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Mitsubishi 35C manual

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Table of contents for the manual

  • Page 1

    BASIC BRAKE SYSTEM 35A ......................................... ANTI-SKID BRAKING SYSTEM (ABS) <2WD> 35B ...................... ANTI-SKID BRAKING SYSTEM (ABS) <4WD> 35C ...................... NOTE THE GROUPS MARKED BY ARE NOT IN THIS MANUAL 35A-1 SER VICE BRAKES CONTENTS 35109000159[...]

  • Page 2

    35A-2 BASIC BRAKE SYSTEM CONTENTS 35109000302 GENERAL INFORMA TION 3 .................. SERVICE SPECIFICA TIONS 4 ................. LUBRICANTS 5 .............................. SEALANTS 5 ................................ SPECIAL T OOLS 5 .......................... ON-VEHICLE SERVICE 6 ..................... Brake Pedal Check and Adjustment 6 ........[...]

  • Page 3

    BASIC BRAKE SYSTEM - General Information 35A-3 GENERAL INFORMA TION 35100010182 The brake system of fers high dependability and durability along with improved braking performance and brake sensitivity . Items Specifications Master cylinder T ype T andem type (with level sensor) I.D. mm 23.8 Brake booster T ype V acuum type, single Effective dia. of[...]

  • Page 4

    BASIC BRAKE SYSTEM - General Information/ Service Specifications 35A-4 CONSTRUCTION DIAGRAM Brake booster Master cylinder Front brake Proportioning valve Brake pedal Rear brake SERVICE SPECIFICA TIONS 35100030201 Items Standard value Limit Brake pedal height mm 162.8 - 165.8 - Brake pedal free play mm 3- 8 - Brake pedal to floor board clearance mm [...]

  • Page 5

    BASIC BRAKE SYSTEM - Service Specifications/Lubricants/ Sealants/Special T ools 35A-5 Items Standard value Limit Rear disc brake Pad thickness mm 10.0 2.0 Disc thickness mm 10.0 8.4 Disc runout mm - 0.08 Drag force (tangential force of wheel mounting bolts) N 69 or less - Rear drum brake Lining thickness mm 4.4 1.0 Drum inside diameter mm 203 205 L[...]

  • Page 6

    BASIC BRAKE SYSTEM - On-vehicle Service 35A-6 ON-VEHICLE SERVICE 35100090186 BRAKE PEDAL CHECK AND ADJUSTMENT BRAKE PEDAL HEIGHT 1. T urn up the carpet, etc under the brake pedal. 2. Measure the brake pedal height as illustrated. If the brake pedal height is not within the standard value, follow the procedure below . Standard value: 162.8 - 165.8 m[...]

  • Page 7

    BASIC BRAKE SYSTEM - On-vehicle Service 35A-7 Standard value: 3 – 8 mm If the free play exceeds the standard value, it is probably due to excessive play between the retaining ring bolt and brake pedal arm. Check for excessive clearance and replace faulty parts as required. CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR BOARD 1. T urn back the carpet etc[...]

  • Page 8

    BASIC BRAKE SYSTEM - On-vehicle Service 35A-8 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 i s defective. 3. With the engine running, step on the brake pedal a nd then s[...]

  • Page 9

    BASIC BRAKE SYSTEM - On-vehicle Service 35A-9 PROPORTIONING V AL VE FUNCTION TEST 351001 10172 1. Connect two pressure gauges, one each to the input side and output side of the proportioning valve, as shown. 2. Bleed the air in the brake line and the pressure gauge. 3. While gradually depressing the brake pedal, make the following measurements and [...]

  • Page 10

    BASIC BRAKE SYSTEM - On-vehicle Service 35A-10 BLEEDING 35100140089 Caution Use the specified brake fluid. A void using a mixture of the specified brake fluid and other fluid. Specified brake fluid: DOT3 or DOT4 MASTER CYLINDER BLEEDING The master cylinder used has no check valve, so if bleeding is carried out by the following procedure, bleeding o[...]

  • Page 11

    BASIC BRAKE SYSTEM - On-vehicle Service 35A-1 1 1. Check brake pad thickness through caliper body check port. Standard value: 10 mm Limit: 2.0 mm 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. 2. If there is a significant difference in the thicknes[...]

  • Page 12

    BASIC BRAKE SYSTEM - On-vehicle Service 35A-12 DISC BRAKE ROTOR CHECK 35100290012 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 shoul[...]

  • Page 13

    BASIC BRAKE SYSTEM - On-vehicle Service 35A-13 RUN-OUT CHECK 35100250010 1. Remove the caliper support; then raise the caliper assembly upward and secure by using wire. 2. Inspect the disc surface for grooves, cracks and rust. Clean the disc thoroughly a nd remove all rust. 3. Place a dial gauge approximately 5 m m from the outer circumference of t[...]

  • Page 14

    BASIC BRAKE SYSTEM - On-vehicle Service 35A-14 BRAKE LINING THICKNESS CHECK 35100300166 1. Remove the brake drum. 2. Measure the wear of the brake lining at the place worn the most. Standard value: 4.4 mm Limit: 1.0 mm Replace the shoe and lining assembly if brake lining thickness is less than the limit or if it is n ot worn evenly . For informatio[...]

  • Page 15

    BASIC BRAKE SYSTEM - Brake Pedal 35A-15 BRAKE PEDAL 35100340243 REMOV AL AND INST ALLA TION Post-installation Operation Brake Pedal Adjustment (Refer to P .35A-6.) 11 5 2 1 9 8 4 7 9 10 3 6 29 Nm 14 Nm 12 Nm 13 Nm 8 Removal steps 1. Stop lamp switch connector 2. Stop lamp switch 3. Snap pin 4. Pin assembly 5. Brake pedal shaft bolt 6. Brake pedal 7[...]

  • Page 16

    BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster 35A-16 MASTER CYLINDER AND BRAKE BOOSTER 35100370242 REMOV AL AND INST ALLA TION Pre-removal Operation Brake Fluid Draining Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to P .35A-10.) D Brake Pedal Adjustment (Refer to P .35A-6.) Sealant: 3M A TD Part No.8661[...]

  • Page 17

    BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster 35A-17 Removal steps 1. Brake pipe connection 2. Brake fluid level sensor connector 3. Master cylinder assembly " B AD Push rod protruding length check and adjustment 4. V acuum hose <4D6> 5. V acuum pipe <4D6> " A A 6. V acuum hose (with built-in check valve) 7. Fitting 8[...]

  • Page 18

    BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster 35A-18 MASTER CYLINDER 35100420145 DISASSEMBL Y AND REASSEMBL Y 10 11 12 1 2 3 4 5 6 7 8 9 Brake fluid: DOT3 or DOT4 11 10 9 12 11 10 Master cylinder kit Disassembly steps 1. Reservoir cap assembly 2. Reservoir cap 3. Diaphragm 4. Brake fluid level indicator assembly 5. Float 6. Spring pin 7. R[...]

  • Page 19

    BASIC BRAKE SYSTEM - Disc Brake 35A-19 DISC BRAKE 35100800017 REMOV AL AND INST ALLA TION Pre-removal Operation Brake Fluid Draining Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to P .35A-10.) 29 Nm 90 - 1 10 Nm 1 2 3 4 55 - 65 Nm <Front> <Rear> 29 Nm 2 1 3 4 Removal steps 1. Brake hose connection 2. [...]

  • Page 20

    BASIC BRAKE SYSTEM - Disc Brake 35A-20 (2) Attach the special tool to the front hub assembly as shown in the illustration, and tighten it to the specified torque. T ightening torque: 19 6 - 25 5 Nm (3) Use a spring balance to measure the rotary-sliding resistance of the h ub in the forward direction. <Rear> Use a spring balance to measure the[...]

  • Page 21

    BASIC BRAKE SYSTEM - Disc Brake 35A-21 DISASSEMBL Y AND REASSEMBL Y 35100820013 10 11 12 13 14 1 2 3 4 5 6 7 8 9 74 Nm 8N m 74 Nm Brake caliper kit Pad repair kit Seal and boots repair kit 14 5 2 3 5 1 10 5 9 8 7 6 4 14 13 12 11 14 14 13 12 14 11 9 3 5 5 7 6 Grease Caliper assembly disassembly steps " A A 1. Guide pin " A A 2. Lock pin 3.[...]

  • Page 22

    BASIC BRAKE SYSTEM - Disc Brake 35A-22 LUBRICA TION POINTS Piston seal Grease: Repair kit grease Caution The piston seal inside the seal and boot kit is coated with special grease, so do not wipe this grease off. Brake fluid: DOT3 or DOT4 Grease: Repair kit grease Grease: Repair kit grease DISASSEMBL Y SERVICE POINTS When disassembling the disc bra[...]

  • Page 23

    BASIC BRAKE SYSTEM - Disc Brake 35A-23 A A " PIST ON BOOT/PIST ON REMOV AL Protect caliper body with cloth. Blow compressed air through brake hose to remove piston boot and piston. Caution Blow compressed air gently . A B " PIST ON SEAL REMOV AL 1. Remove piston seal with finger tip. Caution Do not use a flat-tipped screwdriver or other t[...]

  • Page 24

    BASIC BRAKE SYSTEM - Rear Drum Brake 35A-24 REAR DRUM BRAKE 35100750145 REMOV AL AND INST ALLA TION Pre-removal Operation D Loosening the Parking Brake Cable Adjusting Nut. D Brake Fluid Draining Post-installation Operation D Brake Line Bleeding (Refer to P .35A-10.) D Parking Brake Lever Stroke Adjustment (Refer to GROUP 36 – On-vehicle Service.[...]

  • Page 25

    BASIC BRAKE SYSTEM - Rear Drum Brake 35A-25 REMOV AL SERVICE POINT A A " RET AINER REMOV AL Use a flat-tipped screwdriver or the like to open up the retainer joint, and remove retainer . INST ALLA TION SERVICE POINTS " A A W A V E W ASHER INST ALLA TION Install the washer in the direction shown in the illustration. " B A RET AINER IN[...]

  • Page 26

    BASIC BRAKE SYSTEM - Rear Drum Brake 35A-26 WHEEL CYLINDER 35100930082 REMOV AL AND INST ALLA TION Pre-removal Operation Brake Fluid draining Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to P .35A-10.) 1 2 3 4 5 6 7 15 Nm 10 Nm 8N m Removal steps 1. Brake drum 2. Shoe-to-lever spring 3. Shoe-to-shoe spring 4. Aut[...]

  • Page 27

    BASIC BRAKE SYSTEM - Rear Drum Brake 35A-27 DISASSEMBL Y AND REASSEMBL Y 35100770097 1 2 3 4 5 6 Grease: Repair kit grease Brake fluid: DOT3 or DOT4 Wheel cylinder repair kit 3 6 1 2 3 34 4 6 1 4 Grease Disassembly steps 1. Boots 2. Piston assembly " A A 3. Pistons " A A 4. Piston cups 5. Spring 6. Wheel cylinder body REASSEMBL Y SERVICE [...]

  • Page 28

    BASIC BRAKE SYSTEM - Rear Drum Brake/Proportioning V alve 35A-28 INSPECTION 35100780038 Check the piston an d wheel cylinder walls for rust or damage, and if there is any abnormality , replace the entire wheel cylinder assembly . PROPORTIONING V AL VE 35100570154 REMOV AL AND INST ALLA TION Pre-removal Operation Brake Fluid Draining Post-installati[...]

  • Page 29

    35B-1 ANTI-SKID BRAKING SYSTEM (ABS) <2WD> CONTENTS 35209000206 GENERAL INFORMA TION 3 .................. SERVICE SPECIFICA TIONS 5 ................. LUBRICANTS 5 .............................. SPECIAL T OOLS 5 .......................... TROUBLESHOOTING 6 ....................... ON-VEHICLE SERVICE 19 ................... Brake Pedal Check and [...]

  • Page 30

    35B-2 BRAKE PEDAL Refer to GROUP 35A ........ MASTER CYLINDER AND BRAKE BOOSTER 24 .............................. Master Cylinder 24 ............................. DISC BRAKE Refer to GROUP 35A .......... REAR DRUM BRAKE Refer to GROUP 35A ........................ Wheel Cylinder Refer to GROUP 35A ........... PROPORTIONING V AL VE 25 ...............[...]

  • Page 31

    ABS <2WD> - General Information 35B-3 GENERAL INFORMA TION 35200010222 The ABS consists of components such as the wheel speed sensors, stop lamp switch, hydraulic unit assembly , ABS control unit (ABS-ECU) and t he ABS warning lamp. If a problem occurs in the system, the malfunctioning components can be identified and t he trouble symptoms wi[...]

  • Page 32

    ABS <2WD> - General Information 35B-4 CONSTRUCTION DIAGRAM <L.H. drive vehicles> <R.H. drive vehicles> 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1. ABS relay 2. ABS warning lamp 3. Stop lamp switch 4. ABS rotor 5. Wheel-speed sensor 6. ABS-ECU 7. Diagnosis connector 8. Hydraulic unit[...]

  • Page 33

    ABS <2WD> - Service Specifications/Lubricants/Special T ools 35B-5 SERVICE SPECIFICA TIONS 35200030242 Items Standard value Wheel speed sensor internal resistance k W 1.0 - 1.5 Clearance between the wheel speed sensor mounting surface and the ABS toothed rotor mm 28.2 - 28.5 Wheel speed sensor insulation resistance k W 100 or more LUBRICANTS [...]

  • Page 34

    ABS <2WD> - T roubleshooting 35B-6 TROUBLESHOOTING 35201 1 10129 ST ANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 - How to Use T roubleshooting/Inspection Service Points. NOTES WITH REGARD TO DIAGNOSIS The phenomena listed in the following table are not abnormal. Phenomenon Explanation of phenomenon System check sound When start[...]

  • Page 35

    ABS <2WD> - T roubleshooting 35B-7 With the ABS W arning Lamp 1. Use the special tool to earth terminal (1) (diagnosis control terminal) of the diagnosis connector . (Refer to GROUP 00 - How to Use T roubleshooting/Inspection Service Points.) 2. Stop the engine. 3. T urn on the stop lamp switch. (Depress the brake.) 4. After carrying out step[...]

  • Page 36

    ABS <2WD> - T roubleshooting 35B-8 INSPECTION CHART FOR DIAGNOSIS CODES 35201 130323 Inspect according to the inspection chart that is appropriate for the malfunction code. Diagnosis code No. Inspection item Diagnosis content Reference page 11 Front right wheel speed sensor Open circuit 35B-9 12 Front left wheel speed sensor 13 Rear right whe[...]

  • Page 37

    ABS <2WD> - T roubleshooting 35B-9 INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code Nos.1 1, 12, 1 3 and 14 Wheel speed sensor (open circuit or short circuit) Probable cause Code Nos.21, 22, 23 and 24 Wheel speed sensor Code Nos 1 1, 12, 13 and 14 are output if the ABS-ECU detects an open circuit or short-circuit in the (+) wire or ( - ) wire in[...]

  • Page 38

    ABS <2WD> - T roubleshooting 35B-10 Code No.15 Wheel speed sensor (abnormal output signal) Probable cause This code is output when there i s an abnormality in the output signal from any one of the four wheel speed sensors while driving (except for an open circuit or short circuit). D The four vehicle tires are of different sizes D Improper in[...]

  • Page 39

    ABS <2WD> - T roubleshooting 35B-1 1 Code No.33 Stop lamp switch system (open circuit or stop lamp stays ON) Probable cause This code is output in the following cases. D If the stop lamp switch is continuously on for 15 minutes or more even though the ABS system is not operating. D If there is an open circuit in the stop lamp switch input cir[...]

  • Page 40

    ABS <2WD> - T roubleshooting 35B-12 INSPECTION CHART FOR TROUBLE SYMPTOMS 35201 140289 Get an understanding of the trouble symptoms an d check according to the inspection procedure chart. T rouble symptoms Inspection procedure No. Reference page Communication between the MUT - II and the whole system is not possible. 1 35B-12 Communication be[...]

  • Page 41

    ABS <2WD> - T roubleshooting 35B-13 Inspection Procedure 2 Communication between MUT - II and the ABS-ECU is not possible. Probable cause The cause may be an open circuit in the ABS-ECU power supply circuit or an open circuit in the diagnosis output circuit. D Blown fuse D Malfunction of wiring harness or connector D Malfunction of hydraulic [...]

  • Page 42

    ABS <2WD> - T roubleshooting 35B-14 Inspection Procedure 3 When the ignition key is turned to “ON” (engine stopped), the ABS warning lamp does not illuminate. Probable cause The cause may be an open circuit in the lamp power supply circuit, a blown lamp, a malfunction of the ABS warning lamp relay or an open circuit between the ABS warnin[...]

  • Page 43

    ABS <2WD> - T roubleshooting 35B-15 Inspection Procedure 4 Even after the engine is started, the ABS warning lamp remains illuminated. Probable cause The cause is probably a short-circuit in the ABS warning lamp illumination circuit. D Malfunction of combination meter D Malfunction of ABS warning lamp relay D Malfunction of wiring harness (sh[...]

  • Page 44

    ABS <2WD> - T roubleshooting 35B-16 Inspection Procedure 5 Faulty ABS operation Probable cause This varies depending 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. D Improper installation of wheel speed sensor [...]

  • Page 45

    ABS <2WD> - T roubleshooting 35B-17 DA T A LIST REFERENCE T ABLE 35201 150206 The following items can be read by the MUT - II from the ABS-ECU input data. 1. When the system is normal Item No. Check item Checking requirements Normal value 11 Front-right wheel speed sensor Perform a test run V ehicle speeds 12 Front-left wheel speed sensor dis[...]

  • Page 46

    ABS <2WD> - T roubleshooting 35B-18 CHECK A T ABS-ECU 35201 180229 TERMINAL VOL T AGE CHECK CHART 1. Measure the voltage between each terminal and earth. 2. The terminal layout is shown in the illustration below . T erminal No. Check item Checking requirements Normal condition 4 ABS-ECU power sup- Ignition switch: ON Battery voltage ply Ignit[...]

  • Page 47

    ABS <2WD> - T roubleshooting/On-vehicle Service 35B-19 T erminal No. Normal condition Signal 23 - 22 Wheel speed sensor (rear right) 1.0 - 1.5 k W 8 - Body earth Solenoid valve earth Continuity 24 - Body earth Motor earth ON-VEHICLE SERVICE 35200160224 WHEEL SPEED SENSOR OUTPUT VOL T AGE CHECK 1. Lift up the vehicle an d release the parking b[...]

  • Page 48

    ABS <2WD> - On-vehicle Service 35B-20 Inspecting W aveforms With An Oscilloscope Use the following method to observe the output voltage waveform from each wheel sensor with an oscilloscope. D Start the engine, and rotate the front wheels by engaging 1st gear (vehicles with manual transmission) or D range (vehicles with automatic transmission)[...]

  • Page 49

    ABS <2WD> - On-vehicle Service 35B-21 ABS W ARNING LAMP RELA Y CONTINUITY CHECK 35200930023 Battery voltage T erminal No. 1 2 3 5 Power is not sup- plied Power is supplied <L.H. drive vehicles> <R.H. drive vehicles>[...]

  • Page 50

    ABS <2WD> - On-vehicle Service 35B-22 HYDRAULIC UNIT CHECK 35200170227 Caution T urn the ignition switch off before connecting or disconnecting the MUT - II . 1. Jack up th e vehicle a nd support th e vehicle with rigid racks placed at th e specified jack-up points or place the wheels which are checked on the rollers of the braking force test[...]

  • Page 51

    ABS <2WD> - On-vehicle Service 35B-23 Diagnosis T able No. Operation Judgement - Normal Judgement - Abnormal Probable cause Remedy 01 (1) Depress brake pedal to lock wheel. (2) Using the MU T - II , Brake force released for 3 seconds after Wheel does not lock when brake pedal is de- Clogged brake line other than hydraulic unit Check and clean[...]

  • Page 52

    ABS <2WD> - Master Cylinder and Brake Booster 35B-24 MASTER CYLINDER AND BRAKE BOOSTER 35200400142 REMOV AL AND INST ALLA TION Refer to GROUP 35A. MASTER CYLINDER 35200450147 DISASSEMBL Y AND REASSEMBL Y 14 13 12 1 4 2 3 6 8 9 5 7 10 12 13 14 11 Master cylinder kit Brake fluid: DOT3 or DOT4 12 13 11 10 9 Disassembly steps 1. Reservoir cap ass[...]

  • Page 53

    ABS <2WD> - Proportioning V alve 35B-25 PROPORTIONING V AL VE 35200570126 REMOV AL AND INST ALLA TION Pre-removal Operation Brake Fluid Draining Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to GROUP 35A - On-vehicle Service.) Flared brake line nuts 1 2 15 Nm 1 Removal steps " A A 1. Brake pipe 2. Propo[...]

  • Page 54

    ABS <2WD> - Hydraulic Unit 35B-26 HYDRAULIC UNIT 35200860261 REMOV AL AND INST ALLA TION Pre-removal Operation Brake Fluid Draining Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to GROUP 35A - On-vehicle Service.) D Brake Pedal Adjustment (Refer to GROUP 35A - On-vehicle Service.) 15 Nm 2 2 3 1 4 2 1 3 4 <[...]

  • Page 55

    ABS <2WD> - Hydraulic Unit 35B-27 REMOV AL SERVICE POINT A A " HARNESS CONNECT OR REMOV AL Raise the locking lever as shown in the illustration, and then disconnect the harness connector . A B " HYDRAULIC UNIT ASSEMBL Y REMOV AL Caution 1. The hydraulic unit assembly is heavy , and so care should be taken when removing it. 2. The hy[...]

  • Page 56

    ABS <2WD> - Wheel Speed Sensor 35B-28 WHEEL SPEED SENSOR 35200830279 REMOV AL AND INST ALLA TION Post-installation Operation Wheel Speed Sensor Output V oltage Check (Refer to P .35B-19.) <Front> <Rear> 1 2 4 3 Front speed sensor removal steps D Splash Shield Removal (Refer to GROUP 42 - Fender . ) A A "" A A 1. Front sp[...]

  • Page 57

    ABS <2WD> - Wheel Speed Sensor 35B-29 INST ALLA TION SERVICE POINT " A A FRONT SPEED SENSOR/REAR SPEED SENSOR INST ALLA TION The clearance between the wheel speed sensor and the ABS rotor ’s toothed surface is not adjustable, but measure the distance between the sensor installation surface and the ABS rotor ’s toothed surface. Standa[...]

  • Page 58

    ABS <2WD> - Wheel Speed Sensor 35B-30 SPEED SENSOR INSULA TION INSPECTION 1. Remove all connections from the speed sensor , and then measure the resistance between terminals 1 a nd 2 and the body of the speed sensor . Standard value: 100 k W or more 2. If the speed sensor insulation resistance is outside the standard value range, replace with[...]