Hyundai i-30: Brake System / Rear Disc Brake

Hyundai i30 (PD) 2018-2024 Service Manual / Brake System / Brake System / Rear Disc Brake

Components and components location
Components
[With EPB]

1. Caliper body
2. Guide rod pin
3. Guide rod pin boot
4. Caliper carrier
 5. Pad retainer
6. Brake pad
7. Pad return spring
8. EPB actuator

[Without EPB]

1. Brake pad
2. Pad return spring
3. Caliper carrier
4. Pad retainer
5. Caliper body
 6. Return spring
7. Stopper
8. Operating lever
9. Bleed screw

Repair procedures
Removal
[With EPB]
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the rear wheel and tire (A) from the rear hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

  
•
Be careful not to damage the hub bolts when removing the rear wheel and tire (A).
3.
Release the EPB, push the EPB switch or using diagnostic tool.
(Refer to Paking brake - "Electric Parking Brake")
4.
Disconnect the EPB connector.
5.
Remove the brake hose by loosening the bolt (A).
6.
Loosen the guide rod bolt and then remove the caliper body.
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

7.
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.
8.
Remove the brake pad.
9.
Remove the pad retainer (A).
10.
Loosen the caliper mounting bolts and then remove the rear caliper assembly.
Tightening torque :
78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb-ft)

11.
Remove the rear brake disc by loosening the screws.
Tightening torque :
4.9 - 5.9 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

[Without EPB]
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the rear wheel and tire (A) from the rear hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

  
•
Be careful not to damage the hub bolts when removing the rear wheel and tire (A).
3.
Remove the parking brake cable fixed clip (A).
4.
Pull the operation lever as a arrow in the illustration below and then remove the parking cable.
5.
Loosen the guide rod bolts and then down the caliper body.
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

6.
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.
7.
Remove the brake pad.
8.
Remove the pad retainer and then remove the rear caliper.
Tightening torque :
78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb-ft)

  
•
Do not reuse the brake pad retainer.
9.
Remove the rear brake disc by loosening the screws.
Tightening torque :
4.9 - 5.9 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

Replacement
[With EPB]
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the rear wheel and tire (A) from the rear hub.

  
•
Be careful not to damage the hub bolts when removing the rear wheel and tire (A).
3.
Release the EPB, push the EPB switch or using diagnostic tool.
(Refer to Paking brake - "Electric Parking Brake")
4.
Disconnect the EPB connector.
5.
Loosen the guide rod bolt and then remove the caliper body.
6.
Remove the pad return spring (A).
7.
Remove the brake pad.
8.
Remove the pad retainer (A).
9.
Replace the brake pad and pad retainer with a new one.

  
•
When installing, use a new one return spring (A), pad retainer (B), inner shim (C).
10.
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.
11.
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)

  
•
When installing, press and rotate the piston into the caliper body until it is fully retracted.
12.
Install the wheel and tire (A).
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

  
•
Be careful not to damage the hub bolts when isntalling the rear wheel and tire (A).
[Without EPB]
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the rear wheel and tire (A) from the rear hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

  
•
Be careful not to damage the hub bolts when removing the rear wheel and tire (A).
3.
Remove the parking brake cable fixed clip (A).
4.
Pull the operation lever as a arrow in the illustration below and then remove the parking cable.
5.
Loosen the guide rod bolt and then down the caliper body.
6.
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.
7.
Replace the brake pad and pad retainer with a new one.

  
•
When installing, use a new one return spring (A), pad retainer (B), inner shim (C).
8.
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.
9.
Install the caliper body then tighten the guide rod bolt.
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

  
•
When installing, press and rotate the piston into the caliper body until it is fully retracted.
10.
Install the wheel and tire (A).
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

  
•
Be careful not to damage the hub bolts when isntalling the rear wheel and tire (A).
Inspection
Rear 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.
Brake disc thickness
Standard : 10 mm (0.394 in)
Service limit : 8.0 mm (0.315 in)
Deviation : less than 0.015 mm (0.0002 in)

4.
If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
Rear 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 : 10 mm (0.394 in)
Service limit : 2.0 mm (0.0787 in)
2.
Check the damage of pad, backing metal and contamination with grease.
Rear 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 : 0.055 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 exceeds the limit specification, install the brake disc after turning it 180° and 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.
When istalling, press and rotate the piston into the caliper body until it is fully retracted.

  
•
Wind the piston into the caliper body until it is fully retracted.
•
Do not use any power assisted tools for this task.
3.
After installing, bleed the brake system.
(Refer to Brake System - "Brake System Bleeding")
(Refer to Brake System - "ABS System Bleeding")
(Refer to Brake System - "ESP System Bleeding")
Parking Brake Adjustment
  
•
Re-setting of the parking brake is necessary after overhauling the caliper body, or if the brake calipers, housing, parking brake cable or brake discs have been changed.
1.
Remove the floor console to reach the adjusting nut.
2.
Loosen the parking brake cable until both operating levers rest in fully off position.
3.
Bring the brake pads in their operating position by pressing the brake pedal down several times until there is resistance.
4.
Tension the parking brake cable by tightening the adjusting nut, until the operating levers on both calipers lift from the stop, up to a distance of (A) and (D) between operating lever (B) and stopper (C).
Distance (A + D) : Max. 3 mm (0.12 in)

5.
Refit the floor console.
6.
Parking brake lever in the car must be in fully loosened position.
7.
If the handbrake cables where changed, actuate the parking brake a few times with maximum force to stretch the parking brake cables, and then control adjusting as above.
8.
Check the wheels of their free operation.
9.
Test drive.

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