SsangYong Korando II (1996-2006 year). Manual - part 231

SSAMGYONG MY2002

4A-2 HYDRAULIC BRAKES

DESCRIPTION AND OPERATION

GENERAL DESCRIPTION

Brake fluid should meet the DOT 4 specification. Use
only clear fluid from a sealed container.

Fluid that is exposed to the air will absorb moisture.
Water in the brake fluid will cause the fluid to boil and
the rubber components to deteriorate.

Thoroughly clean the master cylinder reservoir cap be-
fore removing it. Do not let any dirt or foreign material
fall into the fluid reservoir.

There is a brake fluid level switch under the master
cylinder reservoir.

When the fluid level is low, the BRAKE lamp in the
instrument cluster will turn on.

The correct brake fluid level is marked on the both
side of the brake fluid reservoir. If the fluid level is
below the MIN indicator mark, check the hydraulic brake
system for leaks. Fix any leaks. Then refill the reservoir
to the MAX indicator mark.

The hydraulic brake system is parallel split on Antilock
Brake Systems. This means the left front and left rear
brakes are on one hydraulic circuit and the right front
and right rear are on the other.

HYDRAULIC BRAKES 4A-3

SSANGYONG MY2002

DIAGNOSTIC INFORMATION AND PROCEDURES

BRAKE SYSTEM TESTING

Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy,
or covered with loose dirt which can cause tires not to
grip the road unequally. Testing also will be inaccurate
on a crowned roadway because the wheels tend to
bounce.

Test the brakes at different vehicle speeds with both
light-and heavy-pedal pressure; however, avoid locking
the brakes and sliding the tires. Locked brakes and
slid-ing tires do not indicate brake efficiency since
heavily braked but turning wheels will stop the vehicle
in less distance than locked brakes. More tire-to-road
friction is present with a heavily braked, turning tire
than with a sliding tire.

Because of the high deceleration capability, a firmer
pedal may be felt at higher deceleration levels.

There are three major external conditions that affect
brake performance:

•

Tires having unequal contact and grip of the road
will cause unequal braking. Tires must be equally
inflated, and the tread pattern of the right and the
left tires must be approximately equal.

•

Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.

•

Misalignment of the wheels, particularly conditions
of excessive camber and caster, will cause the
brakes to pull to one side.

To check for brake fluid leaks, hold constant foot pres-
sure on the pedal with the engine running at idle and
the shift lever in NEUTRAL. If the pedal gradually falls
away with the constant pressure, the hydraulic system
may be leaking. Perform a visual check to confirm any
suspected leaks.

Check the master cylinder fluid level. While a slight
drop in the reservoir level results from normal lining
wear, an abnormally low level indicates a leak in the
system. The hydraulic system may be leaking either
internally or externally. Refer to the procedure below
to check the master cylinder. The system may appear
to pass this test while still having a slight leak. If the
fluid level is normal, check the vacuum booster pushrod
length. If an incorrect pushrod length is found, adjust
or replace the rod.

Check the master cylinder using the following proce
dure:

•

Check for a cracked master cylinder casting or a
brake fluid leak around the master cylinder. Leaks
are indicated only if there is at least one drop of
fluid. A damp condition is not abnormal.

•

Check for a binding pedal linkage and for an
incorrect pushrod length. If both of these parts are
in satisfactory condition, disassemble the master
cylinder and check for an elongated or swollen
primary cylinder or piston seals. If swollen seals
are found, substandard or contaminated brake fluid
should be suspected. If contaminated brake fluid
i s f o u n d , a l l t h e c o m p o n e n t s s h o u l d b e
disassembled and cleaned, and all the rubber
components should be replaced. All of the pipes
must also be flushed.

Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration
of the rubber components. If the primary piston cups in
the master cylinder are swollen, the rubber parts have
deteriorated.

If deterioration of the rubber is evident, disassemble
all the hydraulic parts and wash the parts with alcohol.
Dry these parts with compressed air before reassembly
to keep the alcohol out of the system. Replace all the
rubber parts in the system, including the hoses. When
working on the brake mechanisms, check for fluid on
the linings. If excessive fluid is found, replace the
linings.

If the master cylinder piston seals are in satisfactory
condition, check for leaks or excessive heat conditions.
If these conditions are not found, drain the fluid, flush
the master cylinder with brake fluid, refill the master
cylinder, and bleed the system.

BRAKE HOSE INSPECTION

The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be
checked for road hazard damage, cracks, chafing of
the outer cover, and for leaks or blisters. Inspect the
hoses for proper routing and mounting. A brake hose
that rubs on a suspension component will wear and
eventually fail. A light and a mirror may be needed for
an adequate inspection. If any of the above conditions
are observed on the brake hose, adjust or replace the
hose as necessary.

SSAMGYONG MY2002

4A-4 HYDRAULIC BRAKES

KAA4A010

BRAKE WARNING LAMP CIRCUIT DESCRIPTION

Diagnostic Aids

The BRAKE lamp glows brightly when the ignition is
ON and either the parking brake lever switch or the
brake fluid level switch is closed.

If neither switch is closed, the BRAKE lamp receives
a ground through the generator, and it glows dimly
when the ignition is ON and the engine is off. When
the engine starts, the generator creates voltage. With
voltage on both sides of the lamp, the lamp turns off.

Test Description

The numbers below refer to steps in the diagnostic
table.

1. This step begins the test sequence for a BRAKE

warning lamp that stays on when the engine is run-
ning.

2. This step begins the test sequence for a BRAKE

warning lamp that never turns on.

HYDRAULIC BRAKES 4A-5

SSANGYONG MY2002

Value(s)

BRAKE WARNING LAMP DIAGNOSIS

Step

Action

Start the engine and leave it running.
Does the BRAKE warning lamp stay on?
With the engine running, release the parking brake.
Is the BRAKE warning lamp off?
Check the brake fluid level.
Is the fluid level OK?
1. Fill the brake fluid reservoir with clean DOT-3

hydraulic fluid.

2. Check the cap on the fluid reservoir.
3. Start the engine and leave it running.
Is the BRAKE warning lamp on?
Disconnect the wiring harness connector from the
brake fluid level switch.
Is the BRAKE warning lamp on?
Replace the brake fluid lever switch.
Is the repair complete?
1. Connect the brake fluid level switch.
2. Disconnect the parking brake lever switch.
3. Start the engine and leave it running.
Is the BRAKE warning lamp on?
Replace the parking brake lever switch.
Is the repair complete?
1. Connect the parking brake lever switch.
2. Disconnect the STICS (Super Time and Alarm

Integrated System).

3. Start the engine and leave it running.
Is the BRAKE warning lamp on?
Replace the STICS.
Is the repair complete?
Repair the short circuit in the instrument wiring
harness between terminal D10 of the instrument
cluster and ground.
Is the repair complete?
1. Disconnect the electrical connector from the fluid

level switch.

2. Connect a jumper wire between ground and

terminal 1 of the fluid level switch harness
connector.

Does the BRAKE warning lamp turn on?
1. Disconnect the electrical connector from the fluid

level switch.

2. Connect a jump wire between terminals 1 and 2

of the fluid level switch harness connector.

Does the BRAKE warning lamp turn on?
1. Replace the brake fluid level switch.
2 The switch can be removed and replaced without

draining the brake fluid from the reservoir.

Is the repair complete?

Yes

Go To Step 2

System OK

Go To Step 5

Go To Step 7

System OK

Go To Step 9

System OK

Go To Step 11

System OK

Go To Step 13

Go To Step 14

System OK

Go To Step 12

Go To Step 3

Go To Step 4

System OK

Go To Step 6

Go To Step 8

Go To Step 10

Go To Step 15

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