air bleeding SSANGYONG MUSSO 1998 Workshop Repair Manual

SECTION 4A
HYDRAULIC BRAKES
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
General Specifications . . . . . . . . . . . . . . . . . . 4A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Noise or Vehicle Vibration When Applied
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Pulls to One Side When Braking . . . . . . . . . . . 4A-2
Poor Braking . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Increasing Pedal Stroke (Pedal Goes to
Floor) or Brake Dragging . . . . . . . . . . . . . . . 4A-3
Poor Braking of Parking Brake . . . . . . . . . . . . 4A-3
TABLE OF CONTENTS
Component Locator . . . . . . . . . . . . . . . . . . . 4A-4
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4
ABS / ABD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Non-ABS / ABD . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
Maintenance and Repair . . . . . . . . . . . . . . . 4A-7
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4A-7
Bleeding the Brakes . . . . . . . . . . . . . . . . . . . . 4A-7
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9
LCRV (Load Conscious Reducing Valve) . . . 4A-12
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.
Type
Pedal Ratio
Pedal Stroke
Pedal Freeplay
Type
Inner Diameter
Type
Ratio
Type
I.D. of Caliper Cylinder
Thickness of Brake Pad
Thickness of Disc Plate
Type
I.D. of Caliper Cylinder
Thickness of Brake Pad
Thickness of Disc Plate
Type
Operation
SpecificationPBR Brake
4.3 : 1
132 mm
f23.81 mm
5.0 : 1
f60.4 mm
¬
f40.5 mm
9.5 mm
¬ Suspended
1 - 4 mm
Tandem Type with Lever Sensor
Vacuum Booster Type
Ventilated Disc
10 mm
24 mm
Rear Wheel Internal Expansion Type
Mechanical
SAE J1703, DOT3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Brake Pedal
Master Cylinder
Brake Booster
Front Brake
Rear Brake
Parking Brake
Brake FluidMANDO Brake
4.3 : 1
138 mm
f25.4 mm
5.6 : 1
f60 mm
Solid Disc
f38.2 mm
10.0 mm
10.4 mm
Application

4A-2 HYDRAULIC BRAKES
Check
Dirty or Lack of Fluid
Air in Brake System
Faulty Brake Booster
Poor Contact of Pad or Lining
Oil or Grease on Pad
Faulty Auto Adjuster
Over Heated Rotor Due to Dragging Pad or Lining
Clogging Brake Line
Faulty Proportioning ValveCheck
Incorrect Tire Pressure Between Left and Right
Poor Contact of Pad or Lining
Oil or Grease is Applied to Pad or Lining
Bent or Uneven Wear of Drum
Incorrectly Mounted Wheel Cylinder
Faulty Auto AdjusterAction
Repair
Retighten
Replace
Replace
Repair
Repair
Lubricate
Retighten Check
Incorrectly Mounted Back Plate or Caliper
Loosened Bolt of Back Plate or Caliper
Crack or Uneven Wear of Brake Drum or Disc
Pad or Lining Sticking to Contact Surface
Excessive Clearance Between Caliper and Pad
Uneven Contact of Pad
Lack of Lubrication
Loosened Suspension
DIGNOSIS
NOISE OR VEHICLE VIBRATION WHEN APPLIED BRAKE
PULLS TO ONE SIDE WHEN BRAKING
Action
Adjust
Repair
Replace
Replace
Repair
Replace
Action
Replenish or Replace(Check eventual leakage)
Bleeding
Replace
Repair
Replace
Replace
Repair
Repair
Repair
POOR BRAKING
( If low cut-in : Adjust )
( If Leakage : Replace )

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.

HYDRAULIC BRAKES 4A-13
Construction
LCRV consists of sensing part and hydraulic control part.
1. Sensing Part
It detects the changes of vehicle height caused by vehicle
load. It consists of load sensing spring and control lever
which change according to vehicle load.
2. Hydraulic Control Part
It consists of valve stem devices which controls hydraulic
pressure according to load detected by sensing part.
Trouble Shooting
Poor Braking
Possible Cause
Air in Brake System
Poor Adjustment of Sensor Spring
Damaged Sensor Spring
Fluid Leaking from LCRVRemedy
Bleeding
Adjust
Replace
Replace
Possible Cause
Poor Adjustment of Sensor Spring
Internal Fluid Leaking of LCRVRemedy
Adjust
Replace
Abnormal Locking

Type
Clutch Pedal
Clutch Disc
Clutch Master Cylinder
Clutch Release Cylinder
Clutch FluidDescription
Hydraulic
Suspended
158 mm
5 - 10 mm
Single Dry Diaphragm
9.85 - 10.2 mm
9.2 mm
19.8 mm
f15.87 mm
14.0 mm
f17.46 mm
SAE J1703 / DOT3
SECTION 5C
CLUTCH
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5C-1
General Specifications . . . . . . . . . . . . . . . . . . 5C-1
Fastener Tightening Specifications . . . . . . . . . 5C-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5C-3
Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5C-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4
Clutch Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4
Poor Disengagement . . . . . . . . . . . . . . . . . . . 5C-4
Hard to Shift or Will not Shift . . . . . . . . . . . . . . 5C-4
Clutch Chatters When Starting . . . . . . . . . . . . 5C-4
Difficult Pedal Operation . . . . . . . . . . . . . . . . . 5C-5
SPECIFICATIONS
GENERAL SPECIFICATIONS
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.
Application
Type
Max. Pedal Stroke
Pedal Free Play
Type
Thickness of Disc
Stroke
Inner Diameter
Stroke
Inner DiameterFree
With Load
Clutch Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5
Component Locator . . . . . . . . . . . . . . . . . . . 5C-6
Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . 5C-6
Pedal and Master Cylinder . . . . . . . . . . . . . . . 5C-7
Maintenance and Repair . . . . . . . . . . . . . . . 5C-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 5C-8
Bleeding of Clutch System . . . . . . . . . . . . . . . 5C-8
Clutch Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 5C-13
Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15
Clutch Oil Chamber . . . . . . . . . . . . . . . . . . . 5C-17

5C-8 CLUTCH
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
BLEEDING OF CLUTCH SYSTEM
Bleeding procedure
Notice
Keep the fluid level over ‘MAX’ in reservoir during
bleeding operation.
Do not let fluid contact a painted surface.
1. Remove the air bolt cap of the release cylinder.
Connect a vinyl tube to the bolt.
2. Insert the other end of the tube in a vacant container.
3. Slowly depress the clutch pedal several times.
4. With clutch pedal fully depressed, open the air bolt and
release air rind fluid in the fluid line,
5. Repeat this procedure until there are no more air bubbles
in the fluid flows.

Application
Steering Wheel
Steering Gear Box
Oil Pump
Steering Column
Minmum Turning Radius
Oil
SECTION 6A
POWER STEERING SYSTEM
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6A-1
General Specifications . . . . . . . . . . . . . . . . . . 6A-1
Fastener Tightening Specifications . . . . . . . . . 6A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Hard Steering . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Steering Pulls to One Side . . . . . . . . . . . . . . . 6A-2
Excessive Wheel Play . . . . . . . . . . . . . . . . . . . 6A-2
Poor Return of Steering Wheel . . . . . . . . . . . . 6A-2
Steering Wheel Shimmy . . . . . . . . . . . . . . . . . 6A-3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Abnormal Noise From Steering System . . . . . 6A-3
Component Locator . . . . . . . . . . . . . . . . . . . 6A-4
Steering System . . . . . . . . . . . . . . . . . . . . . . . 6A-4
Maintenance and Repair . . . . . . . . . . . . . . . 6A-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 6A-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5
Oil Pump Pressure Check . . . . . . . . . . . . . . . . 6A-6
Bleeding of Power Steering System . . . . . . . . 6A-6
Steering Gear Box . . . . . . . . . . . . . . . . . . . . . 6A-7
Number of Spoke
Outer Diameter
Type
Gear Ratio
Inner Steering Angle
Outer Steering Angle
Type
Maximum Pressure
Upper Tilting Angle
Lower Tilting Angle
Type
Capacity
Change Interval
Description
4
396 mm
Rack and Pinion
¥
33°37'
31°50'
Vane
75-82 kg/cm
2
4.646°
6.969°
5.25m
ATF DEXRON II
1 L
Every 24,000 km
FASTENER TIGHTENING SPECIFICATIONS
Application
Steering Shaft Bolt
Pressure Hose Bolt
Return Pipe Nut
Slotted Nut
Steering Gearbox BoltNlm
30 - 40
12 - 18
12 - 18
35 - 45
35 - 45

6A-6 POWER STEERING SYSTEM
OIL PUMP PRESSURE CHECK
Oil Pump Pressure Check
1. Disconnect the pressure hose from the oil pump connect a
pressure gauge between the oil pump and pressure hose
2. Bleed the system . Start the engine and turn the steering
wheel form lock several times until oil temperature is up to
50°C
3. Run the engine at 1,000 rpm.
4. Close the pressure gauge valve and check oil pressure.
Notice
Do not keep the valve closed for more than 10 seconds.
5. Remove the pressure gauge and connect the pressure
hose.
6. Do bleeding procedure.
BLEEDING OF POWER STEERING
SYSTEM
Bleeding of Power Steering System
1. Disconnect the fuel line. Using a starter motor, crank the
engine and turn the steering wheel from lock to lock 5 or 6
times.
Notice
Do bleeding with engine cranking. If bleed with idling, there
can be a air contact with oil.
2. Connect the fuel feed line and start the engine at idle speed.
3. Turn the steering wheel from lock to lock until there is no
more air in oil reservoir.
4. Connect the oil level is within specification.
5. By turning the steering wheel left to right, check the oil level
change.
Notice
lIf oil is not changes more than 5mm, do bleeding again.
lIf oil level rises suddenly when stopped engine, again.
Relief Pressure75 - 82 kg/cm2