Brake System Hyundai Santa Fe III

Operation and Leakage Check

Check all of the following items

Scheme 1

Note. Do not reuse the drained fluid. Always use genuine DOT3/DOT4 brake Fluid. Using a non-genuine DOT3/DOT4 brake fluid can cause corrosion and decrease the life of the system. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. 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. The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure and checked after bleeding each brake caliper. Add fluid as required.

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1. Make sure the brake fluid in the reservoir is at the MAX (upper) level line.
2. Have someone slowly pump the brake pedal several times, and then apply pressure.
3. Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw securely. [Front] [Rear]
4. Repeat the procedure for wheel in the sequence shown below until air bubbles no longer appear in the fluid.
5. Refill the master cylinder reservoir to MAX (upper) level line.

This procedure should be followed to ensure adequate bleeding of air and filling of the ESC unit, brake lines and master cylinder with brake fluid.

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1. Remove the reservoir cap and fill the brake reservoir with brake fluid. CAUTION: If there is any brake fluid on any painted surface, wash it off immediately. NOTE: When pressure bleeding, do not depress the brake pedal. Recommended fluid........ DOT3 or DOT4
2. Connect a clear plastic tube to the bleeder plug and insert the other end of the tube into a half filled clear plastic bottle.
3. Connect the GDS to the data link connector located underneath the dash panel.
4. Select and operate according to the instructions on the GDS screen. CAUTION: You must obey the maximum operating time of the ESC motor with the GDS to prevent the motor pump from burning. Select vehicle name. Select Anti-Lock Brake system. Select HCU air bleeding mode. Press "OK" to operate motor pump and solenoid valve. Wait 60 sec. before operating the air bleeding. (If not, you may damage the motor.) Perform the air bleeding.
5. 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 (A). [Front] [Rear]
6. Repeat step 5 following the order described below until there are no more bubbles in the fluid for each wheel.
7. Tighten the bleeder screw. Bleed screw tightening torque: 6.9 ~ 12.7 N.m (0.7 ~ 1.3 kgf.m, 5.1 ~ 9.4 lb-ft)

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Brake Booster Operating Test

For simple checking of the brake booster operation, carry out the following tests.

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1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the booster is inoperative.
2. With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is inoperative.
3. With the engine running, step on the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if the pedal rises, the booster is inoperative. If the above three tests are okay, the booster performance can be determined as good. Even if one of the above three tests is not okay, check the check valve, vacuum hose and booster for malfunction.

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1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the air cleaner assembly. Refer to «AIR CLEANER»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) .
3. Remove the master cylinder. Refer to «MASTER CYLINDER»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical-hydraulic/#brake-system) .
4. Disconnect the vacuum hose (A) from the brake booster.
5. Remove the snap pin (A) and clevis pin (B).
6. Remove the mounting nuts (A). Tightening torque: 16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft)
7. Remove the brake booster (A).

Inspection

1. Inspect the check valve in the vacuum hose, intensifier and the connecting section. NOTE: Do not remove the check valve from the vacuum hose.
2. Check the boot for damage.

Installation

1. Installation is the reverse of removal. NOTE: 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 BLEEDING»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical-hydraulic/#brake-system) .

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1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the air cleaner assembly. Refer to «AIR CLEANER»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) .
3. Disconnect the brake fluid level switch connector (B), and remove the reservoir cap.
4. Remove the brake fluid from the master cylinder reservoir with a syringe. NOTE: 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. Disconnect 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)
6. Remove the master cylinder (B) from the brake booster after loosening the mounting nuts (A). Tightening torque: 12.7 ~ 16.7 N.m (1.3 ~ 1.7 kgf.m, 9.4 ~ 12.3 lb-ft)

1. Installation is the reverse of removal.
2. After installation, bleed the brake system. Refer to «BRAKE SYSTEM BLEEDING»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical-hydraulic/#brake-system) .

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1. Disconnect the brake fluid level switch connector, and remove the reservoir cap.
2. Remove the brake fluid from the master cylinder reservoir with a syringe. NOTE: 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. Remove the wheel & tire.
4. Disconnect the brake tube by 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) [Front] [Rear]
5. Remove the brake hose clip (A).
6. Disconnect the brake hose from the brake caliper by loosening the bolt (A). Tightening torque: 24.5 ~29.4 N.m (2.5 ~3.0 kgf.m, 18.1 ~21.7 lb-ft) [Front] [Rear]

1. Check the brake tubes for cracks, crimps and corrosion.
2. Check the brake hoses for cracks, damage and fluid leakage.
3. Check the brake tube flare nuts for damage and fluid leakage.
4. Check brake hose mounting bracket for crack or deformation.

Scheme 29

1. Installation is the reverse of removal. NOTE: Use a new washer (A) whenever installing.
2. After installation, bleed the brake system. Refer to «BRAKE SYSTEM BLEEDING»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical-hydraulic/#brake-system) .
3. Check the spilled brake oil.

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1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the crash pad lower panel. Refer to «CRASH PAD LOWER PANEL»(/hyundai/santa-fe/iii-2012-2016/remont/gauges-instrument-panels/#crash-pad) .
3. Remove the shower duct (A).
4. Disconnect the stop lamp switch connector (A).
5. Remove the brake pedal member mounting nut (A).
6. Remove the snap pin (A) and clevis pin (B).
7. Remove the brake pedal member assembly mounting nuts (A) and then remove the brake pedal assembly.

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1. Check the bushing for wear.
2. Check the brake pedal for bending or twisting.
3. Check the brake pedal return spring for damage.
4. Check the stop lamp switch. Connect a circuit tester to the connector of stop lamp switch, and check whether or not there is continuity when the plunger of the stop lamp switch is pushed in and when it is released. The stop lamp switch is in good condition if there is no continuity when plunger (A) is pushed.

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1. Pre-tighten the bracket fixing bolt (A) in dash panel.
2. Install the brake booster and brake pedal member fixing nuts (A) securely. Tightening torque: 16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft)
3. Tighten the bolt (A) securely in dash panel. Tightening torque: 16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft)
4. Install the snap pin (A) and clevis pin (B). NOTE: Before installing the pin, apply the grease to the clevis pin. Use a new snap pin whenever installing.
5. Install the stop lamp switch securely.
6. Connect the stop lamp switch connector (A).
7. Adjust the brake pedal height and free play.
8. Check the brake pedal operation after installing the brake pedal.
9. Install the shower duct (A).
10. Install the crash pad lower panel.
11. Reconnect the battery negative cable.

Stop lamp switch clearance adjustment

If the gap between stop lamp switch and bracket is not 1.0 ~ 2.0mm (0.04~ 0.08in), perform the procedure below.

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1. Disconnect the stop lamp switch connector (A).
2. Pull the locking plate (A) as indicated by the arrow.
3. Turn stop lamp switch 45° counterclockwise and remove it.
4. While holding the brake pedal, insert the stop lamp switch until the plunger is fully pressed in against the stopper on the pedal assembly.
5. After inserting, turn the stop switch (A) 45° clockwise, and then assemble locking plate (B) by pushing.
6. Confirm the gap between stop lamp switch and bracket. Stop lamp clearance: 1.0 ~ 2.0 mm (0.04 ~ 0.08 in)
7. Connect the stop lamp switch connector.

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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 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 ~ 3.4 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)
3. Remove the front brake disc by loosening the screws (A).

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1. Loosen the guide rod bolt (B) and then remove caliper body (A). 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 carrier (A).

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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 Standard: 28 mm (1.10 in) Service limit: 26 mm (1.02 in) Deviation: Less than 0.005 mm (0.0002 in)
4. If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.

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1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value. Pad thickness Standard value: 11 mm (0.43 in) Service limit: 2.0 mm (0.0787 in)
2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.

Scheme 56

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, 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.

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1. Installation is the reverse of removal.
2. Use a SST (09581-11000) when installing the brake caliper assembly.
3. After installation, bleed the brake system.

Refer to BRAKE SYSTEM BLEEDING .

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1. Remove the rear 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 hose eyebolt (B) and caliper mounting bolts (C), then remove the rear caliper assembly (A). Tightening torque: Brake hose to caliper (B): 24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft) Caliper assembly to knuckle (C): 63.7 ~ 73.5 N.m (6.5 ~ 7.5 kgf.m, 47.0 ~ 54.2 lb-ft)
3. Remove the rear brake disc by loosening the screws (A).

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1. Remove the rear wheel & tire.
2. Loosen the guide rod bolt (B) and pivot the caliper (A) up out of the way.
3. Replace pad shim (D), pad retainers (C) and brake pads (B) in the caliper carrier (A).
4. Use a SST (09581-11000) when installing the brake caliper assembly.
5. Place the caliper body (A) on the caliper carrier and tighten the guide rod bolts (B). Tightening torque: 21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
6. Install the rear wheel & tire. Tightening torque: 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

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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. Rear Brake disc thickness Standard: 11 mm (0.43 in) Service limit: 9.4 mm (0.37 in) Deviation: less than 0.005 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 (0.393 in) Service limit: 2.0 mm (0.0787 in)
2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.

Scheme 66

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: 0.03 mm (0.00118 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.

Scheme 67

1. Installation is the reverse of removal.
2. Use a SST (09581-11000) when installing the brake caliper assembly.
3. After installation, bleed the brake system. Refer to «BRAKE SYSTEM BLEEDING»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical-hydraulic/#brake-system) .

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1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the lower crash pad. Refer to «CRASH PAD LOWER PANEL»(/hyundai/santa-fe/iii-2012-2016/remont/gauges-instrument-panels/#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.

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1. Fix the brake pedal arm and insert fully the stop lamp switch as hiding contact part.
2. After inserting, turn the stop switch (A) 45° clockwise, and then assemble locking plate (B) by pushing.
3. Confirm the gap between stop lamp switch and bracket. Stop lamp clearance : 1.0 ~ 2.0 mm (0.04~ 0.08 in.)
4. Connect the stop lamp switch connector. NOTE: If the gap between stop lamp switch and bracket is not 1.0 ~ 2.0mm (0.04~ 0.08in), perform the above process again.
5. Install the lower crash pad. Refer to «CRASH PAD LOWER PANEL»(/hyundai/santa-fe/iii-2012-2016/remont/gauges-instrument-panels/#crash-pad) .

See also:
• AIR CLEANER
• CRASH PAD LOWER PANEL
• MASTER CYLINDER