Kia Forte: Brake System / Front Disc Brake

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

Components and components location
Components

1. Caliper body
2. Caliper carrier
3. Brake pad [In]
4. Brake pad [Out]
5. Return spring
6. Pad liner
7. Bleed screw cap
8. Bleed screw

Repair procedures
Removal
1.

Remove the front wheel and tire (A).

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.

2.

Loosen the guide rod bolt (A) and then pivot the caliper body (B) 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 springs (A).

4.

Remove the brake pads (A).

5.

Remove the pad liner (A).

6.

Disconnect the brake hose (A) from the brake caliper by loosening the bolt.

Tightening torque :

24.5 - 29.4 N·m (2.5 - 3.0 kgf·m, 18.1 - 21.7 lb·ft)

7.

Remove the brake caliper (A) by loosening the bolts.

Tightening torque:

78.4 - 98.0 N·m (8.0 - 10.0 kgf·m, 57.8 - 72.3 lb·ft)

8.

Remove the front brake disc (A) by loosening the screws.

Tightening torque:

4.9 - 5.9 N·m (0.5 - 0.6 kgf·m, 3.6 - 4.3 lb·ft, 43.4 - 52.1 lb·in)

Replacement

Brake pad

1.

Remove the front wheel and tire (A).

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.

2.

Loosen the guide rod bolt (A) and then pivot the caliper body (B) 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 springs (A).

4.

Remove the brake pads (A).

5.

Remove the pad liner (A).

  

Place the return spring, pad liner, inner brake shim, and brake pad all at the same time when replacing the brake pad.

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

Front brake disc thickness

Standard

- 15 inch : 23.0 mm (0.9055 in.)

- 16 inch : 25.0 mm (0.9843 in.)

Service limit

- 15 inch : 21.0 mm (0.8268 in.)

- 16 inch : 23.4 mm (0.9213 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:

- 15 inch : 11.0 mm (0.4331 in.)

- 16 inch : 11.5 mm (0.4528 in.)

Service limit

- 15 inch : 2.0 mm (0.0787 in.)

- 16 inch : 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.

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 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.

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 counterclockwise

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 Bleeding Prcoedures")

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