run-out again.
Before removing the brake disc, chalk both sides or the wheel stud on the side at which run-out is greatest.
- (2) Remove the brake disc, and then place a dial gauge then move the hub in the axial direction and measure the play.
Limit: 0.25 mm (0.0098 in.) or less
- (3) If the play does not exceed the limit specification, in stall the brake disc at a different phase, and ther check the run-out of the brake disc once again.
- 2. If the runout cannot be corrected by changing the phase of the brake disc, replace the disc.
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