Hyundai Elantra CN7: Brake System

Seventh generation (CN7; 2021–2024) / Hyundai Elantra CN7 2021-2024 Workshop Manual / Brake System / Brake System

Repair procedures

Operation and Leakage Check

Component

Procedure

Brake Booster (A)

Apply the brake and check its operation during the test run. If it does not work properly, replace the brake booster. If the brake fluid is found inside the booster when disassembling, replace the booster and master cylinder.

Piston cup and pressure cup inspection (B)

•	Apply the brake and check its operation. See if there is any damage or an oil leakage. If it does not work properly or damaged or an oil leak is found, replace the master cylinder. If the brake fluid is found inside the booster, replace the booster too.

•	Check if there is any difference in brake stroke when it is applied quickly and slowly. If a difference is detected, replace the master cylinder.

Brake hoses (C)

See if there is any damage or an oil leakage. If there is any damage or an oil leak is found, replace the brake hose and washer with new components.

Caliper piston seal and piston boots

•	Apply the brake and check its operation.

•	If the brake pedal does not work properly, it means there is a brake-slip or damage or an oil leak. Replace the brake caliper with a new one.

Brake System (Judder Inspection)

Brake Booster

Components and components location

Components

1. Reservoir cap
2. Reservoir
3. Brake fluid lever sensor

4. Master cylinder
5. Brake booster
6. Push road

Repair procedures

Brake Booster Operating Test

1.	Start the engine for 1 - 2 minutes and stop. If the brake stroke gradually reduces when the brake is pressed for several times, it means it works properly. But if the brake stroke doesn't change, inspect the check valve, vacuum hose and booster.

2.	Turn the engine off. And press the pedal for several times until the brake stroke reduces. And then, start the engine and press the pedal. When there is no change in brake stroke, it means the brake works properly. If it is not, inspect the check valve, vacuum hose and booster.

Press the pedal and stop the engine when the engine is running. Press the pedal for 30 seconds. When the position is fixed, It means that there is nothing wrong in the check valve, vacuum hose and booster. But if the pedal tries to return to its original position, the one before pressing, inspect the check valve, vacuum hose and booster for proper operation.

The booster can be seen that it works properly if it passes all three tests stated above. But if it fails to one of the tests, check the check valve, vacuum hose and booster.

Removal

[LHD]

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Remove the battery and battery tray. (Refer to Engine Electrical System - "Battery")

3.	Remove the master cylinder. (Refer to Brake System - "Brake Master Cylinder")

4.	Remove the fixing clip and the vacuum hose (A) from the brake booster.

5.	Remove the snap pin (A) and the clevis pin (B).

Loosen the fixed nut (A) and then removing the brake booster (B).

Tightening torque :

16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

[RHD]

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Remove the master cylinder. (Refer to Brake System - "Brake Master Cylinder")

3.	Remove the roll rod bracket. (Refer to Engine Mechanical System - "Engine Mounting")

4.	Remove the engine mounting bracket. (Refer to Engine Mechanical System - "Engine Mounting")

5.	Remove the fixing clip and the vacuum hose (A) from the brake booster.

6.	Remove the snap pin (A) and the clevis pin (B).

Loosen the fixed nut (A) and then removing the brake booster (B).

Tightening torque :

16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

[G 1.6 T-GDI]

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Drain the coolant. (Refer to Engine Mechanical System - "Coolant")

3.	Remove the battery and battery tray. (Refer to Engine Electrical System - "Battery")

4.	Remove the master cylinder. (Refer to Brake System - "Brake Master Cylinder")

5.	Disconnect the heater hose quick connector (A) from the heater pipe.

6.	Remove the fixing clip and the vacuum hose (A) from the brake booster.

7.	Remove the snap pin (A) and the clevis pin (B).

Loosen the fixed nut (A) and then removing the brake booster (B).

Tightening torque :

16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

Inspection

1.	Inspect the vacuum hose.

2.	Check the boot for damage.

Installation

To install, reverse the removal procedure.

•	Before installing the pin, apply the grease to the joint pin.

•	Use a new snap pin whenever installing.

2.	Refill the coolant. [G 1.6 T-GDI] (Refer to Engine Mechanical System - "Coolant")

3.	After installation, bleed the brake system. (Refer to Brake System - "Brake Bleeding Prcoedures")

4.	Check the brake oil leakage and pedal operating condition.

Master Cylinder

Components and components location

Components

1. Reservoir cap
2. Reservoir
3. Brake fluid lever sensor

4. Master cylinder
5. Brake booster
6. Push road

Repair procedures

Removal

[LHD]

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

Remove the brake fluid from the master cylinder reservior with a syringe.

•	Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

•	Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.

3.	Remove the battery. (Refer to Engine Electrical System - "Battery")

4.	Disconnect the brake fluid level sensor connector (A) and then removing the wiring clip (B).

Separate the brake tube (A) from the master cylinder by loosening the tube flare nut.

Tightening torque :

18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)

Remove the master cylinder (A) after loosening the master cylinder nuts.

Tightening torque :

12.7 - 15.7 N.m (1.3 - 1.6 kgf.m, 9.4 - 11.6 lb-ft)

[RHD]

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

Remove the brake fluid from the master cylinder reservior with a syringe.

•	Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

•	Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.

3.	Disconnect the brake fluid level sensor connector (A).

Remove the brake tube after loosening the mounting bolts (A).

Tightening torque :

18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)

Remove the master cylinder (A) after loosening the mounting nuts.

Tightening torque :

12.7 - 15.7 N.m (1.3 - 1.6 kgf.m, 9.4 - 11.6 lb-ft)

Installation

To install, reverse the removal procedure.

•	Before installing the pin, apply the grease to the joint pin.

•	Use a new snap pin whenever installing.

2.	After installation, bleed the brake system. (Refer to Brake System - "Brake Bleeding Prcoedures")

3.	Check the brake oil leakage and pedal operating condition.

Brake Line

Components and components location

Components

Repair procedures

Removal

Brake Tube [Engine Room]

1.	Disconnect the brake fiuid level switch connector, and remove the reservoir cap.

Remove the brake fluid from the master cylinder reservior with a syringe.

•	Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

•	Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.

Remove the brake tube after loosening the flare nuts from the ESC, master cylinder and brake tube connector.

Tightenning torque

ESC :

16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

Master cylinder :

12.7 - 16.7 N.m (1.3 - 1.7 kgf.m, 9.4 - 12.3 lb-ft)

Brake tube connector :

18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)

Brake Hose [Front]

1.	Disconnect the brake fluid level sensor connector (A).

Remove the brake fluid from the master cylinder reservior with a syringe.

•	Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

3.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

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

Tightenning 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 front wheel and tire (A).

5.	Remove the brake hose clip (A).

Disconnect the tube after loosening the tube flare nut (B).

Tightening torque :

12.7 - 16.7 N.m (1.3 - 1.7 kgf.m, 9.4 - 12.3 lb-ft)

Remove the brake hose bracket mounting bolt (A).

Tightening torque :

8.8 - 13.7 N.m (0.9 - 1.4 kgf.m, 6.5 - 10.1 lb-ft)

Remove the hose after loosening the brake hose bolt (A) from the caliper.

Tightening torque :

24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)

Brake Hose [Rear]

1.	Disconnect the brake fluid level sensor connector (A).

Remove the brake fluid from the master cylinder reservior with a syringe.

•	Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

3.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

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

5.	Remove the brake hose clip (A).

Disconnect the tube after loosening the tube flare nut (B).

Tightening torque :

12.7 - 16.7 N.m (1.3 - 1.7 kgf.m, 9.4 - 12.3 lb-ft)

Remove the hose after loosening the brake hose bolt (A) from the caliper.

Tightening torque :

24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)

[Rear torsion beam parking cable type]

[Rear torsion beam EPB type]

[Rear multi link parking cable type]

[Rear multi link EPB type]

Drum brake hose [Rear]

1.	Disconnect the brake fluid level sensor connector (A).

Remove the brake fluid from the master cylinder reservoir with a syringe.

•	Be careful not to let the brake fluid come into contact with your vehicle or body. If contacted, wipe immediately.

3.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

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).

5.	Loosen the tube flare nut (A).

Loosen the brake hose bracket bolt (B).

Tightening torque

(A) : 12.7 - 16.7 N.m (1.3 - 1.7 kgf.m, 9.4 - 12.3 lb-ft)

(B) : 8.8 - 13.7 N.m (0.9 - 1.4 kgf.m, 6.5 - 10.1 lb-ft)

Loosen the brake hose bracket bolt (A).

Tightening torque :

13.7 - 16.7 N.m (1.4 - 1.7 kgf.m, 10.1 - 12.3 lb-ft)

Remove the brake hose after loosening the hose flare nut (A).

Tightening torque :

12.7 - 16.7 N.m (1.3 - 1.7 kgf.m, 9.4 - 12.3 lb-ft)

Inspection

1.	Check the brake tubes for cracks, crimps and corrosion.

2.	Check the brake tube flare nuts for damage and fluid leakage.

Installation

To install, reverse the removal procedures.

•	Use a new washer (A) whenever installing. [Front] [Rear torsion beam parking cable type] [Rear torsion beam EPB type] [Rear multi link parking cable type] [Rear multi link EPB type]

2.	After installation, bleed the brake system. (Refer to Brake System - "Brake Bleeding Prcoedures")

Brake oil

Specifications

Specification

Fluid Type

DOT 4

Reservoir Quantity (cc)
Total Volume	A + B + C + D + E + F	405 ± 20
MAX LEVEL	A + B + C + D + E	392 ± 20
ON LEVEL	B + C + D + E	155 ± 10
MIN LEVEL	C + D + E	107 ± 10
PART LEVEL	D	Pri : 44 ± 5
PART LEVEL	E	Sec : 37 ± 5
CLUTCH LEVEL	F	13 ± 5

Repair procedures

Replacement

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Disconnect the brake fluid level sensor connector (A).

Remove the brake fluid from the master cylinder reservior with a syringe.

•	Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

•	Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.

Loosen the bleed screw (A) and depress the brake pedal repeatedly several times until the brake fluid reaches the caliper cylinder.

[Front]

[Rear torsion beam parking cable type]

[Rear torsion beam EPB type]

[Rear multi link parking cable type]

[Rear multi link EPB type]

[Rear Drum Brake Type]

•	Work from rear right, front left, rear left to front right.

•	Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

5.	Retighten the bleed screw and then make sure the brake fluid in the reservoir is at the MAX (upper) level line.

Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw securely.

[Front]

[Rear torsion beam parking cable type]

[Rear torsion beam EPB type]

[Rear multi link parking cable type]

[Rear multi link EPB type]

[Rear Drum Brake Type]

•	Work from rear right, front left, rear left to front right.

•	Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

•	Make sure the brake fluid in the reservoir is at the MAX (upper) level line.

7.	Re-tighten the bleed screw.

8.	Have an assistant press the brake pedal several times to pressurize it and keep it pressed.

Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without bubbles. Then close the bleeder screw.

[Front]

[Rear torsion beam parking cable type]

[Rear torsion beam EPB type]

[Rear multi link parking cable type]

[Rear multi link EPB type]

[Rear Drum Brake Type]

•	Work from rear right, front left, rear left to front right.

•	Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

•	Make sure the brake fluid in the reservoir is at the MAX (upper) level line.

10.	Repeat the procedure for wheel in the sequence until air bubbles no longer appear in the fluid.

11.	Connect the negative (-) cable.

12.	Connect the brake fluid level sensor.

Rear Disc Brake

Components and components location

Components

[Rear parking cable type]

1. Rear caliper
2. Caliper carrier

3. Brake pad
4. Pad liner

[Rear EPB type]

1. Rear caliper
2. Caliper carrier

3. Brake pad
4. Pad liner

Repair procedures

Removal

1.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

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).

Loosen the brake hose bolt (A) from the caliper seperate the brake hose.

Tightening torque :

24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)

4.	Remove the return spring (A).

5.	Disconnect the parking brake cable (B) after remove fixing clip (A).

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

Tightening torque :

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

7.	Remove the brake pad (A).

8.	Remove the pad liner (A).

Remove the caliper carrier (A) by loosening the caliper mouniting bolts.

Tightening torque :

78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb-ft)

10.

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

Tightening torque :

4.9 - 5.8 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

[Rear torsion beam EPB type]

1.	Before removing the rear caliper, perform "Brake Pad Replacement Mode" using the diagnostic tool.

2.	Select C2 (Release) on the screen below.

3.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

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).

5.	Disconnect the EPB actuator connector (A).

Remove the hose after loosening the brake hose bolt (A) from the caliper.

Tightening torque :

24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)

7.	Remove the caliper body (A) after loosening the guide rod bolt.

8.	Remove the brake pad (A).

9.	Remove the pad liner (A).

10.

Remove the caliper carrier (A) after loosening the caliper mounting bolt.

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 (A) after loosening the screw.

Tightening torque :

4.9 - 5.9 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

[Rear multi link parking cable type]

1.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

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).

Remove the hose from the caliper after loosening the brake hose bolt (A).

Tightening torque :

24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)

4.	Remove the return spring (A).

5.	Disconnect the parking brake cable (A) after removing the fixing clip.

Remove the caliper body (A) after loosening the guide rod bolts.

Tightening torque :

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

7.	Remove the brake pad (A).

8.	Remove the pad liner (A).

Remove the caliper carrier (A) after loosening the caliper mounting bolts.

Tightening torque :

78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb-ft)

10.

Remove the brake disc (A) after loosening the mounting screw.

Tightening torque :

4.9 - 5.8 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

[Rear multi link EPB type]

1.	Before removing the rear caliper, perform "Brake Pad Replacement Mode" using the diagnostic tool.

2.	Select C2 (Release) on the screen below.

3.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

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).

5.	Disconnect the EPB actuator connector (A).

Remove the hose after loosening the brake hose bolt (A) from the caliper.

Tightening torque :

24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)

7.	Remove the caliper body (A) after loosening the guide rod bolt.

8.	Remove the brake pad (A).

9.	Remove the brake pad (A).

10.	Remove the caliper carrier (A) after loosening the caliper mounting bolt.

11.

Remove the rear brake disc (A) after loosening the screw.

Tightening torque :

4.9 - 5.9 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

Inspection

Front Brake Disc Thickness Check

1.	Check the brake disc for damage and cracks.

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.

Front brake disc thickness

Standard : 10 mm (0.39 in)

Service limit : 8.4 mm (0.33 in)

Difference in thickness of each measuring part : Less than 0.015 mm (0.0004 in.) (Circumferential direction), 0.015 mm (0.0004 in.) (Radial)

3.	If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.

Front Brake Disc Runout Check

Place a dial gauge about 10mm (0.20 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

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 cannot be corrected by changing the position of the brake disc, replace the brake disc.

Installation

1.	To install, reverse the removal procedures.

Press in the caliper piston.

[Rear parking cable type]

[Rear EPB type]

•	For the brake pad to locate on the normal operation position, depress the brake pedal halfway several times until the brake pedal gains resistance.

•	After disassembling/assembling the caliper body or replacing the brake caliper, parking brake cable or brake disc, re-adjust the parking brake.

3.	After installation, bleed the brake system. (Refer to Brake System - "Brake Bleeding Prcoedures")

4.	After installing the rear caliper (EPB applied), perform “Brake Pad Replacement Mode” using the diagnostic tool.

5.	Select C1 (Apply) on the screen below.

6.	After replacing the rear caliper, make sure that the caliper is installed correctly by performing "Check assembling (ECU replaced)" from the option.

Adjustment

[Rear parking cable type]

•	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.

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)

[G 1.6 MPI / LPI]

[G 1.6 T-GDI]

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.

Brake Pad

Repair procedures

Replacement

[Front]

1.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

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

•	Be careful not to damage the hub bolts when removing the front wheel and tire (A).

3.	Up the brake caliper body (A) by loosening the guide rod bolt.

4.	Remove the brake pad (A).

5.	Replace the pad retainer (A) with a new one.

Replace the brake pad (A) with a new one.

•	When installing, use a new one return brake pad (A), pad liner (B), pad cover shim (C).

7.	Use a SST (09581-11000) when installing the brake caliper assembly.

Install the caliper body (A) 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)

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

[Rear torsion beam parking cable type]

1.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

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.	Remove the return spring (A).

4.	Disconnect the parking cable (B) after remove the parking brake cable fixing clip (A).

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

6.	Remove the brake pad (A).

7.	Replace the pad liner (A) with a new one.

Replace the brake pad (A) with a new one.

•	When installing, use a new one brake pad (A), pad liner (B).

9.	Press in the caliper piston.

10.

Install the caliper body (A) 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)

11.	Connect the parking cable (B) and than install the parking brake cable fixing clip (A).

12.	Install the return spling (A).

13.

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

[Rear torsion beam EPB type]

1.	Before removing the rear caliper, perform "Brake Pad Replacement Mode" using the diagnostic tool.

2.	Select C2 (Release) on the screen below.

3.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

Remove the rear wheel and tire (A) from the rear hub.

•	Be careful not to damage the hub bolts when removing the front wheel and tire (A).

5.	Disconnect the EPB actuator connector (A).

6.	Remove the caliper body (A) after loosening the guide rod bolt.

7.	Remove the brake pad (A).

8.	Replace the pad retainer (A) with a new one.

Replace the brake pad (A) with a new one.

•	When installing, use a new one brake pad (A), pad liner (B).

10.	Press in the caliper piston.

11.

Install the caliper body (A) 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)

12.	Connect the EPB actuator connector (A).

13.

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

14.	After replacing the brake pad (EPB applied), perform "Brake Pad Replacement Mode" using the diagnostic tool.

15.

Select C1 (Apply) on the screen below.

•	After replacing the brake pad is complete, make sure to repeat engagement/disengagement 3 times at "Brake Pad Replacement Mode".

16.	After replacing the brake pad, make sure that the caliper is installed correctly by performing "Check assembling (ECU replaced)" from the optional function.

[Rear multi link parking cable type]

1.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

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 return spring (A).

4.	Disconnect the parking brake cable (A) after removing the fixing clip.

Remove the caliper body (A) after loosening the guide rod bolts.

Tightening torque :

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

6.	Remove the brake pad (A).

7.	Replace the pad liner (A) with a new product.

Replace the brake pad (A) with a new grease coated product.

•	When installing, use a new one brake pad (A), pad liner (B).

9.	Press in the caliper piston.

10.

Install the caliper body (A) 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)

11.	Connect the parking cable (A) and than install the parking brake cable fixing clip.

12.	Install the return spling (A).

13.

Install the rear 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 removing the rear wheel and tire (A).

[Rear multi link EPB type]

1.	Before removing the rear caliper, perform "Brake Pad Replacement Mode" using the diagnostic tool.

2.	Select C2 (Release) on the screen below.

3.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

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).

5.	Disconnect the EPB actuator connector (A).

Remove the caliper body (A) after loosening the guide rod bolts.

Tightening torque :

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

7.	Remove the brake pad (A).

8.	Replace the pad liner (A) with a new product.

Replace the brake pad (A) with a new grease coated product.

•	When installing, use a new one brake pad (A), pad liner (B).

10.	Press in the caliper piston.

11.

Install the caliper body (A) 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)

12.	Connect the EPB actuator connector (A).

13.

Install the rear 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 removing the rear wheel and tire (A).

14.	After replacing the brake pad (EPB applied), perform "Brake Pad Replacement Mode" using the diagnostic tool.

15.

Select C1 (Apply) on the screen below.

•	After replacing the brake pad is complete, make sure to repeat engagement/disengagement 3 times at "Brake Pad Replacement Mode".

16.	After replacing the brake pad, make sure that the caliper is installed correctly by performing "Check assembling (ECU replaced)" from the optional function.

Inspection

Front Brake Pad Check

Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.

Pad thickness

Standard (15 inch) : 10.5 mm (0.41 in)

Service Limit (15 inch) : 2.0 mm (0.78 in)

2.	Check that grease is applied, to sliding contact points and the pad and backing metal for damage.

Rear Brake Pad Check

Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.

Pad thickness

Standard : 10 mm (0.39 in)

Service Limit : 2.0 mm (0.78 in)

2.	Check the damage of pad, backing metal and contamination with grease.

Stop Lamp Switch

Components and components location

Components

1. Brake member assembly
2. Stop lamp switch

3. Brake pedal arm assembly
4. Brake pedal pad

Troubleshooting

Part diagnosis

Items

Cause

Symptom

Switch fuse

Faulty fuse connection, Damaged fuse

–	DTC Code : P0504

–	Symptom : Shifting gear trouble, Starting failure, Cruise control function cancelation trouble, EPB function cancelation trouble, Stop lamp lighting trouble, ESP OFF light illuminated.

① A waveform inspection is performed using an oscilloscope on each part during vehicle acceleration/braking. (Refer to stop lamp switch circuit inspection procedures)

② Refer to the relevant repair procedures of the part when something abnormal is discovered in the waveform (Refer to the repair procedures of the relevant part and if necessary replace it)

Relay fuse

Faulty fuse connection, Damaged fuse

–	DTC Code : P0504

–	Symptom : Shifting gear trouble, Starting failure, Cruise control function cancelation trouble, EPB function cancelation trouble, Stop lamp lighting trouble , ESP OFF light illuminated.

Stop lamp switch

•	Damaged wiring of each part

•	Faulty connection to connector

•	Each part is defective

–	DTC Code : P0504

–	Symptom : Shifting gear trouble, Starting failure, Cruise control function cancelation trouble, EPB function cancelation trouble, Stop lamp lighting trouble , ESP OFF light illuminated.

Stop signal electronic module (If it applies)

–	DTC Code : P0504, C2130, C2131

–	Symptom : Shifting gear trouble, Starting failure, Cruise control function cancelation trouble, EPB function cancelation trouble, Stop lamp lighting trouble , ESP OFF light illuminated.

Engine control module (ECM)

–	DTC Code : P0504

–	Symptom :Shifting gear trouble,Cruise control function cancelation trouble

Body control module (BCM)

–	Shifting gear trouble

Shift-lock solenoid

–	Shifting gear trouble

Inhibitor switch

–	Symptom : Shifting gear trouble, Starting failure, Cruise control function cancelation trouble, EPB function cancelation trouble

Smart Key Unit (SMK)

–	Starting failure

Electronic parking brake

–	Symptom : EPB function cancelation trouble , ESP OFF light illuminated.

ABS/VDC control module
(Pressure sensor)

–	Symptom : ESP OFF light illuminated.

Symptom diagnosis

Symptom	Part that could be the cause
Trouble starting	Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, ABS/VDC control module, Each wire, Connector	① Inspect waveform using an oscilloscope on each part during vehicle acceleration/braking. (Refer to stop lamp switch circuit inspection Procedures) ② Refer to the relevant repair procedures of the part when something abnormal is discovered in the waveform (Refer to the repair procedures of the relevant part and if necessary replace it)
Trouble shifting gears	Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, BCM, ECM, Inhibitor switch, Each wire, Connector
ESP OFF light illuminated	Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, ABS/VDC control module, Each wire, Connector
P0504	Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, ECM, Each wire, Connector
Stop lamp does notworking	Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, Wire/Connector disconnected
Stop lamp always turns on	Stop lamp switch, Stop signal electronic module, Wiring short circuit, Damaged fuse

3.	Stop lamp switch system diagnosis SSEM : Stop Signal Electronic Module

4.	Refer to DTC guide when the related DTC codes are displayed.

Schematic diagrams

Schematic Diagram

System Circuit Diagram

Terminal Function

Teminal	Description
1	IGN1
2	Engine Control Module (ECM)
3	-
4	B+
5	Stop Lamp
6	Gruound

Repair procedures

Adjustment

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Remove the lower crash pad. (Refer to Body - "Crash Pad")

Confirm the gap between stop lamp switch and bracket.

Stop lamp clearance (A) : 1.0 - 2.0 mm (0.04 - 0.08 in.)

4.	If the gap between stop lamp switch and bracket is not 1.0-2.0 mm (0.04-0.08 in), check the mounting clip and other part of around stop lamp.

5.	If there is normal, remove the stop lamp switch and then install again.

Inspection

1. Fuse Inspection

Mount the test fuse to the switch fuse and relay fuse part to confirm a normal joint fit.

2. GDS Data Analysis

Analyze GDS data and confirm if there is anything wrong with the stop lamp switch.

(1)	Connect the GDS to the self-diagnosis connector.

(2)	Turn the spark switch on

(3)	Step on the brake pedal.

(4)

Inspect the "brake switch" category that displays the "sensor data" GDS.

Normal waveform : The pressure sensor signal value will change according to the brake ON/OFF switch.

3. Inspection of Connector by Each Part

Check to see whether or not each connector has been damaged, or terminal surge, or incomplete connection has taken place

[Engine Room Junction Box]

[ABS / VDC Control Module]

4. Inspect the Stop Lamp Circuit

Connect probe to each terminal wire and confirm oscilloscope waveform.

[Stop Lamp Switch Input / Output]

[Oscilloscope Waveform Screen]

Removal

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Remove the lower crash pad. (Refer to Body - "Crash Pad")

3.	Disconnect the stop lamp switch connector (A).

4.	Pull the locking plate (A) as indicated by the arrow.

5.	Turn stop lamp switch 45° counterclockwise and remove it.

Inspect a removed stop lamp switch along the below procedures.

(1)

Confirm a normal connection with terminal part

–	Confirmation can be made to see if the connector has been secured properly and if a connection mark is present.

Installation

1.	Insert fully the stop lamp switch as hiding contact part.

2.	After inserting, turn the stop switch 45° clockwise, and then assemble locking plate (A) by pushing.

Confirm the gap between stop lamp switch.

Stop lamp clearance (A) : 1.0 - 2.0 mm (0.04 - 0.08 in.)

•	If the gap between stop lamp switch and bracket is not 1.0-2.0mm (0.04-0.08in), perform the above process again.

4.	Connect the stop lamp switch connector (A).

5.	Install the lower crash pad. (Refer to Body - "Crash Pad")

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