8/11/2019 manual pajero 4x4 service brakes.docx
1/70
35A-1
SERVICE
BRAKESCONTENTS 35109000487
BASICBRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A
ANTI-SKIDBRAKING SYSTEM(ABS) . . . . . . . . . . . . . . . . . . . . . . 35B
8/11/2019 manual pajero 4x4 service brakes.docx
2/70
35A-2
BASIC
BRAKE
SYSTEM
CONTENTS 35109000494
GENERAL
INFORMATION . . . . . . . . . . . . . . . . . .
3 Load
Sensing
Proportioning
Valve
FunctionTest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . .5 Disc Brake Pad Check and Replacement . . . . . 15
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Disc Brake Rotor Check . . . . . . . . . . . . . . . . . . . . . 17
Thickness
check . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Brake Lining Thickness C h e c k . . . . . . . . . . . . . . . 20
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Brake Disk Inside Diameter C h e c k . . . . . . . . . . . 21
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . .7
Brake Lining and Brake Disc ConnectionCheck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ON-VEHICLE
SERVICE . . . . . . . . . . . . . . . . . . . . .
9 BRAKE
PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . .
22Brake Pedal Check andAdjustment . . . . . . . . . . . 9 MASTER CYLINDERAND BRAKEStop Lamp Switch Check . . . . . . . . . . . . . . . . . . . . 11 BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake Booster Operating Test . . . . . . . . . . . . . . . . 11
Check Valve Operation Check. . . . . . . . . . . . . . . . 12
Brake Booster Vacuum Switch Check
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
LOAD SENSING PROPORTIONINGVALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 FRONT DISC BRAKE . . . . . . . . . . . . . . . . . . . . 27
Brake Fluid Level Sensor Check . . . . . . . . . . . . . 14REAR DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . 33
Load Sensing Spring Length Check and
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
8/11/2019 manual pajero 4x4 service brakes.docx
3/70
BASIC BRAKE SYSTEM General Information 35A-3
GENERAL INFORMATION 35100010304
Thebrakesystemhashighreliabilityanddurabilitywhichmaintainsexcellentbrakingperformanceandbraking feeling.Themain featuresareasfollows. A dual type mastercylinder isequipped inall
models. A tandem type brake booster has been
adopted.
Thefollowingtypeofbrakehavebeenadopted.Front:Floatingcaliper,2-piston,ventilateddiscbrakes (V5-W43, V6-W43)Rear: Floating caliper, 1-piston, solid discbrakes (S5-S43P)
Items 6G7 4D5
4D5
MastercylinderI.D.mm 23.8
Brake
booster
effective
dia.
of
power
cylinder
mm
205
+
230
180
+
205
Brakeboosterboostingratio 5.0 6.0 5.0
Frontbrakedisceffectivedia.mm 265 227 265
Front
brake
wheel
cylinder
I.D.
mm
42.86
Rearbrakedisceffectivedia.mm 272
RearbrakewheelcylinderI.D.mm 42.85
8/11/2019 manual pajero 4x4 service brakes.docx
4/70
35A-4 BASIC BRAKE SYSTEM General Information
CONFIGURATION DIAGRAM
Brake booster
Loadsensingproportioning valve
Mastercylinder
Rearbrake
Frontbrake
Load sensingproportioning valve
Brake booster
Master
cylinder
Rearbrake
Frontbrake
8/11/2019 manual pajero 4x4 service brakes.docx
5/70
BASIC BRAKE SYSTEM Service Specifications 35A-5
SERVICE SPECIFICATIONS 35100030386
Items Standardvalue Limit
Brakepedalheightmm 176181
Brakepedalfreeplaymm 38
Brakepedaltofloorboardclearancemm 95ormore
Loadsensingspringlengthmm 164168
LoadsensingproportioningvalveoutputpressurekPa(InputpressurekPa)
When load sensingspring length is 144mm(whenunladen)
3,633(5,884)
5,610(13,730)
When load sensingspring length is 208mm(whenladen)
11,160(13,730)
Disc
brake
pad
thickness
mm
10
2.0
Brakediscrun-outmm Front 0.06
Rear 0.08
Fronthubendplaymm 0.05
Rearaxleshaftendplaymm 00.25
Brakediscthicknessmm Front 24 22.4
Rear 18 16.4
Brakeliningthicknessmm 4.5
Brakedruminsidediametermm 197.0 198.0
Booster
push
rod
to
master
cylinder
piston
clearance
mmVehicle
which
brake
booster of powercylinder is 180 mmand 205 mm ineffectivediameter
0.90
1.30
Vehiclewhichbrakebooster of powercylinder is 205 mmand 230 mm ineffectivediameter
0.701.10
Discbrakedragforce(tangentialforceofwheelmountingbolts)N
Front 106orless
Rear
56
or
less
8/11/2019 manual pajero 4x4 service brakes.docx
6/70
35A-6 BASIC BRAKE SYSTEM Lubricants/Sealant/Special Tool
LUBRICANTS 35100040174
Items Specifiedlubricant
Brake
fluid
DOT3
or
DOT4
Brakepistonseal Repairkitgrease
Guide
pin
boot
inner
surface
Lockpinbootinnersurface
Pistonbootmountinggrooves
Sleeveinnersurface
Bushinginnersurface
Pinbootinnersurface
SEALANT 35100050214
Item
Specified
sealant
Remark
Vacuumswitch 3MATDPartNo.8661orequivalent Semi-dryingsealant
Fitting
SPECIAL TOOL 35100060194
Tool Number Name Use
A
B
MB990964
A:MB990520
B:
MB990623
Braketoolset Pushing-inofthediscbrakepiston
Installationofdrumbrakewheelcylinderpistoncup
8/11/2019 manual pajero 4x4 service brakes.docx
7/70
BASIC BRAKE SYSTEM Troubleshooting 35A-7
TROUBLESHOOTING 35100070128
Symptom Probablecause Remedy
Vehicle pulls to one sidewhenbrakesareapplied
Greaseoroilonpadorliningsurface Replace
Inadequatecontactofpadorlining Correct
Insufficientbrakingpower Lowordeterioratedbrakefluid Refillorchange
Airinbrakesystem Bleedair
Overheatedbrakerotorduetodraggingofpadorlining
Correct
Inadequatecontactofpad
Brakeboostermalfunction
Cloggedbrakeline
Greaseoroilonpadsurface Replace
Load
sensing
proportioning
valve
malfunction
Increasedpedalstroke(Reduced pedal to floorboardclearance)
Airinbrakesystem Bleedair
Wornpad Replace
Brokenvacuumhose
Faultymastercylinder
Brakefluidleaks Correct
Excessive push rod to master cylinderclearance
Adjust
Brake
drag
Incomplete
release
of
parking
brake
Correct
Cloggedmastercylinderreturnport
Incorrectparkingbrakeadjustment Adjust
Improper push rod to master cylinderclearance
Faultymastercylinderpistonreturnspring Replace
Wornbrakepedalreturnspring
Lackoflubricationinslidingparts Lubricate
8/11/2019 manual pajero 4x4 service brakes.docx
8/70
35A-8 BASIC BRAKE SYSTEM Troubleshooting
Symptom Probablecause Remedy
Insufficientparkingbrakefunction Wornbrakeliningorpad Replace
Greaseoroilonliningorpadsurface
Parkingbrakecablesticking
Stuckwheelcylinderorcaliperpiston
Excessiveparkingbrakeleverstroke Adjusttheparkingbrakeleverstrokeorchecktheparkingbrakecablerouting
Autoadjustermalfunction Adjust
Scrapingorgrindingnoisewhenbrakesareapplied
Wornbrakepad Replace
Calipertowheelinterference Correctorreplace
Dustcovertodiscinterference
Bentbrakebackingplate
Cracked
brake
disc
Squealing,groaningorchatteringnoisewhenbrakesareapplied
Missing or damaged brake pad anti-squeakshim
Replace
Brakediscsandpadswornorscored Correctorreplace
Burredorrustedcalipers Correctordeburr
Dirty,greased,contaminatedorglazedpad
Cleanorreplace
Incorrectbrakepedalorboosterpushrod Adjust
Squealingnoisewhen
brakes
are
notapplied
Bent or warped backing plate causinginterference
with
drum
Replace
Poor return of brake booster, mastercylinder
Looseorextrapartsinbrakes Retighten
Improperpositioningofpadsincaliper Correct
Improper installationofsupportmount-ingtocaliperbody
Worn, damaged or insufficiently lubri-catedwheelbearings
Lubricateorreplace
Incorrect brake pedal or booster pushrod
Adjust
8/11/2019 manual pajero 4x4 service brakes.docx
9/70
BASIC BRAKE SYSTEM Troubleshooting/On-vehicle Service 35A-9
Symptom Probablecause Remedy
Groaning,clickingorrattlingnoisewhenbrakesarenotapplied
Loosewheelnuts Retighten
Looseinstallationbolts
Worn,damagedordrywheelbearings Lubricateorreplace
Failureofshim Replace
Wearonsleeve
Incorrectbrakepedalorboosterpushrod Adjust
Operatingrod
Operatingrod locknut
Pedaldown
Pedalup
Locknut
Stoplampswitch
Stop lampswitch locknut
Outercase
Locknut
ON-VEHICLE SERVICE 35100090292
BRAKE PEDAL CHECKANDADJUSTMENT
BRAKE PEDAL HEIGHT
1. Turn back the carpet etc. under the brake pedal.2. Measure thebrakepedalheightas illustrated. If it isnot
within the standard value, adjust as follows.
Standard value: 176 181 mm (From the surface of
melting
seat
to
the
face
of
pedal
pad)
(1) Disconnect the stop lamp switch connector, loosenthe lock nut, and move the stop lamp switch to aposition where it does not contact the brake pedalarm.
(2) Adjustthebrakepedalheightbyturningtheoperatingrod with pliers (with the operating rod lock nutloosened).
(3) Screw in the stop lamp switch until it contacts thebrakepedalstopper(justbeforebrakepedaliscausedto move), return the stop lamp switch 1/2 to 1 turn
and
secure
with
the
lock
nut.
(4) Connect the connector of the stop lamp switch.(5) Checktobesurethatthestop lamp isnotilluminated
with the brake pedal released.3. Return the carpet etc.
1.0mm
8/11/2019 manual pajero 4x4 service brakes.docx
10/70
35A-10 BASIC BRAKE SYSTEM On-vehicle Service
BRAKE PEDAL FREE PLAY
With the engine stopped, depress the brake pedal two orthreetimes.Aftereliminatingthevacuuminthebrakebooster,press thepedaldownbyhand,andconfirm that theamountof movement before resistance is met (free play) is withinthe standard value range.
Standard value: 3 8 mm
If
the
free
play
exceeds
the
standard
value,
it
is
probablyduetoexcessiveplaybetweentheclevispinandbrakepedal
arm.Check for excessive clearance and replace faulty parts asrequired.
CREARANCE BETWEEN BRAKE PEDALAND FLOORBOARD
1. Turn back the carpet etc. under the brake pedal.2. Start the engine, depress the brake pedal with
approximately490Nofforce,andmeasuretheclearancebetween the brake pedal and the floorboard.
Standard value:95mm or more (From the surface of meltingseatto the face of pedal pad)
3. If theclearance isoutside thestandardvalue,checkforairtrappedinthebrakeline,clearancebetweentheliningand the drum and dragging in the parking brake.
Adjust and replace defective parts as required.4. Return the carpet etc.
8/11/2019 manual pajero 4x4 service brakes.docx
11/70
BASIC BRAKE SYSTEM On-vehicle Service 35A-11
Nocontinuity
Continuity
Plunger
a
b
STOP LAMP SWITCH CHECK 35100890168
Connect a circuit tester to the stop lamp switch, and checkwhether or not there is continuity when the plunger of thestop lamp switch is pushed in and when it is released. Thestop lampswitch is ingoodcondition if there isnocontinuitywhen the plunger is pushed in to a depth of within 4 mmfrom the outer case edge surface, and if there is continuitywhen it is released.For
vehicles
with
auto-cruise
control
system,
check
the
continuitybetween the terminals aand bofthestop lampswitch.
Good No goodBRAKE BOOSTER OPERATING TEST 35100100162
For simple checking of the brake booster operation, carryout 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 graduallybecomes higher when depressed succeeding times, thebooster isoperatingproperly, if thepedalheight remains
unchanged,
the
booster
is
defective.
When engine isstopped
When engine isstarted
2. Withtheenginestopped,steponthebrakepedalseveraltimes.Then step on the brake pedal and start the engine.If the pedal moves downward slightly, the booster is ingood condition. If there is no change, the booster isdefective.
No good Good3. With the engine running, step on the brake pedal and
then stop the engine.Hold the pedal depressed for 30 seconds. If the pedalheightdoesnotchange,theboosterisingoodcondition,if the pedal rises, the booster is defective.Iftheabovethreetestsareokay,theboosterperformancecan be determined as good.If one of the above three tests is not okay at last, thecheck valve,vacuum hose,or boosterwill bedefective.
8/11/2019 manual pajero 4x4 service brakes.docx
12/70
Vacuumpumpconnection Accept/rejectcriteria
Connectionatthebrakeboosterside(A)
Anegativepressure(vacuum)iscreatedandheld.
Connection at the intakemanifoldside(B)
Anegativepressure(vacuum)isnotcreated.
35A-12 BASIC BRAKE SYSTEM On-vehicle Service
CHECK VALVE OPERATION CHECK 35100900243
1. Remove the vacuum hose. (Refer to P.35A-23.)
CautionThe check valve should not be removed from thevacuum hose.
Boosterside
Valve Spring
A B
Intakemanifoldside
2. Checktheoperationofthecheckvalvebyusingavacuumpump.
Body
earth
CautionIf the check valve is defective, replace it as anassembly unit together with the vacuum hose.
BRAKE BOOSTER VACUUM SWITCH CHECK 35100920041
1. Connect an ohmmeter to the connector of the vacuumswitch.
2. Starttheengineandcheckforcontinuitywhenthevacuumhose is connected, and when it is disconnected.The vacuum switch is in good condition if there is nocontinuity when the vacuum hose is connected, and ifthere is continuity when it is disconnected.
8/11/2019 manual pajero 4x4 service brakes.docx
13/70
BASIC BRAKE SYSTEM On-vehicle Service 35A-13
BLEEDING 35100140201
CautionUse the specified brake fluid. Avoid using a mixtureofthe specified brake fluid and other fluid.
Specified brake fluid: DOT3 or DOT4
MASTER CYLINDER BLEEDING
Themastercylinderusedhasnocheckvalve,so ifbleedingiscarriedoutbythefollowingprocedure,bleedingofairfromthe brake pipeline will become easier. (When brake fluid isnot contained in the master cylinder.)1. Fill the reserve tank with brake fluid.2. Keep the brake pedal depressed.3. Have another person cover the master cylinder outlet
with
a
finger.4. With
the
outlet
still
closed,
release
the
brake
pedal.5. Repeat steps 2 4 three or four times to fill the inside
of the master cylinder with brake fluid.
Vehicles
withoutABS BRAKE PIPE LINE BLEEDING
Start the engine and bleed the air in the sequence shownin the figure.
Load sensingproportioningvalve
Vehicles with ABS
Load sensingproportioningvalve
8/11/2019 manual pajero 4x4 service brakes.docx
14/70
Load sensingproportioningvalve
ressure au es
35A-14 BASIC BRAKE SYSTEM On-vehicle Service
BRAKE FLUID LEVEL SENSOR CHECK35100910086
The brake fluid level sensor is in good condition if there isnocontinuitywhen the floatsurface isabove Aand ifthereis continuity when the float surface is below A.
A
LOAD SENSING SPRING LENGTH CHECKANDADJUSTMENT 35100120045
1. Park the vehicle on a level ground. The vehicle shouldbe unloaded and supported only by wheels.
CautionNever supportthe vehicle withjacks or other similarmeans.
Lever
Stopperbolt
A
2. While the lever of the load sensing proportioning valveis touching the stopper bolt, install the spring supportso that the distance (A) is at the standard value.
Standard value (A): 164 168 mm
3. Ifthespringlengthisnotwithinthestandardvalue,loosenthe bolt attaching the spring support and adjust thedistance by moving the spring support.
Spring
support
LOAD SENSING PROPORTIONINGVALVEFUNCTION TEST 35100130055
1. Connect pressure gauges to the inputand output portsof the load sensing proportioning valve.
2. Bleed the system. (Refer to P.35-13.)
Stopper bolt
10mm
H
Stopper boltcontactposition
3. Disconnect the spring at the support side.4. Place the spring so that it is in parallel with the load
sensing proportioning valve, and pull in the directionindicatedby thearrowso that its lengthHshown in thefigure (the length between its ends) is as noted below.
NOTEAt this time the lever ispressed all the way to the loadsensing proportioning valve.
8/11/2019 manual pajero 4x4 service brakes.docx
15/70
BASIC BRAKE SYSTEM On-vehicle Service 35A-15
Standard value:
SpringlengthHmm
InputfluidpressurekPa
OutputfluidpressurekPa
144*1 5,884 3,633
13,730 5,610
208*2 13,730 11,160
NOTE*1 and*2 indicatetheapplicable lengthsforunladenandladen vehicles respectively.
5. After making the check, install the spring. Disconnectthepressuregaugesfrom the loadsensingproportioningvalve and bleed the air. (Refer to P.35A-13.)
Pad
When new When worn
Brake
DISC BRAKE PAD CHECKANDREPLACEMENT 35100150242
NOTEThe brake pads have indicators that contact the brakediscwhen the brake pad thickness becomes 2 mm, and emita squealing sound to warn the driver.
Wear indicatordisc
1. Check thebrakepad thickness throughthecaliperbodycheck port.
Standard value: 10 mmLimit: 2.0 mm
Caution(1) When the limit is exceeded, replace the pads at
both sides, andalso thebrake pads for thewheelson the opposite side at the same time.
(2) If
there
is
a
significant
difference
in
the
thicknessesof thepads on the leftand right sides,check the sliding condition of the piston, lockpin and guide pin.
8/11/2019 manual pajero 4x4 service brakes.docx
16/70
35A-16 BASIC BRAKE SYSTEM On-vehicle Service
2. Removethe lockpin.Liftthecaliperassemblyandretainwith wire.
CautionDo not wipe the special grease from the lock pin.Do not contaminate the lock pin.
3
2
4 1
3
Padpin
3. Remove the following parts from caliper support.(1) Pad and wear indicator assembly(2) Pad assembly(3) Clip(4) Outer shim
4. Measurethehubtorquewiththepadremovedtomeasurethe brake drag force after pad installation. (Refer toP.35A-28.)
5. Installthepadandcaliperassembly,andcheckthebrake
drag
force.
(Refer
to
P.35A-28.)
1. Check thebrake pad thickness through the caliperbodycheck port.
Standard Value: 10 mmLimit: 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
thicknessesofthepadsonthe leftandright sides,check the slidingconditionof the pistonand padpin.
2. Remove the clip and pad pin.
8/11/2019 manual pajero 4x4 service brakes.docx
17/70
BASIC BRAKE SYSTEM On-vehicle Service 35A-17
3. Removethepadandshimwitha flat-tippedscrewdriver.(1) Pad and wear indicator assembly(2) Pad assembly(3) Inner shim(4) Outer shim
4. Measurethehubtorquewiththepadsremovedtomeasurethe brake drag force. (Refer to P.35A-33.)
5. Installthepadandcaliperassembly,andcheckthebrake
drag
force.
(Refer
to
P.35A-33.)
3 12
4
DISC BRAKE ROTOR CHECK 35100270092
CAUTIONWhen servicing disc brakes, it is necessary to exercise caution to keep the disc brakes withinthe allowable service values in order to maintain normal brake operation.
Before re-finishing or re-processing the brake disc surface, the following conditionsshould be checked.
Inspectionitems Remarks
Scratches,rust,saturatedliningmaterials
and
wear
If the vehicle is not driven for a certain period, the sections of
the
discs
that
are
not
in
contact
with
lining
will
become
rusty,
causingnoise and shuddering.
If grooves resulting from excessive disc wear and scratches arenot removed prior to installing a new pad assembly, there willmomentarily be inappropriate contact between the disc and thelining (pad).
Run-outordrift Excessiverun-outordriftofthediscswillincreasethepedaldepressionresistanceduetopistonknock-back.
Changeinthickness(parallelism) If the thickness of the disc changes, this will cause pedal pulsation,shudderingandsurging.
Insetorwarping(flatness) Overheatingand improperhandlingwhileservicing willcause insetorwarping.
8/11/2019 manual pajero 4x4 service brakes.docx
18/70
35A-18 BASIC BRAKE SYSTEM On-vehicle Service
FRONT DISC BRAKE RUN-OUT CHECKANDCORRECTION 35100940078
1. Remove the caliper support; then raise the caliperassembly upward and secure by using wire.
2. Inspect the disc surface for grooves, cracks and rust.Clean the disc thoroughly and remove all rust.
3. Place a dial gauge approximately 5 mm from the outercircumferenceofthebrakedisc,andmeasuretherun-out
of
the
disc.
Limit: 0.06 mm
Chalkmark4. Iftherun-outofthebrakediscisequivalenttoorexceeds
the limitspecification, change the phase of the discandhub, and then measure the run-out again.(1) Before removing the brake disc, chalk both sides
of the wheel stud on the side at which run-out isgreatest.
(2) Place a dial gauge as show in the illustration, andthenmovethehub intheaxialdirectionandmeasurethe play.
Standard value: 0.05 mm
Iftheplay isequaltoorexceedsthestandardvalue,adjust the wheel bearing preload. (Refer to GROUP26 Front HubAssembly.)
(3) If the play does not exceed the standard valuespecification, install thebrakediscataposition180awayfromthechalkmark,andthenchecktherun-outof the brake disc one again.
5. Iftherun-outcannotbecorrectedbychangingthephaseof the brake disc, replace the disc or turn rotor with onthe car type brake lathe (MAD, DL-8700PF orequivalent).
8/11/2019 manual pajero 4x4 service brakes.docx
19/70
BASIC BRAKE SYSTEM On-vehicle Service 35A-19
REAR DISC BRAKE RUN-OUT CHECKANDCORRECTION 35100210100
1. Remove the caliper support; then raise the caliperassembly upward and secure with a wire.
2. Checkthediscsurfaceforgrooves,cracksandrust.Cleanthe disc thoroughly and remove all rust.
3. Place a dial gauge approximately 5 mm from the outercircumferenceofthebrakedisc,andmeasuretherun-out
of
the
disc.
Limit: 0.08 mm
4. If the runoutof the brake disc is the limit valueormore,changethephaseofthediscandhub,andthenmeasurethe run-out again.(1) Beforeremovingthebrakedisc,placeamatingmark
on both the wheel stud and disc with chalk on thepoint at which the run-out is greatest.
(2) Place a dial gauge as shown in the illustration, andthenmovethehub intheaxialdirectionandmeasurethe play.
Standard
value:
0
0.25
mm
(3) Iftheplaydoesnotexceed thestandardvalue installthe brake discata different phase,and then checkthe run-out of the brake disc again.
5. If therun-outcannotbecorrectedbychangingthephaseof the brake disc, replace the disc.
8/11/2019 manual pajero 4x4 service brakes.docx
20/70
35A-20 BASIC BRAKE SYSTEM On-vehicle Service
THICKNESS CHECK 35100160221
1. Using a micrometer, measure disc thickness at eightpositions, approximately 45 apart and 10 mm in fromthe outer edge of the disc.
Brake disc thicknessStandard value: 24 mm
Limit:
22.4
mm
Thickness variation (at least 8 positions)The difference between any thickness measurementsshould not be more than 0.015 mm.
2. If the disc is beyond the limits for thickness, remove itand installanewone.If thicknessvariationexceedsthespecification, replace the brake disc or turn rotor withon the car type brake lathe (MAD, DL-8700PF orequivalent).
1. Remove dirt and rust from the brake disc surface.2. Measure the disc thickness at four locations or more.
Standard value: 18 mmLimit: 16.4 mm
Replace the discs and pad assembly for both left andright sides of the vehicle if they are worn beyond thespecified limit.
BRAKE LINING THICKNESS CHECK 35100300272
1. Remove the rear brake assembly, raise the rear brakeassembly and secure it by using a wire, etc.
2. Remove the brake disc.3. Measure the wear of the brake lining at the place worn
the most.
Limit: 4.5 mm
4. Replace the shoe and lining assembly if brake liningthickness is less than the limit if it is not worn evenly.
Caution
Whenever the shoe and lining assembly is replaced,replace bothR.H. andL.H. assembliesas a set topreventcar from pulling to one side when braking.
8/11/2019 manual pajero 4x4 service brakes.docx
21/70
BASIC BRAKE SYSTEM On-vehicle Service 35A-21
BRAKE DISC INSIDE DIAMETER CHECK35100320216
1. Remove the rear brake assembly, raise the rear brakeassembly and secure it by using a wire, etc.
2. Remove the brake disc.3. Measure the inside diameter of the brake disc at two
or more locations.
Standard value: 197.0 mm
Limit:
198.0
mm
Replacebrakedisc,shoeandliningassemblywhenwearexceeds the limit value or is badly imbalanced.
BRAKE LININGAND BRAKE DISCCONNECTION CHECK 351003102751. Remove the rear brake assembly, raise the rear brake
assembly and secure it by using a wire, etc.2. Remove the brake disc.3. Remove the shoe and lining assembly.4. Chalk innersurfaceofbrakediscand rubwithshoeand
lining assembly.
5. Replace
shoe
and
lining
assembly
or
brake
disc
if
very
irregular
contact
area.
NOTEClean off chalk after check.
8/11/2019 manual pajero 4x4 service brakes.docx
22/70
35A-22 BASIC BRAKE SYSTEM Brake Pedal
BRAKE PEDAL 35100340403
REMOVALAND INSTALLATION
Post-installation Operation
Brake PedalAdjustment (Refer to P.35A-9.)
29
Nm
22 Nm
8
1
7 6
13 Nm
64
3 2
5
Removal steps
1. Stop lamp switch}A] 2. Brake pedal return spring
3. Snap pin4. Pin assembly
5. Brake pedal6. Bushing7. Spacer8. Pedal support member
INSTALLATION SERVICE POINT
}A]BRAKE PEDAL RETURN SPRING INSTALLATION
For L.H. drive vehicles, face the coil of brake pedal returnspring toward the steering column side.ForR.H.drivevehicles, face it toward thebrakepedalside.
8/11/2019 manual pajero 4x4 service brakes.docx
23/70
BASIC BRAKE SYSTEM Master Cylinder and Brake Booster 35A-23
MASTER CYLINDERAND BRAKE BOOSTER 35100370419
REMOVALAND INSTALLATION
Pre-removal Operation Brake Fluid Draining
Post-installation Operation
Brake Fluid Supplying Brake Line Bleeding (Refer to P.35A-13.)
Brake PedalAdjustment (Refer to P.35A-9.)
8
8 8
67
8
1
2
29 Nm
9
15
18
Nm 1120
25
Nm
15 Nm 3 135 14
15 Nm 2 1
4
1 15 Nm
12
914
13 Nm
10
Sealant: 3MATD Part No.8661 or equivalent
Removal steps
1. Brake
tube
connection2. Connector3. Brake fluid level sensor connector4. Master
cylinder
assembly}B] Adjustment of clearance between
brake booster push rod and primarypiston
5. Vacuum switch connector Caution
9. Fitting10. Snap pin11. Pin assembly12. Brake booster13. Sealer14. Vacuum switch
6. Vacuum hose7. Vacuum pipe
}A] 8. Vacuum hose (with built-in checkvalve)
Do not remove the check valve from the vacuumhose. If the check valve is defective, replace it
together with the vacuum hose.
8/11/2019 manual pajero 4x4 service brakes.docx
24/70
Brake
booster
size Clearance
A
standardvalvemm
Vehicle
which
brake
boosterofpowercylinderis180mmand205mmineffective
diameter
0.90
1.30
Vehiclewhichbrakeboosterof
power
cylinder
is
205
mm
and
230
mm
in
effectivediameter
0.701.10
35A-24 BASIC BRAKE SYSTEM Master Cylinder and Brake Booster
INSTALLATION SERVICE POINTS
}A]VACUUM HOSE CONNECTION
Insert securely and completely until the vacuumhose at theengine side contacts the edge of the hexagonal part of thefitting, and then secure by using the hose clip.
C}B]CLEARANCE ADJUSTMENT BETWEEN BRAKE
BOOSTER PUSH RODAND PRIMARY PISTON
Calculate clearanceA from the B, C and Dmeasurements.A = B C D
D Standard value:
A B
Measuringdistance
BMeasuringdistance D
NOTEWhenbrakeboosternegativepressure(6G7:66.7kPa,4D5:93.3kPa) is applied, clearance value will become 0.10 0.50 mm.
Blockgauge
Iftheclearance isnotwithinthestandardvaluerange,adjustby changing the push rod length by turning the screw ofthe push rod.
8/11/2019 manual pajero 4x4 service brakes.docx
25/70
BASIC BRAKE SYSTEM Master Cylinder and Brake Booster 35A-25
MASTER CYLINDER 35100420206
DISASSEMBLYAND REASSEMBLY
2
1
3
4
5
7
6 8 8
10
Master cylinder kit11
12
11
13
14
2.5 Nm
101213
14
2.5 Nm 9
13
12
Brake
fluid: DOT3
or
DOT4
Disassembly steps
1. Reservoir cap assembly2. Reservoir cap3. Diaphragm4. Brake fluid level sensor5. Float6. Reservoir stopper bolt7. Reservoir tank
8. Reservoir
seal]A}
9.
Piston
stopper
bolt
Piston stopper ring
10. Gasket]A} 11. Piston stopper ring
12. Primary piston assembly13. Secondary piston assembly14. Master cylinder body
Caution
Do
not
disassemble
the
primary
piston
andsecondary
piston
assembly.
DISASSEMBLY SERVICE POINT
]A}PISTON STOPPER BOLT/PISTON STOPPER RINGDISASSEMBLY
Removethepistonstopperboltandpistonstopperringwhiledepressing the piston.
Pistonstopper bolt
INSPECTION 35100430056
Check the innersurfaceofmastercylinderbody forrustor pitting.
Checktheprimaryandsecondarypistonsforrust,scoring,wear or damage.
Check the diaphragm for cracks and wear.
8/11/2019 manual pajero 4x4 service brakes.docx
26/70
35A-26 BASIC BRAKE SYSTEM Load Sensing Proportioning Valve
LOAD SENSING PROPORTIONING VALVE 35100540032
REMOVALAND INSTALLATION
CautionDo not disassemble the load sensing proportioning valve.
Pre-removal
Operation
Brake Fluid DrainingPost-installation
Operation
Brake Fluid Supplying
Brake
Line
Bleeding
(Refer
to
P.35A-12.)
15
Nm
2
4
13
Removal steps
}A] 1. Spring support2. Brake tube connection
Lever
Stopperbolt
A
3. Load sensing spring4. Load sensing proportioning valve
INSTALLATION SERVICE POINT
}A]SPRING SUPPORT INSTALLATION
While the lever of the load sensing proportioning valve istouching the stopper bolt, install the spring support so thatthe distance (A) is within the standard value.
Standard value (A): 164 168 mm
Springsupport
8/11/2019 manual pajero 4x4 service brakes.docx
27/70
BASIC BRAKE SYSTEM Front Disc Brake 35A-27
FRONT DISC BRAKE 35100600259
REMOVALAND INSTALLATION
Pre-removal Operation Brake Fluid Draining
Post-installation Operation
Brake Fluid Supplying Brake Line Bleeding (Refer to P.35A-13.)
88 Nm
23
1
15 Nm
5
4
88 Nm
Removal
steps
1. Brake tube
2. Clip3. Brake
hose
bracket}A] 4. Front brake assembly
5. Brake disc (Refer to GROUP 26 Front HubAssembly)
8/11/2019 manual pajero 4x4 service brakes.docx
28/70
35A-28 BASIC BRAKE SYSTEM Front Disc Brake
INSTALLATION SERVICE POINT
}A]FRONT BRAKE ASSEMBLY INSTALLATION
1. Measurehubtorque(A)withthepadremovedtomeasurethe brake drag force after pad installation.
CautionEngage 2WD before measurement.
2. Securely
attach
the
pad
clip
to
the
caliper
support.
MB990520
3. Cleanthepistonandinsertintocylinderwithspecialtool.4. Becareful that thepistonbootdoesnotbecomecaught,
when lowering the caliper assembly and installing thelock pin.
5. Check the brake drag force as follows.(1) Start the engineand hold the brakepedaldown for
5seconds. (Pedaldepression force:approx.196N)(2) Stop the engine.(3) Turn the brake disc forward 10 times.
(4) Check the hub torque (B) with a spring balance.(5) Calculatethedragforceofthediscbrake[difference
between hub torque (B) and hub torque (A)].
Standard value: 106 N or less
6. If the brake drag force exceeds the standard value,disassemble and clean the piston. Check for corrosionor worn piston seal, and check the sliding condition ofthe lock pin and guide pin.
8/11/2019 manual pajero 4x4 service brakes.docx
29/70
15
16
Shim set Clip set
BASIC BRAKE SYSTEM Front Disc Brake 35A-29
DISASSEMBLYAND REASSEMBLY 35100620293
212 8 Nm
74 Nm
6
109
8
75
1 4
3 1613
11 1415
610 9
87
2 12
13
116 10
9
6
109
87
87
5
108
Grease
16
10
8
7
6
7
36
14
1313 14
Brake caliper kit Seal and boots kit Pad set
Caliper assembly disassembly
steps}A]
1.
Lock
pin}A] 2. Guide pin
3. Bushing4. Caliper support, pad, clip and shim
assembly5. Caliper support6. Pin boot7. Boot ring
]A} 8. Piston boot]A} 9. Piston]B} 10. Piston seal
11. Caliper body12. Bleeder screw
Pad assembly disassembly steps
}A]
1.
Lock
pin}A] 2. Guide pin
3. Bushing4. Caliper support, pad, clip and shim
assembly13. Pad and wear indicator assembly14. Pad assembly15. Outer shim16. Clip
8/11/2019 manual pajero 4x4 service brakes.docx
30/70
35A-30 BASIC BRAKE SYSTEM Front Disc Brake
LUBRICATION POINTS
10
Grease: Repair kit grease
9
CautionThe
piston
seal
inside
the
seal
andboot
kit is
coated
with a specialgrease, so do not wipe this greaseoff.
Brake fluid: DOT3 or DOT4
Grease: Repair kit greaseGrease: Repair kit grease
8/11/2019 manual pajero 4x4 service brakes.docx
31/70
BASIC BRAKE SYSTEM Front Disc Brake 35A-31
DISASSEMBLY SERVICE POINTS
Whendisassemblingthefrontdiscbrakes,disassemblebothsides (left and right) as a set.
]A}PISTON BOOT/PISTON REMOVAL
Protectcaliperbodywithcloth.Blowcompressedairthroughbrake hose to remove piston boot and piston.
CautionWhen removing the pistons, be sure to use the handleof a plastic hammer and adjust the height of the twopistons
while pumping in air slowly so that the pistonsprotrude evenly.
Do
not
remove
one
piston
completely
before
trying
toremove the other piston, because it will become
impossible to remove the second piston.
]B}PISTON SEAL REMOVAL
(1) Remove piston seal with finger tip.
CautionDo not use a flat-tippedscrewdriver or other tool toprevent damage to inner cylinder.
(2) Clean piston surface and inner cylinder withtrichloroethylene, alcohol or specified brake fluid.
Specified brake fluid: DOT3 or DOT4
GuidepinREASSEMBLY SERVICE POINT
}A]LOCK PIN/GUIDE PIN INSTALLATION
Installthelockpinandguidepintothecaliperbodyasshownin the illustration.
Lockpin
8/11/2019 manual pajero 4x4 service brakes.docx
32/70
35A-32 BASIC BRAKE SYSTEM Front Disc Brake
INSPECTION 35100630104
Check cylinder for wear, damage or rust. Check piston surface for wear, damage or rust. Check caliper body or sleeve for wear. Check pad for damage or adhesion of grease, check
backing metal for damage.
PAD WEAR CHECK
Measure the thicknessat the thinnestandwornarea of thepad.Replace the pad assembly if pad thickness is less than thelimit value.
Standard value: 10 mmLimit: 2.0 mm
Caution1. Replace
the
pads
always
at
both
sides,
and
also
the
brake pads for the wheels on the opposite side atthe same time.
2. If there is significant difference in the thicknessesof the pads on the left and right sides, check thesliding condition of the piston, lock pin and guidepin.
8/11/2019 manual pajero 4x4 service brakes.docx
33/70
BASIC BRAKE SYSTEM Rear Disc Brake 35A-33
REAR DISC BRAKE 35100700140
REMOVALAND INSTALLATION
Pre-removal Operation Brake Fluid Draining
Post-installation Operation
Brake Fluid Supplying Brake Line Bleeding (Refer to P.35A-13.)
88 Nm
115 Nm
15 Nm
88 Nm
2
3
Removal steps
1.
Brake
hose
connection}A] 2. Rear brake assembly
3. Brake disc
INSTALLATION SERVICE POINT
}A]REAR BRAKE ASSEMBLY INSTALLATION
1. Measurehubtorque(1)withthepadremovedtomeasurethe brake drag force after pad installation.
8/11/2019 manual pajero 4x4 service brakes.docx
34/70
35A-34 BASIC BRAKE SYSTEM Rear Disc Brake
MB990520
2. Clean the piston and insert into the cylinderwith specialtool.
3. Install the pad assembly to the caliper.4. Start the engine. Depress the brake pedal fully a few
times, and then stop the engine.5. Turn the brake disc forward 10 times.
6. Check the hub torque (6) with a spring balance.7. Calculate the drag force of the disc brake [difference
between hub torque (1) and hub torque (6)].
Standard value: 56 N
8. If the brake drag torque exceeds the standard value,disassemble and clean the piston. Check for corrosionor worn piston seal, and check the sliding condition ofthe lock pin and guide pin.
8/11/2019 manual pajero 4x4 service brakes.docx
35/70
13
14 19
1518
1316
15 17
1211
10 169
14
9
12
1610
16
Brake caliper kit Seal and boot kit
BASIC BRAKE SYSTEM Rear Disc Brake 35A-35
DISASSEMBLYAND REASSEMBLY 35100720184
44 Nm
13
14 198 Nm 5
6
15 7 2
18 8 41
13
16
15
3 67
12
11
10
916
17Pad
set
58
Shim set
24
1
Clip set
Caliper assembly disassembly steps
1. Clip2. K-spring3. Pad pin4. Spring5. Inner shim
]A} 6. Pad and wear indicator assembly]A} 7. Pad assembly
8. Outer shim9. Retaining ring
]B} 10. Piston boot]B} 11. Piston]C} 12. Piston seal
13. Sleeve bolt14. Bushing15. Sleeve
16. Pin
boot17. Inner caliper18. Torque plate19. Bleeder screw
Pad assembly disassembly steps
1. Clip2. K-spring3. Pad pin4. Spring5. Inner shim6. Pad and wear indicator assembly7. Pad assembly8. Outer shim
8/11/2019 manual pajero 4x4 service brakes.docx
36/70
35A-36 BASIC BRAKE SYSTEM Rear Disc Brake
LUBRICATION POINTS
CautionThe piston seal inside the seal and bootkit is coatedwith special grease,so donot wipe this
grease
off.
Brake fluid: DOT3 or DOT4
Grease: Repair kit grease
Grease: Repair kit grease
Grease: Repair kit grease
DISASSEMBLY SERVICE POINTS
Whendisassembling thereardiscbrakes,disassemblebothsides (left and right) as a set.
8/11/2019 manual pajero 4x4 service brakes.docx
37/70
BASIC BRAKE SYSTEM Rear Disc Brake 35A-37
]A}PADAND WEAR INDICATORASSEMBLY/PADASSEMBLY REMOVAL
Use a flat-tipped screwdriver to remove the pad and wearindicator assembly and the pad assembly.
]B}PISTON BOOT/PISTON REMOVAL
Protectthecaliperbodywithashoptowel.Blowcompressedair through the brake hose to remove the piston boot andpiston.
CautionBlow compressed air gently.
]C}PISTON SEAL REMOVAL
1. Remove the piston seal with your finger tip.
CautionDo not use a flat-tippedscrewdriver or other tool toprevent damage to inner cylinder.
2. Clean the piston surface and inner cylinder withtrichloroethylene, alcohol or specified brake fluid.
Specified break fluid: DOT3 or DOT4
INSPECTION 35100730118
PAD WEAR CHECK
Measure the thicknessat the thinnestandwornarea of thepad.Replace the pad assembly ifpad thickness is less than thelimit value.
Standard value: 10 mmLimit: 2.0 mm
Caution1. Always replace both pads on each wheel as a set
(both front wheels or both rear wheels). Failure todoso will result in un-even brakingwhich maycausean unpredictable vehicle condition.
2. If there is significant difference in the thicknessesof the pads on the left and right sides, check thesliding condition of the piston, lock pin and guidepin.
8/11/2019 manual pajero 4x4 service brakes.docx
38/70
NOTES
8/11/2019 manual pajero 4x4 service brakes.docx
39/70
ANTI-SKID
BRAKING
SYSTEM
(ABS)
35B-1
CONTENTS 35209000282
GENERAL INFORMATION . . . . . . . . . . . . . . . . . .2 Brake Drum Inside Diameter Check
. . . . . . . . . . . . . . . . . . . . . . . . . .
Refer
to
GROUP
35ASERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . .3 Brake Lining and Brake Drum Connection Check
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35ALUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Wheel Speed Sensor Output Voltage
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . .3
Hydraulic Unit Check . . . . . . . . . . . . . . . . . . . . . . . . 24
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . .4 ABS Warning Lamp Relay ContinuityCheck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 22 Remedy for a Flat Battery . . . . . . . . . . . . . . . . . . . 25
Brake Pedal Check andAdjustment. . . . . . . . . . . . . . . . . . . . . . . . . .
Refer
to
GROUP
35A
Stop
Lamp
Switch
Check
BRAKE PEDAL . . . . . . . . Refer to GROUP 35A
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A MASTER CYLINDERAND BRAKE
Brake Booster Operating TestBOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Check Valve Operation Check. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Proportioning Valve Function Test
Master
Cylinder
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
LOAD SENSING PROPORTIONING VALVE. . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Bleeding. . . . . . . . . . . . . . . . . . Refer to GROUP 35A
FRONT DISC BRAKE . . Refer to GROUP 35A
Brake
Fluid
Level
Sensor
Check. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
REAR DISC BRAKE . . . . Refer to GROUP 35A
Disc
Brake
Pad
Check
and
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Disc Brake Rotor Check
HYDRAULIC UNIT . . . . . . . . . . . . . . . . . . . . . . . . 28
WHEEL SPEED SENSOR. . . . . . . . . . . . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Thickness Check . . . . . . . . . . Refer to GROUP 35A
Brake Lining Thickness Check. . . . . . . . . . . . . . . . . . . . . . . . . .
Refer
to
GROUP
35A
G-SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8/11/2019 manual pajero 4x4 service brakes.docx
40/70
8
35B-2 ABS General Information
GENERAL INFORMATION 35200010307
TheABSconsistsofcomponentssuchasthewheelspeed sensors, stop lamp switch, hydraulic unitassembly (integrated inABS-ECU) and theABSwarning lamp. If a problem occurs in the system,the malfunctioning components can be identifiedand the trouble symptoms will be memorized by
the
diagnosis
function.
Inaddition,readingofdiagnosiscodesandservicedata and actuator testing are possible by usingthe MUT-II.
Items Specifications
ABStype 4-sensor,3-channeltype
Speedsensor Magnetcoiltypeon4-wheels
FrontABSrotorteeth 47
RearABSrotorteeth 47
CONSTRUCTION DIAGRAM
34
91
7 56
10 26
5
1. ABS Warning lamp relay2. Hydraulic
unit
assembly
(integratedinABS-ECU)
3. Diagnosis connector4. Stop lamp switch5. ABS rotor
6. Wheel speed sensor7. 4WD
detection
switch8. ABS warning lamp9. G-Sensor
10. Freewheel engage switch
8/11/2019 manual pajero 4x4 service brakes.docx
41/70
ABS Service Specifications/Lubricant/Special Tools 35B-3
SERVICE SPECIFICATIONS 35200030327
Items Standardvalue
Wheelspeedsensorinternalresistancekfi 1.31.5
Wheelspeedsensorinsulationresistancekfi 100ormore
G-sensoroutputvoltageV Stationaryvehicle 2.42.6
Arrowfacingdownward 3.43.6
LUBRICANT 35200040061
Item
Specified
lubricant
Brakefluid DOT3orDOT4
SPECIAL TOOLS 35200060296
Tool
Number
Name
Use
MB991502 MUT-II subassembly
ForcheckingofABS(DiagnosiscodedisplaywhenusingtheMUT-II)
MB991529 Diagnosiscodecheckharness
ForcheckingofABS(DiagnosiscodedisplaywhenusingtheABSwarninglamp)
8/11/2019 manual pajero 4x4 service brakes.docx
42/70
35B-4 ABS Troubleshooting
TROUBLESHOOTING 35201110501
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Refer to GROUP 00 How to Use Troubleshooting/Inspection Service Points.
NOTES WITH REGARD TO DIAGNOSIS
The phenomena listed in the following table are not abnormal.
Phenomenon
Explanationofphenomenon
Systemchecksound Whenstartingtheengine,athuddingsoundcansometimesbeheardcoming from insidethe engine compartment, but this is because the system operation check is beingperformed,andisnotanabnormality.
ABSoperationsound 1. Sound of the motor inside theABS hydraulic unit operation (whine).2. Sound is generated along with vibration of the brake pedal (scraping).3. WhenABSoperates, sound is generated from thevehicle chassisdue to repeated
brake
application
and
release.(Thump: suspension: squeak: tyres)
ABSoperation(Longbrakingdistance)
Forroadsurfacessuchassnow-coveredroadsandgravelroads,thebrakingdistanceforvehicleswithABScansometimesbelongerthanthatforothervehicles.Accordingly,advisethe
customer
to
drive
safely
on
such
roads
by
lowering
the
vehicle
speed
and
not
being
too
overconfident.
Diagnosis detection condition can vary depending on the diagnosis code.Make sure that checking requirements listed in the Comment are satisfied when checking the troublesymptom again.
DIAGNOSIS
FUNCTION 35201120351
DIAGNOSIS CODES CHECK
Read adiagnosiscodeby the MUT-IIorABS warning lamp.(RefertoGROUP00HowtoUseTroubleshooting/InspectionService Points.)
ERASING DIAGNOSIS CODES
With the MUT-II
RefertoGROUP00HowtoUseTroubleshooting/InspectionService Points.
8/11/2019 manual pajero 4x4 service brakes.docx
43/70
ABS Troubleshooting 35B-5
Without the MUT-II
1. Use the special tool to earth terminal (1) (diagnosis control terminal) of the diagnosis connector.(Refer to GROUP 00 How to Use Troubleshooting/Inspection Service Points.)
2. Stop the engine.3. Turn on the stop lamp switch. (Depress the brake.)4. After carrying out steps 1. to 3., turn the ignition switch to ON. Within 3 seconds after turning the
ignition switch to ON, turn off the stop lamp switch (release the brake). Then, turn the stop lampswitch on and off a total of 10 times.
NOTEIf theABS-ECU function has been stopped because of fail-safe operation, it will not be possibleto erase the diagnosis codes.
Ignition switchON
OFF
Stop lamp switch ON
OFF
ABSwarning lampON
OFF
ABS-ECU memoryWithin 3 Within Within Within Within Within Within Within Within Within Within 1se-1
1
1
1
1 1
1
1
1
1
seconds secondsecond second second second second second secondsecond secondcond
1st
2nd
3rd
4th
5th
6th
7th
8th
9th
10th Erasing
of
ABS-ECUdiagnosiscodescomplete.
8/11/2019 manual pajero 4x4 service brakes.docx
44/70
35B-6 ABS Troubleshooting
INSPECTION CHART FOR DIAGNOSIS CODES 35201130576
Inspect according to the inspection chart that is appropriate for the malfunction code.
DiagnosiscodeNo.
Inspectionitem Diagnosiscontent Referencepage
11 Frontrightwheelspeedsensor Openorshortcircuit 35B-7
12
Front
left
wheel
speed
sensor
13 Rearrightwheelspeedsensor
14 Rearleftwheelspeedsensor
15 Wheelspeedsensor Abnormaloutputsignal 35B-8
16 Powersupplysystem 35B-8
21 Frontrightwheelspeedsensor Abnormal 35B-7
22 Frontleftwheelspeedsensor
23
Rear
right
wheel
speed
sensor
24 Rearleftwheelspeedsensor
25 4WDpositiondetectionswitch 35B-9
26 Freewheelengageswitch 35B-10
32 G-sensorsystem 35B-11
33 Stoplampswitchsystem 35B-11
41 Frontrightsolenoidvalve 35B-12
42 Frontleftsolenoidvalve
43 Rearsolenoidvalve
51 Valverelay
53 Motorrelay,motor
63 ABS-ECU RefertoP.35B-28(Replacethehydraulicunitassembly)
8/11/2019 manual pajero 4x4 service brakes.docx
45/70
ABS Troubleshooting 35B-7
INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code No.11,12,13,14Wheel speed sensor open circuitor short circuit
Probable cause
Code No.21,22,23,24Wheelspeed sensor abnormal
The
ABS-ECU
determines
that
an
open
circuit
or
short
circuit
occurs
in
more
than
one
line
of
wheel
speed
sensors.
Malfunction of wheel speed sensor Malfunction of wiring harness or connector Malfunction of hydraulic unit assembly
These
codes
are
output
at
the
following
times: Whenan opencircuitcannotbe found,but more than onewheel speedsensor
does
not
output
any
signal
during
driving
at
8
km/h
or
higher. When a chipped or plugged-up rotor tooth, etc. is detected. When the sensor output drops and anti-lock control is continuously carriedout
due
to
a
defective
sensor
or
a
warped
rotor.
Malfunction
of
wheel
speed
sensor Malfunction ofABS rotor Malfunction of wheel bearing Malfunction of wiring harness or connector Malfunction of hydraulic unit assembly
NG
Wheel
speed
sensor
installation
check.
OK
NG
Measure at theABS-ECU connectorsA-01. Disconnect the connector and
measure
from
the
harness
side. Resistancevalues between1 2,
Repair
NGCheck
the
following
connectors:A-01,
A-87,
A-103,
C-18,
E-23,
E-26,E-42
OK
Repair
3
4,
18
19
and
20
21.OK: 1.3
1.5
kfi
OKNG
NGCheck
trouble
symptoms.
Check
the
harness
wire
between
eachwheel
speed
sensor
andABS-ECU,and
repair
if
necessary.
NGWheel
speed
sensor
output
voltagecheck.
(Refer
to
P.35B-22.)
OK
NGCheck
the
following
connector:A-01
OK
Check
trouble
symptoms.
NG
Wheel
speed
sensor
check.
(Refer
toP.35B-31.)
OK
NG
ABS
Rotor
check.
(Refer
to
P.35B-31.)
Repair OK
Wheel
bearing
check.
(Refer
to
GROUP26
and
27
On-vehicle
Service.)
Replace
the
wheel
speed
sensor.
Replace
the
ABS
rotor.
Replace
the
hydraulic
unit
assembly.
8/11/2019 manual pajero 4x4 service brakes.docx
46/70
35B-8 ABS Troubleshooting
CodeNo.15Wheelspeedsensor (Abnormaloutputsignal) Probable cause
A
wheel
speed
sensor
outputs
an
abnormal
signal
(other
than
an
open
or
short-circuit). Improper installation of wheel speed sensor
Malfunction of wheel speed sensor Malfunction ofABS rotor Malfunction of wheel bearing Malfunction of wiring harness or connector Malfunction of hydraulic unit assembly
NG
Wheel
speed
sensor
installation
check.
OK
NG
Wheel
speed
sensor
output
voltagecheck
(Refer
to
P.35B-22.)
OK
NGCheck
the following connector:
A-01
OK
Check
trouble
symptoms.
NG
Repair
Repair
NG
Wheel
speed
sensor
check.
(Refer
toP.35B-31.)
OK
NG
ABS
Rotor
check.
(Refer
to
P.35B-31.)
OK
OK
Wheel
bearing
check.
(Refer
to
GROUP26
and
27
On-vehicle
Service.)
Replace
the
wheel
speed
sensor.
Replace
the
ABS
rotor.
Check
the
harness
wire
between
each
wheelspeedsensorandABS-ECU,
andrepair
if
necessary.
Replace
the
hydraulic
unit
assembly.
Code No.16Power supplysystem Probable cause
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.
Malfunction of wiring harness or connector. Malfunction of hydraulic unit assembly
CautionIf battery voltage drops or rises during inspection, this code will be outputas well. If the voltagereturns
to standard value, this code is no longer output.Before carrying out the following inspection, check the battery level, and refill distilled water ifnecessary.
NG
Measure
at
the
ABS-ECU
connector
A-01. Disconnect the connector and
measure
at
the
harness
side. Start the engine. Voltage between
9
Body
earthOK:
System
voltage
OK
NGCheck
the
following connector:A-01
NGCheck
the
following
connectors:
A-01,
C-11,
C-18,
D-26,
D-28
OK
NG
Check
trouble
symptoms.
OK
Check
the
battery.
Repair
Repair
Check
the
harnes
wire
between
the
igni-
tion
switch
and
the
ABS-ECU,
and
repair
if necessary.
OK
Check
trouble
symptoms.NG
Replace
the
hydraulic
unit
assembly
8/11/2019 manual pajero 4x4 service brakes.docx
47/70
ABS Troubleshooting 35B-9
Code No.254WDpositiondetectionswitch Probable cause
ABS-ECU
determines
that
an
open
circuit
exists
in
the
4WD
position
detection
switch
system.
Malfunction of wiring harness or connector Malfunction of 4WD indicator-ECU Malfunction of 4WD position detection switch Malfunction of hydraulic unit assembly
No
Does
the
4WD
indicator
lamp
operatenormally?
Yes
NG
Measure
at
ABS-ECU
connector
A-01. Disconnect the connector and
measure
at
the
harness
side. Ignition switch ON
NG4WD
indicator-ECU
check.
(Refer
toGROUP
22
4WD
indicator-ECU.)
NGCheck the following connectors:
A-01,
B-05,
C-12,
C-18,
C-30
OK
Replace the 4WD indicator-ECU.
Repair
Voltagebetween12andbodyearthOK:
System
voltage
or
0
V
OK
NGCheck
the following connector:
A-01
NGCheck trouble symptom. Checktheharnessbetween4WDposi-
tion
detection
switch
and
the
ABS-ECU,and
repair
if
necessary.
Repair
OK
Check
trouble
symptom.NG
Replace
the
hydraulic
unit
assembly
8/11/2019 manual pajero 4x4 service brakes.docx
48/70
35B-10 ABS Troubleshooting
Code No.26Freewheel engage switch Probable cause
This
code
is
output
at
the
following
times: ABS-ECUdetermines that an opencircuit exists in the freewheel engageswitch
system. When the 4WD detection switch is off and the freewheel engage switch is on,
the vehicle will continue running at 20 km/h or more for approximately 5 min.or
more
and
then
will
continue
running
until
a
speed
of
0
km/h
is
reached.
(Code
Nos.
25
and
26
are
output.)
Malfunction of wiring harness or connector Malfunction of freewheel engage switch Malfunction of 4WD indicator-ECU Malfunction of 4WD position detection switch Malfunction of hydraulic unit assembly
Does
the
4WD
indicator
lamp
operate
normally?
No
Yes
NG
Measure
at
ABS-ECU
connec-tor
A-01. Disconnect the connector
andmeasureattheharness
side. Ignition switch ON Transfer lever:2H Voltage between 11 and
body
earth
OKOK:
System
voltage
NGCheck
the
following connectors:A-01,
A-57,
C-71
OK
NG
Check
trouble
symptom.
NGCheck the following connector:
A-01
Repair
Check
the
harnesses
between
free-
wheelengageswitchandtheABS-ECU,and
repair
if
necessary.
Repair
OK
Check
trouble
symptom.NG
Replace
the
hydraulic
unit
assembly.
Troublesymptom Maincause Remedy
Evenwhenthetransfershift leverisin the 4H position, the 4WDindicatorlampdoesnotilluminate.
Broken
harness
wire
between
the
4WD
indicator-ECU and the freewheel en-gageswitch,orbrokenearthwire fromthefreewheelengageswitch
Repairtheharness.
Freewheel engage switch or 4WDpositiondetectionswitchisdefective.
Replacetheswitch.
Brokenharnesswirebetweenthe4WDindicator-ECU and the 4WD positiondetection
switch
Repairtheharness.
Brokenwireinthe4WDindicator-ECUcircuit
4WDindicator-ECUinspection(RefertoGROUP224WDindicator-ECU.)
4WD indicator lamp illuminatesregardless of the position of thetransfershiftlever.
Short in theharness wire in the4WDpositiondetectionswitchcircuit
Repairtheharness.
4WD position detection switch isdefective.
Replacetheswitch.
ShortintheABS-ECUcircuit ReplacetheABS-ECU.
Shortinthe4WDindicator-ECUcircuit 4WD
indicator-ECU
inspection
(Re-
fer
to
GROUP
22
4WD
indicator-
ECU.)
Noindicatorisilluminated Powercircuitinthe4WDindicator-ECUisdefective.
Repairtheharness.
4WDindicator-ECUisdefective. 4WD indicator-ECU inspection (Re-fer to GROUP 22 4WD indicator-ECU.)
NOTEWhen checking a short in theABS-ECU circuit, remove theABS-ECU connector and check if the 4WDindicatorreturnstonormal.Ifitreturnstonormal,theABS-ECUisdefective.Furthermore,iftheABS-ECUis normal, then the 4WD indicator-ECU will be defective.
8/11/2019 manual pajero 4x4 service brakes.docx
49/70
ABS Troubleshooting 35B-11
Code No.32G-sensor system Probable cause
This
code
is
output
at
the
following
times: The G-sensor output is less than 0.5 V or more than 4.5 V. An open or short circuit is present in the G-sensor system.
Malfunction of G-sensor Malfunction of wiring harness or connector Malfunction of hydraulic unit assembly
NG
G-sensor
check
(Refer
to
P.
35B-32.)
OK
NG
Measure
at
ABS-ECU
connector
A-01. Disconnect the connector and
measure
at
the
harness
side. Ignition switch ON
Replace
the
G-sensor.
NGCheck
the
following
connectors:A-01,
C-18,
C-26
OK
Repair
Voltage between 7 and 14OK:
2.4
2.6
V
OK
NGCheck
the
following
connector:A-01
NGCheck
trouble
symptom.
Check
the
harness
between
the
G-sen-sor
and
the
ABS-ECU,
and
repair
if
nec-essary.
Repair
OK
Check
trouble
symptom.
NG
Replace
the
hydraulic
unit
assembly.
Code No.33Stop lamp switchsystem Probable cause
These
codes
are
output
at
the
following
times: Whenthestoplampswitchisnotbeturnedoff(whenthestoplampswitchstays
on
for
15
minutes
or
more
although
the
ABS
is
not
operating) When theABS-ECU determines that there is an open circuit in harness of the
stop
lamp
switch
system.
Malfunction of stop lamp switch Malfunction of harness or connector Malfunction of hydraulic unit assembly
No
Doesthestoplampilluminateandswitchoff
normally?
Yes
NG
Stop
lamp
switch
installation
check.
OK
NG
Stop
lamp
switch
check.
(Refer
to
GROUP
35A
On-vehicle
Service.)OK
Repair
Replace
the
stop
lamp
switch.
Check
the
harness
between
dedicated
fuse
No. 8
and
the
ABS-ECU,
and
repair
if
necessary.
NG
Measure
at
ABS-ECU
connector
A-01. Disconnect the connector and
measure
at
the
harness
side. Stop lamp switch ON. Voltagebetween13andbodyearth
OK:
Systemvoltage
OK
NGCheck the following connectors:
A-01,
C-12,
C-18,
C-59
,
C-60
OK
Check
trouble
symptom.
NG
Repair
NGCheck
the
following connector:A01
Check
the
harness
between
dedicated
fuseNo. 8andtheABS-ECU,andrepairif
necessary.
Repair
OK
Check
trouble
symptom.NG
Replace
the
hydraulic
unit
assembly.
8/11/2019 manual pajero 4x4 service brakes.docx
50/70
35B-12 ABS Troubleshooting
Code No.41,42,43 Solenoidvalve system Probable cause
Code No.51Valve relay system
Code No.53Motor relay, Motor system
These
codes
are
output
in
the
following
cases: If there is an open or short circuit in theABS-ECU power circuit (solenoid
valve,
motor). If there is a malfunction in the hydraulic unit inner circuit.
Malfunction of harness or connector Malfunction of hydraulic unit assembly
NGMeasure
at
ABS-ECU
connector
A-02. Disconnect the connector and
measure
at
the
harness
side. Voltage between 31, 33 and body
earthOK:
System
voltage
OK
Check
and
repair
the
harness
between
the
multipurpose
fuse
No.11
and
ABS-ECU.
NGCheck
the
following
connector:A-02
Repair
OK
Check
trouble
symptom.NG
Replace
the
hydraulic
unit
assembly.
ABSwarninglamp
ABS
warning
lamp
Approx. 3s Approx. 3s
Illuminated
Notilluminated
ABS WARNING LAMP INSPECTION 35201200161
Check that theABS warning lamp illuminates asfollows.
1. Whenthe ignitionkey isturnedtoON,theABSwarninglamp illuminates for approximately 3 seconds and thenswitches off.
2. When the ignition key is turned to START, theABSwarning lamp remains illuminated.
3. When the ignition key is turned from START back to
ON,
the
ABS
warning
lamp
illuminates
for
approximately3 seconds and then switches off.
NOTETheABS warning lampmay remain onuntil thevehiclereachesaspeedofseveralkm/h.This is limited tocaseswhere diagnosis code Nos.21 24 and 55 have beenrecorded because of a previous problem occurring. Inthis case, the ABS-ECU keeps the warning lamp
Ignition START illuminated until the problem corresponding to thatswitch ON
ACC,LOCK
diagnosis code can be detected.
4. If the illumination is other than the above, check thediagnosis codes.
8/11/2019 manual pajero 4x4 service brakes.docx
51/70
ABS Troubleshooting 35B-13
INSPECTION CHART FOR TROUBLE SYMPTOMS 35201140555
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Troublesymptoms InspectionprocedureNo.
Referencepage
CommunicationwithMUT-IIisnotpossible.
Communicationwithallsystemsisnotpossible. 1 35B-14
Communication
with
ABS
only
is
not
possible.
2
35B-14
WhentheignitionkeyisturnedtoON(enginestopped),theABSwarninglampdoesnotilluminate.
3 35B-15
The
ABS
warning
lamp
remains
illuminated
after
the
engine
is
started.
4
35B-16
FaultyABSoperation Unequalbrakingpoweronbothsides 5 35B-17
Insufficientbrakingpower
ABSoperatesundernormalbrakingconditions
ABS operates before vehicle stops under normal
braking
conditions
Largebrakepedalvibration(Caution2.)
Caution1. If steering movementsare made when driving at high speed, or when driving on road surfaces
with low frictional resistance,or when passingover bumps, theABS may operate even thoughsudden brakingisnotbeing applied. Because ofthis, whengettinginformationfrom thecustomer,check if the problem occurred while driving under such conditions as these.
2. During ABS operation, the brake pedal may vibrate or may not be able to be depressed.Suchphenomenaaredue to intermittentchanges inhydraulicpressureinside thebrake line topreventthe wheels from locking and is not an abnormality.
8/11/2019 manual pajero 4x4 service brakes.docx
52/70
35B-14 ABS Troubleshooting
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
Inspection Procedure 1
Communicationwith MUT-IIis not possible.(Communicationwith all systemsis not possible.)
Probable cause
The reason is probably a defect in the power supply system (including earth) forthe
diagnosis
line.
Malfunction of connector Malfunction of harness
Refer
to
GROUP
13A
Troubleshooting.
Inspection Procedure 2
Communicationwith MUT-IIis not possible.(CommunicationwithABSonly is not possible.)
Probable cause
When
communication
with
the
MUT-II
is
not
possible,
the
cause
is
probably
an
open
circuit
in
the
ABS-ECU
power
circuit
or
an
open
circuit
in
the
diagnosis
output
circuit.
Blown fuse Malfunction of wiring harness or connecter Malfunction of hydraulic unit assembly
NGMeasure
at
diagnosis
connector
C-63and
ABS-ECU
connector
A-01. Disconnect the connector and
measure
at
the
harness
side. Continuity between the following
terminalsOK:
Continuity
NGCheck
the
following connectors:A-01,
C12,
C-18,
C-63
OK
NG
Check
trouble
symptoms.
Repair
Check
the
harness
between
the
ABS-
ECU
and
diagnosis
connector,
and
re-
pair
if
necessary.ABS-ECU
side 2423
Diagnosis
connector
side
1
7
OKNG
NGMeasure
at
ABS-ECU
connector
A-01. Disconnect the connector and
measure
at
the
harness
side. Ignition switch: ON Voltage between 9 body earth
OK: System voltage
OK
NG
Measure
at
ABS-ECU
connectors
A-02. Disconnect the connector and
measure
at
the
harness
side. Continuity between 32, 34 body
earthOK:
Continuity
Check
the
following connectors:A-01,
C-11,
C-18,
D26,
D-28
OK
NG
Check
trouble
symptoms.
Repair
Repair
Check
the
harness
wire
between
the
ignition
switch
and
the
ABS-ECU,
and
repair
if
necessary.
OK
NGCheck
the
following
connector:A-02
Repair
OK
Check
trouble
symptoms.NG
Replace
the
hydraulic
unit
assembly.
8/11/2019 manual pajero 4x4 service brakes.docx
53/70
Check
the following conn
A-55,
C04,
C-05,
C-18,
D
19,
D-28
ABS Troubleshooting 35B-15
Inspection Procedure 3
When ignition key is turned to ON (engine stopped),ABS warninglamp does not illuminate.
Probable cause
Lamp
power
supply
circuit
disconnections,
lamp
bulb
burnouts,
ABS
warning
lamp
relay faults, or circuit breaks between theABS warning lamp and the ground arepossible
causes.
Blown fuse Burnt outABS warning lamp bulb Malfunction of theABS warning lamp relay Malfunction of wiring harness or connector Malfunction of hydraulic unit assembly
NG
Fuse
inspection,
Multi-purpose
fuseNo.
11.
OK
Measure
at
ABS
warning
lamp
relay
NG
connector
A-55. Disconnect the connector and
measure
at
harness
side. Ignition switch: ON Does the ABS warning lamp
illuminate
when
terminal
(3)
is
earthed?OK:
Illuminates
OK
NG
ABS warning lamp relay inspection(Refer
to
P.35B-25.)
OK
NG
Measure
at
ABS
warning
lamp
relayconnector
A-55. Disconnect the connector and
measure
at
harness
side. Ignition switch: ON Voltage between 4 and the body
earth.OK:
Continuity
Refer
to
GROUP
00
Inspection
Service
Points
for
a
Blown
Fuse.
NG
Check
whether
the
ABS
warninglamp
bulb
is
burnt
out.
OKNG
ectors:
OKNG
Check
trouble
symptoms.
Replace
the
ABS
warning
lamp
relay.
NGCheck
the
following
connectors:A-55,
C-71
OK
NG
Check
trouble
symptoms.
Replace
the
ABS
warning
lamp
bulb.
Repair
Check
the
harness
wire
between
the
ignition
switch
IG1
and
the
ABS
warning
lamp
relay,
and
repair
if
necessary.
Repair
Check the harness wire between theABS
warning
lamp
relay
and
the
earth,
and
repair
if
necessary.
OK
Replace
the
hydraulic
unit
assembly.
8/11/2019 manual pajero 4x4 service brakes.docx
54/70
35B-16 ABS Troubleshooting
Inspection Procedure 4
The ABS warning lamp remains illuminated after theengine is started.
Probable cause
It
is
probably
a
short
circuit
in
the
ABS
warning
lamp
circuit. Defective combinationmeter
DefectiveABS warning lamp relay Malfunction of wiring or connector Defective hydraulic unit assembly
NOTE
This trouble symptom is limited to cases where communication with the MUT-II is possible (ABS-ECUpower supply is normal) and the diagnosis code is a normal diagnosis code.
YESWhen
the
combination
meter
connectorC-05
is
disconnected
and
the
ignition
switchison,doestheABSwarninglampremain
on?
Replace
the
combination
meter
NO
NG
Check
the
ABS
warning
lamp
relay(Refer
to
P.35B-25.)
OK
Replace
the
ABS
warning
lamp
relay
When
the
ABS
warning
lamp
relay
connector
A-55
is
disconnected
and
the
ignition
switch
is
on,
does
the
ABS
warning
lamp
remain
on?
OK
Measure
at
ABS
warning
lamp
relay
connector
A-55.
YES
NGCheck
the
following
connectors:A-55,
C05,
C-18
OK
NG
Check
trouble
symptoms.
NG
Repair
Check
the
harness
wire
between
the
Combination
meter
and
the
ABS
warning
lamp
relay,
and
repair
if
necessary.
Disconnect the connector andmeasure
at
harness
side. Ignition switch: ON Voltage between terminal 2 and
body
earth.OK:
System
voltage
OK
NG
Measure
at
ABSECU
connectorA-01. Disconnect the connector and
measure
at
harness
side. Ignition switch: ON Voltage between terminal 16 and
the
body
earth.OK:
System
voltage
OK
Check
the
following
connector:
NGA-55.
OK
NG
Check
trouble
symptoms.
Chek
the
following
connectors:
NG
A-01,
A-55
OK
NG
Check
trouble
symptoms.
Repair
Check
the
harness
wire
between
the
ignitionswitchIG2andtheABSwarninglamp
relay,
and
repair
if
necessary.
Repair
Check
the
harness
wire
between
the
ABS
warning
lamp
relay
and
the
ABSECU,
and
repair
if
necessary.
Replace
the
hydraulic
unit
assembly.
8/11/2019 manual pajero 4x4 service brakes.docx
55/70
ABS Troubleshooting 35B-17
Inspection Procedure 5
Brake operationis abnormal. 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.
Improper installation of wheel speed sensor Incorrectsensor harness contact Foreign material adhering to wheel speed sensor Malfunction of wheel speed sensor Malfunction ofABS rotor Malfunction of wheel bearing Malfunction of hydraulic unit assembly
NG
Wheel
speed
sensor
installation
check.
OK
Wheel
speed
sensor
output
voltage
OK
check.
(Refer
to
P.35B-22.)
NG
NG
Wheel
speed
sensor
check.
(Refer
toP.35B-31.)
Repair
Hydraulic
unit
assembly
check.
(Refer
to
P.35B-24.)
Replace
the
wheel
speed
sensor.
OK
NG
ABS
rotor
check.
(Refer
to
P.35B-31.)
OKNG
Wheel
bearing
check.
(Refer
to
GROUP26 and 27 On-vehicle Service.)
OKNG
Check
the
following
connectors:A-01,
A-87,
A-103,
C-18,
E-23,
E26,E-42
Replace
the
ABS
rotor.
Repair
Repair
OK
Check
trouble
symptom.
NGNG
Measure
at
ABS-ECU
connector
A01. Disconnect the connector and
measure
at
the
harness
side.
Resistance
value
between
terminals1
2,
3
4,
18
19
and
20
21OK:
1.3
1.5
kfi(The
sensor
harness
and
connectorshould
be
moved
while
these
inspections
are
carried
out.)
OKNG
Check the following connector:A-01
Repair
Repair
OK
Check
trouble
symptom.NG
Replace the hydraulic unit assembly.
8/11/2019 manual pajero 4x4 service brakes.docx
56/70
35B-18 ABS Troubleshooting
DATA LIST REFERENCE TABLE 35201150299
The following items can be read by the MUT-II from theABS-ECU input data.1. When the system is normal
ItemNo. Checkitem Checkingrequirements Normalvalue
11 Front-rightwheelspeedsensor Performatestrun Vehicle speedsdisplayedonthe
speedometer
and MUT-II areidentical.
12
Front-left
wheel
speed
sensor
13 Rear-rightwheelspeedsensor
14 Rear-left
wheel
speed
sensor
16 ABS-ECUpowersupplyvoltage
Ignition switch power supply voltage and valvemonitorvoltage
916V
25 4WDpositiondetectionswitch Placethetransferleverat4H. ON
Placethetransferleverat2H. OFF
26 Freewheelengageswitch Engage4WD ON
Engage
2WD
OFF
32 G-sensor
output
voltage Stop
the
vehicle. 2.4
2.6
V
Performatestrun. Display valuefluctuates with amean value of2.5V.
33 Stoplampswitch Depressthebrakepedal. ON
Releasethebrakepedal. OFF
2. When theABS-ECU shut off ABS operation.
When the diagnosis system stops theABS-ECU, the MUT-II display data will be unreliable.
ACTUATOR TEST REFERENCE TABLE 35201160209
The MUT-II activates the following actuators for testing.
NOTE1. If theABS-ECU runs down, actuator testing cannot be carried out.2. Actuator testing is only possible when the vehicle is stationary. If the vehicle speed during actuator
testing exceeds 10 km/h, forced actuation will be cancelled.3. Duringtheactuatortest,theABSwarninglampwillilluminateandtheanti-skidcontrolwillbecancelled.
8/11/2019 manual pajero 4x4 service brakes.docx
57/70
1s
No. Item
01 Solenoidvalveforfront-leftwheel
Solenoid valves and pumpmotors in thehydraulic unit(simpleinspectionmode)
02 Solenoidvalveforfront-rightwheel
03
Solenoid valve for rearwheel
ABS Troubleshooting 35B-19
Activation pattern
A
Startofforcedaction
End offorcedaction
ACTUATOR TEST SPECIFICATIONS
Solenoidvalve
Pumpmotor
B
C
48ms
ON
OFF
3
s
8ms
NOTEA:Hydraulic pressure increasesB:Hydraulic pressure holdsC:Hydraulic pressure decreases
CHECKATABS-ECU 35201180359
TERMINAL VOLTAGE CHECK CHART
1. Measurethevoltagesbetweenterminals(32)and(34)(groundterminals)andeachrespectiveterminal.
NOTEDo not measure terminal voltage for approximately three seconds after the ignition switch is turnedon. TheABS-ECU performs the initial check during that period.
2. The terminal layouts are shown in the illustrations below.
ConnectorterminalNo.
Signal Checkingrequirement Normalcondition
6 Enginecontrolmodule
Ignitionswitch:ON
(Themotorisonapprox.1secondafterengineisstarted)
2Vorless
7 G-sensorsignal Ignitionswitch:ON 2.382.62V
9 ABS-ECUpowersupply
Ignitionswitch:ON Systemvoltage
Ignitionswitch:START 0V
11 Input
from
freewheelengageswitch
Ignition
switch:
ON Transfer
lever
position:
2H System
voltage
Transferleverposition:4H 0V
8/11/2019 manual pajero 4x4 service brakes.docx
58/70
35B-20 ABS Troubleshooting
ConnectorterminalNo.
Signal Checkingrequirement Normalcondition
12 Inputfrom4WDdetectionswitch
Ignitionswitch:ON Transferleverposition:2H Systemvoltage
Transferleverposition:4H 0V
13 Inputfromstoplampswitch
Ignitionswitch:ON Stoplampswitch:ON Systemvoltage
Stop
lamp
switch:
OFF
0
V
14 G-sensor Always 0V
16 ControloutputtoABSwarninglamprelay.
Ignitionswitch:ON Thelampisswitchoff. 2Vorless
Thelampisilluminated. Systemvoltage
23 MUT-II ConnecttheMUT-II SerialcommunicationwithMUT-II
DonotconnecttheMUT-II 1Vorless
24 Inputfrom
diagnosisindication
selection
ConnecttheMUT-II 0V
Do
not
connect
the
MUT-II Approximately
12
V
31 Solenoidvalvepowersupply
Always Systemvoltage
33 Motorpowersupply
8/11/2019 manual pajero 4x4 service brakes.docx
59/70
ABS Troubleshooting 35B-21
RESISTANCEAND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS
1. Turn the ignitionswitchoffanddisconnect theABS-ECUconnectorsbeforechecking resistanceandcontinuity.
2. Check between the terminals indicated in the table below.3. The terminal layouts are shown in the illustration below.
ConnectorteminalNo. Signal Normalcondition
2021 Front-leftwheelspeedsensor 1.31.5kfi
12 Rear-rightwheelspeedsensor 1.31.5kfi
18
19 Front-right
wheel
speed
sensor 1.3
1.5
kfi
3
4
Rear-left
wheel
speed
sensor
1.3
1.5
kfi
32bodyearth Solenoidvalveearth Continuity
34bodyearth Motorearth Continuity
8/11/2019 manual pajero 4x4 service brakes.docx
60/70
35B-22 ABS On-vehicle Service
ON-VEHICLE SERVICE 35200160316
WHEEL SPEED SENSOR OUTPUT VOLTAGECHECK
1. Lift up the vehicle and release the parking brake.2. Disconnect theABS-ECU connector, and then use the
specialtool(inspectionharnessforconnectorpincontactpressure) to measure the output voltage at theharness-side
connector.
3. Rotatethewheeltobemeasuredatapproximately1/21rotation persecond, and check the output voltage usinga circuit tester or an oscilloscope.
Wheelspeedsensor
Frontleft Frontright
Rearleft Rearright
TerminalNo.
20 18 3 1
21
19
4
2
Output voltage
When measuring with a circuit tester:70 mV or more
When measuring with an oscilloscope:200 mV p-p or more
4. If theoutputvoltage is lowerthan theabovevalues,thereason could be as follow: Faulty wheel speed sensor.So replace the wheel speed sensor.
When turning byhand
When
idling
(56
km/h),
1st
gear
(manual
trans-
mission)orDrange (auto-matic transmission)
Inspecting Waveforms With An Oscilloscope
Use the following method to observe the output voltagewaveform from each wheel sensor with an oscilloscope. Start theengine,androtatetherearwheelsbyengaging
1stgear (vehicles with manual transmission)or D range(vehicles with automatic transmission). Turn the frontwheelsmanuallysothattheyrotateataconstantspeed.
NOTE1. Check the connection of the sensor harness and
connector
before
using
the
oscilloscope.2. The
waveform
measurements
can
also
be
taken
whilethe vehicle is actually moving.
3. The output voltage will be small when the wheel speedis low,andsimilarly itwillbe largewhenthewheelspeedis high.
10.0ms/DIV 1V/DIV
8/11/2019 manual pajero 4x4 service brakes.docx
61/70
ABS On-vehicle Service 35B-23
Points In Waveform Measurement
Symptom Probablecauses Remedy
Toosmallorzerowaveformamplitude
Faultywheelspeedsensor Replacesensor
Wa
Top Related