Hyundai Kona: Brake System / Front Disc Brake Repair procedures

Hyundai Kona (OS) 2018-2025 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.
Remove the brake hose bracket bolt (A).
Tightening torque :
8.8 - 13.7 N.m (0.9 - 1.4 kgf.m, 6.5 - 10.1 lb-ft)

4.
Loosen the brake hose bolt (A) from the caliper seperate the brake hose.
Tightening torque :
24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)

5.
Remove the caliper body (A) by loosening the guided rod bolt.
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

6.
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.
7.
Remove the brake pad (A).
8.
Remove the pad retainer (A).
9.
Remove the caliper carrier (A) by loosening the caliper mouniting bolts.
Tightening torque :
78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb-ft)

10.
Remove the front brake disc (A) by loosening the screws.
Tightening torque :
4.9 - 5.8 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

Replacement
Guide Rod Pin and Boot
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 :
107.8 - 127.4 N.m (11.0 - 13.0 kgf.m, 79.5 - 94.0 lb-ft)
  
•
Be careful not to damage the hub bolts when removing the front wheel and tire (A).

3.
Remove the caliper body (A) by loosening the guided rod bolt.
4.
Replace the guide rod pin boot (A) with a new one.

  
•
Apply the grease on the guide rod pin.
Grease type : GREASE BG-1 (MG511-60)
Capacity : 0.35 - 0.8 g
•
If apply the grease excessively, would not be assembled the guide rod pin.
5.
Install the caliper body (A) then tighten the guide rod bolt.
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

6.
Install the front wheel and tire (A).
  
•
Be careful not to damage the hub bolts when removing the front wheel and tire (A).
Tightening torque :
107.8 - 127.4 N.m (11.0 - 13.0 kgf.m, 79.5 - 94.0 lb-ft)

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 (A) of the SST is surely closed.
•
Input the SST in the caliper and press the caliper piston while opening the valve (A) 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")
Inspection
Front Brake Disc Thickness Check
1.
Check the brake disc for damage and cracks.
2.
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
- 15 in Standard : 23.0 mm (0.90 in)
- 15 in Service limit : 21.4 mm (0.84 in)
- 16 in Standard : 25.0 mm (0.98 in)
- 16 in Service limit : 23.0 mm (0.90 in)
- 17 in Standard : 28.0 mm (1.10 in)
- 17 in Service limit : 26.4 mm (1.04 in)
Deviation : Less than 0.005 mm (0.0002 in.)

3.
If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
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 cannot be corrected by changing the position of the brake disc, replace the brake disc.
Front Disc Brake Components and components location
Components 1. Caliper body 2. Guide rod pin 3. Guide rod pin boot 4. Caliper carrier 5. Pad inner shim 6. Pad retainer 7. Brake pad 8. Pad return ...

Rear Disc Brake Components and components location
Components 1. Brake pad 2. Guide rod pin 3. Guide rod pin boot 4. Caliper carrier 5. Pad retainer 6. Brake pad 7. Pad return spring ...

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