Kia Optima DL3: Chassis / Disc Brakes and Pads

Kia Optima DL3 2019-2025 Service and Repair Manual / Maintenance / Chassis / Disc Brakes and Pads

Repair procedures

Inspection

Check the pads for excessive wear, discs for run out and wear, and calipers for fluid leakage.

Front Brake

Front Brake Disc Thickness Check

1.

Check the brake disc for damage and cracks.

2.

Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) from the brake disc outer circle.

Front brake disc thickness

- 16 inch Standard : 25 mm (0.98 in)

- 16 inch Service limit : 23 mm (0.90 in)

- 17 inch Standard : 30 mm (1.18 in)

- 17 inch Service limit : 28 mm (1.10 in)

- Deviation : Less than 0.005 mm (0.0002 in.)

3.

If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.

Front Brake Disc Runout Check

1.

Place a dial gauge about 5mm (0.20 in) from the outer circumference of the brake disc, and measure the runout of the disc.

Brake disc runout

Limit : 0.040 mm (0.0016 in.) or less (new one)

2.

If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.

3.

If the runout does not exceed the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc again.

Rear Brake

Rear Brake Disc Thickness Check

1.

Check the brake disc for damage and cracks.

2.

Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) from the brake disc outer circle.

Rear Brake disc thickness

Standard : 10 mm (0.39 in.)

Service Limit : 8.0 mm (0.31 in)

Deviation : less than 0.01 mm (0.0004 in)

3.

If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.

Rear Brake Disc Runout Check

1.

Place a dial gauge about 5mm (0.20 in.) from the outer circumference of the brake disc, and measure the runout of the disc.

Brake disc runout

Limit : 0.04 mm (0.0016 in.) or less (new one)

2.

If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.

3.

If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.

Brake Pad Check

1.

Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.

Front brake disc thickness Pad thickness

- Standard : 11 mm (0.43 in)

- Service Limit : 2.0 mm (0.78 in)

Rear brake disc thickness Pad thickness

- Standard : 10 mm (0.3937 in.)

- Service Limit : 2.0 mm (0.78 in)

2.

Check that grease is applied to sliding contact points and check the pad and backing metal for damage.

    Repair procedures Inspection Visually check for proper installation, chafing, cracks, deterioration and any leakage. Replace any deteriorated or damaged parts immediately.

    Repair procedures Inspection Check whether the stroke is within specification when the parking brake lever is depressed with 44 lbf, 196 N(20 kgf) of force.

    Other information:

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    Specifications Specification Item Specification Operating temperature 14 - 140°F (-10 - 60°C) RF Modulation FSK RF Frequency 433.

    Kia Optima DL3 2019-2025 Service and Repair Manual: Intake Actuator

    Components and components location Components Location 1. Intake actuator Description and operation Description The intake actuator is located at the blower unit. It regulates the intake door by a signal from the control unit.

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