service SSANGYONG MUSSO 2003 Service Manual

4B-2 MASTER CYLINDER
1 Nut .......................................................14-22 Nm
2 Washer
3 Master Cylinder Assembly
4 Oil Level Sensor
5 Check V alve
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

SECTION 4C
POWER BOOSTER
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4C-1General Specifications . . . . . . . . . . . . . . . . . . 4C-1
Maintenance and Repair . . . . . . . . . . . . . . . 4C-2 TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Type Ratio
N 

 m
Vacuum Assisted 5.6 : 1
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . .
4C-2
Booster & Brake Master Cylinder . . . . . . . . . . 4C-2
Pedal Stroke Inspection . . . . . . . . . . . . . . . . . 4C-5

4C-2 POWER BOOSTER
1 Nut .......................................................14-22 Nm
2 Washer
3 Master Cylinder Assembly
4 Oil Level Sensor
5 Check V alve
6 Booster
7 Clevis Pin
8 Snap Pin MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
BOOSTER AND BRAKE MASTER CYLINDER9 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

SECTION 4D
FRONT DISC BRAKES
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4D-1 Fastener Tightening Specifications . . . . . . . . . 4D-1
Maintenance and Repair . . . . . . . . . . . . . . . 4D-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4D-2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Caliper Mounting Bolt Brake Hose Bolt & NutCaliper Bolt
N 

 m
85 - 105 25 - 35 22 - 34
Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4D-2
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5 Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4D-5

4D-2 FRONT DISC BRAKES
1 Eye-Hose Bolt...................................... 25-35 Nm
2 Gasket ................................................... Replace
3 Brake Hose
4 Brake Caliper
5 Bolt ........................................................... 20 Nm
6 Washer MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
FRONT DISC BRAKE Preceding Work : Removal of wheels and tires7 Front Disc Assembly
8 Brake Pad
9 Brake Hose and Nut ............................. 25-35 Nm
10 Gasket ................................................... Replace
11 Washer
12 Bolt .................................................... 85-105 Nm

SECTION 4E
REAR DISC BRAKES
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4E-1 Fastener Tightening Specifications . . . . . . . . . 4E-1
Maintenance and Repair . . . . . . . . . . . . . . . 4E-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4E-2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Caliper Mounting Bolt Brake HoseCaliper Bolt
N 

 m
85 - 105 15 - 18
20
Rear Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4E-2
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-4 Rear Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4E-4

4E-2 REAR DISC BRAKES
1 Rear Brake Disc Assembly
2 Brake Pad
3 Brake Caliper
4 Gasket ................................................... Replace
5 Bolt........................................................... 20 Nm
6 Gasket ................................................... Replace MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
REAR DISC BRAKE Preceding Work : Removal of wheels and tires7 Brake Hose
8 Gasket ................................................... Replace
9 Eye-hose Bolt ...................................... 15-18 Nm
10 Washer
11 Bolt .................................................... 85-105 Nm

FrontRear
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 thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Model
ECUNumber of Pins
Operating TemperatureMotor Operating CurrentSolenoid Coil Resistance External Resistance Air Gap
Number of teeth Description
ABS 5.3 31
-40 ~ +120 °C
Below MAX 40A
1.28K - 1.92K
0.35 - 1.60 mm 0.15 - 1.20 mm 52 52 ABS/ABD 5.3
83
-40 ~ +85 °C
Below MAX 45A
8.04 - 9.04 except AV,
HSV 4.04 - 4.54
1.28K - 1.92K
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-7 Self 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

ANTILOCK BRAKE SYSTEM 4F-9
SELF DIAGNOSIS ABS, ABS/ABD 5.3 Initialization
1. Turn the ignition switch to "ON" position.
2. Using a service connector, ground the No.13 terminal ofdiagnosis socket and No.1 ground terminal for 3 - 4 seconds. Notice If it is over 5 seconds, initialization will not be performed.
3. After completing the initialization, ABS warning lamp will beturned on until the ignition switch is turned to "OFF" position.
Output of Fault Code
1. Normal : 1 pulse (normal code 01)
2. Abnormal : 1 pulse (fault code) Notice
If appeared initial fault code and above 2 differnt fault
code, perform again initialization.
Fault code will be output the numbers of fault code with
a interval of 1 second.(turn on : 0.75 sec., turn off : 0.25 sec.)
Fault Code Elimination After repairing the defect parts, eliminate the fault from ECU.
1. Ground the diagnosis No.13 terminal to No.1 ground terminal for over 5 seconds.
2. Turn the igniotion switch to "OFF" position. Notice
If not eliminate the fault code, the code will be maintained.
Check and find the other defect parts with performing
the imitialization again, if the fault code will be output,
repair the defect parts completely.

ANTILOCK BRAKE SYSTEM 4F-11
ABS, ABS/ABD 5.0 Initializing
1. Set the ignition switch n “ON ” position.
2. Connect the No.1 terminal (Ground) and the No.13 (ABS) from diagnosis socket located in E/G room by use of service connector for 3 - 4 seconds and initialize the flash code. Notice Be careful not to connect over 5 seconds.
3. ABS indicator warning light continuously comes on until the ignition switch is “OFF ”.
Dignosis Table
1. When the system is normal One pulse (normal code 01) indicates.
2. When the system is abnormal One pulse (defect code) indicates.
Notice Repeat the initializing procedure when checking the
defect code Defect code is indicated once for 1 sec (light on : 0.75 sec, light off : 0.25 sec).
Removal the Defect Code
1. Repair the defect code and remove the memorized defect code in the ECU.
2. Connect the No. 13 terminal (ABS) from diagnosis socket and No. 1 terminal (ground) for over 5 seconds.
3. Set the ignition switch in the “OFF ” position.
Notice Defect code will be memorized in ECU unless the defect code is not removed.
Repeat the initializing procedure and check the otherdefects.