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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Kia Magentis / Optima (2000 release)

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Kia Magentis
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Hit Counter by Digits


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Caliper front brake



PERFORMANCE ORDER

1. Remove the wheel.

2. Remove the banjo bolt and disconnect the brake hose from the caliper. To eliminate leaking brake fluid, close the hole in the brake hose suitable stopper.

3. Remove the two screws and remove the caliper from the master cylinder.

Dismantling

PERFORMANCE ORDER

1. Remove the guide pins and remove the caliper holder.

2. Use a screwdriver to remove the sting with direct-ring piston dust cover.

3. Remove the cover of the piston.

4. Compressed air squeeze out the piston from the cylinder support.

When extrusion piston compressed air do not place your fingers in front of the piston.

5. Blade screwdriver to remove the O-ring from the piston, thus do not damage the surface of the cylinder.

6. Clean the brake fluid piston outer surface and an inner surface of the cylinder.

Check

PERFORMANCE ORDER

1. Check the support cylinder for wear, damage, cracks and rust.
2. Inspect the piston for rust, damage, cracks and deterioration of the external surface.
3. Check the plug and the guide pin for damage and rust.
4. Check the brake pads for deformation, metal plaque and traces of oil.
5. Check the wear indicator for wear and damage.

6. Measure the thickness of the brake disc. Dial indicator, measure the brake disc run-out at a small distance from the outer edge.

Brake Disc Thickness:

  • Par: 24 mm
  • The minimum allowable: 22.4 mm
  • Maximum allowable runout: 0.08 mm.
  • Maximum allowable difference in the thickness of the brake disc: 0.01 mm

7. If necessary, replace the brake disc.

  1. Lift the car and fix it on support.
  2. Remove the wheel.
  3. Remove the caliper and secure it with wire.
  4. Remove the front brake disc.

Check brake disc

PERFORMANCE ORDER

1. Remove the caliper mounting bolts, lift the support upwards and secure it with wire.

2. Slowly turn the brake disc, visually check the condition of the two sides. Wear pads on the brake disc must be within acceptable limits. If there are cracks on the disk, the disk must be replaced.

3. The indicator of hour type check up palpation of a brake disk. The indicator of hour type fix in any convenient place and, turning the brake disk, define its palpation at a distance of 5 mm from the outer edge.

Maximum allowable runout: 0.05 mm.

Tighten the wheel nuts to secure the brake disc to the hub.

Adjusting the brake disc run-out

PERFORMANCE ORDER

1. If brake disc runout exceeds the limit, change the position of the disc relative to the hub and re-measure the runout of the brake disc.

  1. Before moving the brake disk, check the side of the wheel hub, in which there is a maximum runout.
  2. Remove the brake disc, and then set the dial gauge as shown, move the hub in the axial direction and measure the play.
    Maximum permissible backlash: 0,05 mm
    If play exceeds the legal limit, check each suspension.
  3. If the play does not exceed the maximum permissible value, install the brake disc at a position rotated 180 ? from the tag and re-measure the runout of the brake disc.

2. If the heartbeat can not be eliminated by a permutation of the brake disc, replace the brake disk or process it on a special machine ("MAD, DL -8700 PF" or equivalent). Processed brake discs have a smaller part of the run-out than the new brake discs.

Check the thickness of the brake disc

PERFORMANCE ORDER

1 micrometer, measure disc thickness at eight positions, approximately every 45 ? at a distance of 10 mm from the outer edge of the disc.

Brake Disc Thickness:

  • Par: 24 mm
  • The minimum allowable: 22.4 mm
  • Maximum allowable difference in the thickness of the brake disc (8 places): 0,015 mm

2. If the brake disc thickness less than the maximum permissible, replace the brake disc.

Assembly

PERFORMANCE ORDER

1. Clean all parts with isopropyl alcohol, with the exception of brake pads.

2. Apply special grease on the piston o-ring and install it in the groove of the piston.

3. Lubricate the outer surface of the piston and establish it in the support cylinder.

4. Install the cover of the piston and the ring fixing cover.

5. Install the covers and guide pin guide pins.

Setting

PERFORMANCE ORDER

1. Install the brake pads and caliper.

2. Replace and tighten to a torque of banjo bolt brake hose.

Tightening torques bleeder: 7-13 N ??? m

3. Fill the brake fluid reservoir.
4. Remove air from a hydraulic drive of the brake system. Repeatedly press the brake pedal and check for leakage of brake fluid.





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Replacing the front brake pads
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Rear drum brakes

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