SsangYong Rexton. Manual - part 494

SSANGYONG  Y200

4A-6  BRAKE SYSTEM

YAD4A070

YAD4A080

MAINTENANCE AND REPAIR

BLEEDING THE BRAKES

For Master Cylinder and Wheel Cylinder
Replacement

Notice: The bleeding sequence is as follows; right rear,
left rear, right front and left front.

Check the fluid level and add fluid during the bleeding
operation.

1. Raise the vehicle with the assistance worker riding

up to replenish the oil in the brake oil reservoir
tank.

2. Remove the bleeder screw and cap.

3. Attach a transparent tube over the valve. Allow

the tube to hang submerged in brake fluid in a
transparent container.

4. Slowly push the brake pedal several times and

hold the brake pedal.

5. Tighten the bleeder screw after loosening the

bleeder screw and draining the fluid.

Notice: Hold the brake pedal until tightening the
bleeder screw.

6. Repeat the step 5, 6 until all the air is removed.

7. Check the leaks for the bleeder screw.

8. Bleed air in the system at four wheels in order as

shown in the figure if pressure building is not
enough by depressing the pedal after above air
bleeding.

Notice:

•

Always bleed the air after replacing brake fluid
or master cylinder, caliper, brake hose and pipe.

•

Do not reuse the bled brake fluid.

•

Rapid pumping of the brake pedal pushes the
master cylinder secondary piston down the bore
in a manner that makes it difficult to bleed the
system.

•

Care must be taken to prevent the brake fluid
contacting any painted surface to prevent
damage to the paint finish.

•

Check any leak for the applicable portion after
bleeding.

BRAKE SYSTEM  4A-7

SSANGYONG  Y200

YAD4A090

YAD4A100

YAD4A110

For Hydraulic Unit Replacement

1. Add oil after hydraulic unit replacement.

2. Run the engine and depress the pedal several

times to build pressure and then keep the pedal
fully depressed.

3. Loosen hydraulic pipe screws at the hydraulic unit

outlets to bleed air.

4. Repeat above step No.3 several times until there

are no more air bubbles.

5. Bleed air in the system from the wheel if pressure

building is not enough by pressing the pedal only
after above air bleeding.

For Master Cylinder Replacement

1. Add oil after master cylinder replacement.

2. Run the engine and depress the brake pedal

several times to build pressure and then keep the
pedal fully depressed.

3. Loosen the screw of primary and secondary pipe

at the master cylinder outlets to bleed air.

4. Repeat above step No.3 several times until there

are no more air bubbles.

5. Bleed air in the system at the hydraulic unit outlet

pipe and wheel if pressure building is not enough
by depressing the pedal only after above air
bleeding.

BRAKE PEDAL

Pedal Travel Check

1. Start the engine.

2. Push the pedal three times.

3. With the brake depressed by about 30 kg (66.15 lb)

load, measure the clearance between the pedal
pad and the lower dash panel.

4. Check pad or shoe wear, any leak for the brake

system when the measured value is below the
specified value.

5. If the pedal height is not in the specified value,

loosen the lock nut of the brake booster push rod
and adjust the push rod length.

SSANGYONG  Y200

4A-8  BRAKE SYSTEM

YAD4A120

YAD4A130

YAD4A140

If clearance is less than the specified value, verify
that the clearance between the outer case of the stop
lamp and the brake pedal within the specified value.
If clearance is beyond on the specified value, it means
that the clearance between the clevis pin and brake
pedal arm is beyond. Check the faulty and repair,
adjust as needed.

Specification (A)

177 mm (From the floor mat)

Pedal Height

Notice: If the pedal height is not in the specified value,
loosen the lock nut and adjust the height.

Specification (C)

138 mm

Pedal Free Play

Notice: If the pedal free play is not in the specified
value, loosen the stop bolt and the lock nut and adjust
free play up to max. travel.

Brake Pedal Free Play

Push the brake pedal several times to discharge the
vacuum of the power booster. Measure the pedal
movement until the hardness is felt when pushing the
brake pedal by hand.

Specification

3 - 8 mm

STOPLAMP SWITCH

The multi-meter connects the stoplamp switch
connector and push the plunger. When the stoplamp
switch does not connected with pushing the plunger,
the stoplamp switch is normal.

BRAKE SYSTEM  4A-9

SSANGYONG  Y200

YAD4A150

YAD4A160

YAD4A170

YAD4A180

BRAKE BOOSTER FUNCTIONAL
CHECK

1. With the engine stopped, eliminate vacuum in the

booster by pumping the brake pedal several
times.

2. Push the pedal down and hold in this position.

3. Start the engine.

4. The booster is OK if the pedal drops further

because of extra force produced.

If the brake pedal does not drop, the vacuum system
is probably defective and should be checked. If no
defect is revealed by checking the vacuum system,
the defect is in the booster itself.

LCRV (LOAD CONSCIOUS
REDUCING VALVE)

LCRV consists of sensing part and hydraulic control
part.

1. Sensing Part

It detects the changes of vehicle height caused
by vehicle load. It consists of load sensing spring
and control lever which change according to
vehicle load.

2. Hydraulic Control Part

It consists of valve stem devices which controls
hydraulic pressure according to load detected by
sensing part.