2003 SSANGYONG MUSSO maintenance

4C-2 POWER BOOSTER
1 Nut .......................................................14-22 Nm
2 Washer
3 Master Cylinder Assembly
4 Oil Level Sensor
5 Check V alve
6 Booster
7 Clevis Pin
8 Snap Pin MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
BOOSTER AND BRAKE MASTER CYLINDER9 Seal
10 Spacer 11 Nut ......................................................... 8-18 Nm
12 Front Tube (LH)
13 Front Tube (RH)
14 Rear Tube
15 1st Tube (Primary)
16 2nd Tube (Secondary)
MANDO
PBR

SECTION 4D
FRONT DISC BRAKES
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4D-1 Fastener Tightening Specifications . . . . . . . . . 4D-1
Maintenance and Repair . . . . . . . . . . . . . . . 4D-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4D-2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Caliper Mounting Bolt Brake Hose Bolt & NutCaliper Bolt
N 

 m
85 - 105 25 - 35 22 - 34
Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4D-2
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5 Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4D-5

4D-2 FRONT DISC BRAKES
1 Eye-Hose Bolt...................................... 25-35 Nm
2 Gasket ................................................... Replace
3 Brake Hose
4 Brake Caliper
5 Bolt ........................................................... 20 Nm
6 Washer MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
FRONT DISC BRAKE Preceding Work : Removal of wheels and tires7 Front Disc Assembly
8 Brake Pad
9 Brake Hose and Nut ............................. 25-35 Nm
10 Gasket ................................................... Replace
11 Washer
12 Bolt .................................................... 85-105 Nm

SECTION 4E
REAR DISC BRAKES
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4E-1 Fastener Tightening Specifications . . . . . . . . . 4E-1
Maintenance and Repair . . . . . . . . . . . . . . . 4E-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4E-2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Caliper Mounting Bolt Brake HoseCaliper Bolt
N 

 m
85 - 105 15 - 18
20
Rear Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4E-2
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-4 Rear Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4E-4

4E-2 REAR DISC BRAKES
1 Rear Brake Disc Assembly
2 Brake Pad
3 Brake Caliper
4 Gasket ................................................... Replace
5 Bolt........................................................... 20 Nm
6 Gasket ................................................... Replace MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
REAR DISC BRAKE Preceding Work : Removal of wheels and tires7 Brake Hose
8 Gasket ................................................... Replace
9 Eye-hose Bolt ...................................... 15-18 Nm
10 Washer
11 Bolt .................................................... 85-105 Nm

FrontRear
Front Rear
SECTION 4F
ANTILOCK BRAKE SYSTEM
TABLE OF CONTENTS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Model
ECUNumber of Pins
Operating TemperatureMotor Operating CurrentSolenoid Coil Resistance External Resistance Air Gap
Number of teeth Description
ABS 5.3 31
-40 ~ +120 °C
Below MAX 40A
1.28K - 1.92K
0.35 - 1.60 mm 0.15 - 1.20 mm 52 52 ABS/ABD 5.3
83
-40 ~ +85 °C
Below MAX 45A
8.04 - 9.04 except AV,
HSV 4.04 - 4.54
1.28K - 1.92K
0.35 - 1.60 mm 0.15 - 1.20 mm
52 52
Hydraulic System
Wheel Speed Sensor Impulse Ring
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4F-1
General Specifications . . . . . . . . . . . . . . . . . . 4F-1
Schematic and Routing Diagrams . . . . . . . . 4F-2 ABS 5.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-2
ABS/ABD 5.0 . . . . . . . . . . . . . . . . . . . . . . . . . 4F-3
ABS 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-4
ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . 4F-5
Component Locator . . . . . . . . . . . . . . . . . . . 4F-6 ABS, ABS/ABD . . . . . . . . . . . . . . . . . . . . . . . . 4F-6
ABD System Description . . . . . . . . . . . . . . . 4F-7 Self Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4F-9
ABS, ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . 4F-9
ABS, ABS/ABD 5.0 . . . . . . . . . . . . . . . . . . . . 4F-11
Defect Codes . . . . . . . . . . . . . . . . . . . . . . . . 4F-13
Maintenance and Repair . . . . . . . . . . . . . . 4F-19
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 4F-19
Wheel Speed Sensor . . . . . . . . . . . . . . . . . . 4F-19
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . 4F-21 ABS 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-21
ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . . . . 4F-24

ANTILOCK BRAKE SYSTEM 4F-19
MAINTENANCE AND REPAIRON-VEHICLE SERVICE
WHEEL SPEED SENSOR
1 Bolt
2 Front Wheel Speed Sensor
3 Knuckle 4 Bolt
5 Rear Wheel Speed Sensor
6 Rear Axle

SECTION 4G
PARKING BRAKE
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4G-1General Specifications . . . . . . . . . . . . . . . . . . 4G-1
Fastener Tightening Specifications . . . . . . . . . 4G-1
Component Locator . . . . . . . . . . . . . . . . . . . 4G-2 TABLE OF CONTENTS
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 4G-2
Maintenance and Repair . . . . . . . . . . . . . . . 4G-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4G-3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 4G-3
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Parking Brake Lever Bolt Cable Mounting Bracket Bolt
N 

 m
8 - 18 8 - 18
FASTENER TIGHTENING SPECIFICATIONS
Application
Type
Operating Type
Description
Mechanically Operated Rear Wheel Expansion Manual