Kia Rio: Chassis / Disc Brakes and Pads

Kia Rio 2017-2020 YB Service 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 pads for wear and fade.

2.

Check the brake disc for damage and cracks.

3.

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

Front brake disc thickness

- Standard: 22 mm (0.8661 in)

- Service Limit: 20.4 mm (0.8031 in)

Deviation: Less than 0.005 mm (0.0002 in)

4.

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

Front Brake Pad Check

1.

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

- Standard: 11mm (0.43 in)

- Service limit: 2.0mm (0.0787 in)

2.

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

Front brake disc runout check

1.

Place a dial gauge about 5 mm (0.2 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 specified limit, replace the disc, and then measure the runout again.

3.

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

4.

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

Rear Brake

Rear Brake Disc Thickness Check

1.

Check the brake pads for wear and fade.

2.

Check the brake disc for damage and cracks.

3.

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

Brake disc thickness

-Standard: 10 mm (0.39 in)

-Service limit: 8.4 mm (0.33 in)

-Deviation: less than 0.01 mm (0.0004 in)

4.

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

Rear Brake Pad Check

1.

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

Pad thickness

-Standard value: 10 mm (0.393 in)

-Service limit: 2.0 mm (0.0787 in)

2.

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

Rear Brake Disc Runout Check

1.

Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.

Brake disc runout

-Limit: 0.05 mm (0.002 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 exceeds the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc again.

4.

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

Rear Drum Brake
1.

Raise the rear of the vehicle, and make sure it is securely supported.

2.

Release the parking brake, and remove the rear brake drum.

3.

Check the wheel cylinder (A) for leakage.

4.

Check the brake linings (B) for cracking, glazing, wear, and contamination.

5.

Measure the brake lining thickness (C).Measurement does not include brake shoe thickness.

Brake lining thickness

Standard: 4.5 mm (0.177 in)

Service limit: 1.0 mm (0.039 in)

6.

If the brake lining thickness is less than the service limit, replace the brake shoes as a set.

7.

Check the bearings in the hub unit for smooth operation. If it requires servicing, replace it.

8.

Measure the inside diameter of the brake drum with inside vernier calipers.

Drum inside diameter

Standard: 203.2 mm (8.0 in)

Service limit: 205.2 mm (8.079 in)

Drum roundness

Service limit: 0.06 mm (0.00236 in)

9.

If the inside diameter of the brake drum is more than the service limit, replace the brake drum.

10.

Check the brake drum for scoring, grooves, and cracks.

11.

Inspect the brake lining and drum for proper contact.

12.

Inspect the wheel cylinder outside for excessive wear and damage.

13.

Inspect the backing plate for wear or damage.

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

Drive Shafts and Boots
Repair procedures Inspection 1. Check the drive shaft boots for loose clamps, cracks, grease leaks, kinks or damage. ...

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