Rear brake KIA CARNIVAL 2007 Owner's Manual

2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Raise the rear of the vehicle and make sure it is securely supported. Remove the rear wheel.
2. Remove the guide rod bolt(B), After raising the caliper assembly (A), support it with a wire.
3.Remove pad shim (A), pad retainer (B) and pad assembly (C) in the caliper bracket.
INSTALLATION
1.Install the pad retainer (A) to the caliper bracket.
2. Install the brake pads (B) and pad shims (A) and Install the pad with the wear indicator (C) on the inside.
If you reuse the pads, check for foreign material between the pad shim (A) and the back of the pads (B) and
reinstall the brake pads in their original position to prevent a momentary loss of braking efficiency.
3. Press in the piston with the special tool (09581- 11000).

4.Grease the piston boot to prevent from twisting.
5. Install the guide rod.
6. Install the cylinder assembly (A) to the disc plate.
Be careful not to damage the piston boot.
7.Install the guide rod bolt (B).
Tightening torque Nm(kgf.m,lb - ft) :
22 ~ 32 (2.2 ~ 3.2, 15.9 ~ 23.1)
INSPECTION
REAR BRAKE DISC THICKNESS CHECK
1. Remove all rust and contamination from the disc surface, and then measure the disc thickness at 8 points, al least,
of the same distance (5 mm(0.12 in)) from the brake disc outer circle.
Rear brake disc thickness
Standard value : 12.0 mm (0.47 in)
Limit : 10.4 mm (0.41 in)
2. Thickness variation should not exceed 0.01 mm(0.0004 in) (circumference) and 0.01 mm(0.0004 in) (radius) at any
directions.
3. If wear exceeds the limit, replace the discs and pad assembly for 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 :
10.0 mm ( 0.39 in)
Service limit : 2.0 mm (0.08 in)
2.Check that grease is applied, and the pad and backing metal for damage.
REAR BRAKE DISC RUN OUT CHECK
1.Place a dial gauge about 5 mm (0.2 in) from the outer circumference of the brake disc, and measure the run out of
the disc.
Brake disc run out
Limit : 0.05 mm (0.002 in) or less (new one)
2.If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out
again.

3.If the run out does not exceed the limit specification, install the brake disc after turning it 180° and then check the
run out of the brake disc again.
4. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc.
Seizing of Rear brake disc
1.Remove the brake disc from hub using an M8 screw (A) if the brake disc has been seized with the hub due to
corrosion or overheating.
Be careful not to use a hammer. The disc can be damaged if you remove the disc from the hub by
hammering.

[RHD]
8.Remove the parking brake lamp switch (A).
[LHD]
9.Raise the rear of the vehicle and make sure it is securely supported.
10. Remove the mounting bolt (A) of the parking brake wire bracket from the body.

11.Remove the four mounting bolts (A) of the parking brake wire bracket from the rear cross member.
12.Remove the rear wheels and tires from the rear hubs.
13. Remove the hub cap (A) and the disc (B).
14.Remove the hub nut (A) and washer (B) and remove the rear hub (C).
15.Remove the shoe hold down pin and spring (A) by pressing and rotating the spring.

2.Connect the parking brake wire (B) to the brake shoe (A).
3.Install the shoe hold down pin and spring (A) to hold the brake shoe (B).
4.Install the adjuster assembly (B) and the lower return spring (C).
5. Install the upper return spring (A) and strut (B).
6.Grease where is necessary.
7. Install the rear hubs.
8. Install the hub nut (A). After installation, lock the nut to the spindle as shown in the illustration.

9.Install the hub cap (A) and the disc (B).
10. Install the rear wheels and tires from the rear hubs.
11. Tighten the parking brake adjusting nut.
12. Install the parking brake wire and the pedal assembly.
ADJUSTMENT
ADJUSTMENT OF REAR BRAKE SHOE CLEARANCE
1. Raise the vehicle, and make sure it is securely supported.
2. Remove the rear wheel and tire from the rear hub.
3. After removing the plug from the disc, rotate the toothed wheel by a screw driver until the disc is not moving, and
then return it by 5 notches.
ADJUSTMENT PRECEDURE OF DIH FOOT PARKING BRAKE
1.Adjust the adjusting nut (A) so that parking pedal stoke is to be 88 ~ 98 mm(3.46 ~ 3.86 in) when operating effort
is 200 N(20 kgf, 44 lb) after full stroke operation of parking pedal over 3 times for setting parking wire.

is 200 N(20 kgf, 44 lb) after full stroke operation of parking pedal over 3 times for setting parking wire.
a.The parking brake adjustment must be carried out after adjusting the rear shoe.
b. After adjusting parking brake, notice following matter;
a. Must be free from clearance between adjusting nut and pin.
b. Check securely that the bake is not dragging
BED-IN PROCEDURE FOR DIH FOOT PARKING BRAKE

4FR Wheel speed sensor FR WHEELKm/h
5 RL Wheel speed sensor RL WHEELKm/h
6 RR Wheel speed sensor RR WHEELKm/h
7 ABS Warning lamp ABS LAMP-
8 EBD Warning lamp EBD LAMP-
9 Brake Lamp B/LAMP-
10 Pump relay state PUMP RLY-
11 Valve relay state VALVE RLY-
12 Motor MOTOR-
13 Front Left valve(IN) FL INLET-
14 Front Right valve (IN) FR INLET-
15 Rear Left valve (IN) RL INLET-
16 Rear Right valve (IN) RR INLET-
17 Front Left valve (OUT) FL OUTLET-
18 Front Right valve (OUT) FR OUTLET-
19 Rear Left valve(OUT) RL OUTLET-
20 Rear Right valve (OUT) RR OUTLET-