Kia Forte: Brake System

Kia Forte 2019-2020 (BD) Service Manual / Brake System

Service data
Service Data

Item
Specification
Master cylinder
Type
Single
Cylinder I.D.
Ø 22.22 mm (0.875 in)
Piston stroke
45±1 mm (1.77 ± 0.039 in)
Fluid level switch
Provided
Brake booster
Type
10" Single
Boosting ratio
8:1
Front disc brake (15 inch)
Type
Ventilated disc
Disc O.D.
280 mm (11.0236 in)
 Disc thickness
23 mm (0.9055 in)
Disc Service Limit
21 mm (0.8268 in)
Cylinder type
Single piston
Front disc brake (16 inch)
Type
Ventilated disc
Disc O.D.
305 mm (12.0079 in)
Disc thickness
25.0 mm (0.9843 in)
Disc Service Limit
23.4 mm (0.9213 in)
Cylinder type
Single piston
Rear disc brake
Type
Solid disc
Disc O.D
262 mm (10.3149 in)
 Disc thickness
10.0mm (0.3937 in)
Disc Service Limit
8.4mm (0.3307 in)
Cylinder type
Single  piston
Drum brake
Type
Leading trailing
Drum(Disc) I.D
Ø 203.2 mm (8 in)
Brake lining thickness
4.3 mm (0.1693 in)
Parking brake
Type
BIR (Ball-in-Ramp)
Actuation
Lever

  

O.D. : Outer Diameter

I.D : Inner Diameter

Specification (ABS)

Part
Item
Standard value
Remark
HECU
System
4 Channel 4 Sensor (Solenoid)

Type
Motor, valve relay integrated type
Operating Voltage
10 - 16 V
Operating Temperature
-40 to 120 °C (-40 to 248°F)
Motor power
230 W
Active Wheel speed sensor (ABS)
Supply voltage
DC 4.5 - 20 V

Output current low
5.9 - 8.4 mA

Output current high
11.8  - 16.8 mA

Output range
1 - 2500 Hz

Air gap
0.4 - 1.0 mm


Specification (ESC)

Part
Item
Standard value
Remark
HECU
System
4 Channel 4 Sensor (Solenoid)
Total control
Type
Motor, valve relay integrated type
(ABS, HAC, VSM)
Operating Voltage
10 - 16 V

Operating Temperature
-40 to 120 °C (-40 to 248°F)

Motor power
270 W

Active Wheel speed sensor
Supply voltage
DC 5 - 16 V

Output current low
5.9 - 8.4 mA

Output current high
11.8- 16.8 mA

Output range
0 - 2500 Hz

Tone wheel
46 teeth

Air gap
0.4 - 1.0 mm


Service Standard

Items
Standard value
Brake pedal height
183 mm (7.2047 in)
Brake pedal Full stroke
135 mm (5.3150 in)
Stop lamp clearance
1.0 - 2.0 mm (0.04 - 0.08 in)
Front brake disc pad thickness (15 inch)
11.0 mm (0.4331 in)
Front brake disc pad service limit (15 inch)
2.0 mm (0.0787 in)
Front brake disc pad thickness (16 inch)
11.5 mm (0.4528 in)
Front brake disc pad service limit (16 inch)
2.0 mm (0.0787 in)
Rear brake disc pad thickness
9.0 mm (0.3543 in)
Rear brake disc pad service limit
2.0 mm (0.0787 in)

Tightening torque
Tightening Torques

Items
N·m
kgf·m
lb·ft
Master cylinder to brake booster nut
9.8 - 15.7
1.0 - 1.6
7.2 - 11.6
Brake booster to brake pedal nut
16.7 - 25.5
1.7 - 2.6
12.3 - 18.8
Master cylinder tube flare nuts
ABS
12.7 - 16.7
1.3 - 1.7
9.4 - 12.3
ESC
18.6 - 22.6
1.9 - 2.3
13.7 - 16.6
HECU bracket mounting bolts
16.7 - 25.5
1.7 - 2.6
12.3 - 18.8
HECU brake tube flare nuts
ABS
12.7 - 16.7
1.3 - 1.7
9.4 - 12.3
ESC
18.6 - 22.6
1.9 - 2.3
13.7 - 16.6
Front caliper guide rod bolts
21.6 - 31.4
2.2 - 3.2
15.9 - 23.1
Rear caliper guide rod bolts
21.6 - 31.4
2.2 - 3.2
15.9 - 23.1
Front caliper assembly to knuckle
78.5 - 98.1
8.0 - 10.0
57.9 - 72.3
Rear caliper assembly to rear carrier
78.5 - 98.1
8.0 - 10.0
57.9 - 72.3
Rear caliper assembly to torsion beam axle
63.7 - 73.5
6.5 - 7.5
47.0 - 54.2
Brake hose to caliper bolt
24.5 - 29.4
2.5 - 3.0
18.1 - 21.7
Brake pedal member bracket nuts
16.7 - 25.5
1.7 - 2.6
12.3 - 18.8
Wheel speed sensor mounting bolt
8.8 - 13.7
0.9 - 1.4
6.5 - 10.1

Lubricant
Lubricants

Items
Recommended
Amount
Brake fluid
DOT 3 or DOT 4
505.5 ± 20cc (30.85 ± 1.22 cn.in)
Brake pedal bushing and bolt
Chassis grease
As required
Parking brake shoe and backing plate contacting surface
Heat resistance grease
As required

Special service tools
Special Service Tools

Tool Name / Number
Illustration
Description
Piston expander
09581-2T100

Spreading the front disc brake piston
SCC reflector
09964-C1100

Reflector to align the SCC radar
Calibration beam
09964-C1200

Laser to detect the center of the vehicle.
Tripod
09964-C1300

SCC reflector or vertical / horizontal laser support.
Sensor cap installer
09527-AL200

Used for installing wheel speed sensor cap
(Sensor cap : Φ65.3)

Troubleshooting
Troubleshooting
Problem Symptoms Table

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem.

Check each part in order.

If necessary, replace these parts.

Symptom
Expected cause
Countermeasure
Lower pedal or sponge pedal
Brake system (oil leakage)
Repair
Brake system (air inflow)
Air bleeding out procedure
Piston seal (worn out or damaged)
Replace
Rear brake shoe separation (faulty adjustment)
Adjust
Master cylinder (malfunction)
Replace
Dragged brake
Brake pedal free separation (minimum)
Adjust
Parking brake cable length (adjustment trouble)
Adjust
Parking brake cable (trapped)
Repair
Rear brake shoe separation (adjustment trouble)
Adjust
Pad and lining (twisted or cracked)
Replace
Piston (trapped)
Replace
Piston (frozen)
Replace
Anker or return spring (malfunction)
Replace
Booster system (leakage of vacuum)
Repair
Master cylinder (malfunction)
Replace
Uneven brake
Piston (trapped)
Replace
Pad and lining (oil stain, cracked or twisted)
Replace
Heavy pedal and brake trouble
Brake system (oil leakage, air inflow)
Perform air bleeding procedure
Pad or lining (worned out)
Replace
Pad or lining (cracked or twisted)
Replace
Rear brake shoe separation (adjustment trouble)
Adjust
Pad or lining (oil stain)
Replace
Pad or lining (slippery)
Replace
Disc (scratched)
Replace
Booster system (leakage of vacuum)
Repair
Noise from brake
Pad or lining (cracked or twisted)
Replace
Looseness of wheel bolt and caliper
Adjust
Pad sliding trouble (Pad uneven worn out)
Replace
Pad or lining (dirty)
Cleaning
Pad or lining (slippery)
Pad replacement
Anker or return spring (malfunction)
Replace
Brake pad shim (damaged)
Replace
Hold down spring (damaged)
Replace
Foreign substance stucked between disc and pad
Cleaning
Corrosion on disc
Test drive brake and cleaning
* get rid of corrosion by friction while test drive brake
Caved disc
Replace
Not fully functioning on brake
(when drive speed is fast)
Pad or lining (worned out)
Replace
Master cylinder (malfunction)
Replace
Brake vibration
Brake booster (leakage of vacuum)
Repair
Pedal free separation
Adjust
Master cylinder (malfunction)
Replace
Damaged on master cylinder cap
Replace
Damaged on brake line
Replace
Caliper returning trouble (while tire is turning, check the noise)
Replace
Transformed disc
Replace

Brake bleeding prcoedures
Brake System Bleeding
  

Do not reuse the drained fluid.

Always use genuine DOT3/DOT4 brake Fluid.

Using a non-genuine DOT3/DOT4 brake fluid can cause corrosion and decrease the life of the system.

Make sure that no dirt or other foreign matter is allowed to contaminate the brake fluid.

Do not spill brake fluid on the vehicle as it may damage the paint. If brake fluid comes in contact with the paint, wash off immediately with water.

The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure and checked after bleeding each brake caliper. Add fluid as required.

1.

Make sure that the brake fluid in the reservoir is at the MAX (upper) level line.

2.

Have someone to slowly pump the brake pedal several times, and then apply pressure.

3.

Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw securely.

Front

Rear

4.

Repeat the procedure for wheel in the sequence shown below until air bubbles no longer appear in the fluid.

5.

Refill the master cylinder reservoir to MAX (upper) level line.

Bleeding of ESC Brake System

This procedure should be followed to ensure adequate bleeding of air and filling of the ESC unit, brake lines and master cylinder with brake fluid.

1.

Remove the reservoir cap and fill the brake reservoir with brake fluid.

  

If there is any brake fluid on any painted surface, wash it off immediately.

When pressure bleeding, do not depress the brake pedal.

Recommended fluid : DOT3 or DOT4

2.

Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled clear plastic bottle.

3.

Connect the KDS to the data link connector located underneath the dash panel.

4.

Select and operate according to the instructions on the KDS screen.

5.

Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without bubbles. Then close the bleeder screw (A).

Front

Rear

6.

Repeat step 5 until there are no more bubbles in the fluid for each wheel.

7.

Refill the master cylinder reservoir to MAX (upper) level line

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