Disc & Drum Kia Rio 2002

2001 Kia Rio
2001 BRAKES Disc & Drum
2001 BRAKES
Disc & Drum
DESCRIPTION & OPERATION

All models use front disc brakes. Rear brakes may be either disc type or self-adjusting drum type. 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

BLEEDING PROCEDURE
NOTE:
For bleeding ABS brake system, see appropriate ANTI-LOCK article in BRAKES.
Conventional System
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 by pressurized fluid, do not depress brake pedal.
2. Bleed brakes in the following order: Right front wheel, Left front wheel, Right rear wheel and Left rear
wheel.
3. Depress brake pedal at least 10 times, and then hold it in depressed position. See Fig. 1 . With an
assistant, loosen bleeder screw, drain fluid, and retighten screw.
Helpmelearn Repair Manuals

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4:58:08 PM
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2004 Mitchell Repair Information Company, LLC.
2001 Kia Rio

Fig. 1: Bleeding Brake Fluid Into Container (Typical)

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. Add fluid to reservoir at specified level.
ADJUSTMENTS
PARKING BRAKE
1. Check stroke specification by pulling parking brake lever with a force of 22 lbs. (10 kg) for Rio, Sephia,
Spectra and Sportage and with a force of 44 lbs (20 kg) for Optima. Stroke should be 8-9 notches on
Optima, 6-8 notches on Sportage, or 5-7 notches on Rio, Sephia and Spectra.
2. To adjust, start engine, and depress brake pedal several times while vehicle is moving in reverse. Stop
engine. On Sportage, remove console. On all models, turn adjusting nut at front of parking brake cable.
See Fig. 2 . After adjustment, turn ignition switch on. Pull parking brake lever 1 notch. Ensure parking
brake warning light illuminates. Ensure rear brakes do not drag.

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2001 Kia Rio

Fig. 2: Exploded View Of Parking Brake

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. Free play should be 0.12-0.31" (3-8 mm) for Optima and 0.16-0.28" (4-7 mm) for all
other models. If free play is as specified, no adjustment is necessary.
2. If free play is not as specified, loosen push rod lock nut. See Fig. 3 . Rotate push rod until correct free
play is obtained. Tighten push rod lock nut.

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2001 Kia Rio

Fig. 3: Measuring Brake Pedal Height & Free Play (Typical)

BRAKE PEDAL HEIGHT & BRAKELIGHT SWITCH
1. Measure brake pedal height from upper center pedal pad-to-carpet. On Optima, pedal height should be
6.92-6.94" (173.0-179.0 mm). On Sephia and Spectra, pedal height should be 7.60-7.72" (193.0-196.0
mm). On Sportage, pedal height should be 8.90-9.10" (226.1-231.1 mm). On Rio, pedal height should be
6.69-6.93" (170-176 mm). See Fig. 3 . 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
push rod lock nut.
3. Turn brake master cylinder push 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.
BRAKE PEDAL-TO-FLOOR CLEARANCE
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2001 Kia Rio

1. Depress brake pedal with a force of 110 lbs (50 kg) on Optima, 132 lbs. (59.9 kg) on Sephia and Spectra
or 152 lbs. (68.9 kg) on Sportage. Measure distance between upper center pedal pad-to-carpet. On
Optima, clearance should be 1.73 in (44.0 mm). On Rio, Sephia and Spectra, clearance should be
2.75" (70.0 mm). On Sportage, clearance should be 4.61" (117.1 mm).
2. If clearance is not as specified, check for air in brake hydraulic system, rear brake automatic adjuster
malfunction or worn brake shoes/pads. Replace components as necessary.
TESTING
PROPORTIONING VALVE
NOTE:
Sephia and Spectra do not use a proportioning valve. Information for Rio is not
available from manufacturer.
Sportage
1. Connect pressure gauges to master cylinder rear brake output and to proportioning valve rear brake
output. Apply pressure to brake system, while observing both pressure gauge readings. Rear brake
pressure readings should remain constant until pressure reaches 427 psi (30.2 kg/cm 2 ). See
PROPORTIONING VALVE PRESSURE SPECIFICATIONS (SPORTAGE) table.
2. Once pressure exceeds 427 psi (30.0 kg/cm 2 ), pressure should begin to differentiate. With pressure from
master cylinder at 1422 psi (100 kg/cm 2 ) rear brake pressure should read 744-886 psi (52.3-62.3 kg/cm
2 ) from proportioning valve. If pressure does not differentiate, valve is defective and should be replaced
with a NEW valve.
3. Remove brake pressure gauges. Install brake lines to their original locations. Bleed air from system. See
BLEEDING BRAKE SYSTEM . Top off brake fluid reservoir as necessary.
PROPORTIONING VALVE PRESSURE SPECIFICATIONS (SPORTAGE)
Inlet Pressure - psi (kg/cm 2 )
459 (32)
1422 (100)
(1)
(1)
Outlet Pressure - psi (kg/cm 2 )

430-459 (30-32)
744-886 (52-62)
Outlet pressure specification is approximate.
Optima
1. Connect two pressure gauges, one each to input side and output side of proportioning valve.
NOTE:
Be sure to bleed system after you connect pressure gauges.
2. With brakes applied, measure input pressure and output pressure. If measured pressures are within
permissible ranges, proportioning valve is good. See Fig. 4 and PROPORTIONING VALVE OUTPUT
PRESSURE
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2001 Kia Rio

3. Reconnect brake lines in original position and bleed system.

PROPORTIONING VALVE OUTPUT PRESSURE (OPTIMA
Output Pressure
Front psi (kg/cm 2 )
Rear psi (kg/cm 2 )
A
284 (20)
497 (35)
B
557 (39.2)
702 (49.4)
C
830 (58.4)
976 (68.6)
Fig. 4: Brake Input Pressure & Output Pressure (Optima)

POWER BRAKE BOOSTER
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.
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
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2001 Kia Rio

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. Repair as necessary.
REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS & CALIPER
Removal (Sephia and Spectra)
1. Raise and support vehicle. Remove front wheels. Remove plastic caps. Remove 2 bolts and bushings.
Remove caliper and wire aside. Remove spring clip. Remove brake pads. See Fig. 5 . Measure brake pad
thickness. Replace pad if lining thickness is less than .08" (2.0 mm).
2.
NOTE:
Excessive runout could be caused by a loose wheel hub bearing.
Prepare to catch any brake fluid. Using flare nut wrench, disconnect brake hose. Remove 2 bolts and
supporting plate. Remove caliper. Measure runout at outer braking contact edge of rotor. Maximum
runout should be .004" (.10 mm).

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2001 Kia Rio

Fig. 5: Exploded View Of Front Disc Brakes (Sephia and Spectra Shown; Sportage Is Similar)
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.
Removal & Installation (Sportage)
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2001 Kia Rio

Raise and support vehicle. Remove 2 caliper assembly bolts, and pull caliper from disc. Remove flexible hose
mounting bolt, and disconnect flexible hose from caliper. Remove brake pads from adapter. Remove 2 adapter
mounting bolts, and then remove adapter. Remove 2 screws. Remove caliper. 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.
Removal (Rio)
CAUTION: Do not use a screwdriver or similar tool to pry piston from rotor.
1.
NOTE:
Do not discard shims found behind brake pads.
Raise and support vehicle. Remove wheel and tire assembly.

Remove brake pad pin retainer. Disengage anti-rattle spring from brake pads. Remove brake pad pins and
rattle spring.
Remove brake pads and shims. Remove connector bolt. Discard seal washer. Loosen sleeve bolt and
remove caliper from steering knuckle. See Fig. 6 . Measure brake pad thickness. Replace pad if lining
thickness is less than .08" (2.0 mm).
2. Prepare to catch any brake fluid. Using flare nut wrench, disconnect brake hose. Discard seal washers.
Remove caliper bolts and caliper. Remove anti-squeek caps. Measure runout at outer braking contact
edge of rotor. Maximum runout should be .003" (0.08 mm).

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2001 Kia Rio

Fig. 6: Exploded View Of Front Disc Brake (Rio)

Installation
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2001 Kia Rio

CAUTION: Ensure no wheel bearing looseness is detected.
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.
Removal (Optima)
1. Raise and support vehicle. Remove wheel and tire assembly.

2. Check pad thickness through cylinder inspection hole. If pad lining thickness is out of specification,
replace pads. See DISC PAD THICKNESS
DISC PAD THICKNESS
Application
Pad Lining Thickness
Standard
Service Limit
In. (mm)
.43 (11)
.08 (2)
3. Remove two bolts from torque plate and remove brake cylinder. Suspend cylinder with wire.
NOTE:
Do not disconnect brake hose.
4.
CAUTION: Do not to depress brake pedal while disassembling pads.
Remove pads. See Fig. 7

5. Remove brake hose from caliper. Remove caliper assembly by removing torque plate.

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2001 Kia Rio

Fig. 7: Exploded View Of Front Disc Brake (Optima)

Installation
1.
NOTE:
Replace all four pads as a complete set.
Install pad clips. Install pads onto each clip. Position pad with its pad wear sensor to piston side. Remove
dust before positioning pad clip or replace with a new one if clip is damaged.
2. Press in piston with a hammer handle or similar tool. Lower and insert brake cylinder carefully so as not
to damage boot. Install two guide rod bolts and tighten to specification See TORQUE
SPECIFICATIONS . Install brake hose to caliper. Fill brake reservoir with brake fluid. Bleed brake
system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.
FRONT BRAKE ROTOR
Removal & Installation
Raise and support vehicle. Remove front wheels. Remove brake caliper. See FRONT DISC BRAKE PADS &
CALIPER . Using a micrometer, measure brake rotor thickness. Using a dial indicator, measure brake rotor
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2001 Kia Rio

runout. Compare to specifications and resurface or replace as necessary. See DISC BRAKE
SPECIFICATIONS . To install, reverse removal procedure.
REAR DISC BRAKE PADS & CALIPER
Removal & Installation (Optima)
1. Raise and support vehicle. Remove wheel and tire assembly.

2. Check pad thickness through cylinder inspection hole. If pad lining thickness is out of specification,
replace pads. See DISC PAD THICKNESS
3. Remove caliper mounting bolts and remove caliper assembly. Remove carrier bolt and remove carrier
with brake pad. Remove piston boot and piston assembly. Remove piston seal with finger tip.
CAUTION: Do not use sharp tools to remove brake cylinder components.
4. Check for worn, damaged or rusted piston bore and piston. Replace damaged parts if necessary. Check
for damaged piston seal, boot, and pin insulators.
5. Apply a recommended lubricant to following parts. See RECOMMENDED LUBRICANTS
RECOMMENDED LUBRICANTS
Parts
Recommended Lubricant
Piston Seal
Brake fluid (Dot 3)
Cylinder inner side
Brake fluid (Dot 3)
Piston boot
Brake fluid (Dot 3)
Piston outer surface
Brake fluid (Dot 3)
Guide-rod insulators
Rubber grease
Quantity
As Required
As Required
As Required
As Required
As Required
6. Push piston into caliper. Align piston matching mark upward as shown in Fig. 8

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2001 Kia Rio

Fig. 8: Piston Matching Mark (Optima)

7. Before replacing brake pads, remove brake fluid from master cylinder reservoir until it is half full.
Removal & Installation (Sephia & Spectra)
1. Raise and support vehicle. Remove parking cable and clip. Remove brake hose connecting bolt from
caliper. Clamp rear brake hose. Remove 2 lock bolts from caliper. Remove caliper from rotor. Remove 2
"V" springs from disc pads. See Fig. 9 .
2. Remove disc pads, shims and guide plates. Remove 2 bolts from mounting support. Remove mounting
support from rear wheel spindle. Measure pad thickness. Replace pad if lining thickness is less
than .08" (2 mm). 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.

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2001 Kia Rio

Fig. 9: Exploded View Of Rear Disc Brakes (Sephia and Spectra)

REAR DISC ROTOR (SEPHIA & SPECTRA)
Removal & Installation
Remove rear brake pads and caliper. See REMOVAL & INSTALLATION (SEPHIA AND SPECTRA) under
REAR DISC BRAKE PADS & CALIPER . Using a dial indicator check disc runout. Resurface or replace if
runout exceeds .004" (.10 mm). Remove rotor mounting screws. Using dial indicator check disc rotor thickness.
Resurface or replace rotor if beyond minimum thickness. See DISC BRAKE SPECIFICATIONS .
REAR DRUM BRAKE SHOES & WHEEL CYLINDERS
Removal (Optima)
1. Raise and support vehicle. Remove rear wheels and brake drums.
2.

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2001 Kia Rio

NOTE:
If brake drum is difficult to remove, insert bolts into threaded holes of

drum, then remove it.
Remove rear hub. Remove shoe abut end spring, cylinder end shoe spring, and shoe hold down spring.
See Fig. 10 .
3. Remove shoes and adjuster as an assembly.
Fig. 10: Exploded View Of Rear Drum Brake (Optima)

Installation
1. Apply specified grease to locations indicated in Fig. 10 and to each component.

z Shoe and backing plate contact surfaces
z Shoe and anchor plate contact surfaces
2.
CAUTION: Split pin and hub cap must not be reused.

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2001 Kia Rio

Install shoe hold down pin. Assemble return spring with push rod shortened.
3. Check outside dimension of brake shoes. Adjust to 8.96-8.98" (227.6-228.1 mm). Install brake drums and
rear wheels. Adjust parking brake. See PARKING BRAKE under ADJUSTMENTS
Removal (Rio)
1. Raise and support vehicle after releasing parking brake. Remove wheel and tire. Remove hub cap.
2.
NOTE:
DO NOT damage groove and threads of spindle using cape chisel .
Use a small cape chisel to raise staked edge of lock nut. Remove drum, washer and bearings as an
assembly from spindle.
3. Remove brake shoe hold down springs and pins. See Fig. 11 . Remove brake shoe assembly.
4. Remove parking brake cable from brake shoe assembly. Remove wheel cylinder brake pipe. Remove
wheel cylinder attaching bolt. Remove anti-rattle spring from brake shoe assembly. Remove operating
lever after removing return spring. Remove parking brake operating lever retainer.

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2001 Kia Rio

Fig. 11: Exploded View Of Rear Drum Brake (Rio)

Installation
To install, reverse removal procedure. Coat all internal parts of wheel cylinders with clean brake fluid. Apply
brake grease onto wheel cylinder and anchor sliding points, adjuster threads and shoe contact points on backing
plate. Adjust brake shoes. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed
brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.
Removal (Sephia & Spectra)
1. Raise and support vehicle. Remove rear wheels, and release parking brake. Using impact driver, remove 2
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2001 Kia Rio

mounting screws and brake drum. See Fig. 12 .

2. Remove top return spring. Remove front and rear shoe spring clip and hold pins. Remove anti-rattle
spring and adjuster spring. Note position of operating lever while holding front shoe. Remove bottom
return spring.
3. Disconnect parking brake cable from rear shoe by removing clip and washer. Remove front and rear
brake shoes. Remove attaching bolt, and remove wheel cylinder, if required.
Fig. 12: Exploded View Of Rear Drum Brake (Sephia & Spectra)
Installation
To install, reverse removal procedure. Coat all internal parts of wheel cylinders with clean brake fluid. Apply
brake grease onto wheel cylinder and anchor sliding points, adjuster threads and shoe contact points on backing
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2001 Kia Rio

plate. Adjust brake shoes. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed
brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.
Removal (Sportage)
1. Loosen lug nuts. Raise and support vehicle. Remove front wheel. Set parking brake. Loosen and remove
4 hub nuts and screws. Release parking brake, and remove wheel drum.
2. Using spring wrench or pliers, remove adjuster lever spring. Remove adjuster lever. Using spring wrench
or pliers, remove return spring. Turn adjuster star wheel clockwise to relieve tension on shoes. Remove
adjuster assembly.
3. Turn holding pins until they align with holding spring clip groove. Remove holding pins and spring clips.
Remove primary shoe and anchor spring. Remove secondary brake shoe with parking cable attached.
Remove brake cable from shoe. Remove control lever "C" clip and lever from secondary brake shoe.
4. Disconnect brakeline from wheel cylinder. Remove 2 wheel cylinder mounting bolts, and remove wheel
cylinder. Remove parking brake cable from backing plate. Remove 4 nuts from backing plate. Tap axle
from behind with rubber hammer. Remove axle from housing. Remove backing plate.
Installation
1. Install wheel cylinder, and tighten 2 mounting bolts to specification. See TORQUE
SPECIFICATIONS . Apply grease onto wheel cylinder contact points. Install brakeline onto wheel
cylinder.
2. Install control lever on secondary shoe with NEW "C" clip. Using pliers, connect parking brake cable
onto secondary shoe. Attach secondary shoe onto backing plate with holding pin and spring clip. Attach
one end of anchor spring onto secondary shoe, and other end onto primary shoe. Position primary shoe,
and install holding pin and spring clip.
3. Install adjusting assembly. Using spring wrench, install return spring. Install adjusting lever and adjusting
lever spring. Ensure adjusting lever contacts star wheel on adjuster assembly.
4. Measure outer shoe diameter when installed on drums. Measure drum inner diameter. Calculate clearance
by subtracting shoe diameter from drum diameter. Clearance should be .020-.040" (.51-1.02 mm).
5. Install drum and set parking brake. Install and tighten 3 hub bolts. Release parking brake, and install tire.
Loosely tighten lug nuts. Lower vehicle. Tighten all bolts and nuts to specification. See TORQUE
SPECIFICATIONS . Add brake fluid, and bleed brakes. See BLEEDING BRAKE SYSTEM . Check
for fluid leakage.
MASTER CYLINDER
NOTE:
Brake fluid will damage painted surfaces. If brake fluid is spilled on painted
surface, wipe off immediately and clean with alcohol.
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.
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2001 Kia Rio

Installation
To install master cylinder, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .
Removal (Sportage)
1. Disconnect clutch fluid hose from back of master cylinder reservoir, and drain reservoir. Remove
connector to fluid level and differential sensor. Using line wrench, remove brakelines from master
cylinder to proportioning valve.
2. Using line wrench, remove rear wheel brake line from right side of ABS solenoids Remove front wheel
brakeline from lower left port of proportioning valve. Remove wire harness connector to ABS solenoids.
Remove wire harness connector to proportioning valve.
3. Remove nuts attaching master cylinder to power brake booster. Remove bracket holding ABS solenoids
and proportioning valves. Remove master cylinder from power brake booster.
Installation
1. Position NEW gasket onto master cylinder, and adjust push rod length. Attach proportioning valve and
ABS solenoids onto bracket. Place master cylinder onto power brake booster unit studs. Place bracket
assembly onto power brake booster studs, and install nuts.
2. Install rear wheel brakeline into right side port of ABS solenoid. Install front wheel brakeline into lower
left port of proportioning valve. Install brakelines into master cylinder.
3. Connect fluid level and differential sensor connector. Connect ABS solenoid and proportioning valve
wire harness connectors. Fill reservoir tank to MAX level. Check for fluid leakage. If needed, adjust
brake pedal free play and height. See BRAKE PEDAL FREE PLAY and BRAKE PEDAL HEIGHT
& BRAKELIGHT SWITCH under ADJUSTMENTS. Bleed brake system. See BLEEDING BRAKE
SYSTEM . Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS .
Removal (Optima)
CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediately.
1. Detach brake tubes from master cylinder and then install plugs.
2. Remove master cylinder mounting nuts and then lift out master cylinder.
Installation
1. Inspect length of output rod and adjust 0.32-0.33" (8.125-8.375 mm).

2. Install master cylinder on brake booster. Connect brake tubes to master cylinder.
3. Fill brake reservoir with brake fluid and bleed system. See BLEEDING BRAKE SYSTEM .
Removal (Rio)
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2001 Kia Rio

1. Disconnect low fluid level sensor wiring connector.

2. Disconnect brake pipes from master cylinder and ABS control unit by using SST (0K130 430 019). Cap
tubes and plug master cylinder ports and ABS control unit ports to prevent entry of contaminants.
3. Remove two master cylinder attaching nuts and washers. Remove master cylinder from mounting studs
on brake booster.
Installation
1. Position master cylinder onto brake booster. Check push rod length. Install master cylinder attaching
washers and nuts. Tighten master cylinder nuts.
2. Tighten brake pipe flare nut with SST. Connect low fluid level sensor wiring. Bleed brakes. See
BLEEDING BRAKE SYSTEM .
POWER BRAKE BOOSTER
NOTE:
Power brake booster removal and installation information for Rio is unavailable
from manufacturer.
Removal (Optima)
1. Remove master cylinder. Remove vacuum hose. Remove operating rod from brake pedal.
2. Loosen booster mounting nuts to remove booster assembly.
Installation
1. Install master cylinder. Attach booster/master cylinder to dash panel. Reinstall vacuum hose securely to
prevent vacuum leaks. Couple operating rod with brake pedal.
2. 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.
1. Remove master cylinder. See MASTER CYLINDER . Disconnect vacuum hose from booster. From
inside vehicle, remove spring clip from clevis pin.
2. 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 .
2. Attach push rod clevis pin to brake pedal with NEW clevis pin and NEW spring clip. 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 .
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2001 Kia Rio

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.
Removal (Sportage)
Remove master cylinder and bracket assembly. See MASTER CYLINDER . Disconnect vacuum hose at
power brake booster. From inside vehicle, remove cotter pin and clevis pin from brake pedal. From inside
vehicle, remove lock nuts. Remove "U" type link. Remove power brake booster.
Installation
1. Insert brake booster, and connect "U" type link. Attach and tighten lock nuts. Pull brake pedal down to
"U" type link. Insert clevis pin, and fix with NEW cotter pin.
2. Place gasket onto master cylinder. Position push rod adjuster onto gasket, and tighten adjusting bolt until
bolt touches bottom of push rod hole. Apply 20 in. Hg vacuum with vacuum pump. Place Master
Cylinder Gauge (K95U-5200-B) onto power brake booster unit with tip of adjusting bolt touching push
rod.
3. Check clearance between edge of adjusting bolt and power brake unit push rod. Clearance should be
0.004-0.012" (0.10-0.30 mm). If clearance is not within specification, loosen push rod lock nut, and turn
push rod. Install master cylinder and bracket assembly. See MASTER CYLINDER . Tighten bolts and
nuts to specification. See TORQUE SPECIFICATIONS .
OVERHAUL
NOTE:
Overhaul information is not available from manufacturer.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (SEPHIA, SPECTRA & SPORTAGE)
Application
Ft. Lbs. (N.m)
Sephia and Spectra
Brake Booster Nut
15 (20)
Brake Caliper Bolt
20 (27)
Brake Line Flare Nut
9-13 (13-18)
Brake Hose Connecting Bolt
16-21 (22-29)
Caliper Retaining Pin (Front)
18 (24)
Hex-Head Bolts
33-49 (45-67)
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2001 Kia Rio

Master Cylinder Nut

Master Vacuum Mounting Nut
Parking Brake Cable Bolt
Wheel Cylinder Mounting Bolt
Wheel Lug Nut
Sportage
Brake Booster Nut
Brake Caliper Bolt
Brake Hose Mounting Nut
Brake Line-To-Master Cylinder Nut
Brake Pedal Pivot Bolt Nut
Front Brake
Adapter Bolt
Caliper Bolt
Front Wheel Brakeline-To-Valve Nut
Operating Rod Lock Nut
Rear Wheel Backing Plate Nut
Rear Wheel Brakeline-To-ABS Solenoid Nut
Stoplight Switch Lock Nut
Wheel Lug Nut
7-12 (10-16)
14-19 (19-26)
15 (20)
12 (16)
72 (98)
15 (20)
72 (98)
17 (23)
13 (17)
20 (27)
18 (24)
72 (98)
13 (17)
21 (29)
72 (98)
13 (17)
12 (16)
72 (98)
INCH Lbs. (N.m)
Sportage
Brake Line Bolt & Nut
Master Cylinder Nut
Wheel Cylinder Bolt
89 (10)
115 (13)
115 (13)
TORQUE SPECIFICATIONS (OPTIMA & RIO)

Application
Optima
Brake Hose-To-Front Caliper
Caliper Assembly-To-Knuckle
Caliper Guide Rod Bolt
Proportioning Valve Mounting-To-Master Cylinder Bolt
Wheel Cylinder Mounting Bolt
Rio
Brake Booster Mounting Nut
Brake Caliper Bolt
Brake Hose Connecting Bolt
Brake Hose Mounting Nut
Ft. Lbs. (N.m)

18-22 (25-30)
51-63 (69-85)
16-24 (22-32)
26-41 (35-55)
8.8-13 (12-18)
14-19 (19-26)
29-36 (39-49)
16-22 (22-29)
9-16 (13-22)

Monday, April 17, 2006 4:58:09 PM
Page 24
2001 Kia Rio

Brake Pedal Pivot Bolt Nut

Front Brake
Adapter Bolts
Caliper Bolts
Front Wheel Brakeline-To-Valve Nut
Master Cylinder Attaching Nut
Operating Rod Lock Nut
Rear Drum/Bearing Retaining Nut
20 (27)
18 (24)
29-36 (39-49)
13 (17)
7-12 (10-16)
21 (29)
(1)
Rear Wheel Backing Plate Nut

Rear Wheel Brakeline-To-ABS Solenoid Nut
Stoplight Switch Lock Nut
Wheel Lug Nut
72 (98)
13 (17)
12 (16)
72 (98)
INCH Lbs. (N.m)
Optima
Bleeder Screw
Brake Booster Mounting Nut
Brake Tube Flare Nut
Master Cylinder-To-Booster Mounting Nut
Rio
Adapter & Flare Nut
Brake Line Bolt & Nut
Master Cylinder Nut
Wheel Cylinder Bolt
(1)
62-115 (7-13)
115-142 (13-16)
115-150 (13-17)
70-106 (8-12)
115-194 (13-22)
89 (10)
115 (13)
115 (13)
Initially tighten nut to 72-96 INCH lbs. (0.7-1.0 N.m). Loosen nut and retighten to
14 ft. lbs. (20 N.m).
DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS (SEPHIA, SPECTRA & SPORTAGE)
Application
In. (mm)
Brake Pads
Front
Sephia and Spectra
Standard Thickness
.433-.453 (11.0-11.5)
Minimum Thickness
.08 (2.0)
Sportage
Standard Thickness
.37 (9.4)
Minimum Thickness
.08 (2.0)
Rear
Monday, April 17, 2006 4:58:09 PM
Page 25
2001 Kia Rio

Sephia and Spectra

Standard Thickness
Minimum Thickness
Front Disc
Sephia and Spectra
Standard Thickness
Minimum Thickness
Runout
Sportage
Standard Thickness
Minimum Thickness
Runout
Rear Disc
Sephia and Spectra
Standard Thickness
Minimum Thickness
Runout
.37 (9.4)
.079 (2.01)
.79 (20.1)
.71 (18.0)
.004 (.10)
.94 (24.0)
.88 (22.0)
.004 (.10)
.40 (10.0)
.32 (8.1)
.004 (.10)
DISC BRAKE SPECIFICATIONS (OPTIMA & RIO)

Application
Brake Pads
Front
Optima
Standard Thickness
Minimum Thickness
Rio
Standard Thickness
Minimum Thickness
Rear
Rio
Standard Thickness
Minimum Thickness
Front Disc
Optima
Standard Thickness
Minimum Thickness
Runout
Rio
Standard Thickness
In. (mm)
.399 (10.15)
.08 (2.0)
.39 (10.0)
.08 (2.0)
.37 (9.4)
.079 (2.01)
.965 (24.5)
.880 (22.4)
.0012 (.03)
.86 (22.0)

Monday, April 17, 2006 4:58:09 PM
Page 26
2001 Kia Rio

Minimum Thickness
Runout
Rear Disc
Optima
Standard Thickness
Minimum Thickness
Runout
.78 (20.0)
.003 (0.08)
.39 (10.0)
.0.079 (2.0)
.004 (.10)
DRUM BRAKE SPECIFICATIONS

DRUM BRAKE SPECIFICATIONS (SEPHIA, SPECTRA AND SPORTAGE)
Application
In. (mm)
Drum Diameter
Rio, Sephia and Spectra
(1)
Original
Maximum
Sportage
Original
7.91 (201)
(1)
Maximum
Optima
Inner Diameter
Brake Shoes
Minimum Thickness
Rio, Sephia and Spectra
Sportage
(1)
9.89 (251.2)
9.0 (228.6)
.04 (1.0)
.06 (1.5)
Information not available from manufacturer.

Monday, April 17, 2006 4:58:09 PM
Page 27

Disc &amp; Drum Kia Rio 2002

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2001 Kia Rio

2001 BRAKES Disc & Drum

DESCRIPTION & OPERATION

BLEEDING BRAKE SYSTEM

When bleeding by pressurized fluid, do not depress brake pedal.

Helpmelearn Repair Manuals

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

Fig. 1: Bleeding Brake Fluid Into Container (Typical)

Helpmelearn Repair Manuals

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

Fig. 2: Exploded View Of Parking Brake

Helpmelearn Repair Manuals

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

Fig. 3: Measuring Brake Pedal Height & Free Play (Typical)

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

Outlet Pressure - psi (kg/cm 2 )

Outlet pressure specification is approximate.

Be sure to bleed system after you connect pressure gauges.

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

3. Reconnect brake lines in original position and bleed system.

Fig. 4: Brake Input Pressure & Output Pressure (Optima)

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

REMOVAL & INSTALLATION

Helpmelearn Repair Manuals

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

Do not discard shims found behind brake pads.

Raise and support vehicle. Remove wheel and tire assembly.

Helpmelearn Repair Manuals

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

Fig. 6: Exploded View Of Front Disc Brake (Rio)

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

CAUTION: Ensure no wheel bearing looseness is detected.

1. Raise and support vehicle. Remove wheel and tire assembly.

Do not disconnect brake hose.

Remove pads. See Fig. 7

Helpmelearn Repair Manuals

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

Fig. 7: Exploded View Of Front Disc Brake (Optima)

Replace all four pads as a complete set.

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

1. Raise and support vehicle. Remove wheel and tire assembly.

Helpmelearn Repair Manuals

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

Fig. 8: Piston Matching Mark (Optima)

Helpmelearn Repair Manuals

2004 Mitchell Repair Information Company, LLC.

2001 Kia Rio

Fig. 9: Exploded View Of Rear Disc Brakes (Sephia and Spectra)

Helpmelearn Repair Manuals

2004 Mitchell Repair Information Company, LLC.

Disc & Drum Kia Rio 2002

Disc & Drum Kia Rio 2002