Disc & Drum: Removal & Installation Kia Spectra I рестайлинг

REMOVAL

1. Remove brake master cylinder.
2. Disconnect master vacuum hose from master vacuum.
3. From inside vehicle, remove spring clip from clevis pin and clevis pin.
4. Remove four master vacuum nuts. Secure master vacuum to bulkhead.
5. Remove master vacuum.
6. Remove master vacuum mounting bracket gasket.

INSTALLATION

1. Mount master vacuum on vehicle bulkhead (with a new gasket) from inside the vehicle and install four mounting nuts. Tighten mounting nuts. Tightening torque: 14~19 lb.ft (19~26 N.m, 1.9~2.6 kg.m)
2. Attach pushrod clevis pin to the brake pedal with a new clevis pin and new spring clip.
3. From engine compartment, attach vacuum hose to the check valve.
4. Mount master cylinder onto power brake unit and install two nuts. Tighten master cylinder mounting nuts. Tightening torque: 7~12 lb.ft (9.8~16 N.m, 1.0~1.6 kg.m)
5. Connect four brake lines. Tighten brake line flare nuts. Tightening torque: 9~16 lb.ft (13~22 N.m, 1.3~2.2 kg.m)
6. Connect brake fluid level switch.
7. Fill reservoir with new fluid to Max level line. (Brake fluid SAE J1703 DOT-3 or DOT-4.)
8. Bleed system. Refer to «AIR BLEEDING (CBS)»(ref-176969-S17679398692005051800000) .
9. Inspect system for leaks.
10. Check brake pedal height and free play and adjust as necessary.

Scheme 19

1. Remove cotter pin from clevis pin and remove clevis pin.
2. Remove nut, lock washer, flat washer and pivot bolt.
3. Remove return spring brake pedal, and brake pedal spacer.
4. If necessary, remove brake pedal bushing, stopper and brake pedal pad.

1. If necessary, install brake pedal stopper, brake pedal and brake pedal bushing.
2. Position brake pedal spacer and slide pivot bolt through to hold it in position.
3. Position brake pedal return spring on brake pedal.
4. Install flat washer, lock washer and pivot nut.
5. Install clevis pin and a new cotter pin.
6. After installation, check and adjust pedal height and free play, if necessary.

Scheme 20

Scheme 21

1. Disconnect battery ground cable.
2. Disconnect brake fluid level switch connectors.
3. Disconnect two brake line cap lines and plug master cylinder ports to prevent entry of contaminants. NOTE: Do not allow brake fluid to contact painted surfaces. If it does, flush with water and wipe off immediately.
4. Remove two brake master cylinder nuts.
5. Remove brake master cylinder.

1. If a new brake master cylinder is being installed, adjust master vacuum to master cylinder push rod.
2. Position the master cylinder on the master vacuum and install two brake master cylinder nuts.
3. Tighten two brake master cylinder nuts. Tightening torque: 7~12 lb.ft (9.8~16 N.m, 1.0~1.6 kg.m)
4. Connect two brake lines.
5. Tighten brake line flare nuts to specification. Tightening torque: 9~16 lb.ft (13~22 N.m, 1.3~2.2 kg.m)
6. Connect brake fluid level switch connectors.
7. Bleed brakes.
8. Connect battery ground cable.

Scheme 22

1. Raise front of vehicle and properly support it.
2. Remove front wheels.
3. Remove plastic caps and two bolts and bushings.
4. Remove caliper.
5. Remove spring clip.
6. Remove brake pads.
7. Measure brake pad thickness. Minimum brake pad thickness: 0.08 in (2.0 mm)
8. Prepare to catch any brake fluid. Disconnect brake hose using a flare nut wrench.
9. Remove two bolts and supporting plate.
10. Measure rotor thickness at four or more places. Minimum rotor thickness: 0.86 in (22 mm)
11. Mount a dial indicator and measure runout at the outer braking contact edge of the rotor. Maximum runout: 0.004 in (0.10 mm) NOTE: Excessive runout could be caused by a loose wheel hub bearing.
12. To remove rotor, remove two mounting screws with an impact driver.
13. Resurface or replace rotor as required.

Scheme 23

1. Check facing for oil or grease, abnormal wear, cracks, and deterioration or damage from heat. Measure thickness of lining. Specified thickness: 0.433-0.453 in (11.0-11.5 mm) Minimum: 0.08 in (2.0 mm)
2. Visually check for damage or wear on the guide plate.

Scheme 24

Scheme 25

1. Measure thickness of disc plate. Standard: 0.94 in (24 mm) Minimum: 0.86 in (22 mm)
2. Measure runout at outermost edge of brake rotor. Runout: 0.004 in (0.08 mm) Max. CAUTION: There must be no wheel bearing looseness. Measurement location is outer edge of disc plate surface.

1. Mount a new or repaired rotor on hub and fasten with two mounting screws.
2. Mount the supporting plate with two hex-head bolts. Tightening torque: 33~49 lb.ft (45~67 N.m, 4.6~6.8 kg.m)
3. Connect the brake hose to the caliper using a flare nut wrench. Tightening torque: 9~13 lb.ft (13~18 N.m, 1.3~1.8 kg.m)
4. Position brake pads in caliper cavity and install caliper onto supporting plate.
5. Lubricate and install two bolts and bushings, and tighten bolts to specification. Tightening torque: 19~21 lb.ft (26~28 N.m, 2.6~3.0 kg.m)
6. Install caps.
7. Bleed system. See «AIR BLEEDING (CBS)»(ref-176969-S17679398692005051800000) .
8. Inspect system for any leaks.

Scheme 26

1. Remove parking cable and clip.
2. Remove brake hose connecting bolt from caliper.
3. Clamp rear brake hose.
4. Remove two lock bolts from caliper.
5. Remove caliper from rotor.
6. Remove two V-springs from disc pads.
7. Remove disc pads, shims and guide plates.
8. Remove two bolts from the mounting support.
9. Remove the mounting support from rear wheel spindle.

1. Raise and suitably support rear of vehicle.
2. Remove rear wheels and release parking brake.
3. Using an impact driver, remove two mounting screws holding the drum and remove the brake drum. NOTE: If brake drum is difficult to remove, thread two 8 mm jacking bolts into two threaded holes provided on drum face and tighten evenly.
4. Remove top return spring.
5. Remove front and rear shoe spring clip and hold down pins.
6. Remove anti-rattle spring and adjuster spring.
7. Note position of operating lever while holding front shoe, then remove bottom return spring.
8. Disconnect parking brake cable from rear shoe by removing clip and washer.
9. Remove front and rear brake shoes.
10. Clean parts with a brake vacuum or solvent and inspect all parts for wear or damage. Replace as necessary.

Scheme 27

Scheme 28

Scheme 29

1. Raise and suitably support rear of vehicle.
2. Remove rear wheels and release parking brake.
3. Using an impact driver, remove two mounting screws holding brake drum. Remove drum. NOTE: If brake drum is difficult to remove, thread two 8 mm jacking bolts into two threaded holes provided on drum face and tighten evenly.
4. Inspect wheel cylinders for brake fluid leaks.
5. Measure lining thickness. Replace both linings if either is less than specification. Minimum lining thickness: 0.04 in (1.0 mm)
6. Inspect lining for cracks, uneven wear or oil contamination. Repair or replace as necessary.
7. Measure drum inside diameter. Replace drum if diameter is greater than specification. Maximum diameter: 7.87 in (200 mm)
8. Inspect drums for cracks, grooves or uneven wear. Resurface or replace as necessary.
9. Verify new or repaired drum-to-shoe contact.

Scheme 30

1. Using white brake grease, sparingly lubricate all brake shoe contact points: Shoe-to-wheel cylinder contact points Anchor sliding points Backing plate-to-shoe contact points
2. Rest operating lever behind and on hub in approximate position as noted above in Removal.
3. Place rear brake shoe in position and connect parking brake cable to rear shoe with washer and clip.
4. Position front brake shoe in place and connect front and rear shoes together with bottom return spring.
5. Hold brake shoe assembly on backing plate, with operating lever between front and rear shoes, and insert hold-down pins through rear of backing plate and into each shoe.
6. Secure front and rear hold-down pins with spring clips.
7. Make sure operating lever is in place and install top return spring.
8. Install anti-rattle spring and adjuster spring.
9. Mount drum and install two mounting retaining screws.
10. Adjust brakes as required.
11. Install rear wheels, and tighten four nuts. Tightening torque: 65~87 lb.ft (88~118 N.m, 9~12 kg.m)

Scheme 31

Note. Install parking brake switch so that it contacts parking brake lever when the lever is fully release.

1. Remove gearshift lever knob from gearshift lever.
2. Remove two center console screws from console after disconnecting cigarette lighter connector.
3. Remove four console screws and two bolts at rear side of console, and remove console.
4. Remove adjuster nut.
5. Remove two mounting bolts holding lever assembly to floorpan.
6. Remove screw holding parking brake switch to lever assembly. NOTE: If vehicle has recently been running, exhaust system will be extremely hot.
7. Remove return spring and unlatch the two rear parking cables from front parking cable balance bar.
8. Pull front parking brake cable out of rubber feed-through.
9. If one or both rear parking brake cables are to be removed, remove retaining clip attaching forward end of rear cable to vehicle floor pan.
10. Remove the bolt and two nuts attaching each rear parking cable to floor pan and trailing link.
11. Remove the cable-to-backing plate retaining clip.
12. Disconnect cable end from rear brake shoe and pull cable out of backing plate.

1. Feed rear parking cable end into backing plate and install its retaining clip.
2. Attach rear parking cable end to rear brake shoe and install brake assembly.
3. Attach rear parking cable to trailing link and floor pan with bolt and two nuts, and tighten to specification. Tightening torque: Bolts: 5.25~7.5 lb.ft (7~10 N.m, 0.7~1.0 kg.m) Nuts: 14~19 lb.ft (19~26 N.m, 1.9~2.6 kg.m)
4. Attach forward end of rear parking cable to floor pan with a push-on clip.
5. If front cable assembly was removed, insert its forward end through grommet and connect rear brake cable to front parking cable's balance bar.
6. From inside vehicle, insert front cable end into parking brake lever assembly and install cable adjuster nut.
7. Fasten cable adjuster with its clip.
8. If removed, install parking brake switch with its screw.
9. Attach lever assembly to floor pan with two bolts. Tighten bolts to specification. Tightening torque: 14~19 lb.ft (19~26 N.m, 1.9~2.6 kg.m)
10. Adjust parking brake. See «INSPECTION»(ref-176969-S21566213102005051800000) .
11. Install console and tighten two bolts and four screws.
12. Install cigarette lighter connector and center console.
13. Install gearshift lever knob. NOTE: Turn ignition switch ON and check that parking brake warning lamp illuminates with lever pulled back one notch.