brakes SSANGYONG MUSSO 2003 Service Manual

GENERAL INFORMATION 0B-7
MAINTENANCE AND REPAIR
MAINTENANCE AND LUBRICATION
Fuel Filter Replacement
Replace the engine fuel filter every.
Gasoline Engine : 60,000km (36,000 miles)
Diesel Engine : 45,000km (24,000 miles)
Spark Plug Replacement Replace spark plugs with same type.
Type : BOSCH : F8DC4
BERU : 14F-8DU4
Champion : C11YCC
Gap : 0.8 ± 0.1 mm
Spark Plug Wire Replacement Clean wires and inspect them for burns, cracks or other damage. Check the wire boot fit at the Distributor and at the spark plugs. Replace the wires as needed. Brake System Service Check the disc brake pads or the drum brake linings.
Check the pad and the lining thickness carefully. Tire and Wheel Inspection and Rotation
Check the tires for abnormal wear or damage. To equalize wear and obtain maximum tire life, rotate the tires. If irregular or premature wear exists, check the wheel alignment and check for damaged wheels. Whilethe tires and wheels are removed, inspect the brakes.
NORMAL VEHICLE USE The maintenance instructions contained in the maintenance schedule are based on the assumption that the vehicle will be used for the following reasons:

To carry passengers and cargo within the limitation
of the tire inflation prassure. Refer to “Tire and Wheel” in section 2E.
To be driven on reasonable road surfaces and withinlegal operating limits.
EXPLANATION OF SCHEDULED MAINTENANCE SERVICES The services listed in the maintenance schedule are
further explained below. When the following maintenance services are performed, make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle. Always use the proper fluid and lubricants. Engine Oil and Oil Filter Change Always use above the API SH grade or recommended engine oil. Engine Oil Viscosity Engine oil viscosity (thickness) has an effect on fuel economy and cold weather operation. Lower viscosity engine oils can provide better fuel economy and cold
weather performance; however, higher temperatureweather conditions require higher viscosity engine oils for satisfactory lubrication. Using oils of any viscosity other than those viscosities recommended could result in engine damage. Cooling System Service Drain, flush and refill the system with new coolant. Refer to “Recommended Fluids And Lubricants” in this section. Air Cleaner Element Replacement
Clean the air cleaner element every.
Gasoline Engine : 15,000km (10,000 miles)
Diesel Engine : 10,000km (6,000 miles)
Replace the air cleaner element every .
Gasoline Engine : 60,000km (36,000 miles)
Diesel Engine : 30,000km (18,000 miles)
Replace the air cleaner more often under dusty conditions.
Tire Rotation (Left - Hand Drive Type)

GENERAL INFORMATION 0B-13
Weather-Strip Lubrication Apply a thin film silicone grease using a clean cloth. EACH TIME THE OIL IS CHANGED Brake System Inspection This inspection should be done when the wheels are removed for rotation. Inspect the lines and the hoses for proper hookup, binding, leaks, cracks, chafing, etc.
Inspect the disc brake pads for wear. Inspect the rotors for surface condition. Inspect other brake parts, theparking brake, etc., at the same time. Inspect the brakes more often if habit or conditions result in frequent braking. Steering, Suspension and Front Drive Axle Boot And Seal Inspection Inspect the front and rear suspension and the steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect the power steering line and the hoses for proper hookup, binding, leaks, cracks, chafing, etc. Clean and inspect the drive axle boot and seals for damage, tears or leakage. Replace
the seals if necessary. Exhaust System Inspection Inspect the complete system (including the catalytic converter if equipped). Inspect the body near the exhaustsystem. Look for broken, damaged, missing, or out-of- position parts as well as open seams, holes, loose connections, or other conditions which could cause heat buildup in the floor pan or could let exhaust fumes seep into the trunk or passenger compartment. Throttle Linkage Inspection Inspect the throttle linkage for interference or binding, damaged, or missing parts. Lubricate all linkage joints and throttle cable joints, the intermediate throttle shaft
bearing, the return spring at throttle valve assembly, and the accelerator pedal sliding face with suitable grease. Check the throttle cable for free movements. Engine Drive Belts Inspect all belts for cracks, fraying, wear and proper tension. Adjust or replace the belts as needed. Hood Latch Operation When opening the hood, note the operation of the secondary latch. It should keep the hood from opening all the way when the primary latch is released. The hood
must close firmly. AT LEAST ANNUALLY Lap and Shoulder Belts Condition and Operation Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops and the anchors. Movable Head Restraint Operation On vehicles with movable head restraints, the restraints must stay in the desired position. Spare Tire and Jack Storage Be alert to rattles in the rear of the vehicle. The spare tire, all the jacking equipment, and the tools must besecurely stowed at all times. Oil the jack ratchet or the screw mechanism after each use. Key Lock Service
Lubricate the key lock cylinder. Body Lubrication Service Lubricate all the body door hinges including the hood,
the fuel door, the rear compartment hinges and the latches, the glove box and the console doors, and anyfolding seat hardware. Underbody Flushing Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control.
At least every spring clean the underbody. First, loosen the sediment packed in closed areas of the vehicle. Then
flush the underbody with plain water. Engine Cooling System Inspect the coolant and freeze protection fluid. If the fluid
is dirty or rusty, drain, flush and refill the engine cooling system with new coolant. Keep the coolant at the propermixture in order to ensure proper freeze protection, corrosion protection and engine operating temperature. Inspect the hoses. Replace the cracked, swollen, or
deteriorated hoses. Tighten the clamps. Clean the outside of the radiator and the air conditioning
condenser. Wash the filler cap and the neck. Pressure test the cooling system and the cap in order to help ensure proper operation.

2B-4 WHEEL ALIGNMENT1. Perform wheel alignment preliminary inspection.
2. Check the brakes for dragging.
3. Road test the vehicle.Does the vehicle lead/pull?
1. Cross switch the front tire and wheel assemblies. 2. Road test the vehicle. Does the vehicle lead/pull? 1. Check the front wheel alignment. Is the alignment within specifications?
1. Compare the front camber and front caster to specifications.Are they within specifications?
1. Check the vehicle frame. Is the frame bent?
1. Straighten the frame. Is the repair complete?
1. The probable cause is the tires.
2. Switch the left front tire and wheel assembly with
the left rear tire and wheel assembly.
3. Road test the vehicle. Does the vehicle still lead/pull?
1. Switch the left front tire and wheel assembly with the left rear tire and wheel assembly and replace theleft front tire. Does the repair complete?
1. Switch the right front tire and wheel assembly with
the right rear tire and wheel assembly.
2. Road test the vehicle. Does the vehicle still lead/pull?
1. Switch the right front tire and wheel assembly with the right rear tire and wheel assembly and replace the right front tire. Is the repair complete? Action
Radial Tire Lead/Pull Diagnosis Chart
Step
1Values(s)
- Ye s
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 7
Go to Step 6
Go to Step 3
Go to Step 9
System OK
Go to Step 1
System OK No
System OK System OK Adjust
alignment
Go to Step 5
Go to Step 1
-
Go to Step 8
Go to Step 1
Go to Step 10
Go to Step 1
2 345 6 7 8 9
10 - - - - - - - - -

SECTION 4A
HYDRAULIC BRAKES
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
General Specifications . . . . . . . . . . . . . . . . . . 4A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Noise or Vehicle Vibration When Applied
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Pulls to One Side When Braking . . . . . . . . . . . 4A-2
Poor Braking . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2Increasing Pedal Stroke (Pedal Goes to
Floor) or Brake Dragging . . . . . . . . . . . . . . . 4A-3
Poor Braking of Parking Brake . . . . . . . . . . . . 4A-3 TABLE OF CONTENTS
Component Locator . . . . . . . . . . . . . . . . . . . 4A-4
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4
ABS / ABD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Non-ABS / ABD . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
Maintenance and Repair . . . . . . . . . . . . . . . 4A-7
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4A-7
Bleeding the Brakes . . . . . . . . . . . . . . . . . . . . 4A-7
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9
LCRV (Load Conscious Reducing Valve) . . . 4A-12
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 thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
Type
Pedal Ratio
Pedal Stroke
Pedal Freeplay Type
Inner Diameter Type
Ratio
Type
I.D. of Caliper Cylinder
Thickness of Brake Pad Thickness of Disc Plate Type
I.D. of Caliper Cylinder
Thickness of Brake Pad Thickness of Disc Plate
Type
Operation
Specification PBR Brake
4.3 : 1
132 mm
23.81 mm
5.0 : 1
60.4 mm

40.5 mm
9.5 mm

Suspended
1 - 4 mm
Tandem Type with Lever Sensor
Vacuum Booster Type
Ventilated Disc 10 mm 24 mm
Rear Wheel Internal Expansion Type Mechanical
SAE J1703, DOT3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Brake Pedal
Master Cylinder Brake Booster Front Brake
Rear Brake
Parking Brake Brake Fluid MANDO Brake
4.3 : 1
138 mm
25.4 mm
5.6 : 1
60 mm
Solid Disc
38.2 mm
10.0 mm 10.4 mm
Application

4A-2 HYDRAULIC BRAKESCheck
Dirty or Lack of Fluid Air in Brake SystemFaulty Brake Booster Poor Contact of Pad or Lining Oil or Grease on PadFaulty Auto AdjusterOver Heated Rotor Due to Dragging Pad or LiningClogging Brake Line
Faulty Proportioning Valve Check
Incorrect Tire Pressure Between Left and Right Poor Contact of Pad or LiningOil or Grease is Applied to Pad or LiningBent or Uneven Wear of DrumIncorrectly Mounted Wheel Cylinder Faulty Auto Adjuster Action
Repair
Retighten Replace Replace
RepairRepair
Lubricate
Retighten
Check
Incorrectly Mounted Back Plate or CaliperLoosened Bolt of Back Plate or CaliperCrack or Uneven Wear of Brake Drum or DiscPad or Lining Sticking to Contact Surface Excessive Clearance Between Caliper and Pad Uneven Contact of PadLack of LubricationLoosened Suspension DIGNOSIS
NOISE OR VEHICLE VIBRATION WHEN APPLIED BRAKE
PULLS TO ONE SIDE WHEN BRAKING
Action Adjust
Repair
Replace Replace
Repair
Replace
Action
Replenish or Replace(Check eventual leakage) Bleeding
Replace
Repair
Replace Replace RepairRepair
Repair
POOR BRAKING
( If low cut-in : Adjust ) ( If Leakage : Replace )

HYDRAULIC BRAKES 4A-3
Check
Air in Brake system Fluid LeakingExcessive Clearance Between Push Rod and M/cylinder Parking Brake is not Fully Released Incorrect Adjustment of Parking BrakeWeak Return Spring of Brake PedalIncorrect Pedal FreeplayBroken Rear Drum Brake Shoe Return Spring Lack of Lubrication
Damaged Master Cylinder Check Valve or Piston Return Spring Action
Bleeding
RepairAdjust
Repair Adjust
Replace
Repair
Replace
lubricate Replace
INCREASING PEDAL STROKE (PEDAL GOES TO FLOOR)
OR BRAKE DRAGGING
Check
Insufficient Clearance Between Push Rod and Master Cylinder Worn Brake Lining Oil or Grease on Lining Binding Parking Brake CableFaulty Auto AdjusterExcessive Lever Stroke Action
Adjust
Replace Replace ReplaceReplace
Adjust or Check Cable
POOR BRAKING OF PARKING BRAKE

4A-4 HYDRAULIC BRAKES
COMPONENT LOCATOR
ABS
1 Actuation Assembly (Booster+TMC)
2 ABS Control Unit
3 Master Cylinder 2nd Tube (Secondary)
4 Master Cylinder 1st Tube (Primary)
5 Front Tube (LH)
6 Front Tube (RH) 7 Brake Hose
8 Rear Tube
9 Bolt
...................................................... 25-35 Nm
10 2-way Connector 11 3-way Connector

HYDRAULIC BRAKES 4A-5
ABS / ABD1 Actuation Assembly (Booster+TMC)
2 Master Cylinder 1st Tube (Primary)
3 Master Cylinder 2nd Tube (Secondary)
4 Hydraulic Modulator
5 Front Tube (LH) 6 Front Tube (RH)
7 Rear Tube (RH)
8 Rear Tube (LH)
9 2-way Connector

4A-6 HYDRAULIC BRAKES
NON-ABS/ABD1 Actuation Assembly (Booster+TMC)
2 3-way Connector
3 Front Tube (LH)
4 Front Tube (RH)
5 2-way Connector
6 Rear Tube
7 3-way Connector
8 LCRV

HYDRAULIC BRAKES 4A-7
MAINTENANCE AND REPAIRON-VEHICLE SERVICE
BLEEDING THE BRAKES For Master Cylinder Replacement
1. Add oil after master cylinder replacement.
2. Run the engine and depress the brake pedal several times to build pressure and then keep the pedal fully depressed.
3. Loosen the screws of primary and secondary pipe at the master cylinder outlets to bleed air.
4. Repeat above step No.3 several times until there are no more air bubbles.
5. Bleed air in the system at the hydraulic unit outlet pipe and wheel if pressure building is not enough by depressing the pedal only after above air bleeding.
For Caliper and Brake Hose Replacement
1. Check the oil level from the oil reservoir and refill if necessary.
2. Run the engine and depress the pedal several times to build pressure and then keep the pedal fully depressed.
3. Connect a vinyl tube to the caliper breather and prepare a container to coentain brake oil.
4. Loosen the breather screw until there are no more bubbles.
5. Bleed air in the system at four (4) wheels in order as shown in right figure if pressure building is not enough by depressing the pedal after above air bleeding.
Tightening Torque
9 - 14 NmItem
Front Bleeder Screw
Rear Bleeder Screw
Notice
Do not reuse the bled brake fluid.
Always bleed the air after replacing brake fluid or
master cylinder, caliper, brake hose and pipe.
Always operate in normal order.