air bleeding SSANGYONG KORANDO 1997 Service Repair Manual

SSANGYONG MY2002
3D-16 REAR AXLE
KAA3D360
KAA3D370
KAA3D390
KAA3D380
2. Install the lateral rod in axle hosing.
Notice: Do not tighten the nuts completely.
Installation Notice
3. Install the shock absorber in axle housing.
Installation Notice
Tightening Torque30 - 45 Nm
(22 - 33 lb-ft)
Tightening Torque150 - 180 Nm
Tightening Torque70 - 80 Nm
(52 - 59 lb-ft) 4. Install the stabilizer bar and upper/lower arm in
axle housing
Installation Notice
5. Install the propeller shaft of rear axle side and
tighten above the fixing bolts/nuts.
Installation Notice
6. Install the brake cable, air bleeder hose, oil pipe,
LCRV unit in rear axle assembly with assembled
completely.
Installation Notice
7. Bleeding the air in brake, install the tire.30 - 45 Nm
(22 - 33 lb-ft)
150 - 180 Nm
(111 - 133 lb-ft)
150 - 180 Nm
(111 - 133 lb-ft)
Stabilizer bar cap bolt
Upper arm nut
Lower arm nut
12 - 23 Nm
(9 - 17 lb-ft)
6 - 8 Nm
(53 - 71 lb-in)
15 - 19 Nm
(11 - 14 lb-ft)LCRV Mounting Bolt
Air Breather Hose Bolt
Brake Oil Pipe (M10)

SECTION 4A
HYDRAULIC BRAKES
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when
a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this
cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK
unless otherwise noted.
TABLE OF CONTENTS
Description 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-10On-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

HYDRAULIC BRAKES 4A-9
SSANGYONG MY2002
Inspection
When it occurs the malfunction in the LCRV, the sensor
spring, valve body assembly, rear axle or rear spring
may be replaced. For these replacement, the following
inspection should perform;
Symptom
Poor Braking Performance
Rear Wheels Lock EarlyPossible 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 LCRVAction
Bleeding
Adjust
Replace
Replace
Adjust
Replace
Notice:
Fluid leaking from LCRV results from poor valve
open/close or sealing wear caused by the foreign
materials in the LCRV.
When you change or repair the LCRV, it may affect
the braking performance. Thus, ensure to use the
approved part.

SSAMGYONG MY2002
4A-10 HYDRAULIC BRAKES
KAA4A020
KAA4A030
Notice: Keep brake fluid away from painted surfaces
because 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 SERVICE
MANUAL BLEEDING THE BRAKES
Removal and Installation Procedure
Important: Manual bleeding of the hydraulic modulator
is not possible. If air enters the antilock brake hydraulic
modulator, or if an unfilled modulator is installed, use
the scan tool to bleed air out of the brake system.
Replacement modulators are shipped already filled
and bled. In normal on-vehicle service procedures
involving the modulator, such as the procedure to
replace the electronic brake control module, air will
not enter the modulator. In such cases, use the
bleeding procedure in this section.
1. Remove the booster reserve by applying the
brakes several times with the engine off, until all
the reserve is depleted.
Important: If no air is suspected to be in the
master cylinder, begin the bleeding procedure at
Step 12. If it is suspected that air is in the master
cylinder bore, then the master cylinder must be
bled, beginning with step 2.
REPAIR INSTRUCTIONS

SSAMGYONG MY2002
4A-12 HYDRAULIC BRAKES
13. Slowly push and hold the brake pedal. Avoid rapid
pumping of the brake pedal.
14. While the brake pedal is pushed down, loosen the
bleeder valve to purge the air from the caliper.
15. After the air bubbles have escaped into the
container of brake fluid, slightly tighten the rear
bleeder valve.
16. Slowly release the brake pedal. Wait 15 seconds
before proceeding with the next step.
Notice: Keep brake fluid away from painted
surfaces because brake fluid will damage the paint
finish.
17. Repeat Steps 13 - 16 until all of the air is removed.
You will know all of the air is removed when no
bubbles appear in the container when the bleeder
valve is loosened. Keep the master cylinder reser
voir at least one-half full during the bleeding
operation.
18. Tighten the front bleeder valve.
Installation Notice 12. Attach a transparent tube over the rear bleeder
valve at the right rear caliper. Allow the tube to
hang submerged in the brake fluid in a transparent
container. (After the right rear caliper is bled in
the following steps, use this procedure at the left
front, 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 the
procedure in Steps 12 - 17.
20. After all calipers have been bled, check the brake
pedal for sponginess. If the brake pedal is not firm,
repeat the entire bleeding procedure to correct this
condition.
Tightening Torque 10 Nm (89 lb-ft)
KAA4A060
KAA4A070

ABS AND TCS 4F-99
SSANGYONG MY2002
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
Caution: Brake Fluid may irritate eyes and skin. In
case of contact, take the following actions:
Eye contact - rinse thoroughly with water.
Skin contact - wash with soap and water.
Ingestion - consult a physician immediately.
Caution: To help avoid personal injury due to poor
braking. DO NOT Tap into the vehicle’s brake system
to operate a trailer brake system.
Notice: When fasteners are removed, always reinstall
them at the same location from which they were
removed. If a fastener needs to be replaced, use the
correct part number fastener for is not available, a
fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those
requiring thread-locking compound will be called out.
The correct torque values must be used when installing
fasteners that require them. If the above procedures
are not followed, parts or system damage could result.
Notice: Use only DOT-3 equivalent hydraulic brake
fluid. The use of DOT-5 (silicone) brake fluid is not
recommended. Reduced brake performance or
durability may result.
Notice: Avoid spilling brake fluid on any the vehicle’s
painted surfaces, wiring, cables or electrical
connectors. Brake fluid will damage paint and electrical
connections. If any fluid is spilled on the vehicle, flush
the area with water to lessen the damage.
Electronic System Service Precautions
Take care to avoid electronic brake control module
(EBCM) circuit overloading. In testing for opens or
shorts, do not ground or apply voltage to any circuit
unless instructed to do so by the diagnostic procedure.
Test circuits only with a high-impedance multi-meter.
Never remove or apply power to any control module
with the ignition switch in the ON position. Always turn
the ignition to the OFF position before removing or
connecting battery cables, fuses or connectors.
General Service Precautions
Disconnect the EBCM connector before performing any
vehicle welding work using an electric arc welder.
Do not attempt to disassemble any component
designated as nonserviceable. The hydraulic modulator
and the EBCM can be separated from each other and
replaced separately but cannot be serviced. They have
no replaceable parts, and there is no replaceable parts,
and there is no access to the components they contain.
Bleeding System
Replacement modulators are shipped already filled
and bled. In normal procedures requiring removal of
the modulator, such as to replace the EBCM, air will
not enter the modulator, and normal bleeding will be
all that is needed.
If air enters the hydraulic modulator, or if an unfilled
modulator is installed, use the brake bleeding program
in the scan tool to bleed the modulator. Manual
bleeding of the hydraulic modulator is not possible.

SSANGYONG MY2002
4F-100 ABS AND TCS
1
KAA4F330
KAA4F340
ABS 5.3 ASSEMBLY
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect the 15 or 31-pin ABS wiring harness
connector from its socket on the EBCM.
3. Cover the connector and the socket with shop
cloths to protect them from brake fluid.
Notice: Take care not to allow air into the hydraulic
modulator. If air gets into the hydraulic unit, it will
require a bleeding procedure using a scan tool
programmed for the ABS 5.3 system. As long as
no air enters the hydraulic unit, a simple bleeding
procedure is all the system will require.
4. Remove the brake pipes from the hydraulic
modula tor.
Installation Notice
Tightening Torque 14 Nm (124 lb-in)
5. Loosen the mounting nuts on the hydraulic unit.
6. Move the brake pipes aside far enough to allow for
lifting the ABS 5.3 unit out of the mounting bracket.
7. Cap the brake pipes.
Installation Notice
ABS/TCS UNIT
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect the ABS/TCS wiring harness connector
from its socket on the ABS/TCS unit.
3. Remove the ABS/TCS unit mounting bolts.
Installation Notice
KAA4F350
KAA4F360
Tightening Torque 6 Nm (53 lb-in)
Bleed the hydraulic system. Refer to Section
4A, Hydraulic Brakes.
8. Installation should follow the removal procedure in
the reverse order.
Tightening Torque 7 Nm (62 lb-in)
4. Installation should follow the removal procedure
in the reverse order.

Specifications.......................................................5C-2
General Specifications.........................................5C-2
Fastener Tightening Specifications.......................5C-2
Component Locator.............................................5C-3
Clutch Assembly.................................................5C-3
Pedal and Master Cylinder...................................5C-4
Maintenance and Repair.....................................5C-5
On-Vehicle Service.................................................5C-5
Bleeding of Clutch System...................................5C-5
Clutch Disc......................................................... 5C- 6
Master Cylinder.................................................5C-10Clutch Pedal...................................................... 5C-12
Clutch Oil Chamber........................................... 5C-14
Diagnosis............................................................ 5C-15
Clutch Slips....................................................... 5C-15
Poor Disengagement ......................................... 5C-15
Hard to Shift or Will not Shift............................... 5C-15
Clutch Chatters When Starting........................... 5C-15
Difficult Pedal Operation.................................... 5C-16
Clutch Noisy...................................................... 5C-16
Special Tools and Equipment............................ 5C-17
Special Tools Table............................................ 5C-17
SECTION 5C
CLUTCH
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.
TABLE OF CONTENTS

CLUTCH 5C-5
SSANGYONG MY2002
ON-VEHICLE SERVICE
BLEEDING OF CLUTCH SYSTEM
Bleeding procedure
Notice: Keep the fluid level over ‘MAX’ in reservoir
during bleeding operation.
Do not let fluid contact a painted surface.
1. Remove the air bolt cap of the release cylinder.
Connect a vinyl tube to the bolt.
2. Insert the other end of the tube in a vacant
container.
3. Slowly depress the clutch pedal several times.
4. With clutch pedal fully depressed, open the air
bolt and release air rind fluid in the fluid line,
5. Repeat this procedure until there are no more air
bubbles in the fluid flows.
KAA5C030
MAINTENANCE AND REPAIR

SECTION 6A
POWER STEERING SYSTEM
TABLE OF CONTENTS
Description and Operation...................................6A-2
General Description.............................................6A-2
Component Locator.............................................6A-3
Diagnostic Information and Procedures..............6A-4
Power Steering System Pressure Test..................6A-4
Power Steering System Leak Test........................6A-4
Maintenance .........................................................6A-5
Bleeding the Power Steering System....................6A-5
Checking and Adding Fluid..................................6A-5Repair Instructions................................................6A-6
On-Vehicle Service.................................................6A-6
Power Steering Fluid Reservoir.............................6A-6
Power Steering Pump Hoses and Pipes................6A-7
Specifications.......................................................6A-9
General Specification...........................................6A-9
Fastener Tightening Specifications.......................6A-9
Special Tools and Equipment............................ 6A-10
Special Tools Table............................................6A-10