SSANGYONG NEW ACTYON SPORTS 2013 Service Manual

08-14
3) Caster
The angle between the vertical line and king pin, which fixes the steering knuckle and front axle, (steering
column which connects the top and bottom ball joints in the independent axle type) when viewed the
tires from the side.
Caster: With considering the height difference between the wheel centers of the front and rear
wheels. (Under standard condition that the vehicle is on a level ground) ▶
Positive caster: Top of the king pin is tilted backward from the vertical line of the wheel center
when viewed the tires from the side ▶
Advantages:Directional force to go straight (following control)
Restoring force of the wheel (restored to the straight ahead direction)
Prevention of wheel shimmy (wheels wobble left and right) -
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Negative caster: Top of the king pin is tilted forward from the vertical line of the wheel center when
viewed the tires from the side ▶
Advantages:
Disadvantages:Impact from the road is transferred to the steering wheel (steering wheel turns)
Poor straightness -
- Smaller turning radius -
Caster
4.6 ± 0.4°

09-34850-01
1. SPECIFICATION
Unit Description Specification
Front brake Type Ventilated disc
Outer diameter of discØ294 mm
Inner diameter of caliper cylinderØ43.0 x 2 mm
Thickness of disc 28 mm (wear limit: 25.4 mm)
Area of brake pad Above 60 cm2
Pad wear indicator Mechanical type
Rear brake Type Solid disc
Outer diameter of discØ299 m
Thickness of disc 10.4 mm (wear limit: 8.5 mm)
Area of brake pad Above 28.8 cm2
Pad wear indicator Mechanical type
Brake booster Type Vacuum assist type
Size8” + 9” (Tandem)
Master cylinder Type Tandem type(integrated level sensor)
Inner diameter of cylinderØ26.99 mm
Brake pedal Maximum operating stroke 150 mm
Pedal ratio 4 : 1
Free play 3 to 10 mm
Parking brake Type Mechanically expanded rear lining
Operating type Hand operated type
Inner diameter of drumØ190 mm
Brake oil Specification DOT 4
Capacity As required
Service Interval: Change the brake oil at every 2 years
DOT?
It is the quality grade of brake fluid established by US Department of Transportation.

09-4
2. SYSTEM OVERVIEW
1) Terms and Definition
CBS: Conventional Brake System
ABS: Anti-Lock Brake System
EBD: Electronic brake-Force Distribution
ESP: Electronic Stability Program
ABD: Automatic Braking Differential
ASR: Acceleration Slip Regulation
AYC: Active Yaw Control (Understeer and Oversteer Control)
HBA: Hydraulic Brake Assistant
ARP: Active Rollover Protection
HSA: Hill Start Assistant
Brake pad: Brake pad is a component of disk brakes used in automotive and other applications.
Brake pad is steel backing plates with friction material bound to the surface that faces the brake disc.
Brake disc: The brake disc is a device for slowing or stopping the rotation of a wheel while it is in
motion.
Brake caliper: To stop the wheel, friction material in the form of brake pads (mounted on a device
called a brake caliper) is forced hydraulically against both sides of the disc. Friction causes the disc
and attached wheel to slow or stop.
Brake master cylinder: The brake master cylinder is a control device that converts non-hydraulic
pressure (commonly from a driver's foot) into hydraulic pressure, in order to move other device(s)
which are located at the other end of the hydraulic system, such as one or more slave cylinders. As
piston(s) move along the bore of the master cylinder, this movement is transferred through the
hydraulic fluid, to result in a movement of the slave cylinder(s). The hydraulic pressure created by
moving a piston (inside the bore of the master cylinder) toward the slave cylinder(s) compresses the
fluid evenly, but by varying the comparative surface-area of the master cylinder and/or each slave
cylinder, one will vary the amount of force and displacement applied to each slave cylinder (relative to
the amount of force and displacement that was applied to the master cylinder). -
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FunctionVehicle with CBS
Vehicle with ABS/EBD Vehicle with ESP
ABS
Not appliedApplied
Applied EBD Applied
ABD
Not applied ASR
AYC
HBA
ARP
2) Functions

09-54850-01
3) Parts Arrangement
Part nameVehicle with
CBSVehicle with ABS/EBDVehicle with ESP
HECU
Not appliedAppliedApplied Front wheel speed sensor
Rear wheel speed sensor
ABS warning lamp
EBD indicator
Longitudinal G sensor 2WD: N/A, 4WD: Applied Not applied
Sensor cluster
(Yaw rate sensor,
lateral/longitudinal G sensor)
Not applied Applied
ESP indicator
ESP OFF switch and warning
lamp
Steering wheel angle sensor
4) Components
ABS ESP+ARP
2WD 4WD 2WD 4WD
Whhel speed sensor 4 4 4 4
Sensor cluster N/A N/A Applied Applied
G-sensor N/A Applied N/A N/A
2H G-sensor - Operating - -
4H G-sensor - Operating - -
4L G-sensor - Operating - -
2H sensor cluster - - Operating Operating
4H sensor cluster - - Operating Operating
4L sensor cluster - - Operating Operating

09-6
LampIndicator/Warning Lamp
Description
EBD warning lamp ON when EBD function is failed
ABS warning lamp ON when ABS function is failed
ESP indicator Blinking when ESP function is operating
ESP OFF indicator ON when the ESP OFF switch is pressed
ESP warning lamp ON when ESP function is failed
ESP buzzer Sound when ESP function is operating
5) Indicators and Warning Lamps for ABS/ESP

09-74850-01
Problem Possible Cause Action
Noise or vehicle
vibration when appliedIncorrectly mounted back plate or caliper Repair
Loosened bolt of back plate or caliper Retighten
Uneven wear of brake disc Replace
Brake pad contamination Clean or replace
Sticking brake pad on contact surface Replace
Wear or hardening of brake pad Replace
Excessive clearance between caliper and pad Repair
Uneven contact of pad Repair
Lack of lubrication in sliding parts Lubricate
Improper operation of caliper Replace
Dust cover missing Repair
Loosened suspension mounting bolt Retighten
Pulls to one side when
brakingUnbalanced tire pressure between left and right Adjust
Poor contact of brake pad Repair
Oil or grease on brake pad Replace
Scratch, uneven wear, distortion of brake disc Replace
Improperly installed brake caliper Repair
Improper operation of auto adjuster Repair
Crack or distortion of brake pad Replace
Poor braking Oil leak or contamination Repair or replace
Air in brake line Bleed air
Improper operation of brake booster Repair
Poor contact of brake pad Repair
Oil or grease on brake pad Replace
Improper operation of auto adjuster Repair
Clogged brake line Repair
Improper operation of proportioning valve Repair
3. TROUBLESHOOTING

09-8
Problem Possible Cause Action
Increased pedal stroke Air in brake line Bleed air
Oil leak Repair
Worn brake pad Replace
Excessive clearance between push rod and master
cylinderAdjust
Worn or damaged piston seal Replace
Brake dragging Parking brake is not fully released Release
Incorrect adjustment of parking brake Adjust
Incorrectly adjusted clearance of parking brake shoe Adjust
Faulty brake pedal return spring Replace
Incorrectly adjusted free play of brake pedal Adjust
Faulty master cylinder Replace
Lack of lubrication in sliding parts Lubricate
Faulty brake booster (vacuum leak) Repair
Wear, hardening or poor contact of brake pad Replace
Oil or water on lining Repair or replace
Fixed or broken parking brake cable Replace
Excessive stroke of brake lever Adjust notch
Faulty auto clearance adjuster Repair
Poor parking
brake
Increased stroke of
parking brake leverLoosened parking brake cable Adjust or replace
Incorrectly adjusted parking brake cable Adjus
Defective automatic lining clearance adjuster Repair or replace
Worn brake lining Replace

09-94850-01
Problem Cause Action
Burning smell around
tireToo frequent braking in high driving speed Reduce the use of
foot brake/use
engine brake
properly Used only foot brake during downhill driving
Driving with foot on brake pedal Get off the foot from
pedal
Foreign materials such as dirt or sand in brake system Replace: caliper,
wheel cylinder,
master cylinder,
return spring
Broken return spring in shoe assembly Replace
Incorrectly adjusted parking brake cable Adjust
Incorrect wheel or wheel cover
(generating the heat)Replace

09-10
This section describes the noise phenomena occurred possibly in the brake system operation.
Distinguish between the information given below and the actual problems and then, inspect the vehicle
and take appropriate measures.
Noise symptoms and Causes -
Symptom 1. If depressing the brake pedal when the engine is cold, "screeching" sound always
occurs and, after driving for a while, the sound disappears..
This usually occurs in the morning. When the temperature goes down, the dew condensation
phenomenon sets moisture on the brake disc as the window frost forms. Due to this moisture, the iron
within the brake disc and pad oxidizes, forming undetectable micro-rusts on the disc surface. When
starting the engine under this condition, noise may sound due to the friction of micro-rusts. When
operating the brake several times, the disc temperature goes up and the micro-rusts come off and the
noise goes away. Depending on the driving conditions, noise gets louder when slightly depressing the
brake pedal and oppositely, noise is smaller when deeply depressing the brake pedal. This is simply a
physical phenomenon, called "morning effect" in professional terms, and does not imply any problems
with the brake system.
Symptom 2. Slip or screech after the brake pad replacement.
This usually occurs when the bed-in is not made between the disc and the pad's friction material. The
bed-in is a state that the brake system normally works and gives no noise out, when, after about 300 km
city driving, the contact area of the pad friction material is enlarged and the disk is in complete contact
with the pad's friction material. Therefore, for some time after the brake disk/pad replacement, the brake
system poorly operates or noise (abnormal sound) occurs due to the partial contact.
Symptom 3. "Groaning" sound occurs in the automatic transmission vehicle when slightly taking the foot
off the brake pedal to slowly start after waiting for the signal, or slightly depressing the brake pedal.
This is the noise "Creep groan" that occurs when, in both the automatic and manual transmission,
slightly releasing the brake pedal in the neutral gear at downhill roads.
It frequently occurs at the low braking power and low speed, through the following process. When
operating the brake system at low speed and low pressure, adhesion and slip repeatedly take place
between the brake disk and the friction material, and this makes the braking power inconstant, instantly
increasing or decreasing, and gives out the brake noise.
It is also a physical phenomenon and has no relation with the brake performance.BRAKE OPERATION AND NOISE ▶

09-114850-01
4. AIR BLEEDING
Fill up the brake fluid up to "MAX" line on the
reservoir. 1.
Fill the reservoir with brake fluid and pump the
brake pedal several times. Then keep it
depressed. 2.
Loosen the bleed screw and collect the
bleeding brake fluid from the brake line with
the order in the figure. 3.
Fill the reservoir with the brake fluid as much
as it bleeded, and continue to bleeding
operation. Never reuse the used brake fluid.
Use only specifies brake fluid (DOT 4). Add brake fluid between MAX and MIN lines on the
reservoir (0.7 to 0.8 liters).
Be careful not to splash the brake fluid on painted area or body.
Make sure that any foreign material does not get into brake line.
Always work with another staff. -
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