Front

FRONT BRAKE

COMPONENTS:

REMOVAL
1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: If brake fluid leaks onto any painted surface of the vehicle, wash or otherwise remove it completely.

3. REMOVE DISC BRAKE CYLINDER ASSEMBLY
a. Remove the union bolt and gasket from the disc brake cylinder assembly, then disconnect the flexible hose.





b. Hold the front disc brake cylinder slide pin No. 1, slide pin No. 2 and remove the 2 bolts and disc brake cylinder assembly.

DISASSEMBLY
1. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Remove the 2 brake pads from the front disc brake cylinder mounting.
2. REMOVE ANTI SQUEAL SHIM KIT FRONT
a. Remove the 2 anti-squeal shims and the pad wear indicator plate from each pad.
3. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE NO. 1
4. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE NO. 2





5. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN NO. 1
a. Remove the cylinder slide pin No. 1 from the front disc brake cylinder mounting.
6. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN NO. 2
a. Remove the cylinder slide pin No. 2 from the front disc brake cylinder mounting.





7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSHING
a. Using a screwdriver, remove the cylinder slide bushing from the front disc brake cylinder slide pin No. 2.

NOTICE: Do not damage the front disc brake cylinder slide pin No. 2.

HINT: Tape the screwdriver tip before use.





8. REMOVE FRONT DISC BRAKE BUSHING DUST BOOT
a. Remove the 2 bushing dust boots from the front disc brake cylinder mounting.





9. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING
a. Remove the 2 bolts and the front disc brake cylinder mounting.





10. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the cylinder boot.

HINT: Tape the screwdriver tip before use.

11. REMOVE FRONT DISC BRAKE PISTON
a. Place a shop rag or a piece of cloth between the piston and the disc brake cylinder assembly.





b. Use compressed air to remove the piston from the disc brake cylinder assembly.

CAUTION: Do not place your fingers in front of the piston when using compressed air.

NOTICE: Do not spatter the brake fluid.





12. REMOVE PISTON SEAL
a. Using a screwdriver, remove the piston seal from the disc brake cylinder assembly.

NOTICE: Do not damage the inner cylinder or cylinder groove.

HINT: Tape the screwdriver tip before use.

13. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
14. REMOVE FRONT DISC BRAKE BLEEDER PLUG





15. REMOVE FRONT DISC

HINT: Put matchmarks on the disc and the axle hub.

REASSEMBLY





1. INSTALL FRONT DISC
a. Align the matchmarks and install the front disc.

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

2. INSPECT DISC RUNOUT
a. Temporarily install the front disc with hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)





b. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the front disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
c. If the disc runout is greater than the maximum value, check the bearing play in the axial direction and check the axle hub runout. If the bearing looseness and axle hub runout are normal, adjust the disc to find the position where the disc has the minimum runout. When the disc is still unadjustable, grind it on an on-car brake lathe. In case the disc is too thin and ungrindable, try with a new disc.
3. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
a. Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder sub-assembly.
4. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
a. Install the bleeder plug cap to the front disc brake bleeder plug.
5. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the disc brake cylinder assembly.
6. INSTALL FRONT DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the piston and a new cylinder boot.





b. Install the cylinder boot to the piston.

NOTICE: Do not install the piston forcibly in the cylinder assembly.





7. INSTALL CYLINDER BOOT
a. Install the cylinder boot to the disc brake cylinder assembly.

NOTICE: Install the boot securely to the grooves of the cylinder and piston.





8. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
a. Install the cylinder mounting with the 2 bolts.
Torque: 104 Nm (1,060 kgf-cm, 78 ft. lbs.)





9. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT
a. Apply lithium soap base glycol grease to the seal surface of 2 new bushing dust boots.
b. Install the 2 bushing dust boots to the front disc brake cylinder mounting.





10. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING
a. Apply lithium soap base glycol grease to a new front disc brake cylinder slide bushing.
b. Install the front disc brake cylinder slide bushing to the front disc brake cylinder slide pin No. 2.
11. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN NO. 2
a. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the slide pin No. 2.





b. Install the front disc brake cylinder slide pin No. 2 to the bottom side of the cylinder mounting.
12. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN NO. 1
a. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the slide pin No. 1.
b. Install the front disc brake cylinder slide pin No. 1.
13. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE NO. 2
14. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE NO. 1
15. INSTALL ANTI SQUEAL SHIM KIT FRONT
a. Apply disc brake grease to the anti-squeal shims and install them to each pad.

NOTICE:
^ When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
^ Install the shims correctly in the proper positions and directions.





b. Install 2 anti-squeal shims and the pad wear indicator to the inner pad.

NOTICE: Install the pad wear indicator correctly in the proper positions and directions.

16. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Install the 2 brake pads with anti-squeal shim to the disc brake cylinder mounting.

INSTALLATION





1. INSTALL DISC BRAKE CYLINDER ASSEMBLY
a. Install the disc brake cylinder assembly with the 2 bolts.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
b. Connect the flexible hose with the union bolt and a new gasket.
Torque: 29 Nm (300 kgf-cm, 21 ft. lbs.)
2. ADD RESERVOIR WITH BRAKE FLUID
3. DISABLE BRAKE CONTROL (ECB)
4. BLEED FRONT BRAKE SYSTEM
5. CANCEL BRAKE CONTROL (ECB) DISABLE
6. CLEAR DTC
7. PERFORM ACCUMULATOR ZERO DOWN
8. CHECK BRAKE FLUID LEVEL
9. CHECK BRAKE FLUID LEAKAGE
10. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
11. CLEAR DTC