Kia Picanto: Brake System / Rear Disc Brake

Kia Picanto JA 2017-2024 Service & Repair Manual / Brake System / Brake System / Rear Disc Brake

Components and components location

Components

1. Return spring
2. Brake pad assembly [OUT]
3. Brake pad assembly [IN]
4. Pad liner

5. Brake member
6. Caliper body
7. Cable guide

Repair procedures

Removal

Remove the wheel tire (A).

Tightening torque:

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

2.	Disconnect the parking brake calbe pin.

3.	Remove the brake lever spring and then loosening the nut.

4.	Disconnect the parking brake cable.

5.	Loosen the bolt and then removing the brake lever bracket.

6.	Loosen the eyebolt (A) and guide bolts (B) and then remove the caliper body.

7.	Remove the return spring and brake pad.

Loosen the bolt and then remove the caliper member.

Tightening torque:

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

Loosen the screw and then remove the brake disc.

Tightening torque :

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

10.	Install in the reverse order of removal.

Replacement

[Brake Pad]

Remove the wheel tire (A).

Tightening torque:

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

Loosen the bolts (A) and then removing the rear caliper body.

Tightening torque :

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

Remove the return spring and brake pad.

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

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, at the same distance apart (5mm) from the brake disc outer circle.

Rear Brake disc thickness

Standard: 10 mm (0.3937 in)

Service limit: 8.4 mm (0.3307 in)

Deviation: less than 0.005 mm (0.0002 in)

4.	If wear exceeds the limit, swab left and right discs and pad assemblies 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:

Service limit: 2.0 mm (0.0787 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.

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: 0.03 mm (0.00118 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.	Rotate the caliper piston and push the direction of the arrow.

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

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