Kia Optima Hybrid: AHB(Active Hydraulic Boost) System / Front Disc Brake Repair procedures

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual / Brake System / AHB(Active Hydraulic Boost) System / Front Disc Brake Repair procedures

Removal

Remove the front wheel & tire.

Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

Loosen the hose eyebolt (C) and caliper mounting bolts (B), then remove the front caliper assembly (A).

Tightening torque:

Brake hose to caliper (C):

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

Caliper assembly to knuckle (B):

78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)

Do not loosen the bolts(E) instead of guide rod bolt.

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

Replacement

Front brake pads

Loosen the guide rod bolt (B) and pivot the caliper (A) up out of the way.

Tightening torque:

21.6 ~ 31.4 N.m (2.2 ~ 3.2 k .m, 15.9 ~ 23.1 lb-ft)

2.	Replace pad shim (D), pad retainers (C) and brake pads (B) in the caliper carrier (A).

Inspection

Front 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, of same distance (5mm) from the brake disc outer circle.

Front brake disc thickness

- Standard: 28 mm (1.10 in)

- Service Limit: 26.4 mm (1.04 in)

Deviation: Less than 0.005mm (0.0002in)

4.	If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.

Front 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: 11 mm (0.43 in)

Service limit: 2.0 mm (0.0787 in)

2.	Check that grease is applied, to sliding contact points. Check for metal damage to the pad and backing.

Front 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: 0.04 mm (0.0016 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 meet the limit specification, remove the disc, turn it 180° and reinstall. Then check the runout of the brake disc again.

4.	If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.

Installation

1.	Installation is the reverse of removal.

2.	Use a SST (09581-11000) when installing the brake caliper assembly.

3.	After installation, bleed the brake system. (Refer to Brake system bleeding)

•	Do not hit piston end with a hammer or pry against piston face with screwdriver to push in piston.

•	Use wood or a used pad to protect piston end. Pushing an the wood or used pad is recommended.

•	When spreading a piston, it is best to use SST 09581-11000.

Front Disc Brake Components and Components Location

Components 1. Guide rod bolt2. Bleed screw3. Caliper carrier4. Caliper body5. Inner pad shim6. Brake pad7. Pad retainer ...

Rear Disc Brake Components and Components Location

Components 1. Guide rod bolt2. Bleed screw3. Caliper carrier4. Caliper body5. Inner pad shim6. Brake pad7. Pad retainer ...

Other information:

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual: Side Airbag (SAB) Module Repair procedures

Removal The side airbag cannot be disassembled from the seat back assembly, so replace the seat back assembly when replacing the side airbag. 1. Disconnect the battery negative cable and wait for at least 3 minutes before beginning work. 2. Remove the front seat assembly. (Refer to the ...

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual: Fuel Filter Repair procedures

Replacement 1. Remove the fuel pump (Refer to “Fuel Pump” in this group). 2. Disconnect the electric pump wiring connector (A) and the fuel sender connector (B). 3. Remove the cushion pipe fixing clip (C), and then separate the head assembly (D). 4. Remove the return nozzle (B) after releasing the ...