1997 SSANGYONG KORANDO light

HYDRAULIC BRAKES 4A-15
SSANGYONG MY2002
Front Disc Brake Rotor
Type
Diameter
Thickness (New)
Discard Thickness
Thickness Variation
Lateral Runout (Installed)
Light Scoring of the Rotor Surface
Rear Disc Brake Rotor
Type
Diameter
Thickness (New)
Discard Thickness
Thickness Variation
Lateral Runout (Installed)
Booster
Dual
Ratio
Master Cylinder
Bore Diameter (Nominal)
Caliper
Minimum Piston Diameter (Front)
Minimum Piston Diameter (Rear)
Pad and lining
Front
Thickness (New)
Minimum Discard Thickness
Rear (Disc)
Thickness (New)
Minimum Discard ThicknessApplication
Ventialated
278.30
24.00
22.00
0.013
0.03
0.40
Solid
299.00
10.40
8.50
0.013
0.03
-
7 : 1
25.40
60.00
38.00 (42.9)
10.00
2.00
9.50
1.50
E32
SPECIFICATIONS
GENERAL SPECIFICATION
mm in
Application
Capacity
LublicantDescription
0.7
(0.7 qt)
DOT 4
10.96
0.95
0.87
0.0005
0.001
0.002
11. 77
0.41
0.33
0.0005
0.001
8″
& 9″
-
1.00
2.36
1.50
0.39
0.08
0.39
0.06

FRONT BRAKES 4D-5
SSANGYONG MY2002





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DIAGNOSTIC INFORMATION AND PROCEDURES
KAA4D020
PAD INSPECTION
1. Raise and suitably support the vehicle.
2. Remove the front wheel. Refer to Section 2E, Tires
and Wheels.
3. Visually check the linings for minimum thickness
and wear.
4. Measure the thickness.
Important: The minimum discard thickness of the
lining is 2 mm (0.08 inch).
5. Install the pads in axle sets only.
6. Install the rear wheels. Refer to Section 2E, Tires
and Wheels.
7. Lower the vehicle.
FRONT DISC BRAKE ROTOR
INSPECTION
Thickness variation can be checked by measuring the
thickness of the rotor at four or more points around the
circumference of the rotor. All measurements must be
made at the same distance in from the edge of the
rotor.
A rotor that varied by more than 0.013 mm (0.0005
inch) can cause pedal pulsations and/or front end
vibration during brake applications. A rotor that does
not meet these specifications should be refinished to
specifications or replaced.
During manufacturing, the brake rotor and the toler-
ances of the braking surface regarding flatness, thick-
ness variation, and lateral runout are held very close.
The maintenance of close tolerances on the shape of
the braking surfaces is necessary to prevent brake
roughness.In addition to these tolerances, the surface finish must
be held to a specified range. The control of the braking
surface finish is necessary to avoid pulls and erratic
performance and to extend lining life.
Light scoring of the rotor surfaces not exceeding 0.4
mm (0.016 inch) in depth, which may result from normal
use, is not detrimental to brake operation.
Using a commercially available dial indicator, check
lateral runout as follows:
Notice: Permissible lateral runout is a maximum 0.07
mm (0.003 inch). If lateral runout exceeds the specifica-
tion, ensure that there is no dirt between the rotor and
the hub and that contact surfaces are smooth and free
from burrs.
1. Position the transaxle in NEUTRAL.
2. Remove the rotor. Refer to “Rotor” in this section.
3. Fasten the brake rotor to the wheel hub with two
wheel nuts. Refer to Section 2E, Tires and Wheels.
KAA4D030
4. Fasten a dial indicator to the brake caliper.
5. Set the gauge probe tip to approximately 10 mm
(0.394 inch) from the outer edge of the brake rotor,
perpendicular to the disc and under slight preload.
6. Remove the dial indicator and the wheel nuts that
connect the rotor to the hub.
Important: Since accurate control of the tolerances
is necessary for proper performance of the disc
brakes, refinishing of the rotor should be done only
with precision equipment.
7. Refinish the rotor, if required, with precision equip-
ment. Discard the rotor if it fails to meet the above
specifications after refinishing.
8. Install the rotor. Refer to “Rotor” in this section.

REAR BRAKES 4E-13
SSANGYONG MY2002
5. Disconnect the parking brake cable from the
parking brake lever.
6. Remove the brake disc.
7. Using the rubber hammer, hit to separate the
parking brake lining lightly and move the lining
upward.
Inspection
1. Clean the dissembled parts and visually check
the followings;
Wear, rust and damage on the cylinder and
piston
Damage, crack on the caliper body and
damage, wear on the guide pin
Pad uneven wear and oil contamination
Boot’s damage and tear
YAD4C160
YAD4C170
YAD4C180
YAD4C190

ABS AND TCS 4F-3
SSANGYONG MY2002
GENERAL DESCRIPTION AND SYSTEM OPERATION
BASIC KNOWLEDGE REQUIRED
Before using this section, it is important that you have
a basic knowledge of the following items. Without this
knowledge, it will be difficult to use the diagnostic
procedures contained in this section.
•Basic Electrical Circuits - You should understand
the basic theory of electricity and know the meaning
of voltage, current (amps), and resistance (ohms).
You should understand what happens in a circuit
with an open or shorted wire. You should be able to
read and understand a wiring diagram.
Use of Circuit Testing Tools - You should know
how to use a test light and how to bypass
components to test circuits using fused jumper
wires. You should be familiar with a digital
multimeter. You should be able to measure voltage,
resistance, and current, and be familiar with the
controls and how to use them correctly.
ABS SYSTEM COMPONENTS
The ABS 5.3 Antilock Braking System (ABS) consists
of a conventional hydraulic brake system plus antilock
components. The conventional brake system includes
a vacuum booster, master cylinder, front disc brakes,
rear disc brakes, interconnecting hydraulic brake pipes
and hoses, brake fluid level switch and the BRAKE
indicator.
The ABS components include a hydraulic unit, an elec-
tronic brake control module (EBCM), two system fuses,
four wheel speed sensors (one at each wheel), intercon-
necting wiring, the ABS indicator, the EBD indicator
and the TCS indicator. See “ABS Component Locator”
in this section for the general layout of this system.
The hydraulic unit with the attached EBCM is located
between the surge tank and the bulkhead on the left
side of the vehicle.
The basic hydraulic unit configuration consists of hy-
draulic check valves, two solenoid valves for each
wheel, a hydraulic pump, and two accumulators. The
hydraulic unit controls hydraulic pressure to the front
calipers and rear calipers by modulating hydraulic
pressure to prevent wheel lockup.
Units equipped with TCS add two more valves for each
drive wheel for the purpose of applying the brake to a
wheel that is slipping. This is done with pressure from
the hydraulic pump in the unit. There is also a TCS
indicator lamp on the instrument panel to alert the driver
to the fact that the TCS system is active. The
components identified in the drawing are those added
to the basic ABS 5.3 system to provide traction control.
Nothing in the hydraulic unit or the EBCM is serviceable.
In the event of any failure, the entire ABS unit withattached EBCM must be replaced. For more
information, refer to “Base Braking Mode” and
“Antilock Braking Mode” in this section.
TRACTION CONTROL SYSTEM
(TCS) DESCRIPTION
General Information
The traction control system (TCS) is a traction system
by means of brake intervention only, available in a low
speed range (< 60kph).
It workes on µ - split roads with sidewise different friction
coefficients.
The spinning driven wheel is braked and the drive
torque can be transferred to the wheel on the high-µ
side. During TCS active, the TCS information lamp is
blinking.
The temperature of the brakes is calculated by a mathe-
matical model and TCS is switched passive if the calcu-
lated temperature is greater than a threshold value (500
°C).
TCS is permitted again, when the calculated tempera-
ture is less than 350 °C.
Control Algorithm
The input signals for the control algorithm are the
filtered wheel speed signals from the ABS speed
processing.
With the speed difference of the driven wheels, the
control deviation is calculated.
If the control deviation exceeds a certain threshold
value, the wheel with the greater slip is braked actively.
The threshold value depends on the vehicle speed:
It is reduced with increasing vehicle speed down to a
constant value.
KAA4F010

SSANGYONG MY2002
4F-14 ABS AND TCS
COMPONENT LOCATOR
ABS, ABS/TCS 5.3
1 ABS/TCS Hydraulic Unit
(with EBCM in case of ABS only)
2 ABS/TCS EBCM Unit (in case of TCS)
3 Rear Wheel Speed Sensor
KAA4F100
4 ABS Warning Indicator Light
5 Diagnosis Connector
6 Front Wheel Speed Sensor
7 Acceleration Sensor

SSANGYONG MY2002
4F-16 ABS AND TCS
1. Install the scan tool.
2. Turn ignition switch to ON.
3. Select the Data List mode.
Is the scan tool receiving data from the electronic
brake control module (EBCM)?
Check the display.
Are there any current DTCs displayed?
1. Turn the ignition to LOCK for 10 seconds.
2. Turn the ignition to ON and observe the ABS
indicator.
Does the indicator light for 2 seconds and then go off?
Check the ABS indicator.
Did the ABS indicator turn on and stay on?
Check whether the vehicle is equipped with traction
control.
Is the vehicle equipped with traction control?
1. Turn the ignition to LOCK for 10 seconds.
2. Turn the ignition to ON and observe the TCS
indicator.
Does the indicator light for 2 seconds and then go off?
1. Turn the ignition to LOCK.
2. Disconnect the EBCM harness connector.
3. Turn the ignition to ON.
4. Use a digital voltmeter (DVM) to measure the
voltage from ground to terminal 1 and 50 of the
EBCM harness connector.
Is the voltage equal to the specified value?
1. Turn the ignition to LOCK.
2. Use a DVM to measure the resistance from the EBCM
harness connector, terminals 28 and 29 to ground.
Is the resistance equal to the specified value?
Repair the open in the circuit that failed.
Is the repair complete?
Use a DVM to measure the resistance between
terminal 46 of the EBCM harness connector and
terminal 8 of the data link connector (DLC).
Is the resistance below the specified value?
Replace the ABS unit.
Is the repair complete?
Repair the open or high resistance in circuit BrG
between terminal 11 of the EBCM harness connector
and terminal 13 of the DLC.
Is the repair complete?
Perform the road test described above.
Are any DTCs set? Step
1
2
3
4
5
6
7
8
9
10
11
12
13
Diagnostic Circuit Check
Action Yes
Go to Step 2
Refer to the
applicable DTC
table
Go to Step 5
Go to “ABS
Indicator Lamp
Illuminated
Constantly”
Go to Step 6
Go to Step 13
Go to Step 8
Go to Step 10
System OK
Go to Step 11
System OK
Go to Step 1
Go to the table
for the DTCNo
Go to Step 7
Go to Step 3
Go to Step 4
Go to
“ABS Indicator
Lamp Inopera-
tive
Go to Step 13
Go to “Traction
Control System
Indicator Lamp
Inoperative”
Go to “Power
Supply to
Control Mod-
ule, No DTCs
Stored
Go to Step 9
-
Go to Step 12
-
-
System OK Value(s)
-
-
-
-
-
-
11 - 14 v
≈ 0 Ω
-
2 Ω
-
-
-

SSANGYONG MY2002
4F-80 ABS AND TCS
DIAGNOSTIC TROUBLE CODE (DTC) 27
STOPLAMP SWITCH FAULT
KAA4F230
Circuit Description
When the brake pedal is pressed, the contacts on the
brake light switch close to illuminate the brake lights.
Battery voltage is also applied to terminal 48 of the
elec-tronic brake control module (EBCM), which signals
the ABS controller that the brakes are applied and ABS
may be needed. Without this, signals from a wheel
speed sensor that may indicate the need for ABS
intervention are questionable. When the brake pedal is
not pressed, the EBCM terminal 48 is grounded through
the stoplamps.
Diagnosis
This procedure will check whether there is no output or
constant output from the stoplamp switch and will deter-
mine the cause as a faulty switch or a problem in the
circuitry.Cause(s)
The ground connection or the positive connection
at the EBCM has failed.
There is an open, short to ground, or short to positive
in the vehicle wiring.
The stoplamp switch has failed.
Fail Action
The system records a DTC 27. ABS operation is not
dis-abled.
Test Description
The number(s) below refer to step(s) on the diagnostic
table.
12. This step begins the process of troubleshooting
stoplamps that are always on.
Diagnostic Aids
Inspect the wiring and the connectors carefully and
thoroughly. Failure to do so could result in misdiagnosis,
causing part replacement with the reappearance of the
malfunction.

SSANGYONG MY2002
4G-2 PARKING BRAKE
DESCRIPTION AND OPERATION
BRAKE CALIPER
This braking system uses a BRAKE warning light lo-
cated in the instrument panel cluster.
The following conditions will activate the BRAKE lamp:
•The parking brake is applied when the ignition is
ON. The lamp will turn off when the parking brake
is released.
The fluid level is below the minimum mark in the
master cylinder reservoir. The lamp will turn off when
the fluid level is above the minimum.
As a test of the lamp circuit, the BRAKE lamp will
glow dimly when the ignition is ON, even if the
parking brake is off and fluid level is above the
minimum. The lamp will turn off when the engine is
started. When the brake is firmly applied, the parking
brake should hold the vehicle with ample pedal
travel remaining.
Check for frayed cables, rust, etc. or any condition
that may inhibit present (or future) free movement of
the parking brake lever assembly.