FRONT BRAKE > INSTALLATION

for Preparation Click here

HINT:

1. Use the same procedure for the LH side and RH side.
   
2. The following procedure is for the LH side.
   

1. Align the matchmarks of the disc and axle hub, and install the disc.
   

   Text in Illustration 

   *a

   Matchmark

   NOTICE:

   When replacing the disc with a new one, select the installation position where the front disc has minimal runout.

1. Install the front disc brake cylinder mounting to the steering knuckle with the 2 bolts.
   

   Torque:

   137 N*m{ 1394 kgf*cm , 101 ft.*lbf }

1. Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bushing dust boots.
   

   Text in Illustration 

   Lithium Soap Base Glycol Grease

   HINT:

   Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to each front disc brake bushing dust boot.

2. Install the 2 front disc brake bushing dust boots to the front disc brake cylinder mounting.
   

1. Apply a light layer of lithium soap base glycol grease to the sliding part and the seal surface of the front No. 2 disc brake cylinder slide pin.
   

   Text in Illustration 

   Lithium Soap Base Glycol Grease

2. Install the front No. 2 disc brake cylinder slide pin to the front disc brake cylinder mounting.
   

3. Push the front No. 2 disc brake cylinder slide pin into the front disc brake bushing dust boot to align them.
   

1. Apply a light layer of lithium soap base glycol grease to the sliding part and the seal surface of the front No. 1 disc brake cylinder slide pin.
   

   Text in Illustration 

   Lithium Soap Base Glycol Grease

2. Install the front No. 1 disc brake cylinder slide pin to the front disc brake cylinder mounting.
   

3. Push the front No. 1 disc brake cylinder slide pin into the front disc brake bushing dust boot to align them.
   

1. Install the 2 front No. 1 disc brake pad support plates and 2 front No. 2 disc brake pad support plates to the front disc brake cylinder mounting.
   

   Text in Illustration 

   *1	Front No. 1 Disc Brake Pad Support Plate
   *2	Front No. 2 Disc Brake Pad Support Plate

   NOTICE:

   Be sure to install each front disc brake pad support plate in the correct position and direction.

1. Install the pad wear indicator plate to each front disc brake pad.
   

   NOTICE:

   Install each pad wear indicator plate in the correct position and direction.

2. Apply disc brake grease to both sides of each front No. 1 anti-squeal shim as shown in the illustration.
   

   Text in Illustration 

   *A	Inner
   *B	Outer
   	Disc Brake Grease

   NOTICE:

   1. When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
      

3. Install the front No. 1 anti-squeal shim and front No. 2 anti-squeal shim to each front disc brake pad.
   

   Text in Illustration 

   *1	Front No. 1 Anti-squeal Shim
   *2	Front No. 2 Anti-squeal Shim

   NOTICE:

   1. Install the shims in the correct positions and directions.
      
   2. Disc brake grease can seep out slightly from the area where the anti-squeal shim is installed.
      
   3. Make sure that disc brake grease is not applied onto the lining surface.
      

1. Install the 2 front disc brake pads to the front disc brake cylinder mounting.
   

   NOTICE:

   There should be no oil or grease on the friction surfaces of the disc brake pads or the front disc.

1. Hold the front disc brake cylinder slide pin, and install the disc brake cylinder assembly to the front disc brake cylinder mounting with the 2 bolts.
   

   Text in Illustration 

   *a	Hold
   *b	Turn

   Torque:

   34 N*m{ 347 kgf*cm , 25 ft.*lbf }

1. Connect the front flexible hose to the disc brake cylinder assembly with a new union bolt and a new gasket.
   

   Torque:

   33 N*m{ 340 kgf*cm , 25 ft.*lbf }

   NOTICE:

   Install the flexible hose lock securely into the lock hole in the disc brake cylinder.

1. Connect the cable to the negative (-) auxiliary battery terminal (Click here).
   

2. Perform the following procedure if air bleeding is not necessary:
   
   

   1. Connect the reservoir level switch connector.
      

   2. Clear the DTCs (Click here).
      

1. Disengage the 5 claws and 2 guides to remove the center cowl top ventilator louver.
   

2. Bleed brake line.
   
   

   
   
   

   1. Remove the brake master cylinder reservoir filler cap assembly.
      

   2. Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.
      

      Brake fluid:

      SAE J1703 or FMVSS No. 116 DOT3
      

   3. Connect the intelligent tester to the DLC3 and turn the power switch on (IG).
      

   4. Turn the intelligent tester on and enter the following menus: Chassis / ABS/VSC/TRC / Air Bleeding.
      

   5. Select "Usual air bleeding" on the intelligent tester display, and bleed air from the brake fluid following the instructions on the intelligent tester.
      

   6. After air bleeding, tighten each bleeder plug.
      

      Torque:

      front bleeder plug:

      8.3 N*m{ 85 kgf*cm , 73 in.*lbf }

      rear bleeder plug:

      11 N*m{ 112 kgf*cm , 8 ft.*lbf }

   7. Clear the DTCs (Click here).
      

   8. Turn the intelligent tester off and turn the power switch off.
      

3. Inspect for brake fluid leaks.
   

4. Install the brake master cylinder reservoir filler cap.
   

5. Engage the 5 claws and 2 guides to install the center cowl top ventilator louver.
   

Torque:

103 N*m{ 1050 kgf*cm , 76 ft.*lbf }