Kia Optima Hybrid: AHB(Active Hydraulic Boost) System / Rear Disc Brake Repair procedures

Removal
1.
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.
Remove the rear upper arm (A).

3.
Loosen the hose eyebolt (C) and caliper mounting bolts (B), then remove the rear caliper assembly (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)
Caliper assembly to carrier (B):
63.7 ~ 73.5 N.m (6.5 ~ 7.5 kgf.m, 47.0 ~ 54.2 lb-ft)

   
Do not loosen the bolts (E) instead of guide rod bolt.
4.
Remove the rear brake disc by loosening the screws (A).

Replacement
Rear brake pads
1.
Loosen the guide rod bolt (B) and pivot the caliper (A) up out of the way.

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

2.
Replace pad shim (D), pad retainers (C) and brake pads (B) in the caliper carrier (A).

Inspection
Rear Brake Disc Thickness Check
1.
Check the brake pads for wear and fade.
2.
Check the brake disc for damage and cracks.
3.
Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) from the brake disc outer circle.

Brake disc thickness
Standard: 10 mm (0.39 in)
Service limit: 8.4 mm (0.33 in)
Deviation: less than 0.01 mm (0.0004 in)

4.
If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
Rear Brake Pad Check
1.
Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.

Pad thickness
Standard value: 10 mm (0.393 in)
Service limit: 2.0 mm (0.0787 in)

2.
Check that grease is applied, to sliding contact points. Check for metal damage to the pad and backing.
Rear Brake Disc Runout Check
1.
Place a dial gauge about 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 (0.002 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 meet the limit specification, remove the disc, turn it 180° and reinstall. 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.
Installation is the reverse of removal.
2.
Use a SST (09581-11000) when installing the brake caliper assembly.

3.
After installation, bleed the brake system.
(Refer to Brake system bleeding)
   
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 on the wood or used pad is recommended.
When spreading a piston, it is best to use SST 09581-11000.
Rear Disc Brake Components and Components Location

Components 1. Guide rod bolt2. Bleed screw3. Caliper carrier4. Caliper body5. Inner pad shim6. Brake pad7. Pad retainer ...

ESC(Electronic Stability Control) System

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