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Disc & Drum: Other Kia Rio I рестайлинг

Mechanical - Hydraulic 7 illustrations ~1120 words

BLEEDING PROCEDURE

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

  1. Raise vehicle and support it with safety stands. Ensure master cylinder exterior is clean of dirt, moisture or any other type of contaminates that may enter master cylinder reservoir. Fill reservoir with clean brake fluid.
  2. Remove the cap from bleed screw and attach a vinyl tube. Place the other end of the vinyl tube in a clear container. Depress brake pedal at least 10 times, and then hold it in depressed position. (Scheme 3) Have an assistant loosen bleed screw. Drain fluid and retighten bleed screw. CAUTION: Ensure the pedal remains depressed until the bleed screw is tightened.
  3. Repeat previous step until no air bubbles are visible. Check for correct brake operation. Ensure that there is no fluid leakage. Clean away any spilled fluid with rags. After bleeding, add brake fluid to the reservoir to the specified level. Tighten bleed screw to specification. See «TORQUE SPECIFICATIONS»(ref-162294-S28263525742004052400000).

Scheme 3

Scheme 3
Scheme 3

PARKING BRAKE

  1. Check stroke specification by pulling parking brake lever with a force of 22 lbs. (10 kg). Stroke should be 5-7 notches.
  2. To adjust rear brake linings, start engine, and depress brake pedal several times while vehicle is moving in Reverse. Stop engine. Recheck notches required to set parking brake. If further adjustment is necessary, go to next step.
  3. If necessary, remove console to access adjuster nut. Turn adjuster nut at front of parking brake cable. (Scheme 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 4

Scheme 4
Scheme 4

BRAKE PEDAL FREE PLAY

  1. With engine off, depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check pedal free play. Free play should be 0.16-0.28" (4-7 mm). 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-162294-S28263525742004052400000) .

Scheme 5

Scheme 5
Scheme 5

BRAKE PEDAL HEIGHT & BRAKELIGHT SWITCH

  1. Measure brake pedal height from upper center pedal pad-to-carpet. Brake pedal height should be 6.69-6.93" (170-176 mm). (Scheme 5) 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-162294-S28263525742004052400000). Reconnect brakelight switch connector. Check brakelight operation.

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. Brake pedal-to-floor clearance should be 2.75" (70.0 mm).
  2. If clearance is not as specified, check for air in brake hydraulic system, rear brake automatic adjuster malfunction or worn brake shoes/pads. Replace components as necessary.

PROPORTIONING VALVE

CAUTIONDO NOT attempt to adjust the proportioning valve.
  1. Disconnect brakelines from proportioning valve. Connect Fluid Pressure Gauge and Adapter (0KK30-140-001) to proportioning valve. Reconnect brakelines to fluid pressure gauge and adapter. (Scheme 6) Tighten adapter and brakeline flare nuts 10-16 ft. lbs. (14-22 N.m). Bleed air from brake system.
  2. Depress the brake pedal until the front brake pressure is equal to brake pressure specification "A". Observe and record rear brake pressure specification "A". See «PROPORTIONING VALVE PRESSURE SPECIFICATIONS»(ref-162294-S20342169402004052700000) table. (Scheme 7) PROPORTIONING VALVE PRESSURE SPECIFICATIONS Application Specification Front Brake Pressure "A" 427 psi (30 kg/cm 2 ) "B" 782 psi (55 kg/cm 2 ) Rear Brake Pressure "A" 427 psi (30 kg/cm 2 ) "B" 533 psi (37.5 kg/cm 2 )
  3. Depress the brake pedal again, and apply the additional pressure until front brake pressure specification equals "B". See «PROPORTIONING VALVE PRESSURE SPECIFICATIONS»(ref-162294-S20342169402004052700000) table. Observe and record rear brake pressure specification "B". If fluid pressure is not as specified, replace proportioning valve assembly. See «PROPORTIONING VALVE»(ref-162294-S00287343562004052700000) under REMOVAL & INSTALLATION.
  4. Remove fluid pressure gauge and adapter from proportioning valve. After testing and/or proportioning valve replacement, reconnect brakelines. Bleed the air from brake system and check for the fluid leakage. See «BLEEDING BRAKE SYSTEM»(ref-162294-S39646867562004052400000).

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Vacuum Loss Check (Not Using Tester)

  1. With engine off, depress brake pedal several times. Press and hold brake pedal. Start engine. If brake pedal moves down slightly immediately after engine starts, power brake booster is operating as designed. If brake pedal does not move as specified, go to next step.
  2. Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake booster is operating as designed. If length of strokes is equal, inspect vacuum hose between vacuum source and power brake booster and check installation. Repair as necessary and go to next step.
  3. Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal height remains the same, power brake booster is operating as designed. If pedal height recedes, inspect check valve and vacuum hose between vacuum source and power brake booster. Repair as necessary. If no problem is found, replace power brake booster. See «POWER BRAKE BOOSTER»(ref-162294-S08335590712004052400000) under REMOVAL & INSTALLATION.

Vacuum Loss Check (Using Tester)

  1. Connect a commercially available vacuum gauge and pedal depression force gauge. (Scheme 8) Go to next step.
  2. To conduct test for vacuum test in unloaded condition, start engine and allow it to idle. Stop engine when the vacuum gauge reading reaches 19.7 in. Hg (66.3 kPa). Observe the vacuum gauge for 15 seconds. If the gauge indicates 18.7-19.7 in. Hg (62.9-66.3 kPa), the unit is operating normally. Go to next step.
  3. To check system in loaded condition, start the engine. Depress the brake pedal with a force of 44 lbs. (20 kg). With the brake pedal depressed, stop the engine when the vacuum gauge reading reaches 19.7 in. Hg (66.3 kPa). Observe the vacuum gauge for 15 seconds. If the gauge indicates 18.7-19.7 in. Hg (62.9-66.3 kPa), the unit is operating normally. If indicated vacuum values are not as specified in loaded and unloaded condition, replace power brake booster. See «POWER BRAKE BOOSTER»(ref-162294-S08335590712004052400000) under REMOVAL & INSTALLATION.

Scheme 8

Scheme 8
Scheme 8

MASTER CYLINDER

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

POWER BRAKE BOOSTER

Note. Power brake booster removal and installation information is not available from manufacturer. To identify master cylinder and power brake booster components (Scheme 9) See TORQUE SPECIFICATIONS.

Scheme 9

Scheme 9: POWER BRAKE BOOSTER
Scheme 9: POWER BRAKE BOOSTER

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