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Description & Operation: Conventional System
Description & Operation: Conventional System
2001 BRAKES
NOTE: For trouble shooting ABS brake system or servicing ABS hydraulic system, see
appropriate ANTI-LOCK article.
NOTE: For bleeding ABS brake system, see appropriate ANTI-LOCK article in BRAKES.
Conventional System
1. Ensure master cylinder is clean of dirt, moisture or any other type of contaminates that may enter master
cylinder reservoir. Fill reservoir with clean brake fluid. Remove bleeder cap, and attach clear vinyl
bleeder hose onto bleeder plug. Place other end of hose into a clean transparent container.
CAUTION: Do not allow brake fluid remain on a painted surface. Wash it off
immediately.
2. Bleed brakes in the following order: Right front wheel, Left front wheel, Right rear wheel and Left rear
wheel.
3. Depress brake pedal at least 10 times, and then hold it in depressed position. See Fig. 1 . With an
assistant, loosen bleeder screw, drain fluid, and retighten screw.
4. Repeat step 3 until flow of brake fluid is clear and shows no sign of air bubbles. Check for correct brake
operation. Ensure there is no fluid leakage. Add fluid to reservoir at specified level.
ADJUSTMENTS
PARKING BRAKE
1. Check stroke specification by pulling parking brake lever with a force of 22 lbs. (10 kg) for Rio, Sephia,
Spectra and Sportage and with a force of 44 lbs (20 kg) for Optima. Stroke should be 8-9 notches on
Optima, 6-8 notches on Sportage, or 5-7 notches on Rio, Sephia and Spectra.
2. To adjust, start engine, and depress brake pedal several times while vehicle is moving in reverse. Stop
engine. On Sportage, remove console. On all models, turn adjusting nut at front of parking brake cable.
See Fig. 2 . After adjustment, turn ignition switch on. Pull parking brake lever 1 notch. Ensure parking
brake warning light illuminates. Ensure rear brakes do not drag.
1. With engine off, depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check
pedal free play. Free play should be 0.12-0.31" (3-8 mm) for Optima and 0.16-0.28" (4-7 mm) for all
other models. If free play is as specified, no adjustment is necessary.
2. If free play is not as specified, loosen push rod lock nut. See Fig. 3 . Rotate push rod until correct free
play is obtained. Tighten push rod lock nut.
1. Measure brake pedal height from upper center pedal pad-to-carpet. On Optima, pedal height should be
6.92-6.94" (173.0-179.0 mm). On Sephia and Spectra, pedal height should be 7.60-7.72" (193.0-196.0
mm). On Sportage, pedal height should be 8.90-9.10" (226.1-231.1 mm). On Rio, pedal height should be
6.69-6.93" (170-176 mm). See Fig. 3 . If pedal height is as specified, no adjustment is necessary.
2. If pedal height is not as specified, disconnect brakelight switch connector. Loosen brakelight switch lock
nut. Turn brakelight switch until switch plunger does not contact pedal. Loosen brake master cylinder
push rod lock nut.
3. Turn brake master cylinder push rod until pedal height is as specified in step 1 . Tighten brakelight switch
until plunger contacts pedal and then rotate switch an additional 1/2 turn. Tighten both lock nuts.
Reconnect brakelight switch connector. Check brakelight operation.
1. Depress brake pedal with a force of 110 lbs (50 kg) on Optima, 132 lbs. (59.9 kg) on Sephia and Spectra
or 152 lbs. (68.9 kg) on Sportage. Measure distance between upper center pedal pad-to-carpet. On
Optima, clearance should be 1.73 in (44.0 mm). On Rio, Sephia and Spectra, clearance should be
2.75" (70.0 mm). On Sportage, clearance should be 4.61" (117.1 mm).
2. If clearance is not as specified, check for air in brake hydraulic system, rear brake automatic adjuster
malfunction or worn brake shoes/pads. Replace components as necessary.
TESTING
PROPORTIONING VALVE
NOTE: Sephia and Spectra do not use a proportioning valve. Information for Rio is not
available from manufacturer.
Sportage
1. Connect pressure gauges to master cylinder rear brake output and to proportioning valve rear brake
output. Apply pressure to brake system, while observing both pressure gauge readings. Rear brake
pressure readings should remain constant until pressure reaches 427 psi (30.2 kg/cm 2 ). See
PROPORTIONING VALVE PRESSURE SPECIFICATIONS (SPORTAGE) table.
2. Once pressure exceeds 427 psi (30.0 kg/cm 2 ), pressure should begin to differentiate. With pressure from
master cylinder at 1422 psi (100 kg/cm 2 ) rear brake pressure should read 744-886 psi (52.3-62.3 kg/cm
2 ) from proportioning valve. If pressure does not differentiate, valve is defective and should be replaced
with a NEW valve.
3. Remove brake pressure gauges. Install brake lines to their original locations. Bleed air from system. See
BLEEDING BRAKE SYSTEM . Top off brake fluid reservoir as necessary.
Optima
1. Connect two pressure gauges, one each to input side and output side of proportioning valve.
2. With brakes applied, measure input pressure and output pressure. If measured pressures are within
permissible ranges, proportioning valve is good. See Fig. 4 and PROPORTIONING VALVE OUTPUT
PRESSURE
1. With engine off, depress brake pedal several times. Press and hold brake pedal. Start engine. If brake
pedal moves down slightly immediately after engine starts, power brake booster is operating as designed.
If brake pedal does not move as specified, go to next step.
2. Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is
longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake
booster is operating as designed. If length of strokes is equal, test check valve and vacuum hose between
vacuum source and power brake booster and examine installation. Repair as necessary, and go to next
step.
3. Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal
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2001 Kia Rio
2001 BRAKES Disc & Drum
height remains at same height, power brake booster is operating as designed. If pedal height recedes, test
check valve and vacuum hose between vacuum source and power brake booster. Repair as necessary.
1. Raise and support vehicle. Remove front wheels. Remove plastic caps. Remove 2 bolts and bushings.
Remove caliper and wire aside. Remove spring clip. Remove brake pads. See Fig. 5 . Measure brake pad
thickness. Replace pad if lining thickness is less than .08" (2.0 mm).
2.
NOTE: Excessive runout could be caused by a loose wheel hub bearing.
Prepare to catch any brake fluid. Using flare nut wrench, disconnect brake hose. Remove 2 bolts and
supporting plate. Remove caliper. Measure runout at outer braking contact edge of rotor. Maximum
runout should be .004" (.10 mm).
Fig. 5: Exploded View Of Front Disc Brakes (Sephia and Spectra Shown; Sportage Is Similar)
Courtesy of KIA MOTORS AMERICA, INC.
Installation
To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for
leaks.
Raise and support vehicle. Remove 2 caliper assembly bolts, and pull caliper from disc. Remove flexible hose
mounting bolt, and disconnect flexible hose from caliper. Remove brake pads from adapter. Remove 2 adapter
mounting bolts, and then remove adapter. Remove 2 screws. Remove caliper. To install, reverse removal
procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed brake system.
See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.
Removal (Rio)
CAUTION: Do not use a screwdriver or similar tool to pry piston from rotor.
1.
NOTE: Do not discard shims found behind brake pads.
Remove brake pad pin retainer. Disengage anti-rattle spring from brake pads. Remove brake pad pins and
rattle spring.
Remove brake pads and shims. Remove connector bolt. Discard seal washer. Loosen sleeve bolt and
remove caliper from steering knuckle. See Fig. 6 . Measure brake pad thickness. Replace pad if lining
thickness is less than .08" (2.0 mm).
2. Prepare to catch any brake fluid. Using flare nut wrench, disconnect brake hose. Discard seal washers.
Remove caliper bolts and caliper. Remove anti-squeek caps. Measure runout at outer braking contact
edge of rotor. Maximum runout should be .003" (0.08 mm).
Installation
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2001 Kia Rio
2001 BRAKES Disc & Drum
To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for
leaks.
Removal (Optima)
3. Remove two bolts from torque plate and remove brake cylinder. Suspend cylinder with wire.
4.
CAUTION: Do not to depress brake pedal while disassembling pads.
Installation
1.
NOTE: Replace all four pads as a complete set.
Install pad clips. Install pads onto each clip. Position pad with its pad wear sensor to piston side. Remove
dust before positioning pad clip or replace with a new one if clip is damaged.
2. Press in piston with a hammer handle or similar tool. Lower and insert brake cylinder carefully so as not
to damage boot. Install two guide rod bolts and tighten to specification See TORQUE
SPECIFICATIONS . Install brake hose to caliper. Fill brake reservoir with brake fluid. Bleed brake
system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.
Raise and support vehicle. Remove front wheels. Remove brake caliper. See FRONT DISC BRAKE PADS &
CALIPER . Using a micrometer, measure brake rotor thickness. Using a dial indicator, measure brake rotor
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2001 Kia Rio
2001 BRAKES Disc & Drum
runout. Compare to specifications and resurface or replace as necessary. See DISC BRAKE
SPECIFICATIONS . To install, reverse removal procedure.
4. Check for worn, damaged or rusted piston bore and piston. Replace damaged parts if necessary. Check
for damaged piston seal, boot, and pin insulators.
5. Apply a recommended lubricant to following parts. See RECOMMENDED LUBRICANTS
RECOMMENDED LUBRICANTS
Parts Recommended Lubricant Quantity
Piston Seal Brake fluid (Dot 3) As Required
Cylinder inner side Brake fluid (Dot 3) As Required
Piston boot Brake fluid (Dot 3) As Required
Piston outer surface Brake fluid (Dot 3) As Required
Guide-rod insulators Rubber grease As Required
6. Push piston into caliper. Align piston matching mark upward as shown in Fig. 8
7. Before replacing brake pads, remove brake fluid from master cylinder reservoir until it is half full.
1. Raise and support vehicle. Remove parking cable and clip. Remove brake hose connecting bolt from
caliper. Clamp rear brake hose. Remove 2 lock bolts from caliper. Remove caliper from rotor. Remove 2
"V" springs from disc pads. See Fig. 9 .
2. Remove disc pads, shims and guide plates. Remove 2 bolts from mounting support. Remove mounting
support from rear wheel spindle. Measure pad thickness. Replace pad if lining thickness is less
than .08" (2 mm). To install, reverse removal procedure. Tighten bolts and nuts to specification. See
TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect
brake system for leaks.
Remove rear brake pads and caliper. See REMOVAL & INSTALLATION (SEPHIA AND SPECTRA) under
REAR DISC BRAKE PADS & CALIPER . Using a dial indicator check disc runout. Resurface or replace if
runout exceeds .004" (.10 mm). Remove rotor mounting screws. Using dial indicator check disc rotor thickness.
Resurface or replace rotor if beyond minimum thickness. See DISC BRAKE SPECIFICATIONS .
Removal (Optima)
1. Raise and support vehicle. Remove rear wheels and brake drums.
2.
NOTE: If brake drum is difficult to remove, insert bolts into threaded holes of
drum, then remove it.
Remove rear hub. Remove shoe abut end spring, cylinder end shoe spring, and shoe hold down spring.
See Fig. 10 .
3. Remove shoes and adjuster as an assembly.
Installation
2.
CAUTION: Split pin and hub cap must not be reused.
Install shoe hold down pin. Assemble return spring with push rod shortened.
3. Check outside dimension of brake shoes. Adjust to 8.96-8.98" (227.6-228.1 mm). Install brake drums and
rear wheels. Adjust parking brake. See PARKING BRAKE under ADJUSTMENTS
Removal (Rio)
1. Raise and support vehicle after releasing parking brake. Remove wheel and tire. Remove hub cap.
2.
NOTE: DO NOT damage groove and threads of spindle using cape chisel .
Use a small cape chisel to raise staked edge of lock nut. Remove drum, washer and bearings as an
assembly from spindle.
3. Remove brake shoe hold down springs and pins. See Fig. 11 . Remove brake shoe assembly.
4. Remove parking brake cable from brake shoe assembly. Remove wheel cylinder brake pipe. Remove
wheel cylinder attaching bolt. Remove anti-rattle spring from brake shoe assembly. Remove operating
lever after removing return spring. Remove parking brake operating lever retainer.
Installation
To install, reverse removal procedure. Coat all internal parts of wheel cylinders with clean brake fluid. Apply
brake grease onto wheel cylinder and anchor sliding points, adjuster threads and shoe contact points on backing
plate. Adjust brake shoes. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed
brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.
1. Raise and support vehicle. Remove rear wheels, and release parking brake. Using impact driver, remove 2
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2001 Kia Rio
2001 BRAKES Disc & Drum
Fig. 12: Exploded View Of Rear Drum Brake (Sephia & Spectra)
Courtesy of KIA MOTORS AMERICA, INC.
Installation
To install, reverse removal procedure. Coat all internal parts of wheel cylinders with clean brake fluid. Apply
brake grease onto wheel cylinder and anchor sliding points, adjuster threads and shoe contact points on backing
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2001 Kia Rio
2001 BRAKES Disc & Drum
plate. Adjust brake shoes. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed
brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.
Removal (Sportage)
1. Loosen lug nuts. Raise and support vehicle. Remove front wheel. Set parking brake. Loosen and remove
4 hub nuts and screws. Release parking brake, and remove wheel drum.
2. Using spring wrench or pliers, remove adjuster lever spring. Remove adjuster lever. Using spring wrench
or pliers, remove return spring. Turn adjuster star wheel clockwise to relieve tension on shoes. Remove
adjuster assembly.
3. Turn holding pins until they align with holding spring clip groove. Remove holding pins and spring clips.
Remove primary shoe and anchor spring. Remove secondary brake shoe with parking cable attached.
Remove brake cable from shoe. Remove control lever "C" clip and lever from secondary brake shoe.
4. Disconnect brakeline from wheel cylinder. Remove 2 wheel cylinder mounting bolts, and remove wheel
cylinder. Remove parking brake cable from backing plate. Remove 4 nuts from backing plate. Tap axle
from behind with rubber hammer. Remove axle from housing. Remove backing plate.
Installation
1. Install wheel cylinder, and tighten 2 mounting bolts to specification. See TORQUE
SPECIFICATIONS . Apply grease onto wheel cylinder contact points. Install brakeline onto wheel
cylinder.
2. Install control lever on secondary shoe with NEW "C" clip. Using pliers, connect parking brake cable
onto secondary shoe. Attach secondary shoe onto backing plate with holding pin and spring clip. Attach
one end of anchor spring onto secondary shoe, and other end onto primary shoe. Position primary shoe,
and install holding pin and spring clip.
3. Install adjusting assembly. Using spring wrench, install return spring. Install adjusting lever and adjusting
lever spring. Ensure adjusting lever contacts star wheel on adjuster assembly.
4. Measure outer shoe diameter when installed on drums. Measure drum inner diameter. Calculate clearance
by subtracting shoe diameter from drum diameter. Clearance should be .020-.040" (.51-1.02 mm).
5. Install drum and set parking brake. Install and tighten 3 hub bolts. Release parking brake, and install tire.
Loosely tighten lug nuts. Lower vehicle. Tighten all bolts and nuts to specification. See TORQUE
SPECIFICATIONS . Add brake fluid, and bleed brakes. See BLEEDING BRAKE SYSTEM . Check
for fluid leakage.
MASTER CYLINDER
NOTE: Brake fluid will damage painted surfaces. If brake fluid is spilled on painted
surface, wipe off immediately and clean with alcohol.
Disconnect battery ground cable. Disconnect fluid level switch connector. Disconnect and plug brake lines at
master cylinder to prevent entry of dirt and loss of fluid. Remove 2 master cylinder nuts. Remove master
cylinder.
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2001 Kia Rio
2001 BRAKES Disc & Drum
Installation
To install master cylinder, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .
Removal (Sportage)
1. Disconnect clutch fluid hose from back of master cylinder reservoir, and drain reservoir. Remove
connector to fluid level and differential sensor. Using line wrench, remove brakelines from master
cylinder to proportioning valve.
2. Using line wrench, remove rear wheel brake line from right side of ABS solenoids Remove front wheel
brakeline from lower left port of proportioning valve. Remove wire harness connector to ABS solenoids.
Remove wire harness connector to proportioning valve.
3. Remove nuts attaching master cylinder to power brake booster. Remove bracket holding ABS solenoids
and proportioning valves. Remove master cylinder from power brake booster.
Installation
1. Position NEW gasket onto master cylinder, and adjust push rod length. Attach proportioning valve and
ABS solenoids onto bracket. Place master cylinder onto power brake booster unit studs. Place bracket
assembly onto power brake booster studs, and install nuts.
2. Install rear wheel brakeline into right side port of ABS solenoid. Install front wheel brakeline into lower
left port of proportioning valve. Install brakelines into master cylinder.
3. Connect fluid level and differential sensor connector. Connect ABS solenoid and proportioning valve
wire harness connectors. Fill reservoir tank to MAX level. Check for fluid leakage. If needed, adjust
brake pedal free play and height. See BRAKE PEDAL FREE PLAY and BRAKE PEDAL HEIGHT
& BRAKELIGHT SWITCH under ADJUSTMENTS. Bleed brake system. See BLEEDING BRAKE
SYSTEM . Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS .
Removal (Optima)
CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediately.
1. Detach brake tubes from master cylinder and then install plugs.
2. Remove master cylinder mounting nuts and then lift out master cylinder.
Installation
Removal (Rio)
Installation
1. Position master cylinder onto brake booster. Check push rod length. Install master cylinder attaching
washers and nuts. Tighten master cylinder nuts.
2. Tighten brake pipe flare nut with SST. Connect low fluid level sensor wiring. Bleed brakes. See
BLEEDING BRAKE SYSTEM .
NOTE: Power brake booster removal and installation information for Rio is unavailable
from manufacturer.
Removal (Optima)
1. Remove master cylinder. Remove vacuum hose. Remove operating rod from brake pedal.
2. Loosen booster mounting nuts to remove booster assembly.
Installation
1. Install master cylinder. Attach booster/master cylinder to dash panel. Reinstall vacuum hose securely to
prevent vacuum leaks. Couple operating rod with brake pedal.
2. Bleed system. See BLEEDING BRAKE SYSTEM . Inspect system for leaks. Check brake pedal height
and free play. Adjust as necessary. See BRAKE PEDAL FREE PLAY and BRAKE PEDAL HEIGHT
& BRAKELIGHT SWITCH under ADJUSTMENTS.
1. Remove master cylinder. See MASTER CYLINDER . Disconnect vacuum hose from booster. From
inside vehicle, remove spring clip from clevis pin.
2. Remove 4 booster nuts. Remove booster. Remove mounting bracket gasket.
Installation
1. Mount booster to vehicle bulkhead with NEW gasket. Install 4 mounting nuts and tighten to specification.
See TORQUE SPECIFICATIONS .
2. Attach push rod clevis pin to brake pedal with NEW clevis pin and NEW spring clip. From engine
compartment, attach vacuum hose to check valve. Mount master cylinder onto power brake unit, and
install 2 nuts. Tighten master cylinder mounting nuts to specification. See TORQUE
SPECIFICATIONS .
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2001 Kia Rio
2001 BRAKES Disc & Drum
3.
NOTE: When filling reservoir with brake fluid, use DOT 3 or DOT 4 brake fluid.
Connect 4 brakelines. Tighten brakeline flare nuts to specification. See TORQUE SPECIFICATIONS .
Connect brake fluid level switch. Fill reservoir with NEW fluid to MAX level line.
4. Bleed system. See BLEEDING BRAKE SYSTEM . Inspect system for leaks. Check brake pedal height
and free play. Adjust as necessary. See BRAKE PEDAL FREE PLAY and BRAKE PEDAL HEIGHT
& BRAKELIGHT SWITCH under ADJUSTMENTS.
Removal (Sportage)
Remove master cylinder and bracket assembly. See MASTER CYLINDER . Disconnect vacuum hose at
power brake booster. From inside vehicle, remove cotter pin and clevis pin from brake pedal. From inside
vehicle, remove lock nuts. Remove "U" type link. Remove power brake booster.
Installation
1. Insert brake booster, and connect "U" type link. Attach and tighten lock nuts. Pull brake pedal down to
"U" type link. Insert clevis pin, and fix with NEW cotter pin.
2. Place gasket onto master cylinder. Position push rod adjuster onto gasket, and tighten adjusting bolt until
bolt touches bottom of push rod hole. Apply 20 in. Hg vacuum with vacuum pump. Place Master
Cylinder Gauge (K95U-5200-B) onto power brake booster unit with tip of adjusting bolt touching push
rod.
3. Check clearance between edge of adjusting bolt and power brake unit push rod. Clearance should be
0.004-0.012" (0.10-0.30 mm). If clearance is not within specification, loosen push rod lock nut, and turn
push rod. Install master cylinder and bracket assembly. See MASTER CYLINDER . Tighten bolts and
nuts to specification. See TORQUE SPECIFICATIONS .
OVERHAUL
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (SEPHIA, SPECTRA & SPORTAGE)
Application Ft. Lbs. (N.m)
Sephia and Spectra
Brake Booster Nut 15 (20)
Brake Caliper Bolt 20 (27)
Brake Line Flare Nut 9-13 (13-18)
Brake Hose Connecting Bolt 16-21 (22-29)
Caliper Retaining Pin (Front) 18 (24)
Hex-Head Bolts 33-49 (45-67)
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2001 Kia Rio
2001 BRAKES Disc & Drum