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SECTION 4A
HYDRAULIC BRAKESCAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or whena tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
TABLE OF CONTENTSDescription and Operation ................................... 4A-2
General Description ............................................. 4A-2
Diagnostic Information and Procedures .............. 4A-3
Brake System Testing .......................................... 4A-3
Brake Hose Inspection ......................................... 4A-3
Brake Warning Lamp Circuit Description .............. 4A-4
Brake Warning Lamp Diagnosis ........................... 4A-5
LCRV (Load Conscious Reducing Valve) .............. 4A-8
Repair Instructions .............................................. 4A-10
On-Vehicle Service ............................................... 4A-10
Manual Bleeding The Brakes ............................. 4A-10
Front Brake Hose ............................................... 4A-13
Rear Brake Hose ............................................... 4A-13
Stoplamp Switch ................................................ 4A-14
Brake Pedal ....................................................... 4A-14
Specifications ..................................................... 4A-15
General Specification ......................................... 4A-15
Fastener Tightening Specifications ..................... 4A-16
SSAMGYONG MY2002
4A-2 HYDRAULIC BRAKES
DESCRIPTION AND OPERATIONGENERAL DESCRIPTIONBrake fluid should meet the DOT 4 specification. Useonly clear fluid from a sealed container.
Fluid that is exposed to the air will absorb moisture.Water in the brake fluid will cause the fluid to boil andthe rubber components to deteriorate.
Thoroughly clean the master cylinder reservoir cap be-fore removing it. Do not let any dirt or foreign materialfall into the fluid reservoir.
There is a brake fluid level switch under the mastercylinder reservoir.
When the fluid level is low, the BRAKE lamp in theinstrument cluster will turn on.
The correct brake fluid level is marked on the bothside of the brake fluid reservoir. If the fluid level isbelow the MIN indicator mark, check the hydraulic brakesystem for leaks. Fix any leaks. Then refill the reservoirto the MAX indicator mark.
The hydraulic brake system is parallel split on AntilockBrake Systems. This means the left front and left rearbrakes are on one hydraulic circuit and the right frontand right rear are on the other.
HYDRAULIC BRAKES 4A-3
SSANGYONG MY2002
DIAGNOSTIC INFORMATION AND PROCEDURESBRAKE SYSTEM TESTINGBrakes should be tested on a dry, clean, reasonablysmooth and level roadway. A true test of brake perfor-mance cannot be made if the roadway is wet, greasy,or covered with loose dirt which can cause tires not togrip the road unequally. Testing also will be inaccurateon a crowned roadway because the wheels tend tobounce.
Test the brakes at different vehicle speeds with bothlight-and heavy-pedal pressure; however, avoid lockingthe brakes and sliding the tires. Locked brakes andslid-ing tires do not indicate brake efficiency sinceheavily braked but turning wheels will stop the vehiclein less distance than locked brakes. More tire-to-roadfriction is present with a heavily braked, turning tirethan with a sliding tire.
Because of the high deceleration capability, a firmerpedal may be felt at higher deceleration levels.
There are three major external conditions that affectbrake performance:
• Tires having unequal contact and grip of the roadwill cause unequal braking. Tires must be equallyinflated, and the tread pattern of the right and theleft tires must be approximately equal.
• Unequal loading of the vehicle can affect the brakeperformance since the most heavily loaded wheelsrequire more braking power, and thus more brakingeffort, than the others.
• Misalignment of the wheels, particularly conditionsof excessive camber and caster, will cause thebrakes to pull to one side.
To check for brake fluid leaks, hold constant foot pres-sure on the pedal with the engine running at idle andthe shift lever in NEUTRAL. If the pedal gradually fallsaway with the constant pressure, the hydraulic systemmay be leaking. Perform a visual check to confirm anysuspected leaks.
Check the master cylinder fluid level. While a slightdrop in the reservoir level results from normal liningwear, an abnormally low level indicates a leak in thesystem. The hydraulic system may be leaking eitherinternally or externally. Refer to the procedure belowto check the master cylinder. The system may appearto pass this test while still having a slight leak. If thefluid level is normal, check the vacuum booster pushrodlength. If an incorrect pushrod length is found, adjustor replace the rod.
Check the master cylinder using the following procedure:
• Check for a cracked master cylinder casting or abrake fluid leak around the master cylinder. Leaksare indicated only if there is at least one drop offluid. A damp condition is not abnormal.
• Check for a binding pedal linkage and for anincorrect pushrod length. If both of these parts arein satisfactory condition, disassemble the mastercylinder and check for an elongated or swollenprimary cylinder or piston seals. If swollen sealsare found, substandard or contaminated brake fluidshould be suspected. If contaminated brake fluidis found, al l the components should bedisassembled and cleaned, and all the rubbercomponents should be replaced. All of the pipesmust also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,may cause the brake fluid to boil or cause deteriorationof the rubber components. If the primary piston cups inthe master cylinder are swollen, the rubber parts havedeteriorated.
If deterioration of the rubber is evident, disassembleall the hydraulic parts and wash the parts with alcohol.Dry these parts with compressed air before reassemblyto keep the alcohol out of the system. Replace all therubber parts in the system, including the hoses. Whenworking on the brake mechanisms, check for fluid onthe linings. If excessive fluid is found, replace thelinings.
If the master cylinder piston seals are in satisfactorycondition, check for leaks or excessive heat conditions.If these conditions are not found, drain the fluid, flushthe master cylinder with brake fluid, refill the mastercylinder, and bleed the system.
BRAKE HOSE INSPECTIONThe hydraulic brake hoses should be inspected at leasttwice a year. The brake hose assembly should bechecked for road hazard damage, cracks, chafing ofthe outer cover, and for leaks or blisters. Inspect thehoses for proper routing and mounting. A brake hosethat rubs on a suspension component will wear andeventually fail. A light and a mirror may be needed foran adequate inspection. If any of the above conditionsare observed on the brake hose, adjust or replace thehose as necessary.
SSAMGYONG MY2002
4A-4 HYDRAULIC BRAKES
KAA4A010
BRAKE WARNING LAMP CIRCUIT DESCRIPTION
Diagnostic AidsThe BRAKE lamp glows brightly when the ignition isON and either the parking brake lever switch or thebrake fluid level switch is closed.
If neither switch is closed, the BRAKE lamp receivesa ground through the generator, and it glows dimlywhen the ignition is ON and the engine is off. Whenthe engine starts, the generator creates voltage. Withvoltage on both sides of the lamp, the lamp turns off.
Test DescriptionThe numbers below refer to steps in the diagnostictable.
1. This step begins the test sequence for a BRAKEwarning lamp that stays on when the engine is run-ning.
2. This step begins the test sequence for a BRAKEwarning lamp that never turns on.
HYDRAULIC BRAKES 4A-5
SSANGYONG MY2002
Value(s)
-
-
-
-
-
-
-
-
-
-
-
-
-
-
BRAKE WARNING LAMP DIAGNOSIS
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
ActionStart the engine and leave it running.Does the BRAKE warning lamp stay on?With the engine running, release the parking brake.Is the BRAKE warning lamp off?Check the brake fluid level.Is the fluid level OK?1. Fill the brake fluid reservoir with clean DOT-3
hydraulic fluid.2. Check the cap on the fluid reservoir.3. Start the engine and leave it running.Is the BRAKE warning lamp on?Disconnect the wiring harness connector from thebrake fluid level switch.Is the BRAKE warning lamp on?Replace the brake fluid lever switch.Is the repair complete?1. Connect the brake fluid level switch.2. Disconnect the parking brake lever switch.3. Start the engine and leave it running.Is the BRAKE warning lamp on?Replace the parking brake lever switch.Is the repair complete?1. Connect the parking brake lever switch.2. Disconnect the STICS (Super Time and Alarm
Integrated System).3. Start the engine and leave it running.Is the BRAKE warning lamp on?Replace the STICS.Is the repair complete?Repair the short circuit in the instrument wiringharness between terminal D10 of the instrumentcluster and ground.Is the repair complete?1. Disconnect the electrical connector from the fluid
level switch.2. Connect a jumper wire between ground and
terminal 1 of the fluid level switch harnessconnector.
Does the BRAKE warning lamp turn on?1. Disconnect the electrical connector from the fluid
level switch.2. Connect a jump wire between terminals 1 and 2
of the fluid level switch harness connector.Does the BRAKE warning lamp turn on?1. Replace the brake fluid level switch.2 The switch can be removed and replaced without
draining the brake fluid from the reservoir.Is the repair complete?
Yes
Go To Step 2
System OK
Go To Step 5
Go To Step 5
Go To Step 7
System OK
Go To Step 9
System OK
Go To Step 11
System OK
System OK
Go To Step 13
Go To Step 14
System OK
NO
Go To Step 12
Go To Step 3
Go To Step 4
System OK
Go To Step 6
-
Go To Step 8
-
Go To Step 10
-
-
Go To Step 15
Go To Step 15
-
SSAMGYONG MY2002
4A-6 HYDRAULIC BRAKES
Action1. Turn the ignition ON.2. Apply the parking brake.Does the BRAKE warning lamp turn on?Check fuse F30.Is fuse F30 blown?Check for a short circuit and repair it, if necessary.Replace fuse F30.1. Turn the ignition ON.2. Check the voltage at F30.Is the voltage equal to the specified value?Repair the power supply to fuse F30.Is the repair complete?1. Disconnect terminal A1 of the instrument cluster.2. Turn the ignition ON.3. Use a voltmeter to check the voltage at terminal A1.Is the voltage equal to the specified value?Repair the open circuit between terminal A1 of theinstrument cluster and fuse F30.Is the repair complete?1. Reconnect terminal A1 of the instrument cluster.
Turn the ignition ON.2. Use a voltmeter to backprobe terminal D10 of the
instrument cluster.Is the voltage equal to the specified value?1. Remove the BRAKE warning lamp from its socket.2. Test the Brake warning lamp.Is the BRAKEwarning lamp OK?Replace the instrument cluster.Is the repair complete?Replace the BRAKE warning lamp.Is the repair complete?1. Disconnect terminal C10 of the STICS.2. Connect a jumper wire between terminal C10 and
ground.3. Turn the ignition ON.Is the BRAKE warning lamp on?Replace the STICS.Is the repair complete?1. Disconnect the STICS connector.2. Connect a jump wire between terminal C19 and
ground.3. Turn the ignition ON.Is the BRAKE warning lamp on?Replace the brake warning lamp switch.Is the repair complete?Repair the open circuit between the brake warninglamp switch and terminal C19 of the STICS
BRAKE LAMP WARNING CIRCUIT (Cont’d)
Yes
Go To Step 31
Go To Step 17
System OK
Go To Step 20
System OK
Go To Step 22
System OK
Go To Step 26
Go To Step 24
System OK
System OK
Go To Step 27
System OK
Go To Step 29
System OK
System OK
NO
Go To Step 16
Go To Step 18
-
Go To Step 19
-
Go To Step 21
-
Go To Step 23
Go To Step 25
-
-
Go To Step 28
-
Go To Step 30
-
-
Step
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Value
-
-
-
11 - 14 v
-
11 - 14 v
-
11 - 14 v
-
-
-
-
-
-
-
-
HYDRAULIC BRAKES 4A-7
SSANGYONG MY2002
BRAKE LAMP WARNING CIRCUIT (Cont’d)
Action1. Disconnect the brake fluid level switch.2. Use an ohmmeter to check the resistance between
terminal 2 of the switch connector and ground.Is the resistance equal to the specified value?Repair the open circuit between ground and the brakefluid level switch.Is the repair complete?Repair the open circuit between terminal 1 of the brakefluid level switch and terminal D10 of the instrumentcluster.Is the repair complete?
Yes
Go To Step 32
System OK
System OK
NO
Go To Step 33
-
-
Step
31
32
33
Value(s)
≈ 0 Ω
-
-
SSAMGYONG MY2002
4A-8 HYDRAULIC BRAKES
YAD4A170
YAD4A180
LCRV (LOAD CONSCIOUSREDUCING VALVE)LCRV consists of sensing part and hydraulic controlpart.
1. Sensing Part
It detects the changes of vehicle height causedby vehicle load. It consists of load sensing springand control lever which change according tovehicle load.
2. Hydraulic Control Part
It consists of valve stem devices which controlshydraulic pressure according to load detected bysensing part.
YAD4A190
4. Place alignment marks between the lock nut (b)and adjusting screw (c) after the valve setting.
5. LCRV setting should be performed with unloadedvehicle condition.
Setting Method1. Install the connecting rod (a) to the No.1 hole.
2. Adjust the clearance “X” to be 0mm and tightenthe bolt (c) using the lock nut (b).
Installation Notice
Tightening Torque 14 - 18 N•m (10 - 13 lb-ft)
3. Remove the connecting rod (a) from the No.1 holeand reinstall it to the No.2 hole.
Installation Notice
Tightening Torque 14 - 18 N•m (10 - 13 lb-ft)
HYDRAULIC BRAKES 4A-9
SSANGYONG MY2002
InspectionWhen it occurs the malfunction in the LCRV, the sensorspring, valve body assembly, rear axle or rear springmay be replaced. For these replacement, the followinginspection should perform;
Symptom
Poor Braking Performance
Rear Wheels Lock Early
Possible Cause
Air in Brake System
Poor Adjustment of Sensor Spring
Damaged Sensor Spring
Fluid Leaking from LCRV
Poor Adjustment of Sensor Spring
Internal Fluid Leaking of LCRV
Action
Bleeding
Adjust
Replace
Replace
Adjust
Replace
Notice:
• Fluid leaking from LCRV results from poor valveopen/close or sealing wear caused by the foreignmaterials in the LCRV.
• When you change or repair the LCRV, it may affectthe braking performance. Thus, ensure to use theapproved part.
SSAMGYONG MY2002
4A-10 HYDRAULIC BRAKES
KAA4A020
KAA4A030
Notice: Keep brake fluid away from painted surfacesbecause brake fluid will damage the paint finish.
2. Fill the master cylinder reservoir with brake fluid.Keep the master cylinder reservoir at least one-half full during the bleeding operation.
ON-VEHICLE SERVICEMANUAL BLEEDING THE BRAKESRemoval and Installation ProcedureImportant: Manual bleeding of the hydraulic modulatoris not possible. If air enters the antilock brake hydraulicmodulator, or if an unfilled modulator is installed, usethe scan tool to bleed air out of the brake system.Replacement modulators are shipped already filledand bled. In normal on-vehicle service proceduresinvolving the modulator, such as the procedure toreplace the electronic brake control module, air willnot enter the modulator. In such cases, use thebleeding procedure in this section.
1. Remove the booster reserve by applying thebrakes several times with the engine off, until allthe reserve is depleted.
Important: If no air is suspected to be in themaster cylinder, begin the bleeding procedure atStep 12. If it is suspected that air is in the mastercylinder bore, then the master cylinder must bebled, beginning with step 2.
REPAIR INSTRUCTIONS
HYDRAULIC BRAKES 4A-11
SSANGYONG MY2002
KAA4A040
KAA4A020
KAA4A040
KAA4A050
3. Disconnect the brake line at the front of the mastercylinder.
4. Allow the brake fluid to fill the master cylinder untilit begins to flow from the port.
5. Reconnect the brake line at the front of the mastercylinder.
6. Slowly push and hold the brake pedal.
7. While the brake pedal is pushed down, loosen thebrake fitting at the front of the master cylinder topurge the air from the cylinder.
8. Slightly tighten the brake fitting. Then release thebrake pedal slowly. Wait 15 seconds before continu-ing with the next step.
9. Repeat Steps 6-8 until all of the air is removedfrom the master cylinder bore.
10. Tighten the brake line fitting.
Installation Notice
11. After the air has been bled at the front connection,bleed the master cylinder at the rear connectionusing the same sequence as with the topconnection.
Installation Notice
Tightening Torque 22 N•m (16 lb-ft)
Tightening Torque 17 N•m (13 lb-ft)
SSAMGYONG MY2002
4A-12 HYDRAULIC BRAKES
13. Slowly push and hold the brake pedal. Avoid rapidpumping of the brake pedal.
14. While the brake pedal is pushed down, loosen thebleeder valve to purge the air from the caliper.
15. After the air bubbles have escaped into thecontainer of brake fluid, slightly tighten the rearbleeder valve.
16. Slowly release the brake pedal. Wait 15 secondsbefore proceeding with the next step.
Notice: Keep brake fluid away from paintedsurfaces because brake fluid will damage the paintfinish.
17. Repeat Steps 13 - 16 until all of the air is removed.You will know all of the air is removed when nobubbles appear in the container when the bleedervalve is loosened. Keep the master cylinder reservoir at least one-half full during the bleedingoperation.
18. Tighten the front bleeder valve.
Installation Notice
12. Attach a transparent tube over the rear bleedervalve at the right rear caliper. Allow the tube tohang submerged in the brake fluid in a transparentcontainer. (After the right rear caliper is bled inthe following steps, use this procedure at the leftfront, the left rear and the right front bleeder valves.)
19. Bleed the remaining calipers in the following order: left rear, right front, and left front. Use theprocedure in Steps 12 - 17.
20. After all calipers have been bled, check the brakepedal for sponginess. If the brake pedal is not firm,repeat the entire bleeding procedure to correct thiscondition.
Tightening Torque 10 N•m (89 lb-ft)
KAA4A060
KAA4A070
HYDRAULIC BRAKES 4A-13
SSANGYONG MY2002
Tightening Torque 17 N•m (13 lb-ft)
FRONT BRAKE HOSERemoval and Installation Procedure
1. Raise and suitably support the vehicle.
2. Disconnect the brake line from the brake hose support bracket on the front frame on each side of thevehicle and remove the retainer.
Installation Notice
KAA4A080
KAA4A090
KAA4A100
KAA4A110
3. Remove the brake hose from the brake hosesupport bracket on the upper control arm.
4. Remove the front brake hose-to-front caliperassembly bolt.
5. Remove the ring seals and the disc brake hose.
Installation Notice
Tightening Torque 30 N•m (22 lb-ft)
• Bleed the brake system. Refer to “ManualBleeding the Brakes” in this section.
• Check the brake system for leaks.
6. Installation should follow the removal procedurein the reverse order.
REAR BRAKE HOSERemoval and Installation Procedure
1. Raise and suitably support the vehicle.
2. Disconnect the brake line from the disc brake hoseat the rear axle bracket on each side of the vehicle.
Installation Notice
Tightening Torque 17 N•m (13 lb-ft)
SSAMGYONG MY2002
4A-14 HYDRAULIC BRAKES
KAA4A120
KAA4A130
KAA4A140
STOPLAMP SWITCHRemoval and Installation Procedure
1. Remove the stoplamp switch connector.
2. Remove the stoplamp switch.
3. Installation should follow the removal procedurein the reverse order.
BRAKE PEDALRemoval and Installation Procedure
1. Remove the stoplamp switch connector.
2. Remove the clevis pin and disconnect the brakebooster pushrod.
Installation Notice:
• Install in the upper hole.
• Install the snap pin fully in the hole of clevispin.
• Apply the grease around the hold of clevis pin.
3. Remove the brake pedal mounting nut and removethe brake pedal assembly.
Installation Notice
Tightening Torque 13 N•m (10 lb-ft)
4. Installation should follow the removal procedurein the reverse order.
KAA4A070
3. Remove the rear bleeder valve from the caliper assembly.
Installation Notice
Tightening Torque 10 N•m (89 lb-ft)
• Bleed the brake system. Refer to “ManualBleeding the Brakes” in this section.
• Check the brake system for leaks.
4. Installation should follow the removal procedure inthe reverse order.
HYDRAULIC BRAKES 4A-15
SSANGYONG MY2002
Front Disc Brake Rotor
Type
Diameter
Thickness (New)
Discard Thickness
Thickness Variation
Lateral Runout (Installed)
Light Scoring of the Rotor Surface
Rear Disc Brake Rotor
Type
Diameter
Thickness (New)
Discard Thickness
Thickness Variation
Lateral Runout (Installed)
Booster
Dual
Ratio
Master Cylinder
Bore Diameter (Nominal)
Caliper
Minimum Piston Diameter (Front)
Minimum Piston Diameter (Rear)
Pad and lining
Front
Thickness (New)
Minimum Discard Thickness
Rear (Disc)
Thickness (New)
Minimum Discard Thickness
Application
Ventialated
278.30
24.00
22.00
0.013
0.03
0.40
Solid
299.00
10.40
8.50
0.013
0.03
-
7 : 1
25.40
60.00
38.00 (42.9)
10.00
2.00
9.50
1.50
E32
SPECIFICATIONSGENERAL SPECIFICATION
mm in
Application
Capacity
Lublicant
Description
0.7 (0.7 qt)
DOT 4
10.96
0.95
0.87
0.0005
0.001
0.002
11. 77
0.41
0.33
0.0005
0.001
8″ & 9″
-
1.00
2.36
1.50
0.39
0.08
0.39
0.06
SSAMGYONG MY2002
4A-16 HYDRAULIC BRAKES
10
13
-
22
-
Brake Pedal Mounting Nut
Brake Lind Fitting
Front Bleeder Valve
Front Brake Hose-to-Front Caliper Assembly Bolt
Rear Bleeder Valve
N•mApplication Lb-In
FASTENER TIGHTENING SPECIFICATIONS
Lb-Ft
13
17
10
30
10
-
-
89
-
89