Kia Soul EV: AHB(Active Hydraulic Boost) System / Front Disc Brake Repair procedures

Kia Soul EV (PS EV) 2015-2020 Service Manual / Brake System / AHB(Active Hydraulic Boost) System / Front Disc Brake Repair procedures

Removal

Brake caliper assembly

Remove the front wheel & tire.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 guide rod bolts (B) and then remove the front caliper body (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)

Guide rod bolts (B):

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

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

Loosen the caliper mounting bolts (B) and then remove the caliper carrier (A).

Tightening torque :

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

Front Wheel Brake disc

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)

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

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

Loosen the caliper mounting bolts (B) and then remove the caliper carrier (A).

Tightening torque :

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

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

Tightening torque :

4.9 ~ 5.9 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)

Replacement

Front brake pads

1.	Remove the front wheel & tire.

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

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

4.	Compress the piston into the caliper body using the SST (09581-11000).

Place the caliper body (A) on the caliper carrier and tighten the guide rod bolt (B).

Tightening torque :

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

Install the front wheel & tire.

Tightening torque :

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

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

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 the level of wear exceeds the limit, replace the discs and pad assembly on the left and right of the vehicle.

Front Brake Pad Check

Check for the pad wear and if the measured pad thickness is below the specified value, replace the pad assembly.

Pad thickness

Standard value: 10.5 mm (0.413 in)

Service limit: 2.0 mm (0.0787 in)

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

Front brake disc runout check

Place a dial gauge at approximately 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 exceed the limit specification, install the brake disc after turning it 180° and 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

Brake caliper assembly

1.	Install in the reverse order of removal.

Compress the piston into the caliper body using the SST (09581-11000).

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

•	Push in wood or a used pad to protect the piston end.

•	When spreading a piston, the whole area of piston end face should be protected from the SST.

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

Front Wheel Brake disc

1.	Install in the reverse order of removal.

Compress the piston into the caliper body using the SST (09581-11000).

•	Do not hit piston end by hammer or prying directly against piston face with screwdriver to push in piston.

•	Use wood or a used pad to protect piston end.Pushing piston with piece of wood or used pad is recommended.

•	When spreading a piston, all area of piston end face should be protected from using the SST.

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. Brake pad6. Pad retainer ...

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