Kia Optima: Brake System / Master Cylinder

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

Components and components location

Components

1. Reservoir cap
2. Reservoir

3. Master cylinder
4. Brake fluid level sensor

Repair procedures

Removal

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Remove the air cleaner assembly. G 2.0 NU MPI (Refer to Engine Mechanical System - "Air Cleaner") G 2.5 GDI THETA II (Refer to Engine Mechanical System - "Air Cleaner")

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.)

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.

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

Separate the brake tube (A) from the master cylinder by loosening the tube flare nut.

•	Be careful of tap damage and chipping when removing the brake tube.

•	When mounting, pay attention to the position of the brake tube and correctly install the flare nut.

Tightening torque :

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

Remove the master cylinder (A) after loosening the master cylinder nuts.

Tightening torque :

9.8 - 15.7 N.m (1.0 - 1.6 kgf.m, 7.2 - 11.5 lb-ft)

Separate the reservoir from the master cylinder after remove the screw (A).

Tightening torque :

0.98 - 1.47 N.m (0.1 - 0.15 kgf.m, 0.7 - 1.08 lb-ft)

Installation

Install in the reverse order of removal.

•	Before installing the pin, apply the grease to the joint pin.

•	Use a new snap pin whenever installing.

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

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

Brake Booster

Components and components location Components 1. Reservoir cap 2. Reservoir 3. Master cylinder 4. Brake fluid level sensor 5. Vacuum sensor 6. Brake ...

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 f ...

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