Disc & Drum Kia Rio 2002

2001 BRAKES

Disc & Drum

DESCRIPTION & OPERATION

All models use front disc brakes. Rear brakes may be either disc type or self-adjusting drum type. Parking brake cable mechanism applies rear brakes.

BLEEDING BRAKE SYSTEM

BLEEDING PROCEDURE

Conventional System

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 into a clean transparent container.

2. Bleed brakes in the following order: Right front wheel, Left front wheel, Right rear wheel and Left rear wheel.

3. Depress brake pedal at least 10 times, and then hold it in depressed position. See Fig. 1 . With an assistant, loosen bleeder screw, drain fluid, and retighten screw.

NOTE: For trouble shooting ABS brake system or servicing ABS hydraulic system, see appropriate ANTI-LOCK article.

NOTE: For bleeding ABS brake system, see appropriate ANTI-LOCK article in BRAKES.

CAUTION: Do not allow brake fluid remain on a painted surface. Wash it off immediately.

NOTE: When bleeding by pressurized fluid, do not depress brake pedal.

2001 Kia Rio

2001 BRAKES Disc & Drum

2001 Kia Rio


Helpmelearn Repair Manuals

Monday, April 17, 2006 4:58:08 PM © 2004 Mitchell Repair Information Company, LLC.


Monday, April 17, 2006 4:58:14 PM Page 1 © 2004 Mitchell Repair Information Company, LLC.

Fig. 1: Bleeding Brake Fluid Into Container (Typical) Courtesy of KIA MOTORS AMERICA, INC.

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. Add fluid to reservoir at specified level.

ADJUSTMENTS

PARKING BRAKE

1. Check stroke specification by pulling parking brake lever with a force of 22 lbs. (10 kg) for Rio, Sephia, Spectra and Sportage and with a force of 44 lbs (20 kg) for Optima. Stroke should be 8-9 notches on Optima, 6-8 notches on Sportage, or 5-7 notches on Rio, Sephia and Spectra.

2. To adjust, start engine, and depress brake pedal several times while vehicle is moving in reverse. Stop engine. On Sportage, remove console. On all models, turn adjusting nut at front of parking brake cable. See Fig. 2 . After adjustment, turn ignition switch on. Pull parking brake lever 1 notch. Ensure parking brake warning light illuminates. Ensure rear brakes do not drag.

2001 Kia Rio




Fig. 2: Exploded View Of Parking Brake Courtesy of KIA MOTORS AMERICA, INC.

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 0.12-0.31" (3-8 mm) for Optima and 0.16-0.28" (4-7 mm) for all other models. If free play is as specified, no adjustment is necessary.

2. If free play is not as specified, loosen push rod lock nut. See Fig. 3 . Rotate push rod until correct free play is obtained. Tighten push rod lock nut.

2001 Kia Rio




Fig. 3: Measuring Brake Pedal Height & Free Play (Typical) Courtesy of KIA MOTORS AMERICA, INC.

BRAKE PEDAL HEIGHT & BRAKELIGHT SWITCH

1. Measure brake pedal height from upper center pedal pad-to-carpet. On Optima, pedal height should be 6.92-6.94" (173.0-179.0 mm). On Sephia and Spectra, pedal height should be 7.60-7.72" (193.0-196.0 mm). On Sportage, pedal height should be 8.90-9.10" (226.1-231.1 mm). On Rio, pedal height should be 6.69-6.93" (170-176 mm). See Fig. 3 . 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. Reconnect brakelight switch connector. Check brakelight operation.

BRAKE PEDAL-TO-FLOOR CLEARANCE

2001 Kia Rio




1. Depress brake pedal with a force of 110 lbs (50 kg) on Optima, 132 lbs. (59.9 kg) on Sephia and Spectra or 152 lbs. (68.9 kg) on Sportage. Measure distance between upper center pedal pad-to-carpet. On Optima, clearance should be 1.73 in (44.0 mm). On Rio, Sephia and Spectra, clearance should be 2.75" (70.0 mm). On Sportage, clearance should be 4.61" (117.1 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.

TESTING

PROPORTIONING VALVE

Sportage

1. Connect pressure gauges to master cylinder rear brake output and to proportioning valve rear brake output. Apply pressure to brake system, while observing both pressure gauge readings. Rear brake pressure readings should remain constant until pressure reaches 427 psi (30.2 kg/cm 2 ). See PROPORTIONING VALVE PRESSURE SPECIFICATIONS (SPORTAGE) table.

2. Once pressure exceeds 427 psi (30.0 kg/cm 2 ), pressure should begin to differentiate. With pressure from master cylinder at 1422 psi (100 kg/cm 2 ) rear brake pressure should read 744-886 psi (52.3-62.3 kg/cm 2 ) from proportioning valve. If pressure does not differentiate, valve is defective and should be replaced with a NEW valve.

3. Remove brake pressure gauges. Install brake lines to their original locations. Bleed air from system. See BLEEDING BRAKE SYSTEM . Top off brake fluid reservoir as necessary.

PROPORTIONING VALVE PRESSURE SPECIFICATIONS (SPORTAGE)

Optima

1. Connect two pressure gauges, one each to input side and output side of proportioning valve.

2. With brakes applied, measure input pressure and output pressure. If measured pressures are within permissible ranges, proportioning valve is good. See Fig. 4 and PROPORTIONING VALVE OUTPUT PRESSURE

NOTE: Sephia and Spectra do not use a proportioning valve. Information for Rio is not available from manufacturer.

Inlet Pressure - psi (kg/cm 2 ) (1) Outlet Pressure - psi (kg/cm 2 ) 459 (32) 430-459 (30-32) 1422 (100) 744-886 (52-62) (1) Outlet pressure specification is approximate.

NOTE: Be sure to bleed system after you connect pressure gauges.

2001 Kia Rio




3. Reconnect brake lines in original position and bleed system.

PROPORTIONING VALVE OUTPUT PRESSURE (OPTIMA

Fig. 4: Brake Input Pressure & Output Pressure (Optima) Courtesy of KIA MOTORS AMERICA, INC.

POWER BRAKE BOOSTER

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, test check valve and vacuum hose between vacuum source and power brake booster and examine 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

Output Pressure Front psi (kg/cm 2 ) Rear psi (kg/cm 2 ) A 284 (20) 497 (35) B 557 (39.2) 702 (49.4) C 830 (58.4) 976 (68.6)

2001 Kia Rio




height remains at same height, power brake booster is operating as designed. If pedal height recedes, test check valve and vacuum hose between vacuum source and power brake booster. Repair as necessary.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS & CALIPER

Removal (Sephia and Spectra)

1. Raise and support vehicle. Remove front wheels. Remove plastic caps. Remove 2 bolts and bushings. Remove caliper and wire aside. Remove spring clip. Remove brake pads. See Fig. 5 . Measure brake pad thickness. Replace pad if lining thickness is less than .08" (2.0 mm).

2.

Prepare to catch any brake fluid. Using flare nut wrench, disconnect brake hose. Remove 2 bolts and supporting plate. Remove caliper. Measure runout at outer braking contact edge of rotor. Maximum runout should be .004" (.10 mm).

NOTE: Excessive runout could be caused by a loose wheel hub bearing.

2001 Kia Rio




Fig. 5: Exploded View Of Front Disc Brakes (Sephia and Spectra Shown; Sportage Is Similar) Courtesy of KIA MOTORS AMERICA, INC.

Installation

To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.

Removal & Installation (Sportage)

2001 Kia Rio




Raise and support vehicle. Remove 2 caliper assembly bolts, and pull caliper from disc. Remove flexible hose mounting bolt, and disconnect flexible hose from caliper. Remove brake pads from adapter. Remove 2 adapter mounting bolts, and then remove adapter. Remove 2 screws. Remove caliper. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.

Removal (Rio)

1.

Raise and support vehicle. Remove wheel and tire assembly.

Remove brake pad pin retainer. Disengage anti-rattle spring from brake pads. Remove brake pad pins and rattle spring.

Remove brake pads and shims. Remove connector bolt. Discard seal washer. Loosen sleeve bolt and remove caliper from steering knuckle. See Fig. 6 . Measure brake pad thickness. Replace pad if lining thickness is less than .08" (2.0 mm).

2. Prepare to catch any brake fluid. Using flare nut wrench, disconnect brake hose. Discard seal washers. Remove caliper bolts and caliper. Remove anti-squeek caps. Measure runout at outer braking contact edge of rotor. Maximum runout should be .003" (0.08 mm).

CAUTION: Do not use a screwdriver or similar tool to pry piston from rotor.

NOTE: Do not discard shims found behind brake pads.

2001 Kia Rio




Fig. 6: Exploded View Of Front Disc Brake (Rio) Courtesy of KIA MOTORS AMERICA, INC.

Installation

2001 Kia Rio




To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.

Removal (Optima)

1. Raise and support vehicle. Remove wheel and tire assembly. 2. Check pad thickness through cylinder inspection hole. If pad lining thickness is out of specification,

replace pads. See DISC PAD THICKNESS

DISC PAD THICKNESS

3. Remove two bolts from torque plate and remove brake cylinder. Suspend cylinder with wire.

4.

Remove pads. See Fig. 7 5. Remove brake hose from caliper. Remove caliper assembly by removing torque plate.

CAUTION: Ensure no wheel bearing looseness is detected.

Application In. (mm) Pad Lining Thickness

Standard .43 (11) Service Limit .08 (2)

NOTE: Do not disconnect brake hose.

CAUTION: Do not to depress brake pedal while disassembling pads.

2001 Kia Rio




Fig. 7: Exploded View Of Front Disc Brake (Optima) Courtesy of KIA MOTORS AMERICA, INC.

Installation

1.

Install pad clips. Install pads onto each clip. Position pad with its pad wear sensor to piston side. Remove dust before positioning pad clip or replace with a new one if clip is damaged.

2. Press in piston with a hammer handle or similar tool. Lower and insert brake cylinder carefully so as not to damage boot. Install two guide rod bolts and tighten to specification See TORQUE SPECIFICATIONS . Install brake hose to caliper. Fill brake reservoir with brake fluid. Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.

FRONT BRAKE ROTOR

Removal & Installation

Raise and support vehicle. Remove front wheels. Remove brake caliper. See FRONT DISC BRAKE PADS & CALIPER . Using a micrometer, measure brake rotor thickness. Using a dial indicator, measure brake rotor

NOTE: Replace all four pads as a complete set.

2001 Kia Rio




runout. Compare to specifications and resurface or replace as necessary. See DISC BRAKE SPECIFICATIONS . To install, reverse removal procedure.

REAR DISC BRAKE PADS & CALIPER

Removal & Installation (Optima)

1. Raise and support vehicle. Remove wheel and tire assembly. 2. Check pad thickness through cylinder inspection hole. If pad lining thickness is out of specification,

replace pads. See DISC PAD THICKNESS 3. Remove caliper mounting bolts and remove caliper assembly. Remove carrier bolt and remove carrier

with brake pad. Remove piston boot and piston assembly. Remove piston seal with finger tip.

4. Check for worn, damaged or rusted piston bore and piston. Replace damaged parts if necessary. Check for damaged piston seal, boot, and pin insulators.

5. Apply a recommended lubricant to following parts. See RECOMMENDED LUBRICANTS

RECOMMENDED LUBRICANTS

6. Push piston into caliper. Align piston matching mark upward as shown in Fig. 8

CAUTION: Do not use sharp tools to remove brake cylinder components.

Parts Recommended Lubricant Quantity Piston Seal Brake fluid (Dot 3) As Required Cylinder inner side Brake fluid (Dot 3) As Required Piston boot Brake fluid (Dot 3) As Required Piston outer surface Brake fluid (Dot 3) As Required Guide-rod insulators Rubber grease As Required

2001 Kia Rio




Fig. 8: Piston Matching Mark (Optima) Courtesy of KIA MOTORS AMERICA, INC.

7. Before replacing brake pads, remove brake fluid from master cylinder reservoir until it is half full.

Removal & Installation (Sephia & Spectra)

1. Raise and support vehicle. Remove parking cable and clip. Remove brake hose connecting bolt from caliper. Clamp rear brake hose. Remove 2 lock bolts from caliper. Remove caliper from rotor. Remove 2 "V" springs from disc pads. See Fig. 9 .

2. Remove disc pads, shims and guide plates. Remove 2 bolts from mounting support. Remove mounting support from rear wheel spindle. Measure pad thickness. Replace pad if lining thickness is less than .08" (2 mm). To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.

2001 Kia Rio




Fig. 9: Exploded View Of Rear Disc Brakes (Sephia and Spectra) Courtesy of KIA MOTORS AMERICA, INC.

REAR DISC ROTOR (SEPHIA & SPECTRA)

Removal & Installation

Remove rear brake pads and caliper. See REMOVAL & INSTALLATION (SEPHIA AND SPECTRA) under REAR DISC BRAKE PADS & CALIPER . Using a dial indicator check disc runout. Resurface or replace if runout exceeds .004" (.10 mm). Remove rotor mounting screws. Using dial indicator check disc rotor thickness. Resurface or replace rotor if beyond minimum thickness. See DISC BRAKE SPECIFICATIONS .

REAR DRUM BRAKE SHOES & WHEEL CYLINDERS

Removal (Optima)

1. Raise and support vehicle. Remove rear wheels and brake drums. 2.

2001 Kia Rio




Remove rear hub. Remove shoe abut end spring, cylinder end shoe spring, and shoe hold down spring. See Fig. 10 .

3. Remove shoes and adjuster as an assembly.

Fig. 10: Exploded View Of Rear Drum Brake (Optima) Courtesy of KIA MOTORS AMERICA, INC.

Installation

1. Apply specified grease to locations indicated in Fig. 10 and to each component. Shoe and backing plate contact surfaces Shoe and anchor plate contact surfaces

2.

NOTE: If brake drum is difficult to remove, insert bolts into threaded holes of drum, then remove it.

CAUTION: Split pin and hub cap must not be reused.

2001 Kia Rio




Install shoe hold down pin. Assemble return spring with push rod shortened. 3. Check outside dimension of brake shoes. Adjust to 8.96-8.98" (227.6-228.1 mm). Install brake drums and

rear wheels. Adjust parking brake. See PARKING BRAKE under ADJUSTMENTS

Removal (Rio)

1. Raise and support vehicle after releasing parking brake. Remove wheel and tire. Remove hub cap. 2.

Use a small cape chisel to raise staked edge of lock nut. Remove drum, washer and bearings as an assembly from spindle.

3. Remove brake shoe hold down springs and pins. See Fig. 11 . Remove brake shoe assembly. 4. Remove parking brake cable from brake shoe assembly. Remove wheel cylinder brake pipe. Remove

wheel cylinder attaching bolt. Remove anti-rattle spring from brake shoe assembly. Remove operating lever after removing return spring. Remove parking brake operating lever retainer.

NOTE: DO NOT damage groove and threads of spindle using cape chisel .

2001 Kia Rio




Fig. 11: Exploded View Of Rear Drum Brake (Rio) Courtesy of KIA MOTORS AMERICA, INC.

Installation

To install, reverse removal procedure. Coat all internal parts of wheel cylinders with clean brake fluid. Apply brake grease onto wheel cylinder and anchor sliding points, adjuster threads and shoe contact points on backing plate. Adjust brake shoes. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.

Removal (Sephia & Spectra)

1. Raise and support vehicle. Remove rear wheels, and release parking brake. Using impact driver, remove 2

2001 Kia Rio




mounting screws and brake drum. See Fig. 12 . 2. Remove top return spring. Remove front and rear shoe spring clip and hold pins. Remove anti-rattle

spring and adjuster spring. Note position of operating lever while holding front shoe. Remove bottom return spring.

3. Disconnect parking brake cable from rear shoe by removing clip and washer. Remove front and rear brake shoes. Remove attaching bolt, and remove wheel cylinder, if required.

Fig. 12: Exploded View Of Rear Drum Brake (Sephia & Spectra) Courtesy of KIA MOTORS AMERICA, INC.

Installation

To install, reverse removal procedure. Coat all internal parts of wheel cylinders with clean brake fluid. Apply brake grease onto wheel cylinder and anchor sliding points, adjuster threads and shoe contact points on backing

2001 Kia Rio




plate. Adjust brake shoes. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.

Removal (Sportage)

1. Loosen lug nuts. Raise and support vehicle. Remove front wheel. Set parking brake. Loosen and remove 4 hub nuts and screws. Release parking brake, and remove wheel drum.

2. Using spring wrench or pliers, remove adjuster lever spring. Remove adjuster lever. Using spring wrench or pliers, remove return spring. Turn adjuster star wheel clockwise to relieve tension on shoes. Remove adjuster assembly.

3. Turn holding pins until they align with holding spring clip groove. Remove holding pins and spring clips. Remove primary shoe and anchor spring. Remove secondary brake shoe with parking cable attached. Remove brake cable from shoe. Remove control lever "C" clip and lever from secondary brake shoe.

4. Disconnect brakeline from wheel cylinder. Remove 2 wheel cylinder mounting bolts, and remove wheel cylinder. Remove parking brake cable from backing plate. Remove 4 nuts from backing plate. Tap axle from behind with rubber hammer. Remove axle from housing. Remove backing plate.

Installation

1. Install wheel cylinder, and tighten 2 mounting bolts to specification. See TORQUE SPECIFICATIONS . Apply grease onto wheel cylinder contact points. Install brakeline onto wheel cylinder.

2. Install control lever on secondary shoe with NEW "C" clip. Using pliers, connect parking brake cable onto secondary shoe. Attach secondary shoe onto backing plate with holding pin and spring clip. Attach one end of anchor spring onto secondary shoe, and other end onto primary shoe. Position primary shoe, and install holding pin and spring clip.

3. Install adjusting assembly. Using spring wrench, install return spring. Install adjusting lever and adjusting lever spring. Ensure adjusting lever contacts star wheel on adjuster assembly.

4. Measure outer shoe diameter when installed on drums. Measure drum inner diameter. Calculate clearance by subtracting shoe diameter from drum diameter. Clearance should be .020-.040" (.51-1.02 mm).

5. Install drum and set parking brake. Install and tighten 3 hub bolts. Release parking brake, and install tire. Loosely tighten lug nuts. Lower vehicle. Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS . Add brake fluid, and bleed brakes. See BLEEDING BRAKE SYSTEM . Check for fluid leakage.

MASTER CYLINDER


Disconnect battery ground cable. Disconnect fluid level switch connector. Disconnect and plug brake lines at master cylinder to prevent entry of dirt and loss of fluid. Remove 2 master cylinder nuts. Remove master cylinder.

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

2001 Kia Rio




Installation

To install master cylinder, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .

Removal (Sportage)

1. Disconnect clutch fluid hose from back of master cylinder reservoir, and drain reservoir. Remove connector to fluid level and differential sensor. Using line wrench, remove brakelines from master cylinder to proportioning valve.

2. Using line wrench, remove rear wheel brake line from right side of ABS solenoids Remove front wheel brakeline from lower left port of proportioning valve. Remove wire harness connector to ABS solenoids. Remove wire harness connector to proportioning valve.

3. Remove nuts attaching master cylinder to power brake booster. Remove bracket holding ABS solenoids and proportioning valves. Remove master cylinder from power brake booster.

Installation

1. Position NEW gasket onto master cylinder, and adjust push rod length. Attach proportioning valve and ABS solenoids onto bracket. Place master cylinder onto power brake booster unit studs. Place bracket assembly onto power brake booster studs, and install nuts.

2. Install rear wheel brakeline into right side port of ABS solenoid. Install front wheel brakeline into lower left port of proportioning valve. Install brakelines into master cylinder.

3. Connect fluid level and differential sensor connector. Connect ABS solenoid and proportioning valve wire harness connectors. Fill reservoir tank to MAX level. Check for fluid leakage. If needed, adjust brake pedal free play and height. See BRAKE PEDAL FREE PLAY and BRAKE PEDAL HEIGHT & BRAKELIGHT SWITCH under ADJUSTMENTS. Bleed brake system. See BLEEDING BRAKE SYSTEM . Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS .

Removal (Optima)

1. Detach brake tubes from master cylinder and then install plugs. 2. Remove master cylinder mounting nuts and then lift out master cylinder.

Installation

1. Inspect length of output rod and adjust 0.32-0.33" (8.125-8.375 mm). 2. Install master cylinder on brake booster. Connect brake tubes to master cylinder. 3. Fill brake reservoir with brake fluid and bleed system. See BLEEDING BRAKE SYSTEM .

Removal (Rio)

CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediately.

2001 Kia Rio




1. Disconnect low fluid level sensor wiring connector. 2. Disconnect brake pipes from master cylinder and ABS control unit by using SST (0K130 430 019). Cap

tubes and plug master cylinder ports and ABS control unit ports to prevent entry of contaminants. 3. Remove two master cylinder attaching nuts and washers. Remove master cylinder from mounting studs

on brake booster.

Installation

1. Position master cylinder onto brake booster. Check push rod length. Install master cylinder attaching washers and nuts. Tighten master cylinder nuts.

2. Tighten brake pipe flare nut with SST. Connect low fluid level sensor wiring. Bleed brakes. See BLEEDING BRAKE SYSTEM .

POWER BRAKE BOOSTER

Removal (Optima)

1. Remove master cylinder. Remove vacuum hose. Remove operating rod from brake pedal. 2. Loosen booster mounting nuts to remove booster assembly.

Installation

1. Install master cylinder. Attach booster/master cylinder to dash panel. Reinstall vacuum hose securely to prevent vacuum leaks. Couple operating rod with brake pedal.

2. Bleed system. See BLEEDING BRAKE SYSTEM . Inspect system for leaks. Check brake pedal height and free play. Adjust as necessary. See BRAKE PEDAL FREE PLAY and BRAKE PEDAL HEIGHT & BRAKELIGHT SWITCH under ADJUSTMENTS.


1. Remove master cylinder. See MASTER CYLINDER . Disconnect vacuum hose from booster. From inside vehicle, remove spring clip from clevis pin.

2. Remove 4 booster nuts. Remove booster. Remove mounting bracket gasket.

Installation

1. Mount booster to vehicle bulkhead with NEW gasket. Install 4 mounting nuts and tighten to specification. See TORQUE SPECIFICATIONS .

2. Attach push rod clevis pin to brake pedal with NEW clevis pin and NEW spring clip. From engine compartment, attach vacuum hose to check valve. Mount master cylinder onto power brake unit, and install 2 nuts. Tighten master cylinder mounting nuts to specification. See TORQUE SPECIFICATIONS .

NOTE: Power brake booster removal and installation information for Rio is unavailable from manufacturer.

2001 Kia Rio




3.

Connect 4 brakelines. Tighten brakeline flare nuts to specification. See TORQUE SPECIFICATIONS . Connect brake fluid level switch. Fill reservoir with NEW fluid to MAX level line.

4. Bleed system. See BLEEDING BRAKE SYSTEM . Inspect system for leaks. Check brake pedal height and free play. Adjust as necessary. See BRAKE PEDAL FREE PLAY and BRAKE PEDAL HEIGHT & BRAKELIGHT SWITCH under ADJUSTMENTS.

Removal (Sportage)

Remove master cylinder and bracket assembly. See MASTER CYLINDER . Disconnect vacuum hose at power brake booster. From inside vehicle, remove cotter pin and clevis pin from brake pedal. From inside vehicle, remove lock nuts. Remove "U" type link. Remove power brake booster.

Installation

1. Insert brake booster, and connect "U" type link. Attach and tighten lock nuts. Pull brake pedal down to "U" type link. Insert clevis pin, and fix with NEW cotter pin.

2. Place gasket onto master cylinder. Position push rod adjuster onto gasket, and tighten adjusting bolt until bolt touches bottom of push rod hole. Apply 20 in. Hg vacuum with vacuum pump. Place Master Cylinder Gauge (K95U-5200-B) onto power brake booster unit with tip of adjusting bolt touching push rod.

3. Check clearance between edge of adjusting bolt and power brake unit push rod. Clearance should be 0.004-0.012" (0.10-0.30 mm). If clearance is not within specification, loosen push rod lock nut, and turn push rod. Install master cylinder and bracket assembly. See MASTER CYLINDER . Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

OVERHAUL

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS (SEPHIA, SPECTRA & SPORTAGE)

NOTE: When filling reservoir with brake fluid, use DOT 3 or DOT 4 brake fluid.

NOTE: Overhaul information is not available from manufacturer.

Application Ft. Lbs. (N.m) Sephia and Spectra

Brake Booster Nut 15 (20) Brake Caliper Bolt 20 (27) Brake Line Flare Nut 9-13 (13-18) Brake Hose Connecting Bolt 16-21 (22-29) Caliper Retaining Pin (Front) 18 (24) Hex-Head Bolts 33-49 (45-67)

2001 Kia Rio




TORQUE SPECIFICATIONS (OPTIMA & RIO)

Master Cylinder Nut 7-12 (10-16) Master Vacuum Mounting Nut 14-19 (19-26) Parking Brake Cable Bolt 15 (20) Wheel Cylinder Mounting Bolt 12 (16) Wheel Lug Nut 72 (98)

Sportage Brake Booster Nut 15 (20) Brake Caliper Bolt 72 (98) Brake Hose Mounting Nut 17 (23) Brake Line-To-Master Cylinder Nut 13 (17) Brake Pedal Pivot Bolt Nut 20 (27) Front Brake

Adapter Bolt 18 (24) Caliper Bolt 72 (98)

Front Wheel Brakeline-To-Valve Nut 13 (17) Operating Rod Lock Nut 21 (29) Rear Wheel Backing Plate Nut 72 (98) Rear Wheel Brakeline-To-ABS Solenoid Nut 13 (17) Stoplight Switch Lock Nut 12 (16) Wheel Lug Nut 72 (98)

INCH Lbs. (N.m)Sportage

Brake Line Bolt & Nut 89 (10) Master Cylinder Nut 115 (13) Wheel Cylinder Bolt 115 (13)

Application Ft. Lbs. (N.m) Optima

Brake Hose-To-Front Caliper 18-22 (25-30) Caliper Assembly-To-Knuckle 51-63 (69-85) Caliper Guide Rod Bolt 16-24 (22-32) Proportioning Valve Mounting-To-Master Cylinder Bolt 26-41 (35-55) Wheel Cylinder Mounting Bolt 8.8-13 (12-18)

Rio Brake Booster Mounting Nut 14-19 (19-26) Brake Caliper Bolt 29-36 (39-49) Brake Hose Connecting Bolt 16-22 (22-29) Brake Hose Mounting Nut 9-16 (13-22)

2001 Kia Rio




DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS (SEPHIA, SPECTRA & SPORTAGE)

Brake Pedal Pivot Bolt Nut 20 (27) Front Brake

Adapter Bolts 18 (24) Caliper Bolts 29-36 (39-49)

Front Wheel Brakeline-To-Valve Nut 13 (17) Master Cylinder Attaching Nut 7-12 (10-16) Operating Rod Lock Nut 21 (29) Rear Drum/Bearing Retaining Nut (1)

Rear Wheel Backing Plate Nut 72 (98) Rear Wheel Brakeline-To-ABS Solenoid Nut 13 (17) Stoplight Switch Lock Nut 12 (16) Wheel Lug Nut 72 (98)

INCH Lbs. (N.m)Optima

Bleeder Screw 62-115 (7-13) Brake Booster Mounting Nut 115-142 (13-16) Brake Tube Flare Nut 115-150 (13-17) Master Cylinder-To-Booster Mounting Nut 70-106 (8-12)

Rio Adapter & Flare Nut 115-194 (13-22) Brake Line Bolt & Nut 89 (10) Master Cylinder Nut 115 (13) Wheel Cylinder Bolt 115 (13)

(1) Initially tighten nut to 72-96 INCH lbs. (0.7-1.0 N.m). Loosen nut and retighten to 14 ft. lbs. (20 N.m).

Application In. (mm) Brake Pads

Front Sephia and Spectra

Standard Thickness .433-.453 (11.0-11.5) Minimum Thickness .08 (2.0)

Sportage Standard Thickness .37 (9.4) Minimum Thickness .08 (2.0)

Rear

2001 Kia Rio




DISC BRAKE SPECIFICATIONS (OPTIMA & RIO)

Sephia and Spectra Standard Thickness .37 (9.4) Minimum Thickness .079 (2.01)

Front Disc Sephia and Spectra

Standard Thickness .79 (20.1) Minimum Thickness .71 (18.0) Runout .004 (.10)

Sportage Standard Thickness .94 (24.0) Minimum Thickness .88 (22.0) Runout .004 (.10)

Rear Disc Sephia and Spectra


Application In. (mm) Brake Pads

Front Optima

Standard Thickness .399 (10.15) Minimum Thickness .08 (2.0)

Rio Standard Thickness .39 (10.0) Minimum Thickness .08 (2.0)

Rear Rio

Standard Thickness .37 (9.4) Minimum Thickness .079 (2.01)

Front Disc Optima


Rio Standard Thickness .86 (22.0)

2001 Kia Rio




DRUM BRAKE SPECIFICATIONS

DRUM BRAKE SPECIFICATIONS (SEPHIA, SPECTRA AND SPORTAGE)

Minimum Thickness .78 (20.0) Runout .003 (0.08)

Rear Disc Optima

Standard Thickness .39 (10.0) Minimum Thickness .0.079 (2.0) Runout .004 (.10)

Application In. (mm) Drum Diameter

Rio, Sephia and Spectra Original (1)

Maximum 7.91 (201) Sportage

Original (1)

Maximum 9.89 (251.2) Optima

Inner Diameter 9.0 (228.6) Brake Shoes

Minimum Thickness Rio, Sephia and Spectra .04 (1.0) Sportage .06 (1.5)

(1) Information not available from manufacturer.

2001 Kia Rio




Disc & Drum Kia Rio 2002

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