Kia Sportage: Brake System / Front Disc Brake Repair procedures

Kia Sportage QL (2015-2019) Service Manual / Brake System / Brake System / Front Disc Brake Repair procedures

Removal
Brake Pad
1.
Remove the front wheel and tire (A) from front hub.
Tightening torque :
107.9 - 127.5 N·m (11.0 - 13.0 kgf·m, 79.6 - 94.0 lb·ft)

  
Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
2.
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).

  
Replace 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.

Cailper Assemble
1.
Remove the front wheel and tire (A) from front hub.
Tightening torque :
107.9 - 127.5 N·m (11.0 - 13.0 kgf·m, 79.6 - 94.0 lb·ft)

  
Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
2.
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).

4.
Remove the brake hose bolt(A).
Tightening torque :
24.5 - 29.4 N·m (2.5 - 3.0 kgf·m, 18.1 - 21.7 lb·ft)

5.
Remove the Caliper carrier mounting bolt(A).
Tightening torque :
78.5 - 98.1 N·m (8.0 - 10.0 kgf·m, 57.9 - 72.3 lb·ft)

Disc
1.
remove the front wheel and tire (A) from front hub.
Tightening torque :
107.9 - 127.5 N·m (11.0 - 13.0 kgf·m, 79.6 - 94.0 lb·ft)

  
Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
2.
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).

4.
Remove the Caliper carrier bolt(A).
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.
5.
Remove the brake disc after loosening the screw.

Inspection
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, of same distance (5mm) from the brake disc outer circle.
Front brake disc thickness
- Standard : 25 mm (0.98 in)
- Service limit : 23.4 mm (0.92 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
1.
Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Pad thickness
Standard value: 11 mm (0.43 in)
Service limit: 2.0 mm (0.0787 in)
2.
Check that grease is applied, to sliding contact points and the pad and backing metal for damage.

Front 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: 0.04 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 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
1.
Install in the reverse order of removal.
2.
Use a SST (09581-2T100 when installing the brake caliper assembly.

  
Connect an air hose(B) to the SST after confirming that the valve of the SST is surely closed.
Input the SST in the caliper and press the caliper piston while opening the valve of the SST slowly couter clock wise.
Close the valve (A) of the SST and disconnect the air hose (B); then, open the valve again to get the rest of air out and remove the SST from the caliper.
3.
After installation, bleed the brake system.
(Refer to Brake system - "Brake system Bleeding")
Front Disc Brake Components and components location
Components 1. Caliper body 2. Caliper carrier 3. Pad retainer 4. Brake pad 5. Pad return spring ...

Rear Disc Brake Components and components location
Components 1. Caliper body 2. Pad return spring 3. Brake pad 4. Pad retainer 5. Caliper carrier 1. EPB motor 2. Calipe ...

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