Hyundai Elantra: Brake System / Front Disc Brake Repair procedures

Hyundai Elantra AD (2016-2020) Service Manual / Brake System / Brake System / Front Disc Brake Repair procedures

Removal
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the front wheel and tire (A) from front hub .
Tightening torque:
107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)

   
•
Be careful not to damage the hub bolts when removing the front wheel and tire (A).
3.
Loosen the brake hose mounting bolt and then remove the brake hose bracket.
Tightening torque:
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

4.
put down the caliper body by loosening the guided rod bolt.
Tightening torque:
2.2 ~ 3.2 kgf.m
5.
Remove the pad return spring (A).

   
•
Pad return springs must be replaced with new ones whenever pads are replaced.
•
Technicians should be careful not to deform pad return springs.
•
When pad return springs are deformed, it may cause improper braking, more fuel consumption.
6.
Remove the brake pad.

7.
Separate the pad retainer. And remove the caliper carrier by loosening the caliper mounting bolts.
Tightening torque:
78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)

8.
Remove the front brake disc by loosening the screws (A).
Tightening torque:
4.9 ~ 5.9 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)

Replacement
1.
Loosen the brake hose mounting bolt and then remove the brake hose bracket.
Tightening torque:
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

2.
put down the caliper body by loosening the guided rod bolt.
Tightening torque:
2.2 ~ 3.2 kgf.m

3.
Remove the pad return spring(A).

   
•
Pad return springs must be replaced with new ones whenever pads are replaced.
•
Technicians should be careful not to deform pad return springs.
•
When pad return springs are deformed, it may cause improper braking, more fuel consumption.
4.
Replace the brake pad with a new one.

5.
Install the pad return spring(A).

   
•
Pad return springs must be replaced with new ones whenever pads are replaced.
•
Technicians should be careful not to deform pad return springs.
•
When pad return springs are deformed, it may cause improper braking, more fuel consumption.
6.
Use a SST (09581-2T100) when installing the brake caliper assembly.

   
•
Connect an air hose(B) to the SST after confirming that the valve of the SST is surely closed.
•
Input the SST in the caliper and press the caliper piston while opening the valve of the SST slowly couter clock wise.
•
Close the valve (A) of the SST and disconnect the air hose (B); then, open the valve again to get the rest of air out and remove the SST from the caliper.
7.
Install the caliper body(A) then tighten the guide rod bolt(B).
Tightening torque :
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)

8.
Install the brake hose mounting bolt with the brake hose bracket at the shock absorber.
Tightening torque:
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

Inspection
Front brake disc thickness check
1.
Check the brake pads for wear and fade.
2.
Check the brake disc for damage and cracks.
3.
Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) from the brake disc outer circle.
Front brake disc thickness
- Standard : 23 mm (0.91 in)
- Service Limit : 21.4 mm (0.84 in)
Deviation: Less than 0.005 mm (0.0002 in)

4.
If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
Front 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: 11 mm (0.43 in)
Service limit: 2.0 mm (0.0787 in)
2.
Check that grease is applied, to sliding contact points and the pad and backing metal for damage.

Front brake disc runout check
1.
Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout
Limit: 0.04 mm (0.0016 in.) or less (new one)

2.
If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.
3.
If the runout does not exceed the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc again.
4.
If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.
Installation
1.
To install, reverse the removal procedure.
2.
Use a SST 09581-2T100) when installing the brake caliper assembly.

   
•
Connect an air hose(B) to the SST after confirming that the valve of the SST is surely closed.
•
Input the SST in the caliper and press the caliper piston while opening the valve of the SST slowly couter clock wise.
•
Close the valve (A) of the SST and disconnect the air hose (B); then, open the valve again to get the rest of air out and remove the SST from the caliper.
3.
After installing, bleed the brake system.
(Refer to Brake System -"Brake System Bleeding")
(Refer to Brake system - "ABS System Bleeding")
(Refer to Brake system - "ESP System Bleeding")
Front Disc Brake Components and Components Location
Components 1. Caliper body2. Bleed screw3. Pad return spring4. Brake pad5. Caliper carrier6. Pad inner shim7. Pad retainer ...

Rear Disc Brake Components and Components Location
Components 1. Brake pad2. Pad return spring3. Caliper carrier4. Pad retainer5. Caliper body6. Return spring7. Stopper8. Operating lever9. Bleed screw ...

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