Kia Optima Hybrid: Brake System / Troubleshooting
| Troubleshooting |
| Symptom | Suspect Area | Reference |
| Lower pedal or spongy pedal | 1. Integrated Brake Actuation Unit (Air in) | air·bleed |
| 2. AHB system (Fluid leaks) | replace | |
| 3. Piston seals in IBAU (Worn or damaged) | replace | |
| Brake drag | 1. Brake pedal free play (Minimum) | adjust |
| 2. Pad or lining (Cracked or distorted) | replace | |
| 3. Piston (Stuck) | replace | |
| 4. Piston (Frozen) | replace | |
| 5. Anchor or Return spring (Inoperative) | replace | |
| 6. Master cylinder (Inoperative) | replace | |
| 7. IBAU (Inoperative) | replace | |
| Brake pull | 1. Piston (Sticking) | replace |
| 2. Pad or lining (Oily) | replace | |
| 3. Piston (Frozen) | replace | |
| 4. Disc (Scored) | replace | |
| 5. Pad or lining (Cracked or distorted) | replace | |
| Hard pedal but brake inefficient | 1. Brake system (Fluid leaks) | repair |
| 2. Brake system (Air in) | air·bleed | |
| 3. Pad or lining (Worn) | replace | |
| 4. Pad or lining (Cracked or distorted) | replace | |
| 5. Rear brake shoe clearance(Out of adjustment) | adjust | |
| 6. Pad or lining (Oily) | replace | |
| 7. Pad or lining (Glazed) | replace | |
| 8. Disc (Scored) | replace | |
| 9. IBAU (Inoperative) | replace | |
| 10. PSU (Inoperative) | replace | |
| Noise from brake | 1. Pad or lining (Cracked or distorted) | replace |
| 2. Installation bolt (Loosen) | adjust | |
| 3. Disc (Scored) | replace | |
| 4. Sliding pin (Worn) | replace | |
| 5. Pad or lining (Dirty) | clean | |
| 6. Pad or lining (Glazed) | replace | |
| 7. Brake pad shim (Damage) | replace | |
| Brake fades | 1. Pad or lining (Worn) | replace |
| 2. Master cylinder (Inoperative) | replace | |
| Brake vibration, pulsation | 1. Pedal free play | adjust |
| 2. Master cylinder (Inoperative) | replace | |
| 3. Caliper (Damage) | replace | |
| 4. Master cylinder cap seal | replace | |
| 5. Damaged brake lines | replace | |
| Heavey pedal (Halt) | 1. Brake pedal sticking (lack of grease) | repair |
| 2. IBAU (Inoperative) | replace | |
| Motor sounds and excessive time to braking when consecutive 2 or 3 times pushing brake pedal (In the case of that accumulator pressure increase rate is under 5bar/sec when checking sensor figures of AHB with GDS) | 1. AHB system (air in) | air·bleed |
| 2. PSU(Inoperative) | replace | |
| Excessive noise when pushing brake pedal | 1. IBAU/PSU system (air in) | air·bleed |
It is not the malfunction of brake when motor sound is noticed with followings.
It is not the malfunction of brake while a brake pedal seems inoperative with followings.
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Special Service Tools
Special Service Tools Tool Name / NumberIllustrationDescription09581-11000Piston expanderUsed when spreading the front and rear brake piston.09580-3D100Air bleeding toolUsed when bleeding the air in the ...
Other information:
Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual: Side Body Body Repair
Side Body A Front side member tooling hole (O20)Fender apron tooling hole (O10)Front door upper hinge mounting hole (O13)Front door lower hinge mounting hole (O13)Fender panel mounting hole (O6.6)Rear door upper hinge mounting hole (O13)Rear door lower hinge mounting hole (O13)Rear door switch mounting ...
Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual: Parking Brake Assembly Repair procedures
Removal Parking Brake Pedal 1. Turn ignition OFF and disconnect the negative (-) battery cable. 2. Remove the crash pad lower panel and reinforcing panel. (Refer to the Body group - crash pad) 3. Remove the junction box. (Refer to the Body Electrical System group - Fuses and Relays) 4. Disconnect the ...