SSANGYONG MUSSO 2003 Service Manual

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

FRONT DISC BRAKES 4D-3
Removal & Installation Procedure
1. MANDO Brake
Tightening Torque 25 - 35 Nm
2. PBR Brake Remove the eye-hose bolt and disconnect the hose. Installation Notice
Tightening Torque 15 - 18 Nm
3. Remove the wheel speed sensor (for ABS vehicies). Installation Notice
Tightening Torque 6 - 8 Nm
4. Remove the mounting bolts and then caliper assembly. Installation Notice
Tightening Torque 85 - 105 Nm
Remove the hose mounting nut and disconnect the hose. Installation Notice

4D-4 FRONT DISC BRAKES
5. Pull out the brake pads. Replace pads if necessary.Notice Always change the all pads on one wheel at a time.
6. Installation should follow the removal procedure in the reverse order.
7. Bleed the air from the system.

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. Check the cylinder and piston for wear, rust or damage.
Check the caliper body and guide pin for wear, damage
or crank.
Check the pads for uneven wear or oiliness.
Check the boots for damage or tear.
2. Measure caliper housing inner diameter.
Item
With PBR
With MANDO Wear Limit

61.4 mm
61.0 mm
Standard
10 mm Wear Limit
2.0 mm
Standard
60.4 mm
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 mm Wear Limit
22 mm

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

REAR DISC BRAKES 4E-3
Tightening Torque 15 - 18 Nm
Tightening Torque 85 - 105 Nm
Removal & Installation Procedure
1. Remove the eye-hose bolt and disconnect the hose.
Installation Notice
2. Unscrew the mounting bolts and remove the brake caliper assembly. Installation Notice
3. Pull out the brake pads. Replace pads if necessary. Notice Always change the all pads on one wheel at a time.
4. Installation should follow the removal precedure in the reverse order.
5. Bleed the air from the system.

4E-4 REAR DISC BRAKES
Standard10.4 mm Wear Limit
9.3 mm
UNIT REPAIR REAR DISC BRAKE Inspection Procedure
1. Clean all components and visually check the followings. Check the cylinder and piston for wear, rust or damage.
Check the caliper body and guide pin for wear, damage
or crank.
Check the pads for uneven wear or oiliness.
Check the boots for damage or tear.
Standard
40.5 mm
38.2 mm Wear Limit
41.5 mm
39.2 mm
2. Measure caliper housing inner diameter.
3. Measure pad thickness.
Standard
9.5 mm Wear 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

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