2012 SSANGYONG NEW ACTYON SPORTS Service Manual

09-94850-01
Problem Cause Action
Burning smell
around tireToo frequent braking in high driving speed Reduce the use of
foot brake/use
engine brake
properly Used only foot brake during downhill driving
Driving with foot on brake pedal Get off the foot
from pedal
Foreign materials such as dirt or sand in brake system Replace: caliper,
wheel cylinder,
master cylinder,
return spring
Broken return spring in shoe assembly Replace
Incorrectly adjusted parking brake cable Adjust
Incorrect wheel or wheel cover
(generating the heat)Replace

09-10
This section describes the noise phenomena occurred possibly in the brake system operation.
Distinguish between the information given below and the actual problems and then, inspect the
vehicle and take appropriate measures.
Noise symptoms and Causes -
Symptom 1. If depressing the brake pedal when the engine is cold, "screeching" sound always
occurs and, after driving for a while, the sound disappears..
This usually occurs in the morning. When the temperature goes down, the dew condensation
phenomenon sets moisture on the brake disc as the window frost forms. Due to this moisture, the
iron within the brake disc and pad oxidizes, forming undetectable micro-rusts on the disc
surface. When starting the engine under this condition, noise may sound due to the friction of
micro-rusts. When operating the brake several times, the disc temperature goes up and the
micro-rusts come off and the noise goes away. Depending on the driving conditions, noise gets
louder when slightly depressing the brake pedal and oppositely, noise is smaller when deeply
depressing the brake pedal. This is simply a physical phenomenon, called "morning effect" in
professional terms, and does not imply any problems with the brake system.
Symptom 2. Slip or screech after the brake pad replacement.
This usually occurs when the bed-in is not made between the disc and the pad's friction material.
The bed-in is a state that the brake system normally works and gives no noise out, when, after
about 300 km city driving, the contact area of the pad friction material is enlarged and the disk is
in complete contact with the pad's friction material. Therefore, for some time after the brake
disk/pad replacement, the brake system poorly operates or noise (abnormal sound) occurs due
to the partial contact.
Symptom 3. "Groaning" sound occurs in the automatic transmission vehicle when slightly taking
the foot off the brake pedal to slowly start after waiting for the signal, or slightly depressing the
brake pedal.
This is the noise "Creep groan" that occurs when, in both the automatic and manual transmission,
slightly releasing the brake pedal in the neutral gear at downhill roads.
It frequently occurs at the low braking power and low speed, through the following process. When
operating the brake system at low speed and low pressure, adhesion and slip repeatedly take
place between the brake disk and the friction material, and this makes the braking power
inconstant, instantly increasing or decreasing, and gives out the brake noise.
It is also a physical phenomenon and has no relation with the brake performance.BRAKE OPERATION AND NOISE ▶

09-114850-01
4. AIR BLEEDING
Fill up the brake fluid up to "MAX" line on
the reservoir. 1.
Fill the reservoir with brake fluid and pump
the brake pedal several times. Then keep it
depressed. 2.
Loosen the bleed screw and collect the
bleeding brake fluid from the brake line with
the order in the figure. 3.
Fill the reservoir with the brake fluid as
much as it bleeded, and continue to
bleeding operation. Never reuse the used brake fluid.
Use only specifies brake fluid (DOT 4). Add brake fluid between MAX and MIN lines on the
reservoir (0.7 to 0.8 liters).
Be careful not to splash the brake fluid on painted area or body.
Make sure that any foreign material does not get into brake line.
Always work with another staff. -
-
-
-
-

09-12
Air bleed screw at front brake 5.Air bleed screw at rear brake 4.
Repeat the air bleeding procedures until
clear brake fluid comes out of air bleed
screw. 6.
Check for oil leaks from the brake lines. 7.
Air in brake
fluid
Deteriorated
fluid
Air bleed screw at front brake
Air bleed screw at rear brake
Air bleeding completed

09-134850-01
Maximum Stroke of Brake Pedal ▶
Check the brake pedal with below
procedures: -
Start the engine.
Pump the brake pedal around 3 times.
Depress the brake pedal with approx. 30
kg and measure the distance (A) between
the upper surface of pedal pad and the
lower dash panel.
If the measured value is out of the
specified value, adjust the length. 1.
2.
3.
4.
Specified value (A)150mm
5. BRAKE SYSTEM CHECK
Over the specified value
Cause Action
Worn brake pad Replace
Worn brake shoe Replace
Improper stroke of hand
brakeAdjust
Air in brake line Air bleeding
Oil leak Repair or replace
Brake booster push rod Replace or adjust
Improperly adjusted
stopper boltAdjust
Below the specified value
Cause Action
Brake booster push rod
Replace or adjust
Air in brake fluid Replace
Improperly adjusted
stopper boltAdjust

09-14
Specified value (B)155mm
Push rod
Stop lamp
switch Pedal Height ▶
Check the pedal height with below
procedures: -
Start the engine and measure the length
(A) between floor mat and pedal.
If the measured value is out of the
specified value, adjust the length. 1.
2.
Adjust the pedal height with below
procedures: -
Disconnect the stop lamp switch connector.
Unscrew the lock nut and remove the stop
lamp switch assembly.
Loosen the lock nut on the pedal push rod.
Turn the pedal push rod to adjust the pedal
height.
Tighten the lock nut.
Install the stop lamp switch assembly.
Connect the stop lamp switch connector.
Check if the stop lamps come on when
pressing the brake pedal around 5 mm.
If the stop lamp dpes not come on, adjust
the stop lamp switch assembly again.
If the stop lamps come on, tighten the lock
nut and measure the pedal height again. 1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

09-154850-01
Specified value (A)3 ~ 10mm
Connect the multimeter to stop lamp
switch connector and check if the
continuity exists when pushing in the
plunger. If the continuity doesn't exist, the
stop lamp switch is normal. - Pedal Free Play ▶
Stop Lamp Switch ▶Check the pedal free play with below
procedures: -
Stop the engine.
Depress the brake pedal several times to
discharge the vacuum pressure of the brake
booster.
Depress the brake pedal until you feel the
resistance, and measure the movement (A). 1.
2.
3.
Below the specified value: Check if the
distance between the outer case of stop
lamp switch and the brake pedal.
Over the specified value: It may be caused
by bigger clearance between the clevis pin
and the brake pedal arm. Replace the
components if necessary. -
-

09-16
Let the engine run for 1 to 2 minutes and
stop it. If the brake pedal stroke is
shortened as pumping the brake pedal,
the system is normal. If not, the system is
defective.
Depress the brake pedal several times
with engine off. If the brake goes down
when starting engine with pedal
depressed, the system is normal. If not,
the system is defective.
Depress the brake pedal when the engine
is running. If the pedal height is not
changed for 30 seconds after stopping
the engine, the system is normal. If not,
the system is defective. 1.
2.
3.
If the above three checks are OK, the system
is normal. If any condition is not met, check
the valve, vacuum hose and brake booster. Brake Booster ▶