2012 SSANGYONG NEW ACTYON SPORTS Service Manual

09-174850-01
Brake Fluid ▶
Brake Fluid Type ▶ 1. Color
Ligh gold (New oil) → Brown → Black -
2. Service Interval/Type
Change: every 2 years, Type: DOT4
The water in the brake fluid has an adverse effect to the brake system. If the fluid contains
around 3% of water, the boiling point of the brake fluid goes down by 25%. It will cause
the vapor lock frequently.
Water content in fluid: around 3% after 18 months, around 7~10% after few years
The water ib fluid makes the corrosion in the brake lines, deforms and deteriorates the
rubber components, brake calipers and pistons. -
DOT4: Brake fluid for premium vehicle. Lower water absorbing rate AND higher boiling point
than DOT3
Brake Fluid Level Check ▶
The brake fluid level should be between "MAX"
and "MIN" on the reservoir. If it is below "MIN"
mark, check for oil leaks and refill the reservoir
with the specified fluid.

09-18
Front Brake ▶
Pad Thickness 1.
Measure the pad thickness and replace
it if it is below the wear limit. -
New pad Wear limit
10.5 mm 2 mm
Wera limit point -
Disc Thickness 2.
Measure the disc thickness at over four
points.
If any of measured points is below the
wear limit, replace the brake disc with
new one. -
-
New disc Wear limit
28 mm 25.4 mm
Disc Run-Out 3.
Install the dial gauge on the side of
brake disc and measure the run-out
while rotating the brake disc.
If the measured value exceeds the limit,
replace the brake disc with new one.
Otherwise, it may cause the pedal
vibration and shimmy when braking. -
-
Limit0.03 mm (before installation)
0.07 mm (when installed)

09-194850-01
Clean the dissembled components and visually check the followings:
Damage and tear on boot 4.
Uneven wear and oil contamination 5.
Damage, crack and wear on cylinder body
(A) and guide pin (B) 6.
Wear, rust and damage on the cylinder and
piston
Scratch and bending on disc plate 7.
8.

09-20
Pad Thickness
Disc thicknessRemove the front tire.
2. Measure the pad thickness and replace
it if it is below the wear limit. 1.
2.
Measure the disc thickness at over four
points.
If any of measured points is below the
wear limit, replace the brake disc with new
one. 1.
2.
New pad Wear limit
10 mm 2mm
New disc Wear limit
10.4mm 8.5mm
Disc Run-Out
Install the dial gauge on the side of brake
disc and measure the run-out while rotating
the brake disc.
If the measured value exceeds the limit,
replace the brake disc with new one.
Otherwise, it may cause the pedal vibration
and shimmy when braking. 1.
2.
Limit0.03 mm (before installation)
0.07 mm (when installed)
Rear Brake ▶

09-214850-01
Check the brake force with below
procedures:
Count the number of the clicks (notches)
when pulling up the parking brake with 19
kg of force.
If the clicks are over or below the
specified value, adjust the clicks to the
specified value with the parking brake
adjusting nut.
Check the parking brake force after
adjustment. 1.
2.
3.
Specified notches5
If the parking brake force is not enough,
check the parking brake lever and cable.
Replace the components if needed. 4.
Never park the vehicle only with the parking
brake on the stiff hill. It may cause roll
down of the vehicle due to release of the
parking brake. Place the wheel chocks
under the wheels. Parking Brake ▶

09-22
6. COMPONENTS
Brake Pedal, Master Cylinder and Booster ▶
Brake master cylinder assembly
Brake booster assembly
Brake master cylinder
Nut (12.8~16.7 Nm)
Booster mounting seal
O-ring
Brake pedal assembly
Brake pedal
Brake pedal return spring 1.
2.
3.
6.
7.
8.
11.
12.
13.Nut - Brake pedal
Stop lamp switch
Stopper
Clevis pin
Snap pin
Bolt - Brake pedal assembly
(17.6~21.6 Nm)
Nut - Brake booster
(17.6~21.6 Nm) 17.
18.
19.
20.
21.
22.
23.

09-234850-01
Brake Pipe ▶
Master cylinder primary tube assembly
Master cylinder secondary tube assembly
Front tube assembly
Front tube assembly
2-way connector tube assembly
Front brake hose assembly
Front brake hose mounting holder
Flexible hose clip
Caliper eye bolt (19.6~29.4 Nm)
Brake tube mounting clip 1.
2.
3.
4.
5.
7.
8.
9.
11.
12.Brake tube mounting clip
Brake tube mounting holder
Brake tube 2-way connector
Screw
Rear hose 2-way connector
3-way connector hose tube assembly
Rear brake hose assembly
Rear brake hose assembly
Bolt (9.8~11.8 Nm) 13.
14.
20.
21.
22.
24.
25.
26.
27.

09-24
Front/Rear Brake Assembly ▶
Front brake caliper assembly
Front brake pad
Washer
Front caliper mounting bolt
(25.5~30.4 Nm)
Caliper clip set 21.
22.
23.
24.
25. Rear brake caliper assembly
Rear brake pad
Washer
Bolt (52.9~63.7 Nm)
Rear brake disc
Rear disc brake dust shield
Bolt
Rear drum brake assembly
Parking brake shoe
Parking brake repair kit
Rear axle shaft grommet 1.
2.
3.
4.
5.
6.
7.
12.
15.
16.
17.