Kia Optima DL3: Brake System / Rear Brake Disc

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

Components and components location

Components

1. Rear brake disc
2. Hub bearing assembly



3. Dust cover
4. Rear carrier



Repair procedures

Removal

[EPB Apply]

1.

Release the parking brake.
2.

Before removing the rear caliper, perform “Brake Pad Replacement Mode” using the KDS.
3.

Select C2 (Release) on the screen below.
4.

Disconnect the (-) battery terminal.
5.

Remove the rear wheel and tire.

(Refer to Suspension System - "Wheel")

6.

Disconnect the EPB actuator connector (A).
7.

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)

8.

Remove the brake pad (A).
9.

Remove the pad retainer (A).
10.

Remove the caliper carrier (A) after loosening the caliper mounting bolt.

Tightening torque :

78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb-ft)

  
•

Caliper carrier mounting bolts must use the new one.
•

Fix the caliper assembly with a wire.

11.

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)

[EPB None Apply]

1.

Release the parking brake.
2.

Disconnect the (-) battery terminal.
3.

Remove the rear wheel and tire.

(Refer to Suspension System - "Wheel")

4.

Disconnect the parking cable (A) after remove the parking brake cable fixing clip.
5.

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)

6.

Remove the brake pad (A).
7.

Remove the pad retainer (A).
8.

Remove the caliper carrier (A) after loosening the caliper mounting bolt.

Tightening torque :

78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb-ft)

  
•

Caliper carrier mounting bolts must use the new one.
•

Fix the caliper assembly with a wire.

9.

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

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.
Installation
1.

Install in the reverse order of removal.
2.

Use a SST (09580-0U000) when installing the brake caliper assembly.

  
•

Be careful not to tilt the piston when inserting the piston.
•

Do not apply excessive force when inserting the piston.
•

Rotate the piston slowly to prevet damage to the piston boot.

3.

After installation, bleed the brake system.

(Refer to Brake system - "Brake Bleeding Procedures")

4.

Apply the parking brake several times and check for normal operation.

  

With EPB : After installing the rear caliper, perform “Brake Pad Replacement Mode” using the KDS.

(Refer to Parking Brake System - "Electronic Parking Brake (EPB)")

Without EPB : After disassembling/assembling the caliper body or replacing the brake caliper, parking brake cable or brake disc, re-adjust the parking brake.

(Refer to Parking Brake System - "Parking Brake Cable")

5.

Check the spilled brake oil.
6.

Apply the parking brake several times and check for normal operation.

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

    Repair procedures Replacement Front Brake Pad 1. Disconnect the (-) battery terminal. 2. Remove the front wheel and tire.

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