torque SSANGYONG KORANDO 1997 Service Repair Manual

SSANGYONG MY2002
4E-16 REAR BRAKES
4. Install the brake hose.
Notice: The washer should be replaced new part.
5. Tighten the air bleeder screw.
Installation Notice
Tightening Torque7 - 13 Nm
(62 - 115 lb-in)
6. Bleed the brake system after replacement.
YAD4C270

REAR BRAKES 4E-19
SSANGYONG MY2002
9. Remove the wheel cylinder mounting bolt and
remove the wheel cylinder.
Inspection
1. Measure the inside diameter of the brake drum
and replace as needed.
I.D.
φ 254 mmWear Limitφ 255.5 mm
Notice: Measure two more position.
2. Inspect the surface between the lining and brake.
Mark the brake drum inside using chalk and scrub
the shoe & lining assembly. If there is excessive
contact problem, replace the shoe & lining
assembly or the brake drum.
Notice: Clean any chalk mark after inspection
complete.
YAD4C370
YAD4C380
YAD4C390
Installation Procedure
1. Install the wheel cylinder to the backing plate.
Installation Notice
Tightening Torque8 - 12 Nm
(71 - 106 lb-in)
YAD4C400

REAR BRAKES 4E-21
SSANGYONG MY2002
7. Connect the brake pipe to the wheel cylinder.
Installation Notice
Tightening Torque15 - 19 Nm
(11 - 14 lb-ft)
8. Bleed the brake system and verify the parking
brake operation.
Install the tire.
YAD4C450

SSANGYONG MY2002
4E-22 REAR BRAKES
UNIT REPAIR
WHEEL CYLINDER
Disassembly Procedure
1. Remove the upper brake return spring and remove
the wheel cylinder with pulling the upper lining
outside.
2. Disassembly the wheel cylinder assembly.
Remove the dust boot and do not reuse them
(1).
Remove the piston (2).
Remove the piston cup and do not reuse it (3).
Remove the spring assembly (4).
Remove the bleeder screw (5).
3. Clean all the parts with the denatured alcohol. Dry
the parts with unlubricated compressed air.
Bleeder Screw7 - 10 Nm
(62 - 89 lb-in)
8 - 12 Nm
(71 - 106 lb-in)
Wheel Cylinder
Mounting Bolt
Notice: Lubricate the new seals, the piston, the
piston cup and the wheel cylinder bore with clean
brake fluid before assembly. 4. Installation should follow the removal procedure
in the reverse order.
5. Tighten the bleeder screw and wheel cylinder as
specified torque.
YAD4C460
YAD4C470
YAD4C480

ABS AND TCS 4F-3
SSANGYONG MY2002
GENERAL DESCRIPTION AND SYSTEM OPERATION
BASIC KNOWLEDGE REQUIRED
Before using this section, it is important that you have
a basic knowledge of the following items. Without this
knowledge, it will be difficult to use the diagnostic
procedures contained in this section.
•Basic Electrical Circuits - You should understand
the basic theory of electricity and know the meaning
of voltage, current (amps), and resistance (ohms).
You should understand what happens in a circuit
with an open or shorted wire. You should be able to
read and understand a wiring diagram.
Use of Circuit Testing Tools - You should know
how to use a test light and how to bypass
components to test circuits using fused jumper
wires. You should be familiar with a digital
multimeter. You should be able to measure voltage,
resistance, and current, and be familiar with the
controls and how to use them correctly.
ABS SYSTEM COMPONENTS
The ABS 5.3 Antilock Braking System (ABS) consists
of a conventional hydraulic brake system plus antilock
components. The conventional brake system includes
a vacuum booster, master cylinder, front disc brakes,
rear disc brakes, interconnecting hydraulic brake pipes
and hoses, brake fluid level switch and the BRAKE
indicator.
The ABS components include a hydraulic unit, an elec-
tronic brake control module (EBCM), two system fuses,
four wheel speed sensors (one at each wheel), intercon-
necting wiring, the ABS indicator, the EBD indicator
and the TCS indicator. See “ABS Component Locator”
in this section for the general layout of this system.
The hydraulic unit with the attached EBCM is located
between the surge tank and the bulkhead on the left
side of the vehicle.
The basic hydraulic unit configuration consists of hy-
draulic check valves, two solenoid valves for each
wheel, a hydraulic pump, and two accumulators. The
hydraulic unit controls hydraulic pressure to the front
calipers and rear calipers by modulating hydraulic
pressure to prevent wheel lockup.
Units equipped with TCS add two more valves for each
drive wheel for the purpose of applying the brake to a
wheel that is slipping. This is done with pressure from
the hydraulic pump in the unit. There is also a TCS
indicator lamp on the instrument panel to alert the driver
to the fact that the TCS system is active. The
components identified in the drawing are those added
to the basic ABS 5.3 system to provide traction control.
Nothing in the hydraulic unit or the EBCM is serviceable.
In the event of any failure, the entire ABS unit withattached EBCM must be replaced. For more
information, refer to “Base Braking Mode” and
“Antilock Braking Mode” in this section.
TRACTION CONTROL SYSTEM
(TCS) DESCRIPTION
General Information
The traction control system (TCS) is a traction system
by means of brake intervention only, available in a low
speed range (< 60kph).
It workes on µ - split roads with sidewise different friction
coefficients.
The spinning driven wheel is braked and the drive
torque can be transferred to the wheel on the high-µ
side. During TCS active, the TCS information lamp is
blinking.
The temperature of the brakes is calculated by a mathe-
matical model and TCS is switched passive if the calcu-
lated temperature is greater than a threshold value (500
°C).
TCS is permitted again, when the calculated tempera-
ture is less than 350 °C.
Control Algorithm
The input signals for the control algorithm are the
filtered wheel speed signals from the ABS speed
processing.
With the speed difference of the driven wheels, the
control deviation is calculated.
If the control deviation exceeds a certain threshold
value, the wheel with the greater slip is braked actively.
The threshold value depends on the vehicle speed:
It is reduced with increasing vehicle speed down to a
constant value.
KAA4F010

ABS AND TCS 4F-95
SSANGYONG MY2002
EBCM CONNECTION FACE VIEW
(WITHOUT TRACTION CONTROL SYSTEM)
EBCM CONNECTOR
KAA4F300
Color
BLK/DK GRN
BRN/BLK
-
BRN/WHT
BRN/BLK
BLK/RED
BRN/RED
BRN/YEL
BLK/DK GRN
YEL
BRN/DK GRN
-
RED/YEL
DK GRN/YEL
WHT/RED
BLK Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16Circuit
Right Rear Ground
Right Rear Sensor
Not Used
Right Front Ground
Right Front Sensor
Left Front Ground
Left Front Sensor
Left Rear Ground
Left Rear Sensor
Acceleration Sensor
Signal Voltage
Data Link Connector
Not Used
Torque On Demand
Stoplamp Switch
Ignition
GroundColor
RED/WHT
RED/WHT
-
BLK
LT GRN
DK GRN/BRN
-
-
-
-
-
RED
-
DK BLU
- Pin
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31Circuit
Battery
Battery
Ground
ABS Warning Lamp
EBD Warning Lamp
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Acceleration Sensor
Supply Voltage
Not Used
Acceleration Sensor
Ground
Not Used

ABS AND TCS 4F-97
SSANGYONG MY2002
KAA4F320
Color
WHT/RED
BLK/DK GRN
YEL/DK GRN
RED/BRN
BRN
LT GRN/BLK
DK BLU/BLK
-
-
BLK/RED
BRN/BLK
BRN/YEL
BLK/LT GRN
BRN/WHT
BRN/BLK
-
-
RED/YEL
RED/BRN
-
-
-
-
-
DK GRN
DK BLU/BLK
- Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27Circuit
Ignition
Relay Supply Voltage
Pilot Valve
Prime Valve
Left Front Inlet Valve
Right Rear Inlet Valve
Motor Relay Actuation
Not Used
Not Used
Left Front Ground
Right Rear Sensor
Left Rear Ground
Left Rear Sensor
Right Front Ground
Right Front Sensor
Not Used
Not Used
Torque On Demand
Motor Monitoring
Not Used
Not Used
Not Used
Not Used
Not Used
Left Rear Outlet Valve
Right Front Inlet Valve
Not UsedColor
BLK
BLK
RED/BLK
LT GRN
DK BLU
RED
DK GRN/BRN
-
BRN/RED
YEL/DK GRN
BLK/DK GRN
DK BLU
-
-
-
RED
-
-
BRN/DK GRN
-
DK GRN/YEL
-
DK BLU/WHT
YEL Pin
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51Circuit
Ground
Ground
EBD Warning Lamp
ABS Warning Lamp
TCS Warning Lamp
Left Front Outlet Valve
Right Rear Outlet
Valve
Not Used
Left Front Sensor
Valve Relay Actuation
Right Rear Ground
Acceleration Sensor
Ground
Not Used
Not Used
Not Used
Acceleration Sensor
Supply Voltage
Not Used
Not Used
Data Link Connector
Not Used
Stoplamp Switch
Not Used
Battery
Acceleration Sensor
Signal Voltage

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.

ABS AND TCS 4F-101
SSANGYONG MY2002
FRONT WHEEL SPEED SENSOR
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect the front wheel speed sensor electrical
connector.
3. Raise and suitably support the vehicle.
4. Turn the steering wheel to expose the front wheel
speed sensor. It is located at the rear of the steering
knuckle near tie rod end.
5. Remove the bolt and the front wheel speed sensor
from the steering knuckle.
Installation Notice
KAA4F370
KAA4F380
Tightening Torque 7 Nm (62 lb-in)
6. Installation should follow the removal procedure in
the reverse order.
REAR WHEEL SPEED SENSOR
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect the rear wheel speed sensor electrical
connector. It is located under the rear seat.
3. Raise and suitably support the vehicle.
4. Remove the rear wheel speed sensor.
Installation Notice
KAA4F390
KAA4F400
Tightening Torque 7 Nm (62 lb-in)
5. Installation should follow the removal procedure
in the reverse order.