Kia Picanto: Brake System
Kia Picanto JA 2017-2024 Service & Repair Manual / Brake System
Specifications
| Specifications |
|
Item
|
Specification
| ||
| Master cylinder | Type | Single | |
| Cylinder I.D. | Ø 20.64 mm (0.812 in) | ||
| Piston stroke | 33±1 mm (1.29 ± 0.039 in) | ||
| Fluid level switch | Provided | ||
| Brake booster | Type | 9" Single | |
| Boosting ratio | 7.5 : 1 | ||
|
Front disc brake
| |||
| 13 in | 14 in | ||
| Type | Ventilated disc | Ventilated disc | |
| Disc O.D. | 241 mm (9.4882 in) | 256 mm (10.0787 in) | |
| Disc thickness | 18 mm (0.7087 in) | 20 mm (0.7874 in) | |
| Disc service limit | 16.0mm (0.6299 in) | 18.0 mm (0.7087 in) | |
| Cylinder type | Single piston | Single piston | |
|
Rear disc brake
| |||
| Type | Solid disc | ||
| Disc O.D | 234 mm (9.2126 in) | ||
| Disc thickness | 10.0mm (0.3937 in) | ||
| Disc service limit | 8.4 mm (0.3307 in) | ||
| Cylinder type | Single piston | ||
|
Drum brake
| |||
| Type | Leading trailing | ||
| Drum(Disc) I.D | Ø 203.2 mm (8.0000 in) | ||
| Brake lining thickness | 4.0 - 4.7 mm (0.1575 - 0.1850 in) | ||
O.D. : Outer Diameter I.D : Inner Diameter |
Specification (ABS)
|
Part
|
Item
|
Standard value
|
Remark
|
| HECU | System | 4 Channel 4 Sensor (Solenoid) | |
| Type | Motor, valve relay integrated type | ||
| Operating Voltage | 9.7 - 17.4 V | ||
| Operating Temperature | -40 to 120 °C (-40 to 248°F) | ||
| Motor power | 230 W | ||
| Active Wheel speed sensor (ABS) | Supply voltage | DC 4.5 - 20 V | |
| Output current low | 5.9 - 8.4 mA | ||
| Output current high | 11.8 - 16.8 mA | ||
| Output range | 1 - 2500 Hz | ||
| Tone wheel | 48 teeth | ||
| Air gap | 0.4 - 1.0 mm |
Specification (ESC)
|
Part
|
Item
|
Standard value
|
Remark
|
| HECU | System | 4 Channel 4 Sensor (Solenoid) | Total control |
| Type | Motor, valve relay integrated type | (ABS, HAC, VSM, ESS) | |
| Operating Voltage | 9.7 - 17.4 V | ||
| Operating Temperature | -40 to 120 °C (-40 to 248°F) | ||
| Motor power | 270 W | ||
| Active Wheel speed sensor | Supply voltage | DC 4.5 - 20 V | |
| Output current low | 5.9 - 8.4 mA | ||
| Output current high | 11.8- 16.8 mA | ||
| Output range | 1 - 2500 Hz | ||
| Tone wheel | 48 teeth | ||
| Air gap | 0.4 - 1.0 mm |
Service Standard
|
Items
|
Standard value
|
| Brake pedal height | 182 mm (7.29 in) |
| Brake pedal Full stroke | 108 mm (4.25 in) |
| Stop lamp clearance | 1.0 - 2.0 mm (0.04 - 0.08 in) |
| Front brake disc thickness (13 in) | 18 mm (0.70 in) |
| Front brake disc thickness (14 in) | 20 mm (0.7874 in) |
| Front brake disc pad thickness | 11 mm (0.4331 in) |
| Rear brake disc thickness | 10 mm (0.39 in) |
| Rear brake disc pad thickness | 10 mm (0.39 in) |
Tightening Torques
|
Items
|
N·m
|
kgf·m
|
lb·ft
| |
| Master cylinder to brake booster nut | 9.8 - 15.7 | 1.0 - 1.6 | 7.2 - 11.6 | |
| Master cylinder tube flare nuts | ABS | 13.7 - 16.7 | 1.4 - 1.7 | 10.1 - 12.3 |
| ESC | 18.6 - 22.6 | 1.9 - 2.3 | 13.7 - 16.6 | |
| Front caliper guide rod bolts | 21.6 - 31.4 | 2.2 - 3.2 | 15.9 - 23.1 | |
| Rear caliper guide rod bolts | 21.6 - 31.4 | 2.2 - 3.2 | 15.9 - 23.1 | |
| Front caliper assembly to knuckle | 78.5 - 98.1 | 8.0 - 10.0 | 57.9 - 72.3 | |
| Rear caliper assembly to knuckle | 78.5 - 98.1 | 8.0 - 10.0 | 57.9 - 72.3 | |
| Brake pedal member bracket bolts | 16.7 - 25.5 | 1.7 - 2.6 | 12.3 - 18.8 | |
| Wheel speed sensor mounting bolt | 7.8 - 11.8 | 0.8 - 1.2 | 5.8 - 8.7 | |
| HECU bracket mounting bolts | 16.7 - 25.5 | 1.7 - 2.6 | 12.3 - 18.8 | |
| HECU brake tube flare nuts | 13.7 - 16.7 | 1.4 - 1.7 | 10.1 - 12.3 | |
Lubricants
|
Items
|
Recommended
|
Amount
|
| Brake fluid | DOT 3 or DOT 4 | 419.5 cc ± 20 cc |
| Brake pedal bushing and bolt | Chassis grease | As required |
| Parking brake shoe and backing plate contacting surface | Heat resistance grease | As required |
Special service tools
| Special Service Tools |
|
|
|
Use
|
| 09581-11000 Piston expander |
| Spreading the front disc brake piston |
| 09964-C1100 SCC reflector |
| Reflector to align the SCC radar |
| 09964-C1200 Calibration beam |
| Laser to detect the center of the vehicle. |
| 09964-C1300 Tripod |
| SCC reflector or vertical / horizontal laser support. |
Troubleshooting
| Troubleshooting |
| Problem Symptoms Table |
Use
the table below to help you find the cause of the problem. The numbers
indicate the priority of the likely cause of the problem.
Check each part in order.
If necessary, replace these parts.
|
Symptom
|
Expected cause
|
Countermeasure
|
| Lower pedal or sponge pedal | Brake system (oil leakage) | Repair |
| Brake system (air inflow) | Air bleeding out procedure | |
| Piston seal (worn out or damaged) | Replace | |
| Rear brake shoe separation (faulty adjustment) | Adjust | |
| Master cylinder (malfunction) | Replace | |
| Dragged brake | Brake pedal free separation (minimum) | Adjust |
| Parking brake cable length (adjustment trouble) | Adjust | |
| Parking brake cable (trapped) | Repair | |
| Rear brake shoe separation (adjustment trouble) | Adjust | |
| Pad and lining (twisted or cracked) | Replace | |
| Piston (trapped) | Replace | |
| Piston (frozen) | Replace | |
| Anker or return spring (malfunction) | Replace | |
| Booster system (leakage of vacuum) | Repair | |
| Master cylinder (malfunction) | Replace | |
| Uneven brake | Piston (trapped) | Replace |
| Pad and lining (oil stain, cracked or twisted) | Replace | |
| Heavy pedal and brake trouble | Brake system (oil leakage, air inflow) | Perform air bleeding procedure |
| Pad or lining (worned out) | Replace | |
| Pad or lining (cracked or twisted) | Replace | |
| Rear brake shoe separation (adjustment trouble) | Adjust | |
| Pad or lining (oil stain) | Replace | |
| Pad or lining (slippery) | Replace | |
| Disc (scratched) | Replace | |
| Booster system (leakage of vacuum) | Repair | |
| Noise from brake | Pad or lining (cracked or twisted) | Replace |
| Looseness of wheel bolt and caliper | Adjust | |
| Pad sliding trouble (Pad uneven worn out) | Replace | |
| Pad or lining (dirty) | Cleaning | |
| Pad or lining (slippery) | Pad replacement | |
| Anker or return spring (malfunction) | Replace | |
| Brake pad shim (damaged) | Replace | |
| Hold down spring (damaged) | Replace | |
| Foreign substance stucked between disc and pad | Cleaning | |
| Corrosion on disc | Test drive brake and cleaning * get rid of corrosion by friction while test drive brake | |
| Caved disc | Replace | |
| Not fully functioning on brake (when drive speed is fast) | Pad or lining (worned out) | Replace |
| Master cylinder (malfunction) | Replace | |
| Brake vibration | Brake booster (leakage of vacuum) | Repair |
| Pedal free separation | Adjust | |
| Master cylinder (malfunction) | Replace | |
| Damaged on master cylinder cap | Replace | |
| Damaged on brake line | Replace | |
| Caliper returning trouble (while tire is turning, check the noise) | Replace | |
| Transformed disc | Replace |
- Brake System
- Brake Booster
- Master Cylinder
- Brake Line
- Brake Pedal
- Front Disc Brake
- Rear Disc Brake
- Rear Drum Brake
- Stop Lamp Switch
- Parking Brake System
- ABS(Anti-Lock Brake System)
- ESC (Electronic Stability Control) System
- ESC Control Module
- Front Wheel Speed Sensor
- Rear Wheel Speed Sensor
- ESP OFF Switch
- Emergency Signal System
- Assist Emergency Braking(AEB) System
Seat Belt Reminder
Components and components location
Components
Seat Belt Reminder (SBR) Unit
1. Seat Belt Reminder (SBR) Unit
Seat Belt Reminder (SBR) Sensnor
1. Seat Belt Reminder (SBR) Sensnor
...
Brake System
Repair procedures
Operation and Leakage Check
Check all of the following items:
Component
Procedure
Brake Booster (A) Check
b ...
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