Kia Rio: Brake System

Kia Rio 2017-2024 YB Service Manual / Brake System

Specifications

Item		Specification
Master cylinder	Type	Single
	Cylinder I.D.	Ø 20.64 mm (0.8125 in)
	Piston stroke	36 ± 1 mm (1.4173 ± 0.0393 in)
	Fluid level switch	Provided
Brake booster	Type	10" Single
	Boosting ratio	8 : 1
Front disc brake (14 in)
Type		Ventilated disc
Disc O.D.		256 mm (10.0787 in)
Disc thickness		22 mm (0.8661 in)
Disc Service Limit		20.4mm (0.8031 in)
Cylinder type		Single piston
Front disc brake (15 in)
Type		Ventilated disc
Disc O.D.		280 mm (11.0236 in)
Disc thickness		22 mm (0.8661 in)
Disc Service Limit		20.4mm (0.8031 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 mm (7.9921 in)
Brake lining thickness		3.9 - 4.5 mm (0.1535 - 0.1772 in)

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
	Tone wheel	48 teeth
	Air gap	0.4 - 1.5 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, ESS)
	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 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
	Tone wheel	48 teeth
	Air gap	0.4 - 1.5 mm

Service Standard

Items	Standard value
Brake pedal height	180.8 mm (7.1181 in)
Brake pedal Full stroke	108 mm (4.2519 in)
Stop lamp clearance	1.0 - 2.0 mm (0.04 - 0.08 in)
Front brake disc pad thickness (14, 15 in)	11 mm (0.4331 in)
Front brake disc pad service limit (14,15 in)	2 mm (0.0787 in)
Rear brake disc pad thickness	10 mm (0.3937 in)
Rear brake disc pad service limit	2 mm (0.0787 in)

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
Master cylinder tube flare nuts	ABS	13.7 - 16.7	1.4 - 1.7	10.1 - 12.3
Master cylinder tube flare nuts	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 knuckle		78.5 - 98.1	8.0 - 10.0	57.9 - 72.3
Brake pedal member bracket bolts		16.7 - 25.5	1.7 - 2.6	12.3 - 18.8
Wheel speed sensor mounting bolt		7.8 - 11.8	0.8 - 1.2	5.8 - 8.7
HECU bracket mounting bolts		16.7 - 25.5	1.7 - 2.6	12.3 - 18.8
HECU brake tube flare nuts		13.7 - 16.7	1.4 - 1.7	10.1 - 12.3

Lubricants

Items	Recommended	Amount
Brake fluid	DOT 3 or DOT 4	As required
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

		Use
09581-11000 Piston expander		Spreading the front disc brake piston
09580 - 0U000 Brake piston adjuster		"Removal and installation of the rear 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 09527-1S010		Used for installing wheel speed sensor cap (Sensor cap : Φ58.4)

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
Uneven brake	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
Not fully functioning on brake (when drive speed is fast)	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

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