How to Replace the Front Rotors on a 2001 KIA Optima

The 2001 model year marked the initial release of the Kia Optima. The Optima remained as the largest and most luxurious of Kia models until the 2004 release of the larger and more luxurious Amanti. The 2001 Optima came standard with a 149-horsepower, 2.4-liter four-cylinder engine, and had an optional 2.7-liter V-6 engine, which produced 170 horsepower. Front ventilated disc brakes and rear drum brakes brought the 2001 Optima to a stop on four-cylinder models, whereas V-6 models used four-wheel disc brakes. Replacing the front rotors on the 2001 Kia Optima requires removing the brake calipers and pads.

Instructions

1

Remove about half of the brake fluid from the Optima's brake master cylinder, using a clean turkey baster. Transfer this fluid to a small container.

2

Loosen, but do not remove, the vehicle's front lug nuts, using a ratchet and socket. Raise the front of the Optima, using a floor jack. Position jack stands beneath the Kia's subframe and lower the Optima onto the jack stands. Remove the lug nuts and pull the wheels off the Kia. Work on one side of the car at a time, so you'll always have a complete assembly as a visual reference.

3

Pull the ends of the pad-retaining spring from the holes in the outer part of the caliper, using needle-nose pliers.

4

Remove the caliper-to-bracket bolts, using a ratchet and socket, while holding the guide pin steady with a combination wrench. Pull the caliper off the brake system and secure it to a suspension component, using a bungee strap. Remove the brake pad retaining spring.

5

Pull the brake pads from the caliper bracket. Remove the two caliper bracket-to-steering knuckle bolts and pull the caliper bracket from the steering knuckle.

6

Remove the two retaining screws on the center of the brake rotor, using a Phillips screwdriver. If the screws do not loosen easily, lightly tap the heads of the screws with a hammer to free them.

7

Pull the rotor off the Kia's hub and discard the rotor. If the new rotor has lubricant on it as a protectant, clean it off with spray brake cleaner. Set the new rotor on the hub, lining up the screw holes on the rotor with those on the Optima's hub. Tighten the retaining screws with a Phillips screwdriver.

8

Set the caliper bracket back on the Kia's hub and tighten the caliper bracket-to-hub bolts to 51 to 63 foot-pounds, using a torque wrench and socket.

9

Insert the new brake pads in the caliper bracket, so the wear indicator tab faces downward on the inner part of the caliper bracket.

10

Place the old inner brake pad in the caliper, so it touches the caliper piston. Compress the caliper piston by positioning an 8-inch C-clamp over the caliper so the screw part touches the brake pad and the fixed part touches the rear of the caliper body. Tighten the C-clamp until the piston presses into the caliper. Remove the C-clamp.

11

Apply a thin coat of disc brake grease to the rear of the brake pads.

12

Set the caliper on the caliper bracket and tighten the caliper guide pins to 16 to 24 foot-pounds, using a torque wrench and socket, while holding the guide pin with a combination wrench.

13

Repeat Steps 3 through 12 for the rotor on the other side of the Optima.

14

Reinstall the front wheels and hand-tighten the lug nuts. Raise the Optima off of the jack stands and remove the stands. Lower the Kia to the ground. Tighten the lug nuts to 65 to 87 foot-pounds, using a torque wrench and socket.

15

Press and release the Kia's brake pedal until it feels firm. Check the brake fluid in the master cylinder and add new DOT 3 brake fluid until the level reaches the "Max" line. Close the master cylinder lid.

16

Pump the brake pedal until it is firm, before driving the car.

17

Take the old brake fluid to an automotive fluid recycling center. Many auto parts stores take old fluids free of charge.