2007 KIA CARNIVAL Rear brake

TIGHTENING TORQUE
ItemsNmkgf.m lb - ft
Master cylinder to booster mounting nut 8 ~ 120.8 ~ 1.2 5.8 ~ 8.7
Brake booster mounting nut 13 ~ 161.3 ~ 1.6 9.4 ~ 11.6
Bleeder screw 7 ~ 130.7 ~ 1.3 5.06 ~ 9.4
Brake tube nut, brake hose 13 ~ 171.3 ~ 1.7 9.4 ~ 12.3
Caliper guide rod bolt (Front) 22 ~ 322.2 ~ 3.215.9 ~ 23.1
Caliper guide rod bolt (Rear) 22 ~ 322.2 ~ 3.215.9 ~ 23.1
Caliper assembly to knuckle (Front) 85 ~ 1008.5 ~ 1061.5 ~ 72.3
Caliper assembly to knuckle (Rear) 50 ~ 605.0 ~ 6.036.2 ~ 43.4
Brake hose to front caliper 25 ~ 302.5 ~ 3.018.1 ~ 21.7
Brake pedal assembly bracket mounting nut 10 ~ 151.0 ~ 1.5 7.2 ~ 10.8
Brake pedal mounting nut 13 ~ 161.3 ~ 1.6 9.4 ~ 11.6
Stop lamp switch mounting nut 8 ~ 100.8 ~ 1.0 5.8 ~ 7.23
Active wheel speed sensor mounting bolt on
the brake plate 7 ~ 10
0.7 ~ 1.0 5.1 ~ 7.2
HECU mounting bracket bolt 17 ~ 261.7 ~ 2.612.3 ~ 18.8
HECU mounting nut 6 ~ 100.6 ~ 1.0 4.3 ~ 7.2
Yaw rate & lateral acceleration sensor bolt 5 ~ 80.5 ~ 0.8 3.62 ~ 5.8
SPECIFICATION (ABS)
Part ItemStandard valueRemark
HECU(Hydraulic and
Electronic Control
Unit) System
4 channel 4 sensor
(Solenoid)
·ABS system:ABS &
EBD control
Type
Motor, valve relay
intergrated type
Operating voltage 8 V ~ 16 V(DC)
Operating temperature - 40 ~ 120 °C
( - 40 ~ 248 °F)
Warning lamp Operating voltage
12 V·ABS W/L:ABS failure
·Brake W/L:Parking,
brake oil, EBD failure
Current consumption 80 mA
Acitve wheel speed
sensor Supply voltage
DC 4.5 ~ 2.0 V
Operating temperature - 40 ~ 150 °C
Output current low 5.9 ~ 8.4 mATyp.7 mA
Output current High 11.8 ~ 16.8 mATyp.14 mA
Frequency range 1 ~ 2500 HZ
Air gap Front
0.15 ~ 1.5 mm Typ.0.7 mm
Rear 0.2 ~ 1.2 mm Typ.0.7 mm
Tone wheel 48 teeth
Output duty 30~70 %
SPECIFICATION(ESP)

PartItemStandard ValueRemark
HECU(Hydraulic and
Electronic Control
Unit) System
4 channel 4
sensor(Solenoid)
·Total control(ABS,
EBD, TCS, ESP)
Type
Motor, valve relay
intergrated type
Operating voltage 8 V ~ 16 V(DC)
Operating temperature - 40 ~ 120 °C(- 40 ~
248 °F)
Warning lamp Operating voltage
12 V
·ESP Operating Lamp
·ESP Warning Lamp
Current consumption 80 mA
Active wheel speed
sensor Supply voltage
DC 4.5 ~ 20V
Operating temperature - 40 ~ 150 °C
Output current low 5.9 ~ 8.4 mA
Output current high 11.8 ~ 16.8 mA
Tone wheel 48 teeth
Frequency range 1 ~ 2500 HZ
Airgap Front
0.15 ~ 1.5 mm Typ. 0.7 mm
Rear 0.2 ~ 1.2 mm Typ. 0.7 mm
Steering Wheel Angle
Sensor Operating Voltage
8V ~ 16 V
Current Consumption Max 150 mA
Operating Angular velocity Max ± 780 °/sec
Yaw - rate & Lateral G
sensor Operating Voltage
8 V ~ 16 V
Current Consumption Max. 120 mA
Output Voltage high 4.35 V~ 4.65 VTyp. 4.5 V
Output Voltage low 0.35 ~ 0.65 VTyp. 0.5 V
Yaw Sensor Operating Range ±100 ° /s
G Sensor Operating Range ±1.8 G
Reference voltage output 2.464 ~ 2.536 VTyp. 2.5 V
LUBRICANT
Item Recommended lubricantQuantity
Brake fluid DOT 3 or DOT 4As required
Brake pedal bushing and brake pedal bolt Chassis greaseAs required
Parking brake shoe and backing plate contact surfaces Bearing greaseAs required
Caliper guide rod and boot RX - 2 grease0.8 ~ 1.3 g
Rear caliper guide rod and boot Rubber grease0.8 ~ 1.3g

a.If the pad thickness is out of specilfication, left and right pads must be replaced as a complete set.
b. When the thickness difference between the left pad and right pad is large, check the sliding condition of
the piston and the guide rod.
INSPECTION OF REAR DISC BRAKE PAD
1.Check the rear disc brake pad thickness through the caliper body inspection hole.
Pad thickness
Standard value : 10.0 mm (0.39 in)
Service limit : 2.0 mm (0.0787 in)
a.If the pad thickness is out of specification, left and right pads must be replaced as a complete set.
b. When the thickness difference between the left pad and right pad is large, check the sliding condition of
the piston and the guide rod.

Rear Disc Brake

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.