Hyundai Sonata: Brake System / Front Disc Brake Repair procedures
1. |
Raise the vehicle, and make sure it is securely supported. |
2. |
Remove the wheel cap(A). 
Be careful not to damage to the wheel cap (A) when removing the it. |
|
3. |
Remove the front wheel and tire (A) from front hub.
Tightening torque:
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)
|

Be careful not to damage to the hub bolts when removing the front wheel and tire (A). |
|
4. |
Loosen the guide rod bolt (B) and pivot the caliper (A) up out of the way.
Tightening torque:
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
|

|
5. |
Replace pad shim, pad retainers (C) and brake pads (B) in the caliper bracket (A). 
|
6. |
Loosen the hose eyebolt (C) and caliper mounting bolts (B), then remove the front caliper assembly (A).
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(B):
78.5 ~98.1 N.m (8.0 ~10.0 kgf.m, 57.9 ~72.3 lb-ft)
|

|
7. |
Remove the front brake disc by loosening the screws (A). 
|
1. |
Loosen the guide rod bolt (B) and pivot the caliper (A) up out of the way.
Tightening torque:
21.6 ~31.4 N.m (2.2 ~3.2 kgf.m, 15.9 ~23.1 lb-ft)
|

|
2. |
Replace pad shim (D), pad retainers (C) and brake pads (B) in the caliper bracket (A). 
|
3. |
Use a SST (09581-2T100) when installing the brake caliper assembly. 
• |
Do not hit piston end by hammer or prying directly against piston face with screwdriver to push in piston. |
|
|
4. |
Down 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)
|

|
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
Front brake disc thickness
[GAMMA1.6 T-GDI / THETA2.4 GDI]
- Standard: 25mm (0.9842in)
- Service limit: 23.4mm (0.9212 in)
[THETA2.0 T-GDI]
- Standard: 28mm (1.1023 in)
- Service limit : 26.4mm (1.0393in)
[EPB]
- Standard: 28mm(1.10 in)
- Service limit: 26.4mm (1.0393in)
|
|
4. |
If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle. 
|
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
[GAMMA1.6 T-GDI / THETA2.4 GDI]
- Standard: 11.5mm (0.4527 in)
- Service limit: 2.0mm (0.0787 in)
[THETA2.0 T-GDI]
- Standard: 10.5mm (0.4133 in)
- Service limit: 2.0mm (0.0787 in)
[EPB]
- Standard: 10.5mm (0.4133 in)
- Service limit: 2.0mm (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: 0.04 mm (0.00157 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 does not exceed 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. |
1. |
Installation is the reverse of removal. |
2. |
Use a SST (09581-2T100) when installing the brake caliper assembly. 
• |
Do not hit piston end by hammer or prying directly against piston face with screwdriver to push in piston |
|
|
3. |
After installation, bleed the brake system.
(Refer to Brake System - "Brake System Bleeding")
(Refer to ABS - "ABS System Bleeding")
(Refer to ESP (Electronic Stability Program) System - "ESP System Bleeding") |
Components
1. Guide rod bolt2. Bleed screw3. Caliper bracket 4. Caliper body5. Inner pad shim6. Brake pad7. Pad retainer
...
Components
[General]
1. Guide rod bolt2. Bleed screw3. Caliper bracket4. Caliper body5. Inner pad shim6. Brake pad7. Pad retainer
[EPB]
1. Guide rod bolt2. Bleed screw3. Caliper carrie ...
Other information:
Hyundai Sonata LF 2014-2019 Service Manual: Assist Handle Repair procedures
Replacement
•
Put on gloves to protect your hands.
•
When prying with a flat-tip screwdriver, wrap it with
protective tape, and apply protective tape around the related parts, to
prevent damage.
•
Use a plastic panel removal ...
Hyundai Sonata LF 2014-2019 Service Manual: Specifications
Specifications
ItemsSpecificationHoodTypeRear hinged, gas lifter typeFront DoorConstructionFront hinged, full door constructionRegulator systemWire drum typeLocking systemPin-fork systemRear DoorConstructionFront hinged, full door constructionRegulator systemWire drum typeLocking systemPin-fork ...