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

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

Removal

Remove the rear wheel & tire.

Tightening torque :

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

2.	Release parking brake (EPB).

3.	Disconnect the electric parking brake actuator connector (A).

Remove the hose eyebolt (B). Loosen the caliper mounting bolts (C) and remove the rear caliper body (A).

The hose eyebolt (A) tightening torque :

24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)

The caliper mounting bolts (B) tightening torque :

63.7 ~ 73.5 N.m (6.5 ~ 7.5 kgf.m, 47.0 ~ 54.2 lb-ft)

5.	Remove the rear brake disc by loosening the screws (A).

Replacement

Rear brake pads

1.	Remove the rear wheel & tire.

2.	Connect the GDS to the data link connector located underneath the dash panel.

3.	Ignition "ON" & Engine "OFF".

4.	Release the electric parking brake.

5.	Select vehicle name and EPB system.

6.	Select the “PAD change mode”.

Perform the " PAD change mode (Before pad change)" procedure with GDS.

When disengaging while the motor is in operation, be sure to press down on the brake pedal.

8.	Ignition "OFF".

9.	Disconnect the electric parking brake actuator connector (A).

10.	Loosen the guide rod bolts (B) and then remove caliper body (A).

11.	Replace pad retainers (C) and brake pads (B) in the caliper carrier (A).

12.	Insert the piston in the cylinder using SST (09580-0U000).

13.

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

Tightening torque:

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

14.	Connect the electric parking brake actuator connector (A).

15.	Ignition "ON".

16.	Select the “PAD change mode”.

17.

Perform the " PAD change mode (Before pad change)"procedure with GDS.

Check that the parking brake operates normally.

18.	IGN switch “OFF” and remove the GDS.

19.

Install the rear wheel & tire.

Tightening torque:

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

Inspection

Rear 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: 10 mm (0.393 in)

Service limit: 8.4 mm (0.331 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.

Rear 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 mm (0.394 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.

Rear 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: 0.05 mm (0.0020 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

1.	Install in the reverse order of removal.

2.	Insert the piston in the cylinder using SST (09580-0U000).

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

Rear Disc Brake Components and Components Location

Components 1. Guide rod bolt2. Bleed screw3. Caliper carrier4. Caliper body5. Brake pad6. Pad retainer ...

Parking Brake System

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