FRONT BRAKE (for 16 inch Front Brake) INSTALLATION

Tech Tips

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

INSTALL FRONT DISC
1. 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.
INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
1. 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 }
INSTALL FRONT DISC BRAKE BUSHING DUST BOOT
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
  
  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. Install the 2 front disc brake bushing dust boots to the front disc brake cylinder mounting.
INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING
1. 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
  
  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.
INSTALL FRONT NO. 1 DISC BRAKE CYLINDER SLIDE PIN
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.
INSTALL FRONT NO. 2 DISC BRAKE CYLINDER SLIDE PIN
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.
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.
INSTALL PAD WEAR INDICATOR PLATE
1. Install the pad wear indicator plate to each front disc brake pad.

Text in Illustration
*a	Matchmark

Text in Illustration
	Lithium Soap Base Glycol Grease

Text in Illustration
	Lithium Soap Base Glycol Grease

Text in Illustration
	Lithium Soap Base Glycol Grease

Text in Illustration
	Lithium Soap Base Glycol Grease

INSTALL FRONT ANTI-SQUEAL SHIM

Text in Illustration
*1	Front Anti-squeal Shim
*2	Front Disc Brake Pad

Install the anti-squeal shims to each brake pad.

INSTALL FRONT DISC BRAKE PAD
1. 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.
INSTALL DISC BRAKE CYLINDER ASSEMBLY
1. Text in Illustration
  
  *a Hold
  
  *b 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 { 350 kgf*cm, 25 ft.*lbf }
CONNECT FRONT FLEXIBLE HOSE
1. 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.
FILL RESERVOIR WITH BRAKE FLUID
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.
INSTALL BATTERY BOX COVER
1. Engage the 3 guides to install the battery box cover.
INSTALL REAR DECK FLOOR BOX
1. Install the rear deck floor box.
INSTALL REAR FLOOR MAT
1. Install the rear floor mat.

Text in Illustration
*a	Hold
*b	Turn

BLEED BRAKE LINE

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

Bleed brake line.

Remove the brake master cylinder reservoir filler cap assembly.

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

Connect the intelligent tester to the DLC3 and turn the power switch on (IG).
Turn the intelligent tester on and enter the following menus: Chassis / ABS/VSC/TRC / Air Bleeding.
Select "Usual air bleeding" on the intelligent tester display, and bleed air from the brake fluid following the instructions on the intelligent tester.
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 }
Clear the DTCs Click here.
Turn the intelligent tester off and turn the power switch off.

Inspect for brake fluid leaks.
Install the brake master cylinder reservoir filler cap.
Engage the 5 claws and 3 guides to install the center cowl top ventilator louver.

INSTALL FRONT WHEEL

Torque:

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