Hyundai Ioniq (AE): Brake System / Front Disc Brake. Repair procedures

Hyundai Ioniq (AE) 2017-2022 Service & Repair 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 the front hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

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 after loosening the guide rod bolt.
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

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 :
98.1 - 117.7 N.m (10.0 - 12.0 kgf.m, 72.3 - 86.8 lb-ft)

   
•
When Replacing the brake pad, replace pad return spring (A), pad retainers (B), inner pad shim (C) and brake pads (D).

8.
Remove the front brake disc 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
Brake Pad
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 the front hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

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 after loosening the guide rod bolt.
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

5.
Remove the pad return spring (A).

6.
Remove the brake pad.

   
•
When Replacing the brake pad, replace pad return spring (A), pad retainers (B), inner pad shim (C) and brake pads (D).

7.
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.
8.
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.
9.
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)

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 24 points, at least, of same distance (5mm) from the brake disc outer circle.
Front brake disc thickness
- Standard : 22 mm (0.87 in)
- Service Limit : 20 mm (0.79 in)
Deviation : Less than 0.015mm (0.0002in)

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 : 17 mm (0.67 in)
Service limit : 8.0 mm (0.31in)
2.
Check that grease is applied, to sliding contact points. Check for metal damage to the pad and backing.

Front brake disc runout check
1.
Place a dial gauge about 10mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout
Limit : 0.050 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 meet the limit specification, remove the disc, turn it 180° and reinstall. 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 - "ESP System Bleeding")

    Components1. Bleed screw2. Caliper body3. Pad inner shim4. Brake pad5. Pad return spring6. Caliper carrier7. Pad retainer

    Components[EPB None Apply]1. Brake pad2. Pad return spring3. Caliper carrier4. Pad retainer5. Caliper body6. Bleed screw7. Stopper8. Return spring9. Operating lever[EPB Apply]1.

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