Kia Rio: Brake System

Kia Rio 2017-2020 YB Service Manual / Brake System

Specifications
Specifications

Item
Specification
Master cylinder
Type
Single
Cylinder I.D.
Ø 20.64 mm (0.8125 in)
Piston stroke
36 ± 1 mm (1.4173 ± 0.0393 in)
Fluid level switch
Provided
Brake booster
Type
10" Single
Boosting ratio
8 : 1
Front disc brake (14 in)
Type
Ventilated disc
Disc O.D.
256 mm (10.0787 in)
 Disc thickness
22 mm (0.8661 in)
Disc
Service Limit
20.4mm (0.8031 in)
Cylinder type
Single piston
Front disc brake (15 in)

Type
Ventilated disc
Disc O.D.
280 mm (11.0236 in)
Disc thickness
22 mm (0.8661 in)
Disc Service Limit
20.4mm (0.8031 in)
Cylinder type
Single piston
Rear disc brake
Type
Solid disc
Disc O.D
262 mm (10.3149 in)
 Disc thickness
10.0mm (0.3937 in)
Disc Service Limit
8.4mm (0.3307 in)
Cylinder type
Single  piston
Drum brake
Type
Leading trailing
Drum(Disc) I.D
Ø 203 mm (7.9921 in)
Brake lining thickness
3.9 - 4.5 mm (0.1535 - 0.1772 in)

  

O.D. : Outer Diameter

I.D : Inner Diameter

Specification (ABS)

Part
Item
Standard value
Remark
HECU
System
4 Channel 4 Sensor (Solenoid)

Type
Motor, valve relay integrated type
Operating Voltage
10 - 16 V
Operating Temperature
-40 to 120 °C (-40 to 248°F)
Motor power
230 W
Active Wheel speed sensor (ABS)
Supply voltage
DC 4.5 - 20 V

Output current low
5.9 - 8.4 mA

Output current high
11.8  - 16.8 mA

Output range
1 - 2500 Hz

Tone wheel
48 teeth

Air gap
0.4 - 1.5 mm


Specification (ESC)

Part
Item
Standard value
Remark
HECU
System
4 Channel 4 Sensor (Solenoid)
Total control
Type
Motor, valve relay integrated type
(ABS, HAC, VSM, ESS)
Operating Voltage
10 - 16 V

Operating Temperature
-40 to 120 °C (-40 to 248°F)

Motor power
270 W

Active Wheel speed sensor
Supply voltage
DC 4.5 - 20 V

Output current low
5.9 - 8.4 mA

Output current high
11.8- 16.8 mA

Output range
1 - 2500 Hz

Tone wheel
48 teeth

Air gap
0.4 - 1.5 mm


Service Standard

Items
Standard value
Brake pedal height
180.8 mm (7.1181 in)
Brake pedal Full stroke
108 mm (4.2519 in)
Stop lamp clearance
1.0 - 2.0 mm (0.04 - 0.08 in)
Front brake disc pad thickness (14, 15 in)
11 mm (0.4331 in)
Front brake disc pad service limit (14,15 in)
2 mm (0.0787 in)
Rear brake disc pad thickness
10 mm (0.3937 in)
Rear brake disc pad service limit
2 mm (0.0787 in)

Tightening Torques

Items
N·m
kgf·m
lb·ft
Master cylinder to brake booster nut
9.8 - 15.7
1.0 - 1.6
7.2 - 11.6
Master cylinder tube flare nuts
ABS
13.7 - 16.7
1.4 - 1.7
10.1 - 12.3
ESC
18.6 - 22.6
1.9 - 2.3
13.7 - 16.6
Front caliper guide rod bolts
21.6 - 31.4
2.2 - 3.2
15.9 - 23.1
Rear caliper guide rod bolts
21.6 - 31.4
2.2 - 3.2
15.9 - 23.1
Front caliper assembly to knuckle
78.5 - 98.1
8.0 - 10.0
57.9 - 72.3
Rear caliper assembly to knuckle
78.5 - 98.1
8.0 - 10.0
57.9 - 72.3
Brake pedal member bracket bolts
16.7 - 25.5
1.7 - 2.6
12.3 - 18.8
Wheel speed sensor mounting bolt
7.8 - 11.8
0.8 - 1.2 
5.8 - 8.7
HECU bracket mounting bolts
16.7 - 25.5
1.7 - 2.6
12.3 - 18.8
HECU brake tube flare nuts
13.7 - 16.7
1.4 - 1.7
10.1 - 12.3

Lubricants

Items
Recommended
Amount
Brake fluid
DOT 3 or DOT 4
As required
Brake pedal bushing and bolt
Chassis grease
As required
Parking brake shoe and backing plate contacting surface
Heat resistance grease
As required

Special service tools
Special Service Tools



Use
09581-11000
Piston expander

Spreading the front disc brake piston
09580 - 0U000
Brake piston adjuster

"Removal and installation of the rear disc brake piston."
SCC reflector
09964-C1100

Reflector to align the SCC radar
Calibration beam
09964-C1200

Laser to detect the center of the vehicle.
Tripod
09964-C1300

SCC reflector or vertical / horizontal laser support.
Sensor cap installer
09527-1S010

Used for installing wheel speed sensor cap
(Sensor cap : Φ58.4)

Troubleshooting
Troubleshooting
Problem Symptoms Table

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem.

Check each part in order.

If necessary, replace these parts.

Symptom
Expected cause
Countermeasure
Lower pedal or sponge pedal
Brake system (oil leakage)
Repair
Brake system (air inflow)
Air bleeding out procedure
Piston seal (worn out or damaged)
Replace
Rear brake shoe separation (faulty adjustment)
Adjust
Master cylinder (malfunction)
Replace
Dragged brake
Brake pedal free separation (minimum)
Adjust
Parking brake cable length (adjustment trouble)
Adjust
Parking brake cable (trapped)
Repair
Rear brake shoe separation (adjustment trouble)
Adjust
Pad and lining (twisted or cracked)
Replace
Piston (trapped)
Replace
Piston (frozen)
Replace
Anker or return spring (malfunction)
Replace
Booster system (leakage of vacuum)
Repair
Master cylinder (malfunction)
Replace
Uneven brake
Piston (trapped)
Replace
Pad and lining (oil stain, cracked or twisted)
Replace
Heavy pedal and brake trouble
Brake system (oil leakage, air inflow)
Perform air bleeding procedure
Pad or lining (worned out)
Replace
Pad or lining (cracked or twisted)
Replace
Rear brake shoe separation (adjustment trouble)
Adjust
Pad or lining (oil stain)
Replace
Pad or lining (slippery)
Replace
Disc (scratched)
Replace
Booster system (leakage of vacuum)
Repair
Noise from brake
Pad or lining (cracked or twisted)
Replace
Looseness of wheel bolt and caliper
Adjust
Pad sliding trouble (Pad uneven worn out)
Replace
Pad or lining (dirty)
Cleaning
Pad or lining (slippery)
Pad replacement
Anker or return spring (malfunction)
Replace
Brake pad shim (damaged)
Replace
Hold down spring (damaged)
Replace
Foreign substance stucked between disc and pad
Cleaning
Corrosion on disc
Test drive brake and cleaning
* get rid of corrosion by friction while test drive brake
Caved disc
Replace
Not fully functioning on brake
(when drive speed is fast)
Pad or lining (worned out)
Replace
Master cylinder (malfunction)
Replace
Brake vibration
Brake booster (leakage of vacuum)
Repair
Pedal free separation
Adjust
Master cylinder (malfunction)
Replace
Damaged on master cylinder cap
Replace
Damaged on brake line
Replace
Caliper returning trouble (while tire is turning, check the noise)
Replace
Transformed disc
Replace

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Brake System
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