SSANGYONG KORANDO 1997 Service Repair Manual

HYDRAULIC BRAKES 4A-11
SSANGYONG MY2002
KAA4A040
KAA4A020
KAA4A040
KAA4A050
3. Disconnect the brake line at the front of the master
cylinder.
4. Allow the brake fluid to fill the master cylinder until
it begins to flow from the port.
5. Reconnect the brake line at the front of the master
cylinder.
6. Slowly push and hold the brake pedal.
7. While the brake pedal is pushed down, loosen the
brake fitting at the front of the master cylinder to
purge the air from the cylinder.
8. Slightly tighten the brake fitting. Then release the
brake pedal slowly. Wait 15 seconds before continu-
ing with the next step.
9. Repeat Steps 6-8 until all of the air is removed
from 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 connection
using the same sequence as with the top
connection.
Installation Notice
Tightening Torque 22 Nm (16 lb-ft)
Tightening Torque 17 Nm (13 lb-ft)

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

HYDRAULIC BRAKES 4A-13
SSANGYONG MY2002
Tightening Torque 17 Nm (13 lb-ft)
FRONT BRAKE HOSE
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Disconnect the brake line from the brake hose sup
port bracket on the front frame on each side of the
vehicle and remove the retainer.
Installation Notice
KAA4A080
KAA4A090
KAA4A100
KAA4A110
3. Remove the brake hose from the brake hose
support bracket on the upper control arm.
4. Remove the front brake hose-to-front caliper
assembly bolt.
5. Remove the ring seals and the disc brake hose.
Installation Notice
Tightening Torque 30 Nm (22 lb-ft)
Bleed the brake system. Refer to “Manual
Bleeding the Brakes” in this section.
Check the brake system for leaks.
6. Installation should follow the removal procedure
in the reverse order.
REAR BRAKE HOSE
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Disconnect the brake line from the disc brake hose
at the rear axle bracket on each side of the vehicle.
Installation Notice
Tightening Torque 17 Nm (13 lb-ft)

SSAMGYONG MY2002
4A-14 HYDRAULIC BRAKES
KAA4A120
KAA4A130
KAA4A140
STOPLAMP SWITCH
Removal and Installation Procedure
1. Remove the stoplamp switch connector.
2. Remove the stoplamp switch.
3. Installation should follow the removal procedure
in the reverse order.
BRAKE PEDAL
Removal and Installation Procedure
1. Remove the stoplamp switch connector.
2. Remove the clevis pin and disconnect the brake
booster pushrod.
Installation Notice:
Install in the upper hole.
Install the snap pin fully in the hole of clevis
pin.
Apply the grease around the hold of clevis pin.
3. Remove the brake pedal mounting nut and remove
the brake pedal assembly.
Installation Notice
Tightening Torque 13 Nm (10 lb-ft)
4. Installation should follow the removal procedure
in the reverse order.
KAA4A070
3. Remove the rear bleeder valve from the caliper as
sembly.
Installation Notice
Tightening Torque 10 Nm (89 lb-ft)
Bleed the brake system. Refer to “Manual
Bleeding the Brakes” in this section.
Check the brake system for leaks.
4. Installation should follow the removal procedure in
the 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 ThicknessApplication
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
SPECIFICATIONS
GENERAL SPECIFICATION
mm in
Application
Capacity
LublicantDescription
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 ValveNm Application
Lb-In
FASTENER TIGHTENING SPECIFICATIONS
Lb-Ft
13
17
10
30
10-
-
89
-
89

Description and Operation...................................4B-2
General Description.............................................4B-2
Component Locator.............................................4B-3
Repair Instructions................................................4B-4
On-Vehicle Service.................................................4B-4Brake Oil Level Switch .........................................4B-4
Brake Fluid Reservoir ...........................................4B-4
Master Cylinder...................................................4B-5
Specifications.......................................................4B-8
Fastener Tightening Specifications.......................4B-8
SECTION 4B
MASTER CYLINDER
TABLE OF CONTENTS

SSANGYONG MY2002
4B-2 MASTER CYLINDER
DESCRIPTION AND OPERATION
GENERAL DESCRIPTION
The master cylinder is designed for use in a parallel
split system. One front and one parallel to rear brakes
are served by the primary piston. The opposite front
and rear brakes are served by the secondary piston.
The master cylinder incorporates the functions of the
standard dual master cylinder, plus a low fluid level
indicator. The brake fluid level switch is attached under
the body of the plastic brake master cylinder reservoir.
Notice: Do not use lubricated shop air on the brake
parts, because oil will damage the rubber components.Important:•Replace all the components included in the repair
kits used to service the master cylinder.
Lubricate the rubber parts with clean brake fluid to
ease assembly.
If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of
the brake system. Refer to Section 4F, Antilock
Brake System and Traction Control System.
The torque values specified are for dry, unlubricated
fasteners.
Perform all service operations on a clean bench,
free from all traces of mineral oil.

MASTER CYLINDER 4B-3
SSANGYONG MY2002
KAA4B070
COMPONENT LOCATOR
1 Brake Fluid Level Switch Connector
2 Brake Fluid Reservoir
3 Power Booster4 Brake Lines
(Master Cylinder-to-Hydraulic Modulator)
5 Master Cylinder

SSANGYONG MY2002
4B-4 MASTER CYLINDER
ON-VEHICLE SERVICE
BRAKE OIL LEVEL SWITCH
Removal and Installation Procedure
1. Disconnect the brake fluid level switch connector.
2. Disconnect the switch wiring connector.
3. Disconnect the switch from the brake oil tank.
4. Installation should follow the removal procedure
in the reverse order.
REPAIR INSTRUCTIONS
BRAKE FLUID RESERVOIR
Removal and Installation Procedure
Important: Remove the brake fluid reservoir only when
it must be replaced because of damage or leaks.
1. Disconnect the brake fluid level switch connector.
2. Drain the brake fluid.
KAA4B020
KAA4B020
KAA4B050
3. Remove the brake fluid reservoir fromthe master
cylinder body by tilting the reservoir and pulling
it up-ward.