SsangYong Korando II (1996-2006 year). Manual - part 233

SSAMGYONG MY2002

4A-10  HYDRAULIC BRAKES

KAA4A020

KAA4A030

Notice: Keep brake fluid away from painted surfaces
because brake fluid will damage the paint finish.

2. Fill the master cylinder reservoir with brake fluid.

Keep the master cylinder reservoir at least one-
half full during the bleeding operation.

ON-VEHICLE SERVICE

MANUAL BLEEDING THE BRAKES

Removal and Installation Procedure

Important: Manual bleeding of the hydraulic modulator
is not possible. If air enters the antilock brake hydraulic
modulator, or if an unfilled modulator is installed, use
the scan tool to bleed air out of the brake system.
Replacement modulators are shipped already filled
and bled. In normal on-vehicle service procedures
involving the modulator, such as the procedure to
replace the electronic brake control module, air will
not enter the modulator. In such cases, use the
bleeding procedure in this section.

1. Remove the booster reserve by applying the

brakes several times with the engine off, until all
the reserve is depleted.

Important:  If no air is suspected to be in the
master cylinder, begin the bleeding procedure at
Step 12. If it is suspected that air is in the master
cylinder bore, then the master cylinder must be
bled, beginning with step 2.

REPAIR INSTRUCTIONS

HYDRAULIC BRAKES  4A-11

SSANGYONG MY2002

KAA4A040

KAA4A020

KAA4A040

KAA4A050

3. Disconnect the brake line at the front of the master

cylinder.

4. Allow the brake fluid to fill the master cylinder until

it begins to flow from the port.

5. Reconnect the brake line at the front of the master

cylinder.

6. Slowly push and hold the brake pedal.

7. While the brake pedal is pushed down, loosen the

brake fitting at the front of the master cylinder to
purge the air from the cylinder.

8. Slightly tighten the brake fitting. Then release the

brake pedal slowly. Wait 15 seconds before continu-
ing with the next step.

9. Repeat Steps 6-8 until all of the air is removed

from the master cylinder bore.

10. Tighten the brake line fitting.

Installation Notice

11. After the air has been bled at the front connection,

bleed the master cylinder at the rear connection
using the same sequence as with the top
connection.

Installation Notice

Tightening Torque

22  N•m (16 lb-ft)

Tightening Torque

17  N•m (13 lb-ft)

SSAMGYONG MY2002

4A-12  HYDRAULIC BRAKES

13. Slowly push and hold the brake pedal. Avoid rapid

pumping of the brake pedal.

14. While the brake pedal is pushed down, loosen the

bleeder valve to purge the air from the caliper.

15. After the air bubbles have escaped into the

container of brake fluid, slightly tighten the rear
bleeder valve.

16. Slowly release the brake pedal. Wait 15 seconds

before proceeding with the next step.

Notice:  Keep brake fluid away from painted
surfaces because brake fluid will damage the paint
finish.

17. Repeat Steps 13 - 16 until all of the air is removed.

You will know all of the air is removed when no
bubbles appear in the container when the bleeder
valve is loosened. Keep the master cylinder reser
voir at least one-half full during the bleeding
operation.

18. Tighten the front bleeder valve.

Installation Notice

12. Attach a transparent tube over the rear bleeder

valve at the right rear caliper. Allow the tube to
hang submerged in the brake fluid in a transparent
container. (After the right rear caliper is bled in
the following steps, use this procedure at the left
front, the left rear and the right front bleeder valves.)

19. Bleed the remaining calipers in the following order

: left rear, right front, and left front. Use the
procedure in Steps 12 - 17.

20.  After all calipers have been bled, check the brake

pedal for sponginess. If the brake pedal is not firm,
repeat the entire bleeding procedure to correct this
condition.

Tightening Torque

10  N•m (89 lb-ft)

KAA4A060

KAA4A070

HYDRAULIC BRAKES  4A-13

SSANGYONG MY2002

Tightening Torque

17  N•m (13 lb-ft)

FRONT BRAKE HOSE

Removal and Installation Procedure

1. Raise and suitably support the vehicle.

2. Disconnect the brake line from the brake hose sup

port bracket on the front frame on each side of the
vehicle and remove the retainer.

Installation Notice

KAA4A080

KAA4A090

KAA4A100

KAA4A110

3. Remove the brake hose from the brake hose

support bracket on the upper control arm.

4. Remove the front brake hose-to-front caliper

assembly bolt.

5. Remove the ring seals and the disc brake hose.

Installation Notice

Tightening Torque

30  N•m (22 lb-ft)

•

Bleed the brake system. Refer to “Manual
Bleeding the Brakes” in this section.

•

Check the brake system for leaks.

6. Installation should follow the removal procedure

in the reverse order.

REAR BRAKE HOSE

Removal and Installation Procedure

1. Raise and suitably support the vehicle.

2. Disconnect the brake line from the disc brake hose

at the rear axle bracket on each side of the vehicle.

Installation Notice

Tightening Torque

17  N•m (13 lb-ft)