FRONT BRAKE (for 15 inch Front Brake) INSTALLATION


  1. INSTALL FRONT DISC


    1. A003RNBE06
      Text in Illustration
      *a 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 the minimum runout.

  2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING


    1. A003V0I

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

      Torque:
      107 N*m  { 1089 kgf*cm, 79 ft.*lbf }

  3. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT


    1. A003S0R

      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
      A003UB0 Lithium Soap Base Glycol Grease

      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. A003TYS

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

  4. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING


    1. A003TN1

      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
      A003UB0 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.

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


    1. A003UVS

      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
      A003UB0 Lithium Soap Base Glycol Grease
    2. A003SLS

      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 NO. 2 DISC BRAKE CYLINDER SLIDE PIN


    1. A003RIC

      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
      A003UB0 Lithium Soap Base Glycol Grease
    2. A003RKG

      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.

  7. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE


    1. Install the 4 front disc brake pad support plates to the disc brake cylinder mounting.

      Note

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

  8. INSTALL FRONT DISC BRAKE PAD


    1. A003U40

      Install the 2 front disc brake pads to the 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. A003TYM

      Install the disc brake cylinder assembly to the front disc brake cylinder mounting with the 2 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Install the upper bolt first and then the lower bolt.

  10. CONNECT FRONT FLEXIBLE HOSE


    1. A003RW2

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

      Torque:
      29 N*m  { 296 kgf*cm, 21 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. INSTALL BATTERY BOX COVER


    1. Engage the 3 guides to install the battery box cover.

  14. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  15. INSTALL REAR FLOOR MAT


    1. Install the rear floor mat.

  16. BLEED BRAKE LINE


    1. A003US5

      Disengage the 5 claws and 3 guides to remove the center cowl top ventilator louver.

    2. Bleed brake line.


      1. A003UQ7

        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
        SAE J1704 or FMVSS No. 116 DOT4

      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 (for 15 inch Front Brake)
        12 N*m  { 122 kgf*cm, 9 ft.*lbf }
        front bleeder plug (for 16 inch Front Brake)
        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. A003US5

      Engage the 5 claws and 3 guides to install the center cowl top ventilator louver.

  17. INSTALL FRONT WHEEL

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