Hyundai Genesis: Brake System / Front Disc Brake Repair procedures

Removal
[4 Piston Type]
1.
Remove the front wheel & tire.

Tightening torque:
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

2.
Remove the brake hose mounting bracket (A).

3.
Remove the cover plate (A) by loosening the bolts.

Tightening torque
7.8 ~ 10.8 N.m (0.8 ~ 1.1 kgf.m, 5.8 ~ 7.9 lb-ft)

   
Apply the specified torque using a torque wrench.
Do not use air ratchet or power tools.
4.
Remove locking pin (A) and guide pin (B).

5.
Remove the brake pad.

   
Do not step on the brake pedal.
6.
Loosen the hose eye-bolt (C) and caliper mounting bolts (A), then remove the front caliper assembly (B).

Tightening torque :
Brake hose to caliper (C) :
24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)
Caliper assembly to knuckle (A) :
98.1 ~ 117.7 N.m (10.0 ~ 12.0 kgf.m, 72.3 ~ 86.8 lb-ft)

   
Do not loosen the hose eyebolt (C) when replacing the rear disc. Fix the rear brake caliper with wire to the other components after loosening the brake caliper mounting bolts (A).
7.
Loosen the coking nut (A) & screw (B) and then remove the disc.

Tightening toque
A :196.1~274.6 N.m (20.0~28.0 kgf.m, 144.7~202.5 lb-ft)
B :4.9~5.9N.m (0.5~0.6kgf.m, 3.6~4.3lb-ft)

[Single Piston Type]
1.
Remove the front wheel & tire.

Tightening torque:
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

2.
Loosen the guide rod bolt (B) and pivot the caliper up out of the way.

Tightening torque :
21.6 ~31.4N.m (2.2 ~3.2kgf.m, 15.9 ~23.1lb-ft)

3.
Remove pad shim (B), pad retainers (C) and brake pads (B) from the caliper bracket (A).

   
Do not step on the brake pedal.
4.
Loosen the hose eyebolt (B) and caliper mounting bolts (C), then remove the front caliper assembly (A).

   
Do not loosen the hose eyebolt (B) when replacing the rear disc. Fix the rear brake caliper with wire to the other components after loosening the brake caliper mounting bolts (C).
5.
Remove the front brake disc by loosening the screws (3EA).

Replacement
Brake pad
[4 Piston Type]
1.
Remove the cover plate (A) by loosening the bolts.

Tightening torque :
7.8 ~ 10.8 N.m (0.8 ~ 1.1 kgf.m, 5.8 ~ 7.9 lb-ft)

   
Apply the specified torque using a torque wrench.
Do not use air ratchet or power tools.
2.
Remove locking pin (A) and guide pin (B).

3.
Remove the brake pad.

   
Do not step on the brake pedal.
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 8 points, at least, of same distance (5mm) from the brake disc outer circle.

Brake disc thickness
Standard value: 30 mm (1.1811in)
Service limit : 28.4mm (1.1181in)

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 (A) : 10.5mm (0.4133 in)
Service limit (B) : 2.0 mm (0.0787 in)

   
The brake pad wear indicator (C) and brake disc make a friction noise when brake pads are worn out below the service limit of 2.0 mm (B).

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: 0.025 mm (0.00098 in.) or less (new one)

2.
If the runout of the brake disc exceeds the limit specification, reinstall the disc after turning the disc 72° clockwise. Recheck the runout. If the runout exceeds the specification, try turning the disc by 72° and recheck the runout until a full revolution(360°, 4 steps).
3.
If the runout cannot be corrected by turning the disc, replace the brake disc.
4.
When installing brake disc, runout peak point markings (A) on disc and hub must be as close as possible (within 72° range).
5.
After installing the new disc repeat procedure above 1~4 again.
Installation
1.
To install, reverse the removal procedure.
2.
Use a SST (A : 09581-11000) when installing the brake caliper assembly.

3.
After installation, bleed the brake system.
(Refer to Brake System - "Brake System Bleeding")
Front Disc Brake Components and Components Location
Components 1. Caliper body2. Guide pin3. Locking pin4. Brake pad5. Cover plate 6. Pad spring7. Bleed screw ...

Rear Disc Brake Components and Components Location
Components 1. Guide rod bolt2. Bleed screw3. Caliper body4. Caliper carrier5. Inner pad shim6. Brake pad7. Pad retainer ...

Other information:

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