brakes SSANGYONG KORANDO 1997 Service Repair Manual

0B -- 8 GENERAL INFORMATION
D AEW OO M Y_2000
MAINTENANCE AND REPAIR
MAINTENANCE AND
LUBRICATION
NORMAL VEHICLE USE
The maintenance instructions contained in the mainte-
nance schedule are based on the assumption that the
vehicle will be used for the following reasons:
DTo carry passengers and cargo within the limitation of
the tire inflation prassure. Refer to “Tire and Wheel” in
section 2E.
DTo be driven on reasonable road surfaces and within
legal operating limits.
EXPLANATION OF SCHEDULED
MAINTENANCE SERVICES
The services listed in the maintenance schedule are fur-
ther explained below. When the following maintenance
services are performed, make sure all the parts are re-
placed and all the necessary repairs are done before
driving the vehicle. Always use the proper fluid and lubri-
cants.
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 temperature
weather 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 sec-
tion.
Air Cleaner Element Replacement
Clean the air cleaner element every.
DGasoline Engine : 15,000km (10,000 miles)
DDiesel Engine : 10,000km (6,000 miles)
Replace the air cleaner element every .
DGasoline Engine : 60,000km (36,000 miles)DDiesel Engine : 30,000km (18,000 miles)
Replace the air cleaner more often under dusty condi-
tions.
Fuel Filter Replacement
Replace the engine fuel filter every.
DGasoline Engine : 60,000km (36,000 miles)
DDiesel Engine : 45,000km (24,000 miles)
Spark Plug Replacement
Replace spark plugs with same type.
DType : BOSCH : F8DC4
BERU : 14F-- 8DU4
Champion : C11YCC
DGap : 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 equal-
ize wear and obtain maximum tire life, rotate the tires. If
irregular or premature wear exists, check the wheel
alignment and check for damaged wheels. While the
tires and wheels are removed, inspect the brakes.
Tire Rotation (Left-hand Drive Type)

0B -- 14 GENERAL INFORMATION
D AEW OO M Y_2000
EACH TIME THE OIL IS CHANGED
Brake System Inspection
This inspection should be done when the wheels are re-
moved for rotation. Inspect the lines and the hoses for
proper hookup, binding, leaks, cracks, chafing, etc. In-
spect the disc brake pads for wear. Inspect the rotors for
surface condition. Inspect other brake parts, the parking
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 ex-
haust system. 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 ten-
sion. Adjust or replace the belts as needed.
Hood Latch Operation
When opening the hood, note the operation of the sec-
ondary 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 be se-
curely 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 any
folding seat hardware.
Underbody Flushing
Flushing the underbody will remove any corrosive mate-
rials 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 proper mixture 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 en-
sure proper operation.

SSANGYONG MY2002
2A-2 SUSPENSION DIAGNOSIS
Inspect the tires for improper pressure and uneven wear.
Inspect the joint from the steering column to the steer-
ing gear for loose connections or wear.
Inspect the front and the rear suspension, the steering
gear, and the linkage for loose or damaged parts.
Inspect for out-of-round tires.
Inspect for out-of-balance tires, bent wheels, and worn
or loose wheel bearings.
Check the power steering pump serpentine belt tension.
Inspect the power steering system for leaks. Also, check
the power steering fluid level.Action
Checks
Checks
Inspect for incorrect toe on the front and the rear wheels.
Inspect for a twisted or a bent suspension arm. Inspect for mismatched or uneven tires.
Inspect for a broken or a sagging spring.
Inspect for a radial tire lateral force.
Check the front-wheel alignment.
Inspect for an off-center steering gear.
Inspect for front-brake dragging.
DIAGNOSIS
GENERAL DIAGNOSIS
Problems in the steering, the suspension, the tires,
and the wheels involve several systems. Consider all
systems when diagnosing a complaint. Some problems,
such as abnormal or excessive tire wear and scuffed
tires, may be the result of hard driving. Always roadtest the vehicle first. If possible, do this road test with
the customer.
Proceed with the following preliminary checks. Correct
any substandard conditions.
Preliminary Checks
Replace the tires.
Replace the spring.
Check the wheel alignment. Switch the tire and the
wheel assemblies. Replace the tires, as needed.
Align the front wheels.
Reseat the pinion valve assembly. Replace the pinion
valve assembly, as needed.
Adjust the front brakes.
Car Lead/Pull
Action
Adjust the toe on the front and the rear wheels.
Replace the suspension arm.
Scuffed Tires
Inflate the tires to the proper pressure.
Tighten the intermediate shaft pinch bolts. Replace the
intermediate shaft, as needed.
Tighten the front and the rear suspension. Tighten the
steering gear mounting bracket bolts. Tighten the inter-
mediate shaft pinch bolts. Replace the front and the rear
suspension, as needed. Replace the steering gear, as
needed. Replace the intermediate shaft, as needed.
Perform a free runout test. Match-mount the tires.
Balance the wheels. Replace the wheels. Replace the
wheel bearings.
Tighten the power steering pump serpentine belt.
Repair any leaks. Perform a power steering system test.
Add power steering fluid, as needed.
Action Checks

SUSPENSION DIAGNOSIS 2A-3
SSANGYONG MY2002
Perform a rack bearing preload adjustment.
Replace the seals and the hoses, as needed.
Lubricate the steering gear. Repair or replace the
steering gear, as needed.
Tighten the steering gear mounting bracket nuts and
the bolts. Check the steering gear preload adjustment.
Check the hydraulic system. Test the power steering
system pressure with a gauge.
Inspect for binding or catching in the steering gear.
Inspect for a loose steering gear mounting.Action ChecksBalance the tire or the wheel.
Measure the hub flange runout. Replace the hub, as
needed.
Adjust the brakes. Replace the brake rotor, as needed.
Replace the outer tie rods.
Balance the wheel.
Replace the lower ball joint.
Measure the wheel runout. Replace the wheel, as
needed.
Match-mount the tire and the wheel assembly. Inspect for an out-of-balance tire or wheel.
Inspect for excessive wheel hub runout.
Inspect for excessive brake rotor imbalance.
Inspect for worn tie rod ends.
Inspect for wheel trim imbalance.
Inspect for a worn lower ball joint.
Inspect for excessive wheel runout.
Inspect for excessive loaded radial runout on the tire
and the wheel assembly.Action ChecksAction
Balance the tire or the wheel. Checks
Inspect for an out-of-balance tire or wheel.Align the front and the rear wheels.
Adjust the toe on the front and the rear wheels.
Replace the spring.
Balance the tires.
Rotate the tires. Replace the tires, as needed.
Maintain the proper load weight.
Inflate the tires to the proper pressure. Check the front-wheel and the rear-wheel alignment.
Inspect for excessive toe on the front and the rear wheels.
Inspect for a broken or a sagging spring.
Inspect for out-of-balance tires.
Check for a failure to rotate tires.
Check for an overloaded vehicle.
Inspect for low tire inflation.
Abnormal or Excessive Tire Wear
Shimmy, Shake, or Vibration
Hard Steering
Wheel Tramp
Action Checks

SUSPENSION DIAGNOSIS 2A-7
SSANGYONG MY2002
KAA2A010
HUB AND BEARING
Perform the following test to check for looseness in
the hub and bearing assembly:
1. Raise and suitably support the vehicle.
2. Remove the rear wheel. Refer to Section 2E, Tires
and Wheels.
3. Remove the caliper and the disc brake rotor. Refer
to Section 4E, Rear Disc Brakes.
4. Mount a dial indicator set with a magnetic base to
a stationary part of the vehicle.
5. Push and pull the wheel hub by hand. If the wheel
hub movement exceeds 0.03 mm (0.001 inch),
replace the hub and bearing assembly. Refer to
Section 2D, Rear Suspension.
6. Install the caliper and the disc brake rotor. Refer
to Section 4E, Rear Disc Brakes.
7. Install the rear wheel. Refer to Section 2E, Tires
and Wheels.
8. Lower the vehicle.

WHEEL ALIGNMENT 2B-5
SSANGYONG MY2002
Step
1
2
3
4
5
6
7
8
9
10
Radial Tire Lead/Pull Diagnosis Chart
Action Yes
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 OKNo
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 Value(s)
-
-
-
-
-
-
-
-
-
-
1. 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?
Check the front wheel alignment.
Is the alignment within specifications?
Compare the front camber and front caster to specifi-
cations.
Are they within specifications?
Check the vehicle frame.
Is the frame bent?
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?
Switch the left front tire and wheel assembly with the
left rear tire and wheel assembly and replace the left
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?
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?

SSANGYONG MY2002
2C-4 FRONT SUSPENSION
REPAIR INSTRUCTIONS
KAA2C020
ON-VEHICE SERVICE
FRONT HUB BEARING ASSEMBLY
Tools Required
DW340-050Sliding Hammer
DW340-060Front Hub Cap Remover/Installer
DW340-070Front Hub Flange Remover
661 589 01 07 00 Front Hub Adjusting Nut Remover/
nstaller
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the front wheels. Refer to Section 2E,
Tires and Wheels.
3. Remove the caliper assembly. Refer to Section
4D, Front Disc Brakes.
4. Remove the hub cap with front hub cap remover/
Installer DW340-060 and sliding hammer DW340-
050.
KAA2C030
5. Remove the hub flange bolts.
Installation Notice
Tightening Torque 55 Nm (41 lb-ft)
6. Remove the snap ring and hub flange with front
hub flange remover DW340-070 and sliding
hammer DW340-050.
Notice:
When installing, coat the hub flange surface with
Loctitte.

FRONT SUSPENSION 2C-11
SSANGYONG MY2002
KNUCKLE ASSEMBLY
Tools Required
661589 13 33 00 BallJointRemover
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the front wheels. Refer to Section 2E,
Tires and Wheels.
3. Remove the caliper assembly. Refer to Section
4D, Front Disc Brakes.
4. Remove the front hub bearing assembly. Refer to
“ Front hub bearing assembl y ” in this section.
KAA2C060
KAA2C210
KAA2C220
5. Remove the splash shield mounting bolts.
Installation Notice
6. Remove the front wheel speed sensor.
Installation Notice
KAA2C230
7. Remove the outer tie rod nuts and disconnect the
tie rod ends from the knuckle using the ball joint
remover 661 589 13 33 00.
Installation Notice
Tightening Torque 6 Nm (53 lb-in)
Tightening Torque 5 Nm (33 lb-in)
Tightening Torque 40 Nm (30 lb-ft)

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

SSAMGYONG MY2002
4A-2 HYDRAULIC BRAKES
DESCRIPTION AND OPERATION
GENERAL DESCRIPTION
Brake fluid should meet the DOT 4 specification. Use
only clear fluid from a sealed container.
Fluid that is exposed to the air will absorb moisture.
Water in the brake fluid will cause the fluid to boil and
the rubber components to deteriorate.
Thoroughly clean the master cylinder reservoir cap be-
fore removing it. Do not let any dirt or foreign material
fall into the fluid reservoir.
There is a brake fluid level switch under the master
cylinder reservoir.When the fluid level is low, the BRAKE lamp in the
instrument cluster will turn on.
The correct brake fluid level is marked on the both
side of the brake fluid reservoir. If the fluid level is
below the MIN indicator mark, check the hydraulic brake
system for leaks. Fix any leaks. Then refill the reservoir
to the MAX indicator mark.
The hydraulic brake system is parallel split on Antilock
Brake Systems. This means the left front and left rear
brakes are on one hydraulic circuit and the right front
and right rear are on the other.