Hyundai i20 Quiz
Braking System

Front Disc Brake Repair Procedures

In this manual: Braking System
General Information — 17Engine Mechanical System — 79Engine Electrical System — 50Emission Control System — 22Engine/Fuel Control System — 107Clutch System — 27MANUAL TRANSMISSION SYSTEM — 21Drive Shaft and Axle — 18Suspension System — 29Steering System — 21Restraint — 41Braking System — 53Body Work (Interior and Exterior) — 190Body Electrical System — 181Heating, Ventilation and Air Conditioning — 58
22steps
~137min
5/5difficulty
1special tools
04080120160200107.980N·mlb·ft
Tightening torque found on this page
Done 0 of 22

DEPOSIT

  1. Remove the front wheel and tire.

    Tightening torque: 88.3 ~ 108 N·m

  2. Loosen the brake hose bracket bolt (A), the guide rod bolt (B), and turn the piston (C) fully upward.

    Tightening torque: 21.6 ~ 31 N·m

  3. Remove the pad return spring (A).
  4. Place the brake pads (B) into the caliper (A).
  5. Loosen the brake hose banjo bolt (B) and the caliper mounting bolts. Remove the front caliper assembly (C), then remove the front caliper assembly (A). Tightening torque: Brake tube clamp: 24.5 ~ 29 N·m Caliper to steering knuckle: 78.5 ~ 98 N·m

REPLACEMENT

  1. Remove the front wheel and tire.

    Tightening torque: 88.3 ~ 108 N·m

  2. Loosen the brake hose bracket bolt (A), the guide rod bolt (B), and turn the piston (C) fully upward.

    Tightening torque: 21.6 ~ 31 N·m

  3. Remove the pad return spring (A).
  4. Replace the pad shim (C), pad retainers (C) and pads (B) on the caliper support (A).

Inspection

BRAKE DISC THICKNESS INSPECTION, FRONT BRAKE

  1. Check the brake pads for wear and discoloration.
  2. Inspect the brake disc for damage and cracks.
  3. Remove all rust and contamination from the surface, then measure the disc thickness at at least 8 points located simultaneously at a distance of (5 mm) from the outer edge of the brake disc. Brake disc thickness Standard value: 22 mm (0.866 in.) Service limit: 20 mm (0.787 in.) Variation: Less than 0.005 mm (0.0002 in.)
  4. If wear exceeds the limit, replace the disc/pad assembly of both the left and right sides of the vehicle.

FRONT BRAKE PAD INSPECTION

  1. Check pad wear. Measure the lining thickness, and if the thickness is less than specified, replace the pads. Pad thickness Standard value: 11 mm (0.433 in.) Maintenance limit: 2.0 mm (0.0787 in.)
  2. Check the brake pad, backing plate, and grease contamination for damage.

FRONT DISC RUNOUT INSPECTION

  1. Place a dial indicator approximately 5 mm (0.2 in.) from the outer edge of the brake disc and measure the disc runout. Brake disc runout Limit: 0.04 mm (0.0016 in.) or less (new part)
  2. If disc runout exceeds the maximum specified value, replace the disc, then measure the runout again.
  3. If the out-of-round condition does not exceed the usable limit, rotate the disc 180° and check the runout again.
  4. If changing the position does not eliminate the out-of-round condition of the brake disc, replace the brake disc.

REMEDY

  1. To install, perform the removal procedure in reverse order.
  2. Use the special service tool (09581-11000) when installing the brake caliper assembly.
  3. After installation, bleed the brake system. (Refer to Brake System Bleeding)

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