2003 Kia Sorento LX

2003 BRAKES Disc - Sorento

2003 BRAKES

Disc - Sorento

DESCRIPTION & OPERATION

All models use front and rear disc brakes. Parking brake cable mechanism applies rear brakes.

NOTE: For trouble shooting ABS brake system or servicing ABS hydraulic system, see
appropriate ANTI-LOCK article.

BLEEDING BRAKE SYSTEM

NOTE: For bleeding ABS brake system, see appropriate ANTI-LOCK article.

BLEEDING PROCEDURE

1. Ensure master cylinder is clean of dirt, moisture or any other type of contaminates that may enter master
cylinder reservoir. Fill reservoir with clean brake fluid. Remove bleeder cap, and attach clear vinyl
bleeder hose onto bleeder plug. Place other end of hose into a clean transparent container.

CAUTION: DO NOT allow brake fluid remain on a painted surface. Wash it off
immediately.

NOTE: When bleeding brake system using a pressure bleeder, DO NOT depress
brake pedal. It is only necessary to open each bleed screw in same order
as manual bleeding to release air from system.

2. Bleed brakes following specified sequence. See BRAKE BLEEDING SEQUENCE table.

BRAKE BLEEDING SEQUENCE

Application Bleeding Sequence
Sorento (Non-ABS Brakes) RR, LR, RF & LF

3. Start engine and allow it to idle. Slowly depress brake pedal several times and then hold it in fully
depressed position. See Fig. 1 . Have an assistant, loosen bleeder screw, drain fluid, and retighten screw.

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Fig. 1: Bleeding Brake Fluid Into Container

Courtesy of KIA MOTORS AMERICA, INC.

4. Repeat step 3 until flow of brake fluid is clear and shows no sign of air bubbles. Check for correct brake
operation. Ensure there is no fluid leakage. Fill reservoir to specified level.

ADJUSTMENTS
PARKING BRAKE

NOTE: Vehicles equipped with rear disc brakes have parking brake linings mounted in
a recess in the rotor. Parking brake system for vehicles so equipped may be
referred to as Drum In Hat (DIH) parking brake.

1. Check stroke specification by pulling parking brake lever with a force of 22 lbs (10 kg). Stroke should be
4-6 clicks. If stroke is as specified, no further adjustment is necessary. If stroke is greater than specified,
go to next step.
2. Raise and support vehicle. Remove rear wheel and tire assemblies. Locate and remove the adjusting hole
plug in rotor. See Fig. 2 . Using a screwdriver, turn adjusting wheel to the direction indicated until the
disc won't rotate by tangential force of 6.6 lbs. (3 kg). Rotate the adjustor as much as 5 clicks to the
opposite direction. Shoe clearance should be 0.0075" (0.19 mm) on each side. Install wheel and tire
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2003 BRAKES Disc - Sorento

assemblies. Recheck parking brake lever stroke. If stroke is 4-6 clicks, no further adjustment is necessary.
If stroke is greater than specified, go to next step.
3. Remove console. Turn adjusting nut at front of parking brake cable. See Fig. 3 . After adjustment, turn
ignition switch to ON position. Pull parking brake lever one click. Ensure parking brake warning light
illuminates. Ensure rear brakes do not drag.

Fig. 2: Adjusting Rear Disc Parking Brake

Courtesy of KIA MOTORS AMERICA, INC.

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Fig. 3: Adjusting Parking Brake Lever

Courtesy of KIA MOTORS AMERICA, INC.

BRAKE PEDAL FREE PLAY

1. With engine off, depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check
pedal free play at top of pedal travel before any resistance is felt. Free play should be 0.16-0.28" (4-7
mm). See Fig. 4 . If free play is as specified, no adjustment is necessary.
2. If free play is not as specified, loosen operating rod lock nut. Rotate push rod until correct free play is
obtained. Tighten operating rod lock nut.

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Fig. 4: Measuring Brake Pedal Free Play

Courtesy of KIA MOTORS AMERICA, INC.

BRAKE PEDAL HEIGHT & BRAKELIGHT SWITCH

1. Measure brake pedal height from upper center pedal pad-to-carpet. Pedal height should be 7.87" (200
mm). See Fig. 5 . If pedal height is as specified, no adjustment is necessary.
2. If pedal height is not as specified, disconnect brakelight switch connector. Loosen brakelight switch lock
nut. Turn brakelight switch until switch plunger does not contact pedal. Loosen brake master cylinder
operating rod lock nut.
3. Turn brake master cylinder operating rod until pedal height is as specified in step 1 . Tighten brakelight
switch until plunger contacts pedal and then rotate switch an additional 1/2 turn. Tighten both lock nuts.
Reconnect brakelight switch connector. Check brakelight operation.

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Fig. 5: Adjusting Brake Pedal Height & Brakelight Switch

Courtesy of KIA MOTORS AMERICA, INC.

TESTING
POWER BRAKE BOOSTER

Vacuum Loss

1. With engine off, depress brake pedal several times. Press and hold brake pedal. Start engine. If brake
pedal moves down slightly immediately after engine starts, power brake booster is operating as designed.
If brake pedal does not move as specified, go to next step.

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2. Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is
longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake
booster is operating as designed. If length of strokes is equal, test check valve and vacuum hose between
vacuum source and power brake booster and examine installation. Repair as necessary, and go to next
step.
3. Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal
height remains at same height, power brake booster is operating as designed. If pedal height recedes, test
check valve and vacuum hose between vacuum source and power brake booster. See VACUUM HOSE
& CHECK VALVE . Repair as necessary.

Vacuum Hose & Check Valve

1.
NOTE: Vacuum hose between power brake booster and engine vacuum source is
equipped with a built-in check valve. If faulty, it must be replaced as a
complete assembly.

Disconnect the brake booster vacuum hose/check valve assembly at the power brake booster. Start the
engine and let it idle.
2. There should be vacuum available. If no vacuum is available, the check valve is not working properly.
Replace the brake booster vacuum hose and check valve assembly. After repair, retest vacuum supply.

PROPORTIONING VALVES

CAUTION: DO NOT attempt to adjust the proportioning valves.

1. Disconnect brake lines from proportioning valves. See Fig. 6 . Connect commercially available oil
pressure gauges to proportioning valve outlet openings. Plug brake line openings to prevent
contamination.
2. Depress the brake pedal until the front brake pressure equals brake pressure specification "A". Observe
and record rear brake pressure specification "A". See PROPORTIONING VALVE PRESSURE
SPECIFICATIONS table. See Fig. 7 .

PROPORTIONING VALVE PRESSURE SPECIFICATIONS

Application Specification
Front Brake Pressure
"A" 370 psi (26 kg/cm 2 )
"B" 1138 psi (80 kg/cm 2 )
Rear Brake Pressure
"A" 370 psi (26 kg/cm 2 )
"B" 569 psi (40 kg/cm 2 )

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3. Depress brake pedal again. Apply additional pressure until front brake pressure specification equals "B".
See PROPORTIONING VALVE PRESSURE SPECIFICATIONS table. Observe and record rear
brake pressure specification "B". If fluid pressure is as specified, proportioning valves are functioning
okay. If fluid pressure is not as specified, replace proportioning valves. See PROPORTIONING
VALVES under REMOVAL & INSTALLATION.
4. Remove pressure gauges from proportioning valves. After testing and/or replacing proportioning valve,
reconnect brake lines. Bleed the air from brake system and check for the fluid leakage. See BLEEDING
BRAKE SYSTEM .

Fig. 6: Identifying Proportioning Valves

Courtesy of KIA MOTORS AMERICA, INC.

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Fig. 7: Brake Input & Output Pressures

Courtesy of KIA MOTORS AMERICA, INC.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS & CALIPER

Removal

1. Raise and support vehicle. Remove front wheel and tire assemblies. Remove plastic caps. Remove 2 bolts
and bushings. Remove caliper and wire aside. Remove spring clip. Remove brake pads. Measure brake
pad thickness. Replace pad if lining thickness is less than .08" (2.0 mm).
2. Remove all rust and contamination from the disc surface. Measure disc thickness in at least 4 positions.
Circumference thickness variation should not exceed 0.0002" (0.005 mm). Radial thickness variation
should not exceed 0.002" (0.05 mm). If wear exceeds the limit, replace the discs and pad assembly for
both sides of vehicle.
3.
NOTE: Excessive runout could be caused by a loose wheel hub bearing.

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Prepare to catch any brake fluid. Using flare nut wrench, disconnect brake hose. Plug openings to prevent
fluid loss and contamination. Remove 2 bolts and supporting plate. Remove caliper.
4.
NOTE: Fix disc to the hub by tightening mounting nut.

Using dial indicator, measure runout at outer braking contact edge of rotor. Compare to specifications and
resurface or replace as necessary. See DISC BRAKE SPECIFICATIONS . If runout is greater than
specification, go to next step.
5. If the runout of the brake disc is equivalent to or exceeds the limit specification, replace the disc and hub,
and then measure the runout again. Before removing the brake rotor, chalk both sides of the screw on the
side at which the runout is greatest. If it exceeds the limit, disassemble the hub knuckle and check each
part. If the runout does not exceed the limit specification, install the brake rotor after turning it 180
degrees from the chalk mark, and then check runout again. If the runout cannot be corrected by changing
the position of the brake disc, replace the brake rotor.

Installation

To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for
leaks.

FRONT BRAKE ROTOR

Removal & Installation

Raise and support vehicle. Remove front wheel and tire assemblies. Remove brake caliper. See FRONT DISC
BRAKE PADS & CALIPER . Remove rotor mounting screws and remove rotor from hub. To install, reverse
removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

MASTER CYLINDER

NOTE: Brake fluid will damage painted surfaces. If brake fluid is spilled on painted
surface, wipe off immediately and clean with alcohol.

Removal

Disconnect battery ground cable. Disconnect fluid level switch connector. Disconnect and plug brake lines at
master cylinder to prevent entry of dirt and loss of fluid. Remove 2 master cylinder nuts. Remove master
cylinder.

Installation

To install master cylinder, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .

PARKING BRAKE CABLES

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Removal

1. Remove the console. Loosen the lever adjusting nut. See Fig. 3 .
2.
WARNING: If vehicle has recently been running, exhaust system will be
extremely hot. Take precautions to avoid personal injury.

Detach the cable from the lever. Remove the cable clips, bolts and nuts attaching each rear parking cable
to floor pan. Remove parking cable from the operating lever.

Installation

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
Adjust parking brake. See PARKING BRAKE under ADJUSTMENTS.

PARKING BRAKE SHOES

Removal

1. Raise and support rear of vehicle. Remove wheel and tire assembly. Remove rear disc caliper and pad
assembly. See REAR DISC BRAKE PADS & CALIPER .
2.
NOTE: If necessary, loosen parking brake shoes by turning the adjuster with
appropriate tool.

Remove rear disc rotor. See REAR DISC ROTOR . After turning the pin to coincide with hole of spring
cap, remove the shoe hold spring. Remove the lower return spring.
3. Remove the parking brake cable mounting nuts. Remove parking brake shoes, springs and hardware.
Measure parking brake shoe lining thickness. If lining thickness is less than 0.059" (1.5 mm), replace
parking brake shoes.

Installation

1. Install parking brake cable to operating lever and then install operating lever. See Fig. 8 . Install and
tighten parking brake cable mounting nuts to specification. See TORQUE SPECIFICATIONS .
2. Apply lubricant to the areas indicated. See Fig. 9 . Install the upper return spring and brake shoes. Install
brake rotor. See REAR DISC ROTOR .
3. Adjust parking brake. See PARKING BRAKE under ADJUSTMENTS.
4. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See
TORQUE SPECIFICATIONS .

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Fig. 8: Attaching Parking Brake Cable To Operating Lever

Courtesy of KIA MOTORS AMERICA, INC.

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Fig. 9: Lubricating Parking Brake Shoe Mounting Points

Courtesy of KIA MOTORS AMERICA, INC.

POWER BRAKE BOOSTER

Removal

1. Remove master cylinder and gasket. See MASTER CYLINDER . Disconnect vacuum hose from
booster.
2. Remove the shift lock cable (A/T) and then remove clevis pin and snap ring.
3. Remove the lock nut. Remove 4 booster nuts. Remove booster. Remove mounting bracket gasket.

Installation

1. Mount booster to vehicle bulkhead with NEW gasket. Install 4 mounting nuts and tighten to specification.
See TORQUE SPECIFICATIONS .
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2. Attach push rod clevis pin to brake pedal with NEW clevis pin and NEW spring clip. Onstall shif lock
cable (A/T). From engine compartment, attach vacuum hose to check valve. Mount master cylinder onto
power brake unit, and install 2 nuts. Tighten master cylinder mounting nuts to specification. See
TORQUE SPECIFICATIONS .
3.
NOTE: When filling reservoir with brake fluid, use DOT 3 or DOT 4 brake fluid.

Connect 4 brakelines. Tighten brakeline flare nuts to specification. See TORQUE SPECIFICATIONS .
Connect brake fluid level switch. Fill reservoir with NEW fluid to MAX level line.
4. Bleed system. See BLEEDING BRAKE SYSTEM . Inspect system for leaks. Check brake pedal height
and free play. Adjust as necessary. See BRAKE PEDAL FREE PLAY and BRAKE PEDAL HEIGHT
& BRAKELIGHT SWITCH under ADJUSTMENTS.

PROPORTIONING VALVES

NOTE: Manufacturer does not provide procedure for removal and installation of brake
proportioning valves. If replacement is desired, see Fig. 6 .

REAR DISC BRAKE PADS & CALIPER

Removal & Installation

1. Raise and support vehicle. Remove wheel and tire assembly. Remove guide bolt and lift up caliper.
Remove brake pads, shims and guide plates. Measure pad thickness. Compare results with specification.
See DISC BRAKE SPECIFICATIONS . Replace pads if thickness is less than minimum specification.
2. Disconnect rear brake hose and plug openings to prevent fluid loss or contamination. Remove remaining
guide bolt and remove caliper.
3. Using micrometer, measure rotor thickness in at least 4 places. Using dial indicator, measure rotor runout.
Compare results with specification. See DISC BRAKE SPECIFICATIONS . If measurements are not
within specification, resurface or replace rotor as necessary.
4. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system
for leaks.

REAR DISC ROTOR

Removal & Installation

Remove rear brake pads and caliper. See REAR DISC BRAKE PADS & CALIPER . Using a dial indicator,
measure disc rotor runout. Remove disc rotor mounting screws. Using micrometer, check disc rotor thickness in
at least 4 places. Compare measurements with specifications. See DISC BRAKE SPECIFICATIONS .
Resurface or replace as necessary if disc rotor measurements exceed allowable limits. To install, reverse
removal procedure.

OVERHAUL
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NOTE: Overhaul information is not available from manufacturer.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Brake Booster Nuts 14-19 (19-26)
Brake Line Flare Nuts 9-16 (13-22)
Front Brake Hose-To-Caliper Bolts 13-15 (17-20)
Front Caliper Guide Rod Bolts 16-24 (22-32)
Front Caliper Support Bracket-To-Knuckle Bolts 33-49 (45-67)
Front Caliper-To-Support Bracket Bolts 19-21 (26-28)
HECU (ABS) Bracket-To-Vehicle Bolts 14-19 (19-26)
Parking Brake Cable Mounting Nuts 35-40 (47-54)
Parking Brake Release Lever Mounting Bolts 14-19 (19-26)
Rear Brake Hose-To-Caliper 13-15 (17-20)
Rear Caliper Support Bracket-To-Spindle Bolts 48-55 (65-75)
Rear Caliper-To-Support Bracket Bolts 16-24 (22-32)
Wheel Lug Nuts 66-89 (90-120)
INCH Lbs. (N.m)
Brake Master Cylinder Nuts 89-142 (10-16)
Bleeder Screw 62-80 (7-9)
HECU (ABS)-To-Mounting Bracket Bolts 71-106 (8-12)
Parking Brake Cables Attaching Brackets Bolts 62-89 (7-10)
Wheel Speed Sensor Bolt 71-89 (8-10)

DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATION
Application In. (mm)
Front Brake Disc
Standard Thickness 1.10 (28)
Minimum Thickness 1.02 (26)
Runout 0.0012 (0.03)
Rear Brake Disc
Standard Thickness 0.79 (20)
Minimum Thickness (1)

Runout (1)

Front Brake Pads

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Standard Thickness 0.413 (10.5)

Minimum Thickness 0.098 (2.5)
Rear Brake Pads
Standard Thickness 0.39 (10)
Minimum Thickness 0.08 (2.0)
(1) Information not available from the manufacturer.

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