Kia Optima DL3: Brake System / Brake Line

Kia Optima DL3 2019-2025 Service and Repair Manual / Brake System / Brake System / Brake Line

Components and components location

Components

1. HECU flare nuts.
2. HECU to body mounting nuts.
3. Master cylinder to HECU flare nut.
4. Front brake line tube flare nut.
5. Front brake line to brake hose.
6. Rear brake line tube flare nut.
7. Rear brake line to brake hose.

Repair procedures

Removal
  

Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift.

(Refer to General Information - "Lift and Support Points")

Brake Tube [Engine Room]

1.

Disconnect the brake fiuid level switch connector, and remove the reservoir cap.
2.

Remove the brake fluid from the master cylinder reservior with a syringe.

  
•

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.
•

Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
3.

Remove the brake tube after loosening the flare nuts from the ESC, master cylinder and brake tube connector.

Tightenning torque

ESC : 18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)

Master cylinder :

18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)

Brake tube connector :

13.7 - 16.7 N.m (1.4 - 1.7 kgf.m, 10.1 - 12.3 lb-ft)

Brake Hose

1.

Disconnect the brake fluid level sensor connector (A).

  

Check that the brake reservoir tank oil level sensor connector is properly installed.

(Brake warning light turns on when not connected.)

2.

Remove the brake fluid from the master cylinder reservoir with a syringe.

  

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.
3.

Remove the front wheel and tire.

(Refer to Tires/Wheels - "Wheel")

4.

Remove the tube flare nut (A).
5.

Loosen the brake hose bracket bolt (B).

Tightenning torque

(A) : 13.7 - 16.7 N.m (1.4 - 1.7 kgf.m, 10.1 - 12.3 lb-ft)

(B) : 19.6 - 29.4 N.m (2.0 - 3.0 kgf.m, 14.5 - 21.7 lb-ft)

[Front]

[Rear]
6.

Loosen the mounting bolt (A) and then remove the brake hose bracket from the strut assembly.

Tightening torque :

8.8 - 13.7 N.m (0.9 - 1.4 kgf.m, 6.5 - 10.1 lb-ft)

7.

Remove the hose after loosening the brake hose bolt (A) from the caliper.

Tightening torque :

24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7)

[Front]

[Rear]
Inspection
1.

Check the brake tubes for cracks, crimps and corrosion.
2.

Check the brake tube flare nuts for damage and fluid leakage.
Installation
1.

Install in the reverse order of removal.

  

Use a new washer (A) whenever installing.

[Front]

[Rear]

2.

After installation, bleed the brake system.

(Refer to Brake System - "Brake Bleeding Prcoedures")

    Components and components location Components 1. Reservoir cap 2. Reservoir 3. Master cylinder 4. Brake fluid level sensor Repair procedures Removal 1.

    Components and components location Components 1. Brake member assembly 2. Stop lamp switch 3. Brake pedal arm assembly 4.

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