FRONT BRAKE INSTALLATION

CAUTION / NOTICE / HINT

Tip:

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

  • The following procedure is for the LH side.

PROCEDURE

  1. INSTALL FRONT DISC

    1. U122892E01

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

      Table 1. Text in Illustration

      *1

      Matchmark
      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. C199489

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

      107 N*m

      1089 kgf*cm

      79 ft.*lbf

  3. INSTALL FRONT DISC BRAKE BUSH DUST BOOT

    1. C199509E01

      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.

      Table 2. Text in Illustration

      *1

      Lithium soap base glycol grease
      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.

      Tip:

      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. C199510E01

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

      Table 3. Text in Illustration

      *1

      Lithium soap base glycol grease

    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. C199480E01

      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.

      Table 4. Text in Illustration

      *1

      Lithium soap base glycol grease
    2. C199486

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

  6. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE

    1. C199485

      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. C203993

      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. C204974

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

    2. C204975

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

      30 N*m

      306 kgf*cm

      22 ft.*lbf

    3. C204976

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

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

      30 N*m

      306 kgf*cm

      22 ft.*lbf

  9. CONNECT FRONT FLEXIBLE HOSE

    1. C153618

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

      29 N*m

      296 kgf*cm

      21 ft.*lbf

      Tip:

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

  10. REMOVE CENTER COWL TOP VENTILATOR LOUVER

    Click here

  11. BLEED BRAKE LINE

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

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

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  14. BLEED CLUTCH LINE (for 1WW)

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  15. INSTALL CENTER COWL TOP VENTILATOR LOUVER

    Click here

  16. INSTALL FRONT WHEEL

    103 N*m

    1050 kgf*cm

    76 ft.*lbf