FRONT BRAKE INSTALLATION

Tech Tips


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

  • The following procedure is for the LH side.


  1. INSTALL FRONT DISC


    1. A01IP0CE01
      Text in Illustration
      *1 Matchmark

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

      Note

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

  2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING


    1. A01ITNE

      Install the 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 BUSH DUST BOOT


    1. A01IQ81E01
      Text in Illustration
      *1 Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bush dust boots where they contact the front disc brake cylinder mounting, and the entire inner circumference of both ends of the boots.

      Note

      Apply a sufficient amount of lithium soap base glycol grease to the entire circumference of the front disc brake bush dust boot and front disc brake cylinder mounting contact surfaces.

      Tech Tips

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

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

  4. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH


    1. A01IPNFE01
      Text in Illustration
      *1 Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the front disc brake cylinder slide pin as shown in the illustration.

    2. Install a new front disc brake cylinder slide bush to the front disc brake cylinder slide pin.

  5. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN


    1. A01ISKXE01
      Text in Illustration
      *1 Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the sliding part and the seal surface of the 2 front disc brake cylinder slide pins.

    2. A01INDR

      Install the 2 front disc brake cylinder slide pins to the disc brake cylinder mounting.

  6. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE


    1. A01IU5Y

      Install 2 new front disc brake pad support plates LH and 2 new front disc brake pad support plates RH 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 DISC BRAKE PAD


    1. A01IQ8C

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

      Note

      Make sure there is no oil or grease on the friction surfaces of the disc brake pads or the front disc.

  8. INSTALL DISC BRAKE CYLINDER ASSEMBLY


    1. A01IOWK

      Hold the front disc brake cylinder slide pins and install the disc brake cylinder assembly to the disc brake.

    2. A01IOXF

      Install a new lower bolt to the front disc brake cylinder.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    3. A01INZI

      Support the brake cylinder slide pin as shown in the illustration.

    4. Install a new upper bolt to the front disc brake cylinder.

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

  9. CONNECT FRONT FLEXIBLE HOSE


    1. A01ISXS

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

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Tech Tips

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

  10. REMOVE CENTER COWL TOP VENTILATOR LOUVER


    1. A01IN40E02

      Slide the hood to cowl top seal and detach the clip as shown in the illustration.

    2. A01IT64

      Detach the 5 claws and remove the center cowl top ventilator louver.

  11. BLEED BRAKE LINE


    1. Bleed brake line


      1. Remove the brake master cylinder reservoir filler cap assembly.

      2. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

        Brake fluid
        SAE J1704 or FMVSS No, 116 DOT 4

      3. Remove the bleeder plug cap.

      4. Connect a vinyl tube to the bleeder plug.

      5. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1

      6. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2

      7. Repeat *1 and *2 until all the air in the fluid is completely bled out.

      8. Tighten the bleeder plug completely.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      9. Install the bleeder plug cap.

      10. Repeat the above procedure for each wheel to bleed the brake line.

    2. Inspect fluid level Click here.

    3. Inspect for brake fluid leak.

  12. BLEED AIR FROM CLUTCH LINE (for 1ZR-FAE with Manual Transaxle)

    A01IUMXE01
    Text in Illustration
    *1 Bleeder Plug Cap
    *2 Bleeder Plug

    1. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

      Brake fluid
      SAE J1704 or FMVSS No, 116 DOT 4

    2. Remove the bleeder plug cap.

    3. Connect a vinyl tube to the bleeder plug.

    4. Depress the clutch pedal 5 times, and then loosen the bleeder plug while the pedal is depressed.

    5. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    6. Repeat both of the previous 2 steps 6 times.

    7. Tighten the bleeder plug.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    8. Depress the clutch pedal 10 times or more and confirm its operation.

      Note

      This must be performed before the engine is started.

    9. Install the bleeder plug cap.

    10. Check that all the air has been bled from the clutch line.

  13. BLEED AIR FROM CLUTCH LINE (for 2ZR-FAE with Manual Transaxle)

    A01IUMXE01
    Text in Illustration
    *1 Bleeder Plug Cap
    *2 Bleeder Plug

    1. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

      Brake fluid
      SAE J1704 or FMVSS No, 116 DOT 4

    2. Remove the bleeder plug cap.

    3. Connect a vinyl tube to the bleeder plug.

    4. Depress the clutch pedal 5 times, and then loosen the bleeder plug while the pedal is depressed.

    5. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    6. Repeat both of the previous 2 steps 6 times.

    7. Tighten the bleeder plug.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    8. Depress the clutch pedal 10 times or more and confirm its operation.

      Note

      This must be performed before the engine is started.

    9. Install the bleeder plug cap.

    10. Check that all the air has been bled from the clutch line.

  14. BLEED AIR FROM CLUTCH LINE (for 1AD-FTV with Manual Transaxle)

    A01IRE3E01
    Text in Illustration
    *1 Bleeder Plug Cap
    *2 Bleeder Plug

    1. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

      Brake fluid
      SAE J1704 or FMVSS No, 116 DOT 4

    2. Remove the bleeder plug cap.

    3. Connect a vinyl tube to the bleeder plug.

    4. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

    5. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    6. Repeat the previous 2 steps until all the air in the fluid is completely bled.

    7. Tighten the bleeder plug.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    8. Install the bleeder plug cap.

    9. Check that all the air has been bled from the clutch line.

  15. BLEED AIR FROM CLUTCH LINE (for 2AD-FHV with Manual Transaxle)

    A01IRE3E01
    Text in Illustration
    *1 Bleeder Plug Cap
    *2 Bleeder Plug

    1. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

      Brake fluid
      SAE J1704 or FMVSS No, 116 DOT 4

    2. Remove the bleeder plug cap.

    3. Connect a vinyl tube to the bleeder plug.

    4. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

    5. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    6. Repeat the previous 2 steps until all the air in the fluid is completely bled.

    7. Tighten the bleeder plug.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    8. Install the bleeder plug cap.

    9. Check that all the air has been bled from the clutch line.

  16. INSTALL CENTER COWL TOP VENTILATOR LOUVER


    1. A01IT64

      Attach the 5 claws to install the center cowl top ventilator louver.

    2. A01IUP1E01

      Push the clip to attach it, and then slide the hood to cowl top seal as shown in the illustration to attach the claw.

  17. INSTALL FRONT WHEEL

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