Front Disc Brake Repair Procedures

Removal

1. 1
   Raise the vehicle and make sure it is securely supported.
2. 2
   Remove the wheel cap (A).

   

3. 3
   Remove the front wheel and tire (A) from the front hub.

   Tightening torque: 88.2 - 108 N·m

   

4. 4
   Loosen the guide rod bolt (B) and rotate the caliper (A) upward so that it does not interfere.

   Tightening torque: 21.6 ~ 31 N·m

   

5. 5
   Replace the pad shim, pad retainers (C) and brake pads (B) in the caliper bracket (A).

   

6. 6
   Loosen the hose banjo bolt (C) and the caliper mounting bolts (B), then remove the front caliper assembly (A). Tightening torque: Brake hose to caliper (C): 24.5 ~ 29 N·m Caliper assembly to knuckle (B): 78.5 ~ 98 N·m

   

7. 7
   Remove the front brake disc by loosening the screws (A).

   

Replacement

1. 1
   Loosen the guide rod bolt (B) and rotate the caliper (A) upward so that it does not interfere.

   Tightening torque: 21.6 ~ 31 N·m

   

2. 2
   Replace the pad shim (D), pad retainers (C) and brake pads (B) in the caliper support (A).

   

3. 3
   Use SST (09581-2T100) when installing the brake caliper assembly.

   

4. 4
   Lower the caliper body (A), then tighten the guide rod bolt (B).

   Tightening torque: 21.6 ~ 31 N·m

   

Inspection

1. 1
   Inspect the brake pads for wear and discoloration.
2. 2
   Inspect the brake disc for damage and cracks.
3. 3
   Remove all rust and contamination from the surface and measure the disc thickness at at least 8 points equally spaced (5 mm) from the outer edge of the brake disc. Front Brake Disc Thickness [GAMMA 1.6 T-GDI / THETA 2.4 GDI] - Standard: 25 mm (0.9842 in.) Service Limit: 23.4 mm (0.9212 in.) [THETA 2.0 T-GDI] Standard: 28 mm (1.1023 in.) Service Limit: 26.4 mm (1.0393 in.) [EPB] Standard: 28 mm (1.10 in.) Service Limit: 26.4 mm (1.0393 in.)
4. 4
   If wear exceeds the limit, replace the discs and pads as a set on both the left and right sides of the vehicle.

   

5. 5
   Check pad wear. Measure the pad thickness and replace it if it is less than the specified value. Pad Thickness [GAMMA 1.6 T-GDI / THETA 2.4 GDI] - Standard: 11.5 mm (0.4527 in.) Service Limit: 2.0 mm (0.0787 in.) [THETA 2.0 T-GDI] - Standard: 10.5 mm (0.4133 in.) Service Limit: 2.0 mm (0.0787 in.) [EPB] - Standard: 10.5 mm (0.4133 in.) Service Limit: 2.0 mm (0.0787 in.)

   

   The pad wear indicator (C) and brake disc create squealing noise when the brake pads wear below the service limit of 2.0 mm (B).

6. 6
   Position 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 (0.00157 in.) or less (new)

   

7. 7
   If brake disc runout exceeds the limit, replace the disc, then measure the runout again.
8. 8
   If runout does not exceed the limit, install the brake disc rotated 180°, then inspect the brake disc runout again.
9. 9
   If runout cannot be corrected by changing the brake disc position, replace the brake disc.

Installation

1. 1
   Installation is the reverse of removal.
2. 2
   Use SST (09581-2T100) when installing the brake caliper assembly.

   

3. 3
   After installation, bleed the brake system. (Refer to Brake System - "Brake Bleeding") (Refer to ABS - "ABS Bleeding") (Refer to ESP (Electronic Stability Program) System - "ESP Bleeding")