Kia Mentor / Sephia Electrical System. Instruction — part 99

Brake pedal drops
intermittently . . . A . . ... (1) Require repair or
replacement.
Fluid level low . . . .. . . . (2) Further inspection
required.
Internal valve failure .. A .. Require repair or replacement.
Master cylinder leaking
brake fluid internally . A .. Require repair or replacement.
Piston does not return .. A .. Require repair or replacement.
Ports plugged . . ... A .. Require repair or replacement.
Rubber master cylinder
cover gasket distorted
and gummy . . . .. A .. (3) Require replacement of the
gasket.

(1) - This condition may be normal on some vehicles equipped with
anti-lock brakes.
(2) - Refer to OEM procedures for adjusting low fluid level.
Inspect for brake hydraulic system leaks and friction
material wear.
(3) - This condition may indicate contaminated brake fluid.
See BRAKE FLUID.

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MODULATORS

See HYDRAULIC MODULATORS.

MOTORS

See ELECTRICAL PUMPS AND MOTORS.

PARKING BRAKE SWITCHES

See SWITCHES.

PARKING BRAKE SYSTEMS

NOTE: The parking brake is an integral part of the brake
system. It is important that the parking brake function
properly when brake service is performed.

PARKING BRAKE SYSTEM INSPECTION

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Condition Code Procedure

1996 Kia SephiaFor 1 1 1 1 1

Attaching hardware
broken . . . . . A ... Require repair or replacement
of hardware.
Attaching hardware
missing . . . . C . . .. Require replacement of
hardware.
Attaching hardware not
functioning . . . A ... Require repair or replacement
of hardware.
Cable improperly
adjusted . . . ... B . ... Require cable adjustment.
Cable or individual
wires in the cable
are broken . . . . A . Require replacement of cable
assembly.
Cable sticking . . .. A . .. Require cable lubrication.
Cable stuck inside conduit
and cannot be lubricated
so that parking brake
functions properly . . A . Require replacement of cable
assembly.
Inoperative (1) . . . A . . .. Require replacement of
inoperative parts.
Parking brake
parts bent . . . . B ... Require repair or replacement
of bent parts.
Parking brake
parts broken . . ... A ... Require replacement of broken
parts.
Parking brake parts
missing . . . . C .. Require replacement of missing
parts.
Threads damaged . . . A .. Require repair or replacement.
Threads stripped (threads
missing) . . . ... A . . . Require replacement.

(1) - Inoperative includes intermittent operation.

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PADS

See FRICTION MATERIAL.

PEDAL TRAVEL SWITCHES

See SWITCHES.

1996 Kia Sephia

PEDALS

See BRAKE PEDALS.

POWERMASTER

See HYDRO-BOOSTERS.

PUMPS

See ELECTRICAL PUMPS AND MOTORS.

PRESSURE DIFFERENTIAL SWITCHES

See SWITCHES.

PRESSURE SWITCHES

See SWITCHES.

RELAYS

NOTE: Copied from Electrical UIGs

RELAY INSPECTION

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Condition Code Procedure

Attaching hardware
broken . . . . . A ... Require repair or replacement
of hardware.
Attaching hardware
missing . . . . C . . .. Require replacement of
hardware.
Attaching hardware not
functioning . . . A ... Require repair or replacement
of hardware.
Housing broken . . .. A . . . Require replacement.
Housing cracked . . . 2 . . . Suggest replacement.
Inoperative (1) . . . A . . . Require replacement.
Missing . . . . . C . . . Require replacement.
Terminal broken . . . A .. Require repair or replacement.
Terminal burned,
affecting performance .. A . . ... (2) Require repair or
replacement.
Terminal burned, not

1996 Kia Sephia

affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance . . . B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM
specification.
(2) - Determine cause and correct prior to repair or
replacement of part.

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ROTORS

Determine the need to recondition based upon individual rotor
conditions that follow. Friction material replacement does not require
rotor reconditioning unless other justifications exist. DO NOT
recondition new rotors unless they are being pressed or bolted onto an
existing hub. It is not necessary to replace rotors in axle sets.
However, when replacing or reconditioning a rotor due to the
conditions that follow, you may suggest reconditioning of the other
rotor on the same axle to eliminate uneven braking behavior.
Determine the need to replace based upon the individual rotor
conditions that follow. Reconditioning is defined as machining and
block sanding, or block sanding only. Block sanding is defined as
using 120-150 grit sandpaper with moderate to heavy force for 60
seconds per side. Always wash rotors after servicing or before
installing.

ROTOR INSPECTION

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Condition Code Procedure

Corrosion affecting
structural integrity ... A . . (1) Require replacement.
Cracked . . . . . B . . . Require replacement.
Hard spots . . . .. 2 . ... Suggest reconditioning or
replacement of rotor according
to OEM specifications.
Lateral runout (wobble)
exceeds OEM
specifications . . . B . . . Require re-indexing,