Kia Optima: Brake System

Kia Optima DL3 2019-2020 Service and Repair Manual / Brake System

Service data
Service Data
Service data

Item
Specification
Master cylinder
Cylinder I.D.
Ø 22.22 mm (0.874 in)
Piston stroke
45 ± 1 mm (1.77 in ± 0.87 in)
Fluid level switch
Provided
Brake booster
Type
11.0" Single
Boosting ratio
10.5:1
Front brake 16 inch (Disc)
Type
Ventilated disc
Disc O.D.
Ø 305 mm (12.00 in)
Disc thickness
25 mm (0.98 in)
Cylinder type
Single
Cylinder I.D.
Ø 60.6 mm (2.38 in)
Front brake 17 inch (Disc)
Type
Ventilated disc
Disc O.D.
Ø 325 mm (12.79 in)
Disc thickness
30 mm (1.18 in)
Cylinder type
Single
Cylinder I.D.
Ø 60.6 mm (2.38 in)
Rear brake 15 inch (Disc) / Foot pedal parking brake type
Type
Solid disc
Disc O.D.
Ø 284 mm (11.18 in)
Disc thickness
10 mm (0.39 in)
Cylinder type
Single
Cylinder I.D.
Ø 38.15 mm (1.50 in)
Rear brake 15 inch (Disc) / Electirc parking brake type
Type
Solid disc
Disc O.D.
Ø 284 mm (11.18 in)
Disc thickness
10 mm (0.39 in)
Cylinder type
Single
Cylinder I.D.
Ø 38.00 mm (1.49 in)
Rear brake 16 inch (Disc) / Electirc parking brake type
Type
Solid disc
Disc O.D.
Ø 300 mm (11.81 in)
Disc thickness
10 mm (0.39 in)
Cylinder type
Single
Cylinder I.D.
Ø 38.00 mm (1.49 in)

Specification (ESC)

Part
Item
Standard value
Remark
HECU
System
4 Channel 4 Sensor control system
Total control (ABS, TCS, EBD, ESC)
Type
Motor, valve relay intergrated type
ECU, TCU and CAN
Operating Voltage
10V - 16V

Operating Temperature
-40°C - 110°C

Motor power
310W [Normal] / 370W [Plus]

Active Wheel speed sensor (ABS)
Supply voltage
Front : DC 4.25 - 20V

Rear : DC 4.5 - 20V
Output current low
Front : 5.95 - 8.05 mA
Typ .7 mA
Rear : 5.9 - 8.4 mA
Output current high
Front : 11.9 - 16.1 mA
Typ .14 mA
Rear : 11.8 - 16.8 mA
Output range
Front : 1 - 2500 Hz

Rear : 0 - 2500 Hz
Tone wheel
Front : 48 teeth, Rear : 47 teeth

Air gap
0.4 - 1.0 mm

Steering Wheel Angle Sensor
Operating Voltage
8V - 16V

Current Consumption
Max. 150 mA

Output measurement range
-780 to + 779.9°

Operating Angular velocity
0 - 1016°/sec


Service Standard

Items
Standard value
Brake pedal height
130.4 ± 3 mm (5.13 ± 0.11 in)
Brake pedal Full stroke
176 mm (6.93 in)
Stop lamp switch clearance
1 - 2 mm (0.04 in - 0.08 in)
Brake pedal free play
2 - 4 mm (0.08 in - 0.16 in)
Front brake disc pad thickness
11 mm (0.43 in)
Front brake disc pad service limit
2.0 mm (0.07 in)
Front brake disc thickness [16 inch]
25 mm (0.98 in)
Front brake disc service limit [16 inch]
23 mm (0.90 in)
Front brake disc thickness [17 inch]
30 mm (1.18 in)
Front brake disc service limit [17 inch]
28 mm (1.10 in)
Rear brake disc pad thickness
10 mm (0.39 in)
Rear brake disc pad service limit
2.0 mm (0.07 in)
Rear brake disc thickness [15 inch]
10 mm (0.39 in)
Rear brake disc thickness [16 inch]
10 mm (0.39 in)

Tightening torque
Tightening Torque

Items
N.m
kgf.m
lb-ft
Master cylinder to brake booster
9.8 - 15.6
1.0 - 1.6
7.2 - 11.6
Brake booster mounting nuts
12.7 - 17.6
1.3 - 1.8
9.4 - 13.0
Air bleeding screw
6.9 - 12.7
0.7 - 1.3
5.1 - 9.4
Brake tube flare nut, brake hose
13.7 - 16.7
1.4 - 1.7
10.0 - 12.3
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 mounting bolt
98.1 - 117.6
10.0 - 12.0
72.3 - 86.8
Rear caliper assembly mounting bolt
78.5 - 98.1
8.0 - 10.0
57.9 - 72.3
Brake hose to caliper
24.5 - 29.4
2.5 - 3.0
18.1 - 21.7
Brake pedal member bracket nut
16.7 - 25.5
1.7 - 2.6
12.3 - 18.8
Wheel speed sensor mounting bolt
6.9 - 10.8
0.7 - 1.1
5.1 - 7.9
HECU bracket mounting nut
19.6 - 29.4
2.0 - 3.0
14.4 - 21.7

Lubricant
Lubricants

Items
Recommended
Quantity
Brake fluid
DOT 4
414 ± 20cc
Brake pedal bushing and bolt
Chassis grease
As required

  

In order to maintain the best braking performance and ABS / ESC performance of the vehicle, please use genuine parts that meet the specifications.

( Standard : SAE J1704 DOT-4 LV, ISO4925 CLASS-6, FMVSS 116 DOT-4)

Special service tools
Special Service Tools

Tool Name / Number
Illustration
Description
Piston expander
09581-11000

Spreading the front disc brake piston.
Piston adjuster
09580-0U000

Spreading the rear disc brake piston.
Sensor cap installer
09527-AL400

Used for installing wheel speed sensor cap
(Sensor cap : Φ72.6)

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
Possible cause
Countermeasure
Lower pedal or sponge pedal
Brake system (oil leakage)
Repair
Brake system (air inflow)
Perform air bleeding procedure
Piston seal (worn out or damaged)
Replace
Rear brake shoe separation (faulty adjustment)
Adjust
Master cylinder (malfunction)
Replace
Brake drag
Brake pedal free separation (minimum)
Adjust
Parking brake cable length (adjustment)
Adjust
Parking brake cable (sticking)
Repair
Rear brake shoe separation (adjustment)
Adjust
Pad and lining (twisted or cracked)
Replace
Piston (sticking)
Replace
Piston (frozen)
Replace
Anker or return spring (malfunction)
Replace
Booster system (leakage of vacuum)
Repair
Master cylinder (malfunction)
Replace
Uneven brake
Piston (sticking)
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
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 vehicle to get rid of corrosion between rotor and pads.

Caved disc
Replace
Poor braking performance
(at highway speeds)
Pad or lining (worned out)
Replace
Master cylinder (malfunction)
Replace
Brake vibration
Brake booster (vacuum leak)
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 for noise)
Replace
Warped rotor
Replace

Brake bleeding procedures
Brake System Bleeding

1st Air Bleeding (Normal Brake System)

  

Do not reuse the drained fluid.

Always use genuine DOT4 brake Fluid.

Using a non-genuine DOT4 brake fluid can cause corrosion and decrease the life of the system.

Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.

Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure and checked after bleeding each brake caliper. Add fluid as required.

Repair should be done in a pair

- Main worker : Check bleed screw operation (open/close) and detect air from the outside of the vehicle.

- Assistance : Operate the brake pedal and the diagnostic equipment from the inside of the vehicle.

1.

Make sure the brake fluid in the reservoir is at the MAX (upper) level line.

2.

Have someone slowly pump the brake pedal several times, and then apply pressure.

3.

Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw securely.

Tightening torque :

6.8 - 12.7 N.m (0.7 - 1.3 kgf.m, 5.0 - 9.4 lb-ft)

[Front]

[Rear]

4.

Repeat the procedure for wheel in the sequence shown below until air bubbles no longer appear in the fluid.

5.

Follow the sequence as shown below.

2nd Air Bleeding (ESC System air bleeding procedures)

This procedure should be followed to ensure adequate bleeding of air and filling of the ESC unit, brake lines and master cylinder with brake fluid.

1.

Remove the reservoir cap and fill the brake reservoir with brake fluid.

  

When pressure bleeding, do not depress the brake pedal.

Recommended fluid........ DOT4

2.

Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled clear plastic bottle.

3.

Connect the diagnostic tool to the data link connector located underneath the dash panel.

4.

Select and operate according to the instructions on the diagnostic tool screen.

5.

Have someone slowly pump the brake pedal several times, and then apply pressure.

6.

Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without bubbles. Then close the bleeder screw (A).

Tightening torque :

6.8 - 12.7 N.m (0.7 - 1.3 kgf.m, 5.0 - 9.4 lb-ft)

[Front]

[Rear]

7.

Repeat the procedure for wheel in the sequence shown below until air bubbles no longer appear in the fluid.

8.

Refill the master cylinder reservoir to MAX (upper) level line.

3rd Air Bleeding

1.

Repeat 1st air bleeding (Normal Brake System) once.

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