Hyundai Kona Quiz
Brake System

Front Disc Brake Repair Procedures

In this manual: Brake System
General Information — 17Engine Mechanical System — 85Engine Electrical System — 50Emission Control System — 26Engine Control System/Fuel System — 152DCT (Dual Clutch Transmission) System — 50Four-Wheel Drive (4WD) System — 21Propeller Shaft and Axle (2WD-FF) — 28Suspension System (without ECS) — 32Steering — 21Restraints — 38Brake System — 64Body (Interior and Exterior) — 205Body Electrical System — 1Heating, Ventilation, and Air Conditioning — 66
25steps
~155min
5/5difficulty
1special tools
04080120160200127.594N·mlb·ft
Tightening torque found on this page
Done 0 of 25

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: 107.9–128 N·m

  3. Remove the brake hose bracket bolt (A).

    Tightening torque: 8.8–13.7 N·m

  4. Loosen the brake hose bolt (A) from the caliper, separating the brake hose.

    Tightening torque: 24.5–29 N·m

  5. Remove the caliper body (A) by loosening the guide rod bolt.

    Tightening Torque: 21.6–31 N·m

  6. Remove the pad return spring (A).
  7. Remove the brake pad (A).
  8. Remove the pad retainer (A).
  9. Remove the caliper support (A) by loosening the caliper mounting bolts.

    Tightening torque: 78.5–98 N·m

  10. Remove the front brake disc (A) by loosening the screws.

    Tightening torque: 4.9–5.8 N·m

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 the front hub.

    Tightening torque: 107.8–127 N·m

  3. Remove the caliper body (A) by loosening the guide rod bolt.
  4. Replace the guide rod pin boot (A) with a new one.
  5. Install the caliper body (A), then tighten the guide rod bolt.

    Tightening Torque: 21.6–31 N·m

  6. Install the front wheel and tire (A).

    Tightening torque: 107.8–127 N·m

Installation

  1. To install, reverse the removal procedure.
  2. Use SST (09581-2T100) when installing the brake caliper assembly.
  3. After installation, bleed the brake system. (Refer to Brake System - "Brake Bleeding") (Refer to Brake System - "ABS Bleeding") (Refer to Brake System - "ESP Bleeding")

Inspection

Front Brake Disc Thickness Inspection
  1. Inspect the brake disc for damage and cracks.
  2. Remove all rust and contamination from the surface and measure the disc thickness at no fewer than 8 points at equal distances (5 mm) from the outer edge of the brake disc. Front brake disc thickness - 15 inch Standard: 23.0 mm (0.90 in) - 15 inch Service limit: 21.4 mm (0.84 in) - 16 inch Standard: 25.0 mm (0.98 in) - 16 inch Service limit: 23.0 mm (0.90 in) - 17 inch Standard: 28.0 mm (1.10 in) - 17 inch Service limit: 26.4 mm (1.04 in) Deviation: Less than 0.005 mm (0.0002 in)
  3. If wear exceeds the service limit, replace the discs and pads as a set, left and right of the vehicle.
  4. Position the 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)

  5. If brake disc runout exceeds the limit, replace the disc, then measure the runout again.
  6. If runout cannot be corrected by changing the position of the brake disc, replace the brake disc.
Front Brake Disc Runout Inspection

Test yourself

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