Kia Optima DL3: Brake System / Front Brake Disc

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

Components and components location

Components

1. Front Brake Caliper
2. Front Brake Disc

3. Front Axle

Repair procedures

Removal

1.	Disconnect the (-) battery terminal.

2.	Remove the front wheel and tire. (Refer to Suspension System - "Wheel")

Loosen the guide rod bolt and then pivot the caliper body (A) up out of the way.

Tightening torque:

21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

4.	Remove the brake pad (A).

5.	Remove the pad retainer (A).

Remove the caliper carrier (A) by loosening the caliper mouniting bolts.

Tightening torque:

98.1 - 117.7 N·m (10.0 - 12.0 kgf·m, 72.3 - 86.8 lb·ft)

•	Caliper carrier mounting bolts must use the new one.

•	Fix the caliper assembly with a wire.

Remove the front brake disc (A) by loosening the screws.

Tightening torque :

4.9 - 5.8 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

Inspection

Front Brake Disc Thickness Check

1.	Check the brake disc for damage and cracks.

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

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.

Installation

1.	Install in the reverse order of removal.

Use a SST (09581-11000) when installing the brake caliper assembly.

•	Carefully press it to avoid damaging the piston inlet.

•	Make sure not to let the piston interfere when assembling the caliper body to the carrier.

3.	After installation, bleed the brake system. (Refer to Brake System - "Brake Bleeding Prcoedures")

4.	Check the brake oil leakage and pedal operating condition.

❮Front Brake Caliper

Components and components location Components 1. Caliper body 2. Caliper carrier 3. Pad inner shim 4. Brake pad 5.

Rear Brake Caliper❯

Components and components location Components [EPB Apply] 1. EPB Actuator 2. Caliper body 3. Caliper carrier 4.

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