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Disc & Drum: Other Kia Optima I

Mechanical - Hydraulic 7 illustrations ~1032 words

BLEEDING BRAKE SYSTEM

Note. For bleeding ABS brake system, see appropriate ANTI-LOCK article.

Scheme 7

Scheme 7: BLEEDING PROCEDURE
Scheme 7: BLEEDING PROCEDURE
  1. Ensure master cylinder is clean of dirt, moisture or any other type of contaminates that may enter master cylinder reservoir. Fill reservoir with clean brake fluid. Remove bleeder cap, and attach clear vinyl bleeder hose onto bleeder plug. Place other end of hose in a clean transparent container half-full of brake fluid. (Scheme 7) CAUTION: Do not allow brake fluid to remain on painted surfaces. Wash it off immediately. NOTE: When bleeding brake system using a pressure bleeder, DO NOT depress brake pedal.
  2. Perform bleeding procedure in appropriate sequence. See «BRAKELINE BLEEDING SEQUENCE»(ref-179107-S20108475782005063000000) table.
  3. Depress brake pedal at least 10 times, and then hold it in depressed position. Have an assistant loosen bleeder screw, then drain fluid and retighten screw.
  4. Repeat step 3 until flow of brake fluid is clear and shows no sign of air bubbles. Check for correct brake operation. Ensure there is no fluid leakage. Fill reservoir with DOT 3 fluid to specified level. BRAKELINE BLEEDING SEQUENCE Application Sequence Optima & Magentis (Canadian) RR, LF, LR & RF

BRAKE PEDAL FREE PLAY

  1. With engine off, depress pedal several times to eliminate vacuum. Depress brake pedal by hand and check pedal free play. Free play should be 0.12-0.31" (3-8 mm). (Scheme 8) If free play is as specified, no adjustment is necessary.
  2. If free play is not as specified, loosen push rod lock nut. Rotate push rod until correct free play is obtained. Tighten push rod lock nut to specification. See «TORQUE SPECIFICATIONS»(ref-179107-S36341252762005063000000).

Scheme 8

Scheme 8
Scheme 8

BRAKE PEDAL HEIGHT & BRAKELIGHT SWITCH

  1. Measure brake pedal height from upper center pedal pad-to-carpet. Pedal height should be 6.81-7.05" (173.0-179.0 mm). (Scheme 9) If pedal height is as specified, no adjustment is necessary.
  2. If pedal height is not as specified, disconnect brakelight switch connector. Loosen brakelight switch lock nut. Turn brakelight switch until switch plunger does not contact pedal. Loosen brake master cylinder push rod lock nut.
  3. Turn brake master cylinder push rod until pedal height is as specified in step 1. Tighten brakelight switch until plunger contacts pedal and then rotate switch an additional 1/2 turn. Tighten both lock nuts to specification. See «TORQUE SPECIFICATIONS»(ref-179107-S36341252762005063000000). Reconnect brakelight switch connector. Check brakelight operation.

Scheme 9

Scheme 9
Scheme 9

BRAKE PEDAL-TO-FLOOR CLEARANCE

  1. Depress brake pedal with a force of 110 lbs. (50 kg). Measure distance between upper center pedal pad-to-carpet. (Scheme 10) Clearance should be 2.95" (75.0 mm).
  2. If clearance is not as specified, check for air in brake hydraulic system, rear brake automatic adjuster malfunction or worn brake shoes or pads. Replace components as necessary.

Scheme 10

Scheme 10
Scheme 10

PARKING BRAKE

Note. Vehicles equipped with rear disc brakes have parking brake linings mounted in a recess in the rotor. Parking brake system for vehicles so equipped may be referred to as Drum In Hat (DIH) parking brake.

With Rear Drum Brakes

  1. Check stroke specification by pulling parking brake lever with a force of 44 lbs. (20 kg). Stroke should be 8-9 notches.
  2. To begin adjustment procedure, start engine, and depress brake pedal several times while vehicle is moving in Reverse. This will actuate rear drum brake self-adjusting feature. Stop engine. Recheck parking brake adjustment.
  3. If further adjustment is necessary, remove console. Turn adjusting nut at front of parking brake cable. (Scheme 11)
  4. After adjustment, turn ignition switch to ON position. Pull parking brake lever one notch. Ensure parking brake warning light illuminates. Ensure rear brakes do not drag.

Scheme 11

Scheme 11
Scheme 11

With Rear Disc Brakes

  1. Check stroke specification by pulling parking brake lever with a force of 44 lbs. (20 kg). Stroke should be 8-9 notches. If stroke is as specified, no further adjustment is necessary. If stroke is greater than specified, go to next step.
  2. Raise and support vehicle. Remove rear wheel and tire assemblies. Locate and remove the adjusting hole plug in rotor. Using a screwdriver, turn adjusting wheel in the direction indicated until the disc won't rotate by force of 6.6 lbs. (3 kg). (Scheme 12) Rotate the adjusting wheel as much as 5 notches to the opposite direction. Shoe clearance should be 0.0075" (0.19 mm) on each side. Install wheel and tire assemblies. Recheck parking brake lever stroke. If stroke is 8-9 notches, no further adjustment is necessary. If stroke is greater than specified, go to next step.
  3. Remove console. Turn adjusting nut at front of parking brake cable. (Scheme 11) After adjustment, turn ignition switch on. Pull parking brake lever one notch. Ensure parking brake warning light illuminates. Ensure rear brakes do not drag.

Scheme 12

Scheme 12
Scheme 12

PROPORTIONING VALVE

  1. Connect 2 pressure gauges to output valve of the front and rear brakes. Reconnect the brakelines in their original positions and bleed the system. See «BLEEDING BRAKE SYSTEM»(ref-179107-S25975970632005063000000).
  2. With the brake applied, measure the input and output pressure. (Scheme 13) Figure shows characteristics of the proportioning valve as the pressure increases. If the measured pressures are within the specified range, the proportioning valve is functioning properly. If measured pressures are not within specified range, replace proportioning valve. See «PROPORTIONING VALVE»(ref-179107-S27942104022005063000000) under REMOVAL & INSTALLATION.

Scheme 13

Scheme 13
Scheme 13

POWER BRAKE BOOSTER

  1. Run the engine for one or 2 minutes, and then turn it off. Depress the brake pedal several times at normal foot pressure. If the pedal goes down deepest the first time, but gradually rises after the second or third time, the brake booster is functioning properly. Go to next step.
  2. With the engine stopped, depress the brake pedal several times. Depress the brake pedal and start the engine. If the pedal goes down slightly, brake booster is operating normally. Go to next step.
  3. With the engine running, depress the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, brake booster is operating normally and no further action is necessary. If results of any of the previous steps is not as specified, check the vacuum hoses. If no problem is found, replace power brake booster. See «POWER BRAKE BOOSTER»(ref-179107-S36808491862005063000000) under REMOVAL & INSTALLATION.

MASTER CYLINDER

Note. Brake fluid will damage painted surfaces. If brake fluid is spilled on painted surface, wipe off immediately and clean with alcohol.

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