SsangYong Rexton. Service manual - part 496

SSANGYONG  Y200

4A-14  BRAKE SYSTEM

YAD4A230

YAD4A240

YAD4A250

REPAIR INSTRUCTIONS

ON-VEHICLE SERVICE

VACUUM HOSE

Removal Procedure

1. Disconnect the vacuum hose from the brake

booster.

2. Disconnect the vacuum hose from the vacuum

pump.

3. Remove the vacuum hose with the vacuum hose

bracket.

BRAKE SYSTEM  4A-15

SSANGYONG  Y200

YAD4A260

YAD4A270

YAD4A280

YAD4A290

Installation Procedure

1. Install the vacuum hose between the vacuum

pump and the power booster (Diesel Engine).

Tightening Torque

2. Install the vacuum hose between the vacuum

pump and the power booster. (Gasoline Engine)

Tightening Torque

Bracket Mounting

Bolt

Union Bolt to Vacuum

Pump

35 - 45 N•m

 (26 - 33 lb-ft)

35 - 45 N•m

 (26 - 33 lb-ft)

Bracket Mounting

Bolt

Union Bolt to Vacuum

Pump

35 - 45 N•m

 (26 - 33 lb-ft)

35 - 45 N•m

 (26 - 33 lb-ft)

BRAKE OIL LEVEL SWITCH

Removal & Installation Procedure

1. Disconnect the brake fluid level switch connector.

2. Disconnect the switch wiring connector.

3. Disconnect the switch from the brake oil tank.

SSANGYONG  Y200

4A-16  BRAKE SYSTEM

4. Installation should follow the removal procedure

in the reverse order.

YAD4A300

YAD4A310

YAD4A320

YAD4A330

BRAKE FLUID RESERVOIR

Removal & Installation Procedure

1. Remove the reservoir tank cap and drain the brake

fluid completely.

2. Remove the brake reservoir tank using the driver.

Notice: Note that pulling the reservoir tank out
excessively result in damage of the tank on
removal.

3. Remove the grommet from the master cylinder.

4. Installation should follow the removal procedure

in the reverse order.

Notice:

•

Lubricate the new brake fluid reservoir seals with
clean brake fluid.

•

After the installation, bleed the brake system.

BRAKE SYSTEM  4A-17

SSANGYONG  Y200

YAD4A340

YAD4A350

YAD4A360

YAD4A370

3. Remove the master cylinder.

•

Retain the master cylinder in the vice and
remove the retainer ring from the master cylinder
using the snap ring plier.

2. Loosen the mounting nut of the master cylinder

and remove the master cylinder from the power
booster.

MASTER CYLINDER

Removal Procedure

1. Disconnect the brake lines from the master

cylinder.

Notice: The brake fluid may damage paintwork, if
spillage onto paintwork, wash with cold water
immediately.

•

Remove the 1st piston and 2nd piston assembly
from the master cylinder assembly.