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# Kia Soul EV: AHB(Active Hydraulic Boost) System / Front Disc Brake Repair procedures

Kia Soul EV (PS EV) 2015-2020 Service Manual / Brake System / AHB(Active Hydraulic Boost) System / Front Disc Brake Repair procedures

Removal

Brake caliper assembly

1. | Remove the front wheel & tire.Remove the front wheel & tire.
Tightening torque : 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

2. | Loosen the hose eyebolt (C) and guide rod bolts (B) and then remove the front caliper body (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) Guide rod bolts (B): 21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)

3. | Remove the pad shim (D), pad retainers (C) and brake pads (B) in the caliper carrier (A).

4. | Loosen the caliper mounting bolts (B) and then remove the caliper carrier (A).
Tightening torque : 78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)

Front Wheel Brake disc

1. | Remove the front wheel & tire.
Tightening torque : 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

2. | Loosen the guide rod bolt (B) and pivot the caliper body (A) up out of the way.

3. | Remove the pad shim (D), pad retainers (C) and brake pads (B) in the caliper carrier (A).

4. | Loosen the caliper mounting bolts (B) and then remove the caliper carrier (A).
Tightening torque : 78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)

5. | Remove the front brake disc by loosening the screws (A).
Tightening torque : 4.9 ~ 5.9 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)

Replacement

Front brake pads

1. | Remove the front wheel & tire.

2. | Loosen the guide rod bolt (B) and pivot the caliper body (A) up out of the way.

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

4. | Compress the piston into the caliper body using the SST (09581-11000).

5. | Place the caliper body (A) on the caliper carrier and tighten the guide rod bolt (B).
Tightening torque : 21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)

6. | Install the front wheel & tire.
Tightening torque : 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

Inspection

Front 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, at the same distance (5mm) from the brake disc outer circle.
Brake disc thickness Standard: 28 mm (1.10 in) Service Limit: 26.4 mm (1.04 in) Deviation: Less than 0.005mm (0.0002in)

4. | If the level of wear exceeds the limit, replace the discs and pad assembly on the left and right of the vehicle.

Front Brake Pad Check

1. | Check for the pad wear and if the measured pad thickness is below the specified value, replace the pad assembly.
Pad thickness Standard value: 10.5 mm (0.413 in) Service limit: 2.0 mm (0.0787 in)

2. | Check that grease is applied to sliding contact points and inspect the pad and backing metal for damage.

Front brake disc runout check

1. | Place a dial gauge at approximately 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout Limit: 0.04 mm (0.0016 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 exceed the limit specification, install the brake disc after turning it 180° and 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

Brake caliper assembly

1. | Install in the reverse order of removal.

2. | Compress the piston into the caliper body using the SST (09581-11000).
• | Do not hit the piston end with a hammer or pry directly against piston face with a screwdriver to push in the piston.
• | Push in wood or a used pad to protect the piston end.
• | When spreading a piston, the whole area of piston end face should be protected from the SST.

3. | After installation, bleed the brake system. (Refer to Brake system bleeding)

Front Wheel Brake disc

1. | Install in the reverse order of removal.

2. | Compress the piston into the caliper body using the SST (09581-11000).
• | 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 piston with piece of wood or used pad is recommended.
• | When spreading a piston, all area of piston end face should be protected from using the SST.

##### Front Disc Brake Components and Components Location

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

##### Rear Disc Brake Components and Components Location

Components 1. Guide rod bolt2. Bleed screw3. Caliper carrier4. Caliper body5. Brake pad6. Pad retainer ...

##### Other information:

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