SSANGYONG KORANDO 1997 Service Repair Manual

MASTER CYLINDER 4B-5
SSANGYONG MY2002
KAA4B060
4. Remove and discard the brake fluid reservoir seals
from the master cylinder body.
Installation Notice:
Lubricate the new brake fluid reservoir seals with
clean brake fluid.
After the installation, bleed the brake system.
Refer to Section 4F, Antilock Brake System and
Traction Control System.
5. Installation should follow the removal procedure
in the reverse order.
YAD4A340
YAD4A350
YAD4A360
3. Remove the master cylinder.
Retain the master cylinder in the vice and
remove the retainer ring from the master cylinder
using the snap ring plier. 2. Loosen the mounting nut of the master cylinder
and remove the master cylinder from the power
booster.
MASTER CYLINDER
Removal Procedure
1. Disconnect the brake lines from the master
cylinder.
Notice: The brake fluid may damage paintwork, if
spillage onto paintwork, wash with cold water
immediately.

SSANGYONG MY2002
4B-6 MASTER CYLINDER
YAD4A370
Remove the 1st piston and 2nd piston assembly
from the master cylinder assembly.
YAD4A380
YAD4A390
YAD4A400
Check the cylinder for excessive wear.
Notice:
Replace the cylinder assembly when there
occurs any damage or wear in the cylinder.
Clean the contaminated oil of the assembly.
Install the 1st piston and 2nd piston assembly
from the master cylinder assembly.
Installation Procedure
1. Install the retainer ring using the snap ring plier.
2. Install the master cylinder into the booster.
Installation Notice
Tightening Torque8 - 12 Nm
(71 - 106 lb-in)

SSANGYONG MY2002
4B-8 MASTER CYLINDER
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
13
16
18 Brake Lines Fitting (M10)
Brake Lines Fitting (M12)
Master Cylinder Mounting NuntsN•m Application
Lb-InLb-Ft
17
22
25-
-
-

Description and Operation....................................4C-2
General Description..............................................4C-2
Component Locator..............................................4C-3
Diagnostic Information and Procedures...............4C-4
Power Booster Functional Check..........................4C-4
Repair Instructions................................................4C-5On-Vehicle Service.................................................4C-5
Power Booster Assembly.....................................4C-5
Vacuum Hose......................................................4C-6
Specifications.......................................................4C-7
General Specification ...........................................4C-7
Fastener Tightening Specifications.......................4C-7
SECTION 4C
POWER BOOSTER
TABLE OF CONTENTS

SSANGYONG MY2002
4C-2 POWER BOOSTER
DESCRIPTION AND OPERATION
GENERAL DESCRIPTION
The power booster is a double-diaphragm, vacuum-sus
pended unit. In normal operating mode, with the service
brakes in the release position, a vacuum-suspended
booster operates with a vacuum on both sides of its
diaphragm. When the brakes are applied, air at
atmospheric pressure is admitted to one side of the
diaphragm to provide the power assist.When the brakes are released, atmospheric air is shut
off from that side of the diaphragm. The air is then
drawn from the booster through the vacuum check
valve by the vacuum source.
Important: If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or part
of the brake system. Refer to Section 4F, Antilock
Brake System and Traction Control System.

POWER BOOSTER 4C-3
SSANGYONG MY2002
KAA4C080
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
4C-4 POWER BOOSTER
DIAGNOSTIC INFORMATION AND PROCEDURES
KAA4C020
2. Push the pedal down and hold in this position.
3. Start the engine.
4. The booster is OK if the pedal drops further because
of extra force produced.
If the brake pedal does not drop, the vacuum system
(vacuum hoses, check valve, etc.) is probably
defective and should be checked. If no defect is
revealed by checking the vacuum system, the defect
is in the booster itself.POWER BOOSTER FUNCTIONAL
CHECK
1. With the engine stopped, eliminate vacuum in the
booster by pumping the brake pedal several times.

POWER BOOSTER 4C-5
SSANGYONG MY2002
REPAIR INSTRUCTIONS
KAA4C030
KAA4A040
KAA4C050
ON-VEHICLE SERVICE
POWER BOOSTER ASSEMBLY
Removal and Installation Procedure
1. Remove the master cylinder. Refer to Section 4B,
Master Cylinder.
2. Remove the vacuum hose from the booster.
3. Remove the clevis pin and disconnect the pedal
and brake booster push rod.
Installation Notice:
•Apply the grease around the hole of clevis pin.
4. Remove the power booster mounting nuts and re-
move the booster from the dash panel.
Installation Notice
Tightening Torque 17 Nm (13 lb-ft)
Install the new gasket.
5. Installation should follow the removal procedure
in the reverse order.

SSANGYONG MY2002
4C-6 POWER BOOSTER
3. Remove the vacuum hose from the booster.
4. Installation should follow the removal procedure in
the reverse order.
VACUUM HOSE
Removal and Installation Procedure
1. Remove the vacuum hose connection bolt to the
intake manifold.
Installation Notice
2. Remove the vacuum hose retaining bolt located
on the intake manifold.
Installation Notice
KAA4C060
KAA4C070
KAA4C030
Tightening Torque 40 Nm (30 lb-ft)
Tightening Torque 13 Nm (10 lb-ft)

POWER BOOSTER 4C-7
SSANGYONG MY2002
10
30
10 Power Booster Mounting Nuts
Vacuum Hose Connection Bolt
Vacuum Hose Retaining BoltN•m Application
Lb-In
FASTENER TIGHTENING SPECIFICATIONS
Lb-Ft
13
40
13-
-
-
SPECIFICATIONS
GENERAL SPECIFICATION
Application
Type
RetioDescription
Vacuum Assisted
5.6 : 1