Brake pad removal
1. |
Remove the 2 guide pin bolt, remove the
caliper assembly from the knuckle and secure it with a wire or some
other retaining method. |
2. |
Remove the pads.
Do not depress the brake pedal while
disassembling the pads.

| |
Brake pad inspection
1. |
Check the pads for wear or oil contamination
and replace, if necessary.
•
|
The pads for the right and left
wheels should be replaced at the same time. Never "drop"
or intermix brake pad
sets. |
•
|
All four pads must be replaced as
a complete set. |
•
|
When replacing the brake pad,
check for deformation. When replacing the guide spring,
use a new one or the used one after cleaning away
foreignmaterial. | | |
2. |
Check the pad for damage or
deformation.
Brake pad
thickness:
Standard value: 11mm (0.43
in.)
Service limited value: 2mm (0.079
in)
|

|
Brake pad installation
1. |
Install the pad
clips. |
2. |
Install the pads onto each pad
clip.
Position the pad with its pad wear
indicator upward on the piston side.

| |
3. |
Insert the piston in the cylinder using the
Special Tool (09581-11000).

|
4. |
Install the new pads. The shims are attached
to the each pad as illustrated.
Be careful so that the disc or pad isn't
contaminated by grease.

| |
5. |
Install the bolt and tighten to the specified
value.
Tightening
torque
Guide rod bolt: 22~32 Nm (220~320
kgf•cm, 16~24 lbf•ft)
|

|
1. |
Remove the wheel and
tire. |
2. |
Disconnect the brake
hose. |
3. |
Remove the cylinder mounting
bolt. |
4. |
Remove cylinder and
pads. |
5. |
Remove the caliper mounting bolts (2EA) from
the knuckle. |
6. |
Remove the caliper.

|
1. |
Install the pads and brake
cylinder. |
2. |
Install the brake hose to the
caliper.
Bleeder screw
tightening torque:
7~13 Nm (70~130 kgf•cm, 5.2~9.6
lbf•ft)
| |
3. |
Fill the brake reservoir with brake
fluid. |
1. |
Remove the piston
boot. |
2. |
Remove the piston using compressed
air.
1. |
Do not put your fingers in front
of the piston when using compressed
air. |
2. |
Be careful not to splatter the
brake fluid.

| | |
3. |
Remove the piston seal from the caliper by
using a screwdriver.

|
1. |
Check the caliper for wear, damage, cracks and
dust. |
2. |
Check the piston for dust, damage, cracks and
wear on the outer surface. |
3. |
Check the sleeve and pin for damage and
dust. |
4. |
Check the pad spring and boots for
damage. |
5. |
Check the carrier for damage, dust, wear and
cracks.
1. |
Do not use sand paper on the
piston surface. |
2. |
All rubber parts must be replaced
with new
parts. | | |
6. |
Inspect the disc by using a calipers and a
dial gauge.
Thickness of
disc mm (in.)
Standard value : 26 (1.024)
Service limit : 24.4
(0.961)
Runout of the disc mm (in.) : 0.08
(0.003)
Difference of thickness : 0.01mm (0.0004
in.)
|

1. |
Using a micrometer, measure the
disc thickness at eight positions approximately 10mm
from the outer edge of the disc and at 45°
intervals.
If you substract the minimum of
measurements from the maximum, you get the difference of
the disc thickness. |
2. |
When measuring the disc runout,
fix a dial gauge approximately 5mm from the outer edge
of the disc, and rotate the disc 360°.
At this time, if you subtract the
minimum of measurements from the maximum, you get the
disc
runout. | | |
7. |
If necessary, replace the brake
disc. |
1. |
Clean all components except the pads and shims
with isopropyl alcohol. |
2. |
Apply rubber grease on the piston seal and
install the piston seal in the cylinder.

|
3. |
Assemble the piston and piston boots according
to the following procedure.
(1) |
Apply rubber grease to the caliper bore,
the outside surface of the piston and the piston
boot. |
(2) |
Install the piston boot on the piston as
illustrated. |
(3) |
Insert the piston boot in the inner
groove of the caliper and push the piston into the
caliper.

| |
4. |
Assemble the sliding parts according to the
following procedure.
(1) |
Apply rubber grease to the outside
surface of the sleeve and pin, pin and sleeve bore of the
caliper, pin boot and sleeve
boot. |
(2) |
Insert the boot into the groove of the
caliper.

| |
5. |
Install the pads.
Be careful so that the disc or pad is
contaminated by grease

| |
6. |
Tighten the brake hose connecting
bolt.
Tightening
torque
|
Nm (kgf•cm,
lbf•ft)
|
Sliding
pin
|
34~44
(350~450, 26~33)
|
Carrier
mounting bolt
|
64~74
(650~750, 48~54)
|
Brake
hose mounting oil bolt
|
25~29
(250~300, 18~22)
|
1. |
Check that the surface of the pin
and bolts is not damaged before
tightening. |
2. |
Bleed the system. Depress the
pedal several times and check for fluid leakage from all
connecting
parts. | | | |