Kia Sportage: Brake System / Repair procedures

Kia Sportage QL (2015-2024) Service Manual / Brake System / Brake System / Repair procedures

Operation and Leakage Check

Check all of the following items:

Component

Procedure

Brake Booster (A)

Check brake operation by applying the brakes during a test drive. If the brakes do not work properly, check the brake booster. Replace the brake booster as an assembly if it does not work properly or if there are signs of leakage.

Piston cup and pressure
cup inspection (B)

•	Check brake operation by applying the brakes. Look for damage or signs of fluid leakage. Replace the master cylinder as an assembly if the pedal does not work properly or if there is damage or signs of fluid leakage.

•	Check for a difference in brake pedal stroke between quick and slow brake applications. Replace the master cylinder if there is a difference in pedal stroke.

Brake hoses (C)

Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it is damaged or leaking.

Caliper piston seal and
piston boots (D)

Check brake operation by applying the brakes.
Look for damage or signs of fluid leakage. If the pedal does not work properly, the brakes drag, or there is damage or signs of fluid leakage, disassemble and inspect the brake caliper. Replace the boots and seals with new ones whenever the brake caliper is disassembled.

Brake System Bleeding

•	Do not reuse the drained fluid.

•	Always use genuine DOT3/DOT4 brake Fluid. Using a non-genuine DOT3/DOT4 brake fluid can cause corrosion and decrease the life of the system.

•	Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.

•	Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

•	The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure and checked after bleeding each brake caliper. Add fluid as required.

1.	Make sure the brake fluid in the reservoir is at the MAX(upper) level line.

2.	Have someone slowly pump the brake pedal several times, and then apply pressure.

3.	Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw securely. Front Rear [Not applied for EPB] [Applied for EPB]

4.	Repeat the procedure for wheel in the sequence shown below until air bubbles no longer appear in the fluid.

5.	Refill the master cylinder reservoir to MAX(upper) level line.

ESP Bleeding of Brake System

This procedure should be followed to ensure adequate bleeding of air and filling of the ESP unit, brake lines and master cylinder with brake fluid.

Remove the reservoir cap and fill the brake reservoir with brake fluid.

•	If there is any brake fluid on any painted surface, wash it off immediately.

•	When pressure bleeding, do not depress the brake pedal.

•	Recommended fluid........ DOT3 or DOT4

2.	Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled clear plastic bottle.

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

Select and operate according to the instructions on the GDS screen.

•	You must obey the maximum operating time of the ESP motor with the GDS to prevent the motor pump from burning.

(1)	Select vehicle name.

(2)	Select ABS/ESP System.

(3)	Select HCU air bleeding mode.

5.	Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without bubbles. Then close the bleeder screw (A). Front Rear [Not applied for EPB] [Applied for EPB]

6.	Repeat step 5 following the order described below until there are no more bubbles in the fluid for each wheel.

Tighten the bleeder screw.

Bleed screw tightening torque:

6.9 - 8.8 N·m (0.7 - 0.9 kgf·m, 5.1 - 6.5 lb·ft)

Brake System

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Brake Booster Components and components location

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