Kia Stinger: Brake System

Kia Stinger CK 2018-2024 Service Manual / Brake System

Special service tools

Special Service Tools

Tool Name / Number	Illustration	Description
Piston expander 09581-11000		Spreading the front disc brake piston

Brake bleeding procedures

Adjustment

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.

•	Avoid contaminating the brake fluid by keeping it away from dirt or other foreign matters.

•	Do not spill brake fluid on the vehicle as 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.

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

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

Loosen the rear right-hand side brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw securely.

[Normal brake]

Front

Rear

[Brembo brake]

Let the inner (A) air bleeding and then let the outer (B) air when the procedure of air bleeding brembo brake air.

Front

Rear

4.	Repeat the procedure for all wheels in the sequence shown below until air bubbles no longer appear in the fluid. [Normal brake] [Brembo brake]

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

Do not reuse the old brake fluid. Use only new clean brake fluid.

ESP Bleeding of Brake System

Follow this procedure 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 KDS to the data link connector located underneath the dash panel.

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

•	Comply with the maximum operating time of the ESP motor on the KDS to prevent the motor pump from burning.

(1)	Select vehicle name.

(2)	Select ABS/ESP system.

(3)	Select HCU air bleeding mode.

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).

[Normal brake]

Front

Rear

[Brembo brake]

Let the inner (A) air bleeding and then let the outer (B) air when the procedure of air bleeding brembo brake air.

Front

Rear

6.	Repeat step 5 in the order shown below until there are no more bubbles in the fluid for each wheel. [Normal brake] [Brembo brake]

Tighten the bleeder screw.

Bleed screw tightening torque:

17 in : 6.9 - 12.7 N·m (0.7 - 1.3 kgf·m, 5.1 - 9.4 lb·ft)

18 in : 16.7 - 19.6 N·m (1.7 - 2.0 kgf·m, 12.3 - 14.4 lb·ft)

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
Uneven brake	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
Not fully functioning on brake (when drive speed is fast)	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

Parking Brake System

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Specifications

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