Kia Rio: Brake System
Kia Rio 2017-2020 YB Service Manual / Brake System
Specifications
| Specifications |
|
Item |
Specification |
|
|
Master cylinder |
Type |
Single |
|
Cylinder I.D. |
Ø 20.64 mm (0.8125 in) |
|
|
Piston stroke |
36 ± 1 mm (1.4173 ± 0.0393 in) |
|
|
Fluid level switch |
Provided |
|
|
Brake booster |
Type |
10" Single |
|
Boosting ratio |
8 : 1 |
|
|
Front disc brake (14 in) |
||
|
Type |
Ventilated disc |
|
|
Disc O.D. |
256 mm (10.0787 in) |
|
| Disc
thickness |
22 mm (0.8661 in) |
|
|
Disc Service Limit |
20.4mm (0.8031 in) |
|
|
Cylinder type |
Single piston |
|
|
Front disc brake (15 in) |
|
|
|
Type |
Ventilated disc |
|
|
Disc O.D. |
280 mm (11.0236 in) |
|
|
Disc thickness |
22 mm (0.8661 in) |
|
|
Disc Service Limit |
20.4mm (0.8031 in) |
|
|
Cylinder type |
Single piston |
|
|
Rear disc brake |
||
|
Type |
Solid disc |
|
|
Disc O.D |
262 mm (10.3149 in) |
|
| Disc
thickness |
10.0mm (0.3937 in) |
|
|
Disc Service Limit |
8.4mm (0.3307 in) |
|
|
Cylinder type |
Single piston |
|
|
Drum brake |
||
|
Type |
Leading trailing |
|
|
Drum(Disc) I.D |
Ø 203 mm (7.9921 in) |
|
|
Brake lining thickness |
3.9 - 4.5 mm (0.1535 - 0.1772 in) |
|
O.D. : Outer Diameter I.D : Inner Diameter |
Specification (ABS)
|
Part |
Item |
Standard value |
Remark |
|
HECU |
System |
4 Channel 4 Sensor (Solenoid) |
|
|
Type |
Motor, valve relay integrated type |
||
|
Operating Voltage |
10 - 16 V |
||
|
Operating Temperature |
-40 to 120 °C (-40 to 248°F) |
||
|
Motor power |
230 W |
||
|
Active Wheel speed sensor (ABS) |
Supply voltage |
DC 4.5 - 20 V |
|
|
Output current low |
5.9 - 8.4 mA |
|
|
|
Output current high |
11.8 - 16.8 mA |
|
|
|
Output range |
1 - 2500 Hz |
|
|
|
Tone wheel |
48 teeth |
|
|
|
Air gap |
0.4 - 1.5 mm |
|
Specification (ESC)
|
Part |
Item |
Standard value |
Remark |
|
HECU |
System |
4 Channel 4 Sensor (Solenoid) |
Total control |
|
Type |
Motor, valve relay integrated type |
(ABS, HAC, VSM, ESS) |
|
|
Operating Voltage |
10 - 16 V |
|
|
|
Operating Temperature |
-40 to 120 °C (-40 to 248°F) |
|
|
|
Motor power |
270 W |
|
|
|
Active Wheel speed sensor |
Supply voltage |
DC 4.5 - 20 V |
|
|
Output current low |
5.9 - 8.4 mA |
|
|
|
Output current high |
11.8- 16.8 mA |
|
|
|
Output range |
1 - 2500 Hz |
|
|
|
Tone wheel |
48 teeth |
|
|
|
Air gap |
0.4 - 1.5 mm |
|
Service Standard
|
Items |
Standard value |
|
Brake pedal height |
180.8 mm (7.1181 in) |
|
Brake pedal Full stroke |
108 mm (4.2519 in) |
|
Stop lamp clearance |
1.0 - 2.0 mm (0.04 - 0.08 in) |
|
Front brake disc pad thickness (14, 15 in) |
11 mm (0.4331 in) |
|
Front brake disc pad service limit (14,15 in) |
2 mm (0.0787 in) |
|
Rear brake disc pad thickness |
10 mm (0.3937 in) |
|
Rear brake disc pad service limit |
2 mm (0.0787 in) |
Tightening Torques
|
Items |
N·m |
kgf·m |
lb·ft |
|
|
Master cylinder to brake booster nut |
9.8 - 15.7 |
1.0 - 1.6 |
7.2 - 11.6 |
|
|
Master cylinder tube flare nuts |
ABS |
13.7 - 16.7 |
1.4 - 1.7 |
10.1 - 12.3 |
|
ESC |
18.6 - 22.6 |
1.9 - 2.3 |
13.7 - 16.6 |
|
|
Front caliper guide rod bolts |
21.6 - 31.4 |
2.2 - 3.2 |
15.9 - 23.1 |
|
|
Rear caliper guide rod bolts |
21.6 - 31.4 |
2.2 - 3.2 |
15.9 - 23.1 |
|
|
Front caliper assembly to knuckle |
78.5 - 98.1 |
8.0 - 10.0 |
57.9 - 72.3 |
|
|
Rear caliper assembly to knuckle |
78.5 - 98.1 |
8.0 - 10.0 |
57.9 - 72.3 |
|
|
Brake pedal member bracket bolts |
16.7 - 25.5 |
1.7 - 2.6 |
12.3 - 18.8 |
|
|
Wheel speed sensor mounting bolt |
7.8 - 11.8 |
0.8 - 1.2 |
5.8 - 8.7 |
|
|
HECU bracket mounting bolts |
16.7 - 25.5 |
1.7 - 2.6 |
12.3 - 18.8 |
|
|
HECU brake tube flare nuts |
13.7 - 16.7 |
1.4 - 1.7 |
10.1 - 12.3 |
|
Lubricants
|
Items |
Recommended |
Amount |
|
Brake fluid |
DOT 3 or DOT 4 |
As required |
|
Brake pedal bushing and bolt |
Chassis grease |
As required |
|
Parking brake shoe and backing plate contacting surface |
Heat resistance grease |
As required |
Special service tools
| Special Service Tools |
|
|
|
Use |
|
09581-11000 Piston expander |
|
Spreading the front disc brake piston |
|
09580 - 0U000 Brake piston adjuster |
|
"Removal and installation of the rear disc brake piston." |
|
SCC reflector 09964-C1100 |
|
Reflector to align the SCC radar |
|
Calibration beam 09964-C1200 |
|
Laser to detect the center of the vehicle. |
|
Tripod 09964-C1300 |
|
SCC reflector or vertical / horizontal laser support. |
|
Sensor cap installer 09527-1S010 |
|
Used for installing wheel speed sensor cap (Sensor cap : Φ58.4) |
Troubleshooting
| Troubleshooting |
| Problem Symptoms Table |
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem.
Check each part in order.
If necessary, replace these parts.
|
Symptom |
Expected cause |
Countermeasure |
|
Lower pedal or sponge pedal |
Brake system (oil leakage) |
Repair |
|
Brake system (air inflow) |
Air bleeding out procedure |
|
|
Piston seal (worn out or damaged) |
Replace |
|
|
Rear brake shoe separation (faulty adjustment) |
Adjust |
|
|
Master cylinder (malfunction) |
Replace |
|
|
Dragged brake |
Brake pedal free separation (minimum) |
Adjust |
|
Parking brake cable length (adjustment trouble) |
Adjust |
|
|
Parking brake cable (trapped) |
Repair |
|
|
Rear brake shoe separation (adjustment trouble) |
Adjust |
|
|
Pad and lining (twisted or cracked) |
Replace |
|
|
Piston (trapped) |
Replace |
|
|
Piston (frozen) |
Replace |
|
|
Anker or return spring (malfunction) |
Replace |
|
|
Booster system (leakage of vacuum) |
Repair |
|
|
Master cylinder (malfunction) |
Replace |
|
|
Uneven brake |
Piston (trapped) |
Replace |
|
Pad and lining (oil stain, cracked or twisted) |
Replace |
|
|
Heavy pedal and brake trouble |
Brake system (oil leakage, air inflow) |
Perform air bleeding procedure |
|
Pad or lining (worned out) |
Replace |
|
|
Pad or lining (cracked or twisted) |
Replace |
|
|
Rear brake shoe separation (adjustment trouble) |
Adjust |
|
|
Pad or lining (oil stain) |
Replace |
|
|
Pad or lining (slippery) |
Replace |
|
|
Disc (scratched) |
Replace |
|
|
Booster system (leakage of vacuum) |
Repair |
|
|
Noise from brake |
Pad or lining (cracked or twisted) |
Replace |
|
Looseness of wheel bolt and caliper |
Adjust |
|
|
Pad sliding trouble (Pad uneven worn out) |
Replace |
|
|
Pad or lining (dirty) |
Cleaning |
|
|
Pad or lining (slippery) |
Pad replacement |
|
|
Anker or return spring (malfunction) |
Replace |
|
|
Brake pad shim (damaged) |
Replace |
|
|
Hold down spring (damaged) |
Replace |
|
|
Foreign substance stucked between disc and pad |
Cleaning |
|
|
Corrosion on disc |
Test drive brake and cleaning * get rid of corrosion by friction while test drive brake |
|
|
Caved disc |
Replace |
|
|
Not fully functioning on brake (when drive speed is fast) |
Pad or lining (worned out) |
Replace |
|
Master cylinder (malfunction) |
Replace |
|
|
Brake vibration |
Brake booster (leakage of vacuum) |
Repair |
|
Pedal free separation |
Adjust |
|
|
Master cylinder (malfunction) |
Replace |
|
|
Damaged on master cylinder cap |
Replace |
|
|
Damaged on brake line |
Replace |
|
|
Caliper returning trouble (while tire is turning, check the noise) |
Replace |
|
|
Transformed disc |
Replace |
- Brake System
- Brake Booster
- Master Cylinder
- Brake Line
- Brake Pedal
- Front Disc Brake
- Rear Disc Brake
- Rear Drum Brake
- Stop Lamp Switch
- Parking Brake Assembly
- ABS(Anti-Lock Brake System)
- ESC (Electronic Stability Control) System
- ESC Control Module
- Front Wheel Speed Sensor
- Rear Wheel Speed Sensor
- ESC OFF Switch
- Emergency Signal System
- Assist Emergency Braking(AEB) System
PAB ON/OFF Switch
Description and operation
Description
Driver can control the passenger airbag operating Condition (Enable or Disable)
by using this PAB ON/OFF switch.
Passenger Airbag (PAB) ON/OFF S ...
Brake System
Repair procedures
Operation and Leakage Check
Check all of the following
items:
Component
Procedure
Brake Booster (A)
Check brak ...
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