SSANGYONG NEW ACTYON SPORTS 2012 Service Manual

09-134850-01
Maximum Stroke of Brake Pedal ▶
Check the brake pedal with below
procedures: -
Start the engine.
Pump the brake pedal around 3 times.
Depress the brake pedal with approx. 30
kg and measure the distance (A) between
the upper surface of pedal pad and the
lower dash panel.
If the measured value is out of the
specified value, adjust the length. 1.
2.
3.
4.
Specified value (A)150mm
5. BRAKE SYSTEM CHECK
Over the specified value
Cause Action
Worn brake pad Replace
Worn brake shoe Replace
Improper stroke of hand
brakeAdjust
Air in brake line Air bleeding
Oil leak Repair or replace
Brake booster push rod Replace or adjust
Improperly adjusted
stopper boltAdjust
Below the specified value
Cause Action
Brake booster push rod
Replace or adjust
Air in brake fluid Replace
Improperly adjusted
stopper boltAdjust

09-14
Specified value (B)155mm
Push rod
Stop lamp
switch Pedal Height ▶
Check the pedal height with below
procedures: -
Start the engine and measure the length
(A) between floor mat and pedal.
If the measured value is out of the
specified value, adjust the length. 1.
2.
Adjust the pedal height with below
procedures: -
Disconnect the stop lamp switch connector.
Unscrew the lock nut and remove the stop
lamp switch assembly.
Loosen the lock nut on the pedal push rod.
Turn the pedal push rod to adjust the pedal
height.
Tighten the lock nut.
Install the stop lamp switch assembly.
Connect the stop lamp switch connector.
Check if the stop lamps come on when
pressing the brake pedal around 5 mm.
If the stop lamp dpes not come on, adjust
the stop lamp switch assembly again.
If the stop lamps come on, tighten the lock
nut and measure the pedal height again. 1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

09-154850-01
Specified value (A)3 ~ 10mm
Connect the multimeter to stop lamp
switch connector and check if the
continuity exists when pushing in the
plunger. If the continuity doesn't exist, the
stop lamp switch is normal. - Pedal Free Play ▶
Stop Lamp Switch ▶Check the pedal free play with below
procedures: -
Stop the engine.
Depress the brake pedal several times to
discharge the vacuum pressure of the brake
booster.
Depress the brake pedal until you feel the
resistance, and measure the movement (A). 1.
2.
3.
Below the specified value: Check if the
distance between the outer case of stop
lamp switch and the brake pedal.
Over the specified value: It may be caused
by bigger clearance between the clevis pin
and the brake pedal arm. Replace the
components if necessary. -
-

09-16
Let the engine run for 1 to 2 minutes and
stop it. If the brake pedal stroke is
shortened as pumping the brake pedal,
the system is normal. If not, the system is
defective.
Depress the brake pedal several times
with engine off. If the brake goes down
when starting engine with pedal
depressed, the system is normal. If not,
the system is defective.
Depress the brake pedal when the engine
is running. If the pedal height is not
changed for 30 seconds after stopping
the engine, the system is normal. If not,
the system is defective. 1.
2.
3.
If the above three checks are OK, the system
is normal. If any condition is not met, check
the valve, vacuum hose and brake booster. Brake Booster ▶

09-174850-01
Brake Fluid ▶
Brake Fluid Type ▶ 1. Color
Ligh gold (New oil) → Brown → Black -
2. Service Interval/Type
Change: every 2 years, Type: DOT4
The water in the brake fluid has an adverse effect to the brake system. If the fluid contains
around 3% of water, the boiling point of the brake fluid goes down by 25%. It will cause
the vapor lock frequently.
Water content in fluid: around 3% after 18 months, around 7~10% after few years
The water ib fluid makes the corrosion in the brake lines, deforms and deteriorates the
rubber components, brake calipers and pistons. -
DOT4: Brake fluid for premium vehicle. Lower water absorbing rate AND higher boiling point
than DOT3
Brake Fluid Level Check ▶
The brake fluid level should be between "MAX"
and "MIN" on the reservoir. If it is below "MIN"
mark, check for oil leaks and refill the reservoir
with the specified fluid.

09-18
Front Brake ▶
Pad Thickness 1.
Measure the pad thickness and replace
it if it is below the wear limit. -
New pad Wear limit
10.5 mm 2 mm
Wera limit point -
Disc Thickness 2.
Measure the disc thickness at over four
points.
If any of measured points is below the
wear limit, replace the brake disc with
new one. -
-
New disc Wear limit
28 mm 25.4 mm
Disc Run-Out 3.
Install the dial gauge on the side of
brake disc and measure the run-out
while rotating the brake disc.
If the measured value exceeds the limit,
replace the brake disc with new one.
Otherwise, it may cause the pedal
vibration and shimmy when braking. -
-
Limit0.03 mm (before installation)
0.07 mm (when installed)

09-194850-01
Clean the dissembled components and visually check the followings:
Damage and tear on boot 4.
Uneven wear and oil contamination 5.
Damage, crack and wear on cylinder body
(A) and guide pin (B) 6.
Wear, rust and damage on the cylinder and
piston
Scratch and bending on disc plate 7.
8.

09-20
Pad Thickness
Disc thicknessRemove the front tire.
2. Measure the pad thickness and replace
it if it is below the wear limit. 1.
2.
Measure the disc thickness at over four
points.
If any of measured points is below the
wear limit, replace the brake disc with new
one. 1.
2.
New pad Wear limit
10 mm 2mm
New disc Wear limit
10.4mm 8.5mm
Disc Run-Out
Install the dial gauge on the side of brake
disc and measure the run-out while rotating
the brake disc.
If the measured value exceeds the limit,
replace the brake disc with new one.
Otherwise, it may cause the pedal vibration
and shimmy when braking. 1.
2.
Limit0.03 mm (before installation)
0.07 mm (when installed)
Rear Brake ▶

09-214850-01
Check the brake force with below
procedures:
Count the number of the clicks (notches)
when pulling up the parking brake with 19
kg of force.
If the clicks are over or below the
specified value, adjust the clicks to the
specified value with the parking brake
adjusting nut.
Check the parking brake force after
adjustment. 1.
2.
3.
Specified notches5
If the parking brake force is not enough,
check the parking brake lever and cable.
Replace the components if needed. 4.
Never park the vehicle only with the parking
brake on the stiff hill. It may cause roll
down of the vehicle due to release of the
parking brake. Place the wheel chocks
under the wheels. Parking Brake ▶

09-22
6. COMPONENTS
Brake Pedal, Master Cylinder and Booster ▶
Brake master cylinder assembly
Brake booster assembly
Brake master cylinder
Nut (12.8~16.7 Nm)
Booster mounting seal
O-ring
Brake pedal assembly
Brake pedal
Brake pedal return spring 1.
2.
3.
6.
7.
8.
11.
12.
13.Nut - Brake pedal
Stop lamp switch
Stopper
Clevis pin
Snap pin
Bolt - Brake pedal assembly
(17.6~21.6 Nm)
Nut - Brake booster
(17.6~21.6 Nm) 17.
18.
19.
20.
21.
22.
23.