SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2000
GROUP
Brake Systems Conventional Brake System
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CALIPER ASSEMBLY 
Removal
  1. Remove the wheel and tire.

  1. Disconnect the brake hose.

  1. Remove the pads.

  1. Remove the sleeve.

  1. Remove the pin boot and sleeve boot.

  1. Remove the caliper assembly.

  1. Check the caliper for wear, damage, cracks and rust.

  1. Check the piston for rust, damage, cracks and wear on the outer surface.

  1. Check the sleeve and pin for damage and rust.

  1. Check the pad spring and boots for damage.

  1. Check the carrier for damage, rust, wear and cracks.

    NOTE
    1. Do not use sand paper on the piston surface.
    1. All rubber parts must be replaced with new ones.
  1. Inspect the disc using a caliper and dial gauge.

    |
    		 Standard value
    		 Service limit
    Thickness of disc mm (in.)
    		 22 (0.876)
    		 20 (0.787)
    Total runout of front axle assembly mm (in.)
    		 -
    		 0.06 (0.0024)
  1. If necessary, replace the brake disc.

    1. Remove the drive shaft nut.
    1. Jack up the vehicle and support it with jack stands.
    1. Remove the wheel and tire.
    1. Remove the front wheel brake assembly from the knuckle and suspend it with a wire.
      NOTE
      Brake hose does not need to be disconnected from brake calliper. Be careful not do depress brake pedal, or piston will popout.
    1. Disconnect the lower arm ball joint from the knuckle using the Special Tool (09568-31000).
    1. Remove the wheel speed sensor mounting bolt and wire clamp and then remove the wheel speed sensor. (For ABS vehicle only).
    1. Disconnect the tie rod and ball joint from the knuckle using the special tool.
      NOTE
      1. Be sure to tie the cord of the special tool to the nearby part.
      2. Loose the nut, but do not remove it.
    1. Disconnect the drive shaft from the hub using the special tool.
    1. Remove the hub and knuckle as an assembly from the strut.
  1. Check the hub for cracks and the splines for wear.

  1. Check the snap ring for cracking or damage.

  1. Check the brake disc for scoring and damage.

  1. Check the steering knuckle for cracks.

  1. Check for a defective bearing. (Refer to "Wheel bearing trouble shooting".)

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INSTALLATION 
  1. Install parts to torque specifications.

  1. Be sure to install the washer and wheel bearing nut in the specified direction.

  1. After installing the wheel, lower the vehicle to the ground and tighten the wheel bearing nut.

  1. If the position of the split pin holes do not match, tighten the nut up to 260 Nm (2600 kg.cm, 188 lb.ft) maximum.

  1. Install the split pin in the first matching holes and bend it over.