Kia Sportage: Chassis / Disc Brakes and Pads Repair procedures

Kia Sportage QL (2015-2020) 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
[GAMMA 1.6 T-GDI / THETA 2.4 GDI]
- Standard: 25 mm (0.9842 in)
- Service Limit: 23.4 mm (0.9212 in)
[THETA 2.0 T-GDI]
- Standard: 30 mm (1.811 in)
- Service Limit: 28.4 mm (1.1181 in)
[EPB]
- Standard: 28 mm (1.1023in)
- Service Limit: 26.4 mm (1.0393 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.
[GAMMA 1.6 T-GDI / THETA 2.4 GDI]
- Standard: 11.5mm (0.4527 in)
- Service limit: 2.0mm (0.0787 in)
[ THETA 2.0 T-GDI]
- Standard: 13.0mm (0.5118 in)
- Service limit: 2.0mm (0.0787 in)
[EPB]
- Standard: 10.5mm (0.4133 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)
[ THETA 2.0 T-GDI]
-Standard: 20.0 mm (0.7874 in)
-Service limit: 18.0 mm (0.7087 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.
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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