Kia Rio: Brake System / Front Disc Brake

Kia Rio 2017-2023 YB Service Manual / Brake System / Brake System / Front Disc Brake

Components and components location

Components

1. Caliper body
2. Caliper carrier
3. Brake pad assembly [IN]

4. Brake pad assembly [OUT]
5. Pad return spring
6. Pad liner

Repair procedures

Removal

Brake Pad

Remove the front wheel & tire.

Tightening torque:

107.9 - 127.5 N·m (11.0 - 13.0 kgf·m, 79.6 - 94.0 lb·ft)

Loosen the guide rod bolt (B) 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)

Remove the pad return spring (A) and then separate the brake pad (B).

Place the return spring (A), pad retainer (B), inner brake shim (C), and brake pad (D) all at the same time when replacing the brake pad.

Caliper Assembly

Remove the front wheel & tire.

Tightening torque:

107.9 - 127.5 N·m (11.0 - 13.0 kgf·m, 79.6 - 94.0 lb·ft)

Loosen the guide rod bolt (B) 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)

3.	Remove the pad return spring (A) and then separate the brake pad (B).

Loosen the bolts (A,B) and then remove the brake caliper.

Tightening torque :

A : 24.5 - 29.4 N·m (2.5 - 3.0 kgf·m, 18.1 - 21.7 lb·ft)

B : 78.5 - 98.1 N·m (8.0 - 10.0 kgf·m, 57.9 - 72.3 lb·ft)

Disc

Remove the front wheel & tire.

Tightening torque:

107.9 - 127.5 N·m (11.0 - 13.0 kgf·m, 79.6 - 94.0 lb·ft)

Loosen the guide rod bolt (B) 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)

3.	Remove the pad return spring (A) and then separate the brake pad (B).

Loosen the bolts (A,B) and then remove the brake caliper.

Tightening torque :

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

Fix the caliper carrier with wire.

Remove the brake disc after loosening the screw.

Tightening torque :

4.9 - 5.9 N·m (0.5 - 0.6 kgf·m, 3.6 - 4.3 lb·ft)

Inspection

Front brake disc thickness check

1.	Check the brake pads for wear and fade.

2.	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, at the same distance (5mm) apart 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 the discs and pad assembly left and right of the vehicle.

Front Brake Pad Check

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

Pad thickness

Standard value: 11.0 mm (0.4331 in.)

Service limit: 2.0 mm (0.0787 in.)

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

Front brake disc runout check

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: 0.04 mm (0.00157 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 brake disc again for runout.

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

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

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