Kia Carens: Rear Disc Brake / Repair procedures

Kia Carens RP (2013-2018) Service Manual / Brake System / Rear Disc Brake / Repair procedures

Removal [Without EPB]

Remove the rear wheel & tire.

Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

2.	Release the parking brake lever and parking brake cable is loose.

Remove the parking brake cable (A), after removing the clip (B).

Parking brake lever in the car must be in fully loosened position.

Remove the hose eyebolt (C).

Tightening torque:

Brake hose to caliper:

24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)

Loosen the guide rod bolt (B) and the remove the rear caliper body (A).

Tightening torque:

21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)

6.	Remove the pad return spring (D). Remove the pad retainers (C) and brake pads (B) in the caliper carrier (A).

Loosen the caliper mounting bolts (B), then remove the rear caliper assembly (A).

Tightening torque:

Caliper assembly to carrier (B) :

63.7 ~ 73.5 N.m (6.5 ~ 7.5 kgf.m, 47.0 ~ 54.2 lb-ft)

Remove the rear brake disc by loosening the screws (A).

Tightening torque:

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

Removal [With EPB]

Remove the rear wheel & tire.

Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

2.	Release the parking brake.

3.	Disconnect the EPB actuator connector (A).

Disconnect the brake hose from the brake caliper by loosening the bolt (C).

Tightening torque:

24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)

Loosen the guide rod bolt (B) and the remove the rear caliper body (A).

Tightening torque:

21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)

6.	Remove the pad return sprign (D). Remove the pad retainers (C) and brake pads (B) in the caliper carrier (A).

Loosen the caliper mounting bolts (A) and then remove the rear caliper assembly (B).

Tightening torque:

63.7 ~ 73.5 N.m (6.5 ~ 7.5 kgf.m, 47.0 ~ 54.2 lb-ft)

8.	Remove the rear brake disc by loosening the screws (A).

Replacement [Without EPB]

Rear Brake Pads

Remove the rear wheel & tire.

Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

2.	Release the parking brake lever and parking brake cable is loose.

Loosen the guide rod bolt (B) and then remove the rear caliper body (A).

Tightening torque:

21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~23.1 lb-ft)

•	Where necessary prevent the guide rods from rotating with an appropriate wrench.

•	Be careful not to damage the dust covers.

Remove the pad return spring (D).

Replace pad retainers (C) and brake pads (B) in the caliper carrier (A).

•	Clean the pad retainer surface at the caliper bracket.

•	Inspect the piston boots for damage and replace if necessary.

•	Check the smooth action of the guide rods, and their dust covers for damage.

5.	Insert the piston in the cylinder the SST (09580-0U000).

Place the caliper body (A) on the caliper carrier and tighten the guide rod bolts (B).

Tightening torque:

21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)

Assemble the caliper body so that the piston groove (A) is in-line with the pad center lobe (B).

* Make sure that the piston and pad are tightly attached.

Install the rear wheel & tire.

Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

Replacement [With EPB]

Rear brake pads

1.	Remove the rear wheel & tire.

2.	Connect the GDS to the data link connector located underneath the dash panel.

3.	Ignition "ON" & Engine "OFF".

4.	Release the electric parking brake.

5.	Select vehicle name and EPB system.

6.	Select the “PAD change mode”.

Perform the " PAD change mode (Before pad change)" procedure with GDS.

When disengaging while the motor is in operation, be sure to press down on the brake pedal.

8.	Ignition "OFF".

9.	Disconnect the electric parking brake actuator connector (A).

10.	Loosen the guide rod bolt (B) and caliper body (A) up out of the way.

11.	Remove the pad return spring (D). Replace pad retainers (C) and brake pads (B) in the caliper carrier (A).

12.	Insert the piston in the cylinder the SST(09580-0U000).

13.

Place the caliper body (A) on the caliper carrier and tighten the guide rod bolts (B).

Tightening torque:

21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)

Assemble the caliper body so that the piston groove (A) is in-line with the pad center lobe (B).

* Make sure that the piston and pad are tightly attached.

14.	Connect the electric parking brake actuator connector (A).

15.	Ignition "ON".

16.	Select the “PAD change mode”.

17.

Perform the "PAD change mode (Before pad change)" procedure with GDS.

•	Check that the parking brake operates normally.

When you activate the EPB for the first time after you change the brake pad, be sure to press down on the brake pedal.

18.	IGN switch “OFF” and remove the GDS.

19.

Install the rear wheel & tire.

Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

Inspection

Rear 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, of same distance (5mm) from the brake disc outer circle.

Brake disc thickness

Standard: 10 mm (0.394 in)

Service limit: 8.4 mm (0.331 in)

Deviation: less than 0.01 mm (0.0004 in)

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

Rear 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: 10 mm (0.394 in)

Service limit: 2.0 mm (0.0787 in)

2.	Check the damage of pad, backing metal and contamination with grease.

Rear 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: 0.05 mm (0.0020 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.

Installation [Without EPB]

1.	Install in the reverse order of removal.

Insert the piston in the cylinder the SST(09580-0U000).

•	Wind the piston into the caliper body until it is fully retracted.

•	Do not use any power assisted tools for this task.

•	Manually insert new screws from the brake pad and tighten the leading-pin bolt(A) first with specified torque, following this tighten the trailing-pin bolt(B) in the same manner.

After installation, bleed the brake system.

(Refer to Brake system bleeding)

•	Bring the brake pads in their operating position by pressing the brake pedal down (half of normal pedal travel) several times until there is resistance.

•	In order to bed the brake pads to the brake disc and ensure performance and endurance, the vehicle user must be instructed to avoid heavy braking or sustained periods with the brakes applied, for the first 200km(124mile) after installing new pads.

•	Re-setting of the parking brake is necessary after overhauling the caliper body, or if the brake calipers, caliper body, parking brake cable or brake discs have been changed.

Installation [With EPB]

1.	Install in the reverse order of removal.

2.	Insert the piston in the cylinder the SST(09580-0U000).

3.	After installation, bleed the brake system. (Refer to Brake system bleeding)

Components and components location

Components [Without EPB] 1. Guide rod bolt 2. Bleed screw 3. Caliper carrier 4. Caliper body 5. Brake pad 6. Pad retainer 7. Pad return spring ...

Parking Brake System

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