OP Rear Brake Pad Kit 41mm for Hyundai iX20 (2010-2019) - Installation and Maintenance Manual

1. Introduction and Overview

This manual provides essential information for the installation, operation, and maintenance of the OP Rear Brake Pad Kit, model BPA1209.02-01. This kit is specifically designed for Hyundai iX20 vehicles manufactured between 2010 and 2019. The brake pads are engineered to offer reduced noise and a long service life, ensuring reliable braking performance.

For optimal safety and performance, it is crucial to follow all instructions carefully. Professional installation is highly recommended for brake system components.

2. Safety Information

• Professional Installation: Brake system components are critical for vehicle safety. Installation should only be performed by qualified automotive technicians with appropriate tools and experience.
• Personal Protective Equipment: Always wear appropriate personal protective equipment, including safety glasses and gloves, when working on vehicle brake systems.
• Vehicle Support: Ensure the vehicle is securely supported on jack stands on a level surface before beginning any work. Never rely solely on a jack.
• Brake Fluid: Handle brake fluid with care. It is corrosive and can damage paint. Dispose of used brake fluid responsibly.
• Component Compatibility: Verify that all components are correct for your specific vehicle model and year before installation. Refer to the OEM codes provided in the specifications section.

3. Package Contents

The OP Rear Brake Pad Kit (BPA1209.02-01) typically includes the following items:

• One set of rear brake pads (4 individual pads for two wheels).

Note: Additional hardware such as shims, clips, or grease may be included depending on the specific kit version. Inspect the package upon receipt to ensure all expected components are present.

4. Setup and Installation

The following steps outline a general procedure for replacing rear brake pads. This is for informational purposes only. Always consult your vehicle's service manual and follow manufacturer-specific procedures. If you are not experienced with brake system repairs, seek professional assistance.

Figure 1: Hyundai iX20 compatible with OP Rear Brake Pads.

1. Prepare the Vehicle: Park the vehicle on a level surface, engage the parking brake, and block the wheels. Loosen the lug nuts on the rear wheels.
2. Lift and Secure: Safely lift the rear of the vehicle using a jack and secure it with jack stands. Remove the rear wheels.
3. Access Caliper: Locate the brake caliper. Depending on your vehicle, you may need to remove retaining clips or bolts to access the caliper.
4. Remove Old Pads: Carefully remove the caliper mounting bolts and swing the caliper out of the way (do not let it hang by the brake hose). Remove the old brake pads from the caliper bracket.
5. Inspect Components: Inspect the brake rotors for wear, scoring, or damage. Check the caliper for leaks or damage. Clean the caliper bracket and apply brake grease to contact points as necessary.
6. Install New Pads: Install the new OP brake pads into the caliper bracket. Ensure they are seated correctly.
7. Compress Piston: Use a brake caliper piston compression tool to push the caliper piston back into its bore. This creates space for the thicker new pads.
8. Reassemble: Reinstall the brake caliper, ensuring all bolts are tightened to the manufacturer's specified torque. Reattach any retaining clips.
9. Repeat for Other Side: Repeat the process for the other rear wheel.
10. Final Steps: Reinstall the wheels and tighten lug nuts. Lower the vehicle. Before driving, pump the brake pedal several times until it feels firm. Check the brake fluid level and top up if necessary.

OEM Compatibility Codes: For verification, this brake pad kit is compatible with vehicles requiring the following OEM part numbers: 58302BVA30, 58302D7A00, 58302J9A50, 58302J9A70, 58302M0A00, 58302M0A01, 58302M0A10, 58302M0A11, 583021GA00, 583021HA10, 583021JA30, 583021JA31, 583021KA30, 583021MA00, 583021MA40, 583022SA00, 583022SA30, 583022SA35, 583022SA70, 583022YA30, 583022YA31, 583022YA50, 583022YA.

5. Operating Instructions (Brake Pad Bedding-In)

After installing new brake pads, a proper "bedding-in" procedure is essential to optimize performance and longevity. This process transfers a thin, even layer of friction material from the pads to the rotors, ensuring maximum braking efficiency and reducing noise.

1. Initial Driving: Drive the vehicle at a moderate speed (e.g., 30-40 mph or 50-65 km/h) for a few minutes, avoiding hard braking.
2. Moderate Stops: Perform approximately 5-7 moderate stops from 30-40 mph (50-65 km/h) down to about 10 mph (15 km/h). Allow a short cool-down period between stops (e.g., 30 seconds of driving without braking).
3. Harder Stops: Perform 2-3 harder stops from 40-50 mph (65-80 km/h) down to about 10 mph (15 km/h). Again, allow a short cool-down period.
4. Final Cool-Down: Drive for several minutes without braking to allow the pads and rotors to cool down completely.

During the bedding-in process, you may notice a slight burning smell or some smoke, which is normal. Avoid sudden, aggressive braking or prolonged heavy braking immediately after installation, as this can overheat the pads and rotors, leading to glazing and reduced performance.

6. Maintenance

Regular inspection and maintenance of your brake system are crucial for safety and performance. It is recommended to have your brake pads inspected at least once a year or every 10,000-12,000 miles (16,000-19,000 km), or as recommended by your vehicle manufacturer.

• Pad Wear: Monitor the thickness of the brake pads. Replace them when they reach their minimum recommended thickness (typically 2-3mm), or if the wear indicators become audible.
• Rotor Condition: Inspect brake rotors for excessive wear, deep grooves, cracks, or warping. Replace or resurface rotors as needed.
• Brake Fluid: Check brake fluid level regularly and ensure it is within the recommended range. Brake fluid should be flushed and replaced according to your vehicle manufacturer's schedule.
• Caliper Operation: Ensure brake calipers are moving freely and not sticking. Lubricate caliper pins as part of routine maintenance.

7. Troubleshooting

If you experience any issues with your braking system after installing new pads, consider the following common problems and potential solutions:

• Squealing/Grinding Noise:
  • Cause: Improper bedding-in, worn pads (wear indicator), foreign material, or improper installation (e.g., lack of anti-squeal shims/grease).
  • Solution: Re-perform bedding-in procedure. Inspect pads for wear. Clean and lubricate caliper components. Ensure shims are correctly installed.
• Reduced Braking Performance:
  • Cause: Air in the brake lines, glazed pads/rotors, contaminated pads, or improper bedding-in.
  • Solution: Bleed the brake system. Re-perform bedding-in. Inspect pads for contamination (oil/grease) and replace if necessary.
• Vibration/Pulsation During Braking:
  • Cause: Warped rotors, uneven pad wear, or loose wheel bearings.
  • Solution: Inspect rotors for warping and replace or resurface as needed. Check wheel bearings.
• Brake Pedal Feels Spongy:
  • Cause: Air in the brake lines, low brake fluid, or a faulty master cylinder.
  • Solution: Bleed the brake system. Check and top up brake fluid. Consult a professional if the issue persists.

If you are unable to resolve a braking issue, discontinue driving the vehicle and consult a qualified mechanic immediately.

8. Specifications

9. Warranty and Support

This OP Rear Brake Pad Kit is covered by a 12-month warranty from the date of purchase. This warranty covers manufacturing defects and material faults under normal use conditions.

For warranty claims or technical support, please contact your retailer or the manufacturer directly. Keep your proof of purchase for warranty validation.

Return Policy: Products may be eligible for return or replacement within 14 days of receipt, subject to the retailer's specific return policy.