Kia Carnival (2009+). Instruction — part 372

2009 > G 2.7 DOHC >

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.