FRONT BRAKE INSTALLATION

Tech Tips


  • Use the same procedure for the LH side and RH side.

  • The following procedure is for the LH side.


  1. INSTALL FRONT DISC


    1. A01JDC0E01
      Text in Illustration
      *1 Matchmark

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

      Note

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

  2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING


    1. A01J9I6

      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 }

  3. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT


    1. A01J9C8E01

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

      Tech Tips

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

    2. A01JB6C

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

  4. INSTALL FRONT NO. 2 DISC BRAKE CYLINDER SLIDE PIN


    1. w/ Front Disc Brake Cylinder Slide Bushing:


      1. A01JB3K

        Apply a light layer of lithium soap base glycol grease to the contact surface of the front No. 2 disc brake cylinder slide pin.

        Text in Illustration
        A01JB8Y Lithium Soap Base Glycol Grease

      2. Install a new front disc brake cylinder slide bushing to the front No. 2 disc brake cylinder slide pin.

    2. A01JB9VE01

      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.

    3. A01JDB5

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

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

  5. INSTALL FRONT NO. 1 DISC BRAKE CYLINDER SLIDE PIN


    1. A01JCH0E01

      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.

    2. A01J9ZW

      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.

  6. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE


    1. A01JAKTE01
      Text in Illustration
      *1 Front No. 1 Disc Brake Pad Support Plate
      *2 Front No. 2 Disc Brake Pad Support Plate

      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.

      Note

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

  7. INSTALL FRONT ANTI-SQUEAL SHIM


    1. A01JAMX

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

      Note

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

    2. A01J973E01

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

      Note


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

      • Apply disc brake grease to the area that contacts the anti-squeal shims.

    3. A01JA3JE01
      Text in Illustration
      *1 Front No. 1 Anti-squeal Shim
      *2 Front No. 2 Anti-squeal Shim

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

      Note


      • Install the shims in the correct positions and directions.

      • Disc brake grease can seep out slightly from the area where the anti-squeal shim is installed.

      • Make sure that disc brake grease is not applied onto the lining surface.

  8. INSTALL FRONT DISC BRAKE PAD


    1. A01J8KO

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

      Note

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

  9. INSTALL DISC BRAKE CYLINDER ASSEMBLY


    1. A01J8MYE01
      Text in Illustration
      *1 Hold
      *2 Turn

      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.

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

  10. CONNECT FRONT FLEXIBLE HOSE


    1. A01JBJZ

      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 }

      Tech Tips

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

  11. FILL RESERVOIR WITH BRAKE FLUID

  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


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

      Note

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected 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.

  13. BLEED BRAKE LINE


    1. Remove the center cowl top ventilator cover.


      1. A01J8MH

        Slide the hood to cowl top seal and disengage the claw.

      2. Disengage the 2 claws and 3 guides, and remove the center cowl top ventilator cover.

    2. Bleed brake line.


      1. A01J8Z1

        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 the "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. Install the center cowl top ventilator cover.


      1. A01J9HO

        Engage the 2 claws and 3 guides to install the center cowl top ventilator cover.

      2. Slide the hood to cowl top seal to engage the claw.

  14. INSTALL REAR NO. 3 FLOOR BOARD


    1. A01JC33

      Engage the 2 guides to install the rear No. 3 floor board.

  15. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  16. INSTALL REAR NO. 2 FLOOR BOARD


    1. A01JCWRE01

      Engage the 3 guides <A>.

    2. Engage the 2 guides <B> and install the rear No. 2 floor board as shown in the illustration.

  17. INSTALL FRONT WHEEL

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