oil SSANGYONG MUSSO 1998 Workshop Repair Manual

HYDRAULIC BRAKES 4A-3
Check
Air in Brake system
Fluid Leaking
Excessive Clearance Between Push Rod and M/cylinder
Parking Brake is not Fully Released
Incorrect Adjustment of Parking Brake
Weak Return Spring of Brake Pedal
Incorrect Pedal Freeplay
Broken Rear Drum Brake Shoe Return Spring
Lack of Lubrication
Damaged Master Cylinder Check Valve or Piston Return SpringAction
Bleeding
Repair
Adjust
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 Cable
Faulty Auto Adjuster
Excessive Lever StrokeAction
Adjust
Replace
Replace
Replace
Replace
Adjust or Check Cable
POOR BRAKING OF PARKING BRAKE

HYDRAULIC BRAKES 4A-7
MAINTENANCE AND REPAIR
ON-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 Nm
Item
Front Bleeder Screw
Rear Bleeder Screw
Notice
lDo not reuse the bled brake fluid.
lAlways bleed the air after replacing brake fluid or
master cylinder, caliper, brake hose and pipe.
lAlways operate in normal order.

4A-8 HYDRAULIC BRAKES
For Hydraulic Unit Replacement
1. Add oil after hydraulic unit replacement.
2. Run the engine and depress the pedal several times to
build pressure and then keep the pedal fully depressed.
3. Loosen hydraulic pipe screws at the hydraulic unit 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 from the wheels if pressure building
is not enough by pressing the pedal only after above air
bleeding.

4B-2 MASTER CYLINDER
1 Nut .......................................................14-22 Nm
2 Washer
3 Master Cylinder Assembly
4 Oil Level Sensor
5 Check Valve
6 Booster
7 Clevis Pin
8 Snap Pin9 Seal
10 Spacer
11 Nut .........................................................8-18 Nm
12 Front Tube (LH)
13 Front Tube (RH)
14 Rear Tube
15 1st Tube (Primary)
16 2nd Tube (Secondary)
MANDO
PBR
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
BOOSTER AND BRAKE MASTER CYLINDER

MASTER CYLINDER 4B-3
Removal & Installation Procedure
1. Remove the oil level sensor connector.
2. Remove the tube from the master cylinder.
Installation Notice
Notice
lBe careful not to drop the oil when removing the tube.
lIf the oil is dropped, promptly sweep up.
3. Remove the booster vacuum hose.
Notice
lConnect fully to the end of vacuum hose when installing.
4. Loosen the nut of master cylinder.
Installation Notice
5. Remove the clevis pin and disconnect the pedal and brake
booster push rod.
Notice
lInstall in the upper hole when PBR brake.
lConnect the snap pin in the hole of clevis pin fully.
lApply the grease around the hole of clevis pin.
Tightening Torque 14 - 22 Nm
Tightening Torque 15 - 19 Nm

4C-2 POWER BOOSTER
1 Nut .......................................................14-22 Nm
2 Washer
3 Master Cylinder Assembly
4 Oil Level Sensor
5 Check Valve
6 Booster
7 Clevis Pin
8 Snap Pin
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
BOOSTER AND BRAKE MASTER CYLINDER
9 Seal
10 Spacer
11 Nut .........................................................8-18 Nm
12 Front Tube (LH)
13 Front Tube (RH)
14 Rear Tube
15 1st Tube (Primary)
16 2nd Tube (Secondary)
MANDO
PBR

POWER BOOSTER 4C-3
Removal & Installation Procedure
1. Remove the oil level sensor connector.
2. Remove the tube from the master cylinder.
Installation Notice
Notice
lBe careful not to drop the oil when removing the tube.
lIf the oil is dropped, promptly sweep up.
3. Remove the booster vacuum hose.
Notice
lConnect fully to the end of vacuum hose when installing.
4. Loosen the nut of master cylinder.
Installation Notice
5. Remove the clevis pin and disconnect the pedal and brake
booster push rod.
Notice
lInstall in the upper hole when PBR brake.
lConnect the snap pin in the hole of clevis pin fully.
lApply the grease around the hole of clevis pin.
Tightening Torque 14 - 22 Nm
Tightening Torque 15 - 19 Nm

FRONT DISC BRAKES 4D-5
4. Measure rotor disc thickness.
UNIT REPAIR
FRONT DISC BRAKE
Inspection Procedure
1. Clean all components and visually check the followings.
lCheck the cylinder and piston for wear, rust or damage.
lCheck the caliper body and guide pin for wear, damage
or crank.
lCheck the pads for uneven wear or oiliness.
lCheck the boots for damage or tear.
2. Measure caliper housing inner diameter.
Item
With PBR
With MANDOWear Limit
f 61.4 mm
f 61.0 mm
Standard
10 mmWear Limit
2.0 mm
Standard
f 60.4 mm
f 60.0 mm
3. Measure pad thickness.
Notice
Always change the all pads on one wheel at a time.
5. Check the rotor disc for score or runout.
Standard
24 mmWear Limit
22 mm

4E-4 REAR DISC BRAKES
Standard
10.4 mmWear Limit
9.3 mm
UNIT REPAIR
REAR DISC BRAKE
Inspection Procedure
1. Clean all components and visually check the followings.
lCheck the cylinder and piston for wear, rust or damage.
lCheck the caliper body and guide pin for wear, damage
or crank.
lCheck the pads for uneven wear or oiliness.
lCheck the boots for damage or tear.
Standard
f40.5 mm
f38.2 mmWear Limit
f41.5 mm
f39.2 mm
2. Measure caliper housing inner diameter.
3. Measure pad thickness.
Standard
9.5 mmWear Limit
2.0 mm
Notice
Always change the all pads on one wheel at a time.
4. Measure rotor disc thickness.
5. Check the rotor disc for score or runout.
Item
With PBR
With MANDO

Front
Rear
Front
Rear
SECTION 4F
ANTILOCK BRAKE SYSTEM
TABLE OF CONTENTS
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.
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Model
ECUNumber of Pins
Operating Temperature
Motor Operating Current
Solenoid Coil Resistance
External Resistance
Air Gap
Number of teethDescription
ABS 5.3
31
-40 ~ +120°C
Below MAX 40A
1.28KW - 1.92KW
0.35 - 1.60 mm
0.15 - 1.20 mm
52
52ABS/ABD 5.3
83
-40 ~ +85°C
Below MAX 45A
8.04 - 9.04W except AV,
HSV 4.04 - 4.54W
1.28KW - 1.92KW
0.35 - 1.60 mm
0.15 - 1.20 mm
52
52 Hydraulic System
Wheel Speed Sensor
Impulse Ring
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4F-1
General Specifications . . . . . . . . . . . . . . . . . . 4F-1
Schematic and Routing Diagrams . . . . . . . . 4F-2
ABS 5.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-2
ABS/ABD 5.0 . . . . . . . . . . . . . . . . . . . . . . . . . 4F-3
ABS 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-4
ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . 4F-5
Component Locator . . . . . . . . . . . . . . . . . . . 4F-6
ABS, ABS/ABD . . . . . . . . . . . . . . . . . . . . . . . . 4F-6
ABD System Description . . . . . . . . . . . . . . . 4F-7Self Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4F-9
ABS, ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . 4F-9
ABS, ABS/ABD 5.0 . . . . . . . . . . . . . . . . . . . . 4F-11
Defect Codes . . . . . . . . . . . . . . . . . . . . . . . . 4F-13
Maintenance and Repair . . . . . . . . . . . . . . 4F-19
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 4F-19
Wheel Speed Sensor . . . . . . . . . . . . . . . . . . 4F-19
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . 4F-21
ABS 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-21
ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . . . . 4F-24