Front
CALIPER AND BRAKE DISC SERVICE
REMOVAL
1. Remove the wheel and tire.
2. Disconnect the brake hose.
3. Remove the pads.
4. Remove the sleeve.
5. Remove the pin boot and sleeve boot.
6. Remove the caliper assembly.
INSPECTION
1. Check the caliper for wear, damage, cracks and rust.
2. Check the piston for rust, damage, cracks and wear on the outer surface.
3. Check the sleeve and pin for damage and rust.
4. Check the pad spring and boots for damage.
5. Check the carrier for damage, rust, wear and cracks.
NOTE
1) Do not use sand paper on the piston surface.
2) All rubber parts must be replaced with new ones.
6. Inspect the disc using a caliper and dial gauge.
Thickness of disc:
1.6, 1.8 DOHC:
Standard value: 22 mm (0.876 inch)
Service limit: 20 mm (0.787 inch)
Total runout of front axle assembly:
Service limit: 0.06 mm (0.0024 inch)
7. If necessary, replace the brake disc.
1) Remove the drive shaft nut.
2) Jack up the vehicle and support it with jack stands.
3) Remove the wheel and tire.
4) 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 caliper. Be careful not do depress brake pedal, or piston will pop-out.
5) Disconnect the lower arm ball joint from the knuckle using the Special Tool (09568-31000).
6) Remove the wheel speed sensor mounting bolt and wire clamp and then remove the wheel speed sensor. (For ABS vehicle only)
7) Disconnect the tie rod and ball joint form 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.
8) Disconnect the drive shaft from the hub using the special tool.
9) Remove the hub and knuckle as an assembly from the strut.
INSPECTION
1. Check the hub for cracks and the splines for wear.
2. Check the snap ring for cracking or damage .
3. Check the brake disc for scoring and damage.
4. Check the steering knuckle for cracks.
5. Check for a defective bearing.
BEARING REPLACEMENT
1. Remove the snap ring.
2. Install the special tools as illustrated.
3. Secure the knuckle in a vise.
4. Tighten the nut of the special tool and remove the front hub from the knuckle.
NOTE When removing wheel hub or wheel bearing from knuckle, replace wheel bearing assembly (outer race, inner races and grease seals) with a new one.
5. Remove the wheel bearing inner race (outside) from the front hub by using the special tool.
NOTE When removing the inner race (outside) from the hub, be careful not be the hub drop.
6. Install the inner race (outside) that was removed from the hub to the wheel bearing, and then use the special tool to remove the wheel bearing.
7. Fill the wheel bearing with multipurpose grease.
8. Apply a thin coating of multipurpose grease to the knuckle and bearing contact surfaces.
9. Press-in the bearing by using the special tool.
NOTE Do not press inner race of wheel bearing assembly.
10. Install snap ring into groove of knuckle.
11. Install the disc to the hub. and torque to specification.
Tightening Torque 50 - 60 Nm (36 - 43 ft. lbs.)
12. Use the special tool to mount the hub onto the knuckle.
13. Tighten the hub to the knuckle to 200 - 260 Nm (148 - 192 ft. lbs.) with the special tool.
14. Rotate the hub to seat the bearing.
15. Measure the hub bearing starting torque.
Hub bearing starting torque [Limit]: 1.3 Nm (11.5 inch lbs.) or less
16. If the starting torque is 0 Nm (0 inch lbs.), measure the hub bearing axial play.
17. If the hub axial play exceeds the limit while the nut is tightened to 200 - 260 Nm (148 - 192 ft. lbs.), the bearing, hub and knuckle have not been installed correctly. Repeat the disassembly and assembly procedure.
Hub bearing axial play [Limit]: 0.008 mm (0.0003 inch) or less
18. Remove the special tool.
INSTALLATION
1. Install parts to torque specifications.
2. Be sure to install the washer and wheel bearing nut in the specified direction.
3. After installing the wheel, lower the vehicle to the ground and tighten the wheel bearing nut.
4. If the position of the split pin holes do not match, tighten the nut up to 260 Nm (188 ft. lbs.) maximum.
5. Install the split pin in the first matching holes and bend it over.