Reassembly

BRAKE: FRONT BRAKE: REASSEMBLY

REASSEMBLY

1. INSTALL FRONT DISC
(a) Align the matchmarks, install the front disc.
HINT: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout.

2. INSPECT DISC RUNOUT






(a) Temporarily install the front disc with hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft-lbf)
(b) Using a dial gauge, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the front disc.
Maximum disc runout:
0.05 mm (0.0020 in.)
(c) If the disc runout is greater than the maximum value, check the bearing play in the axial direction and check the axle hub runout Front Axle Hub. If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a "On-car" brake lathe.
3. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder sub-assembly.
4. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
(a) Install the bleeder plug cap to the front disc brake bleeder plug.
5. INSTALL PISTON SEAL
(a) Apply the lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder sub-assembly.
6. INSTALL FRONT DISC BRAKE PISTON






(a) Apply lithium soap base glycol grease to the front disc brake piston and a new cylinder boot.
(b) Install the cylinder boot to the front disc brake piston.
(c) Install the piston to the front disc brake cylinder sub-assembly.
NOTE: Do not install the piston forcibly in the disc brake cylinder.

7. INSTALL CYLINDER BOOT






(a) Install the cylinder boot to the front disc brake cylinder.

NOTICE:
- Install the boot securely to the grooves of the cylinder and piston.
- Do not damage the cylinder boot.

8. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH






(a) Install the front disc brake cylinder mounting LH with the 2 bolts.
Torque: 104 Nm (1,061 kgf-cm, 77 ft-lbf)
9. INSTALL FRONT DISC BRAKE BUSH DUST BOOT






(a) Apply lithium soap base glycol grease to the sealing surface of 2 new front disc brake bush dust boots.
(b) Install the 2 front disc brake bush dust boots to the front disc brake cylinder mounting LH.
10. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH






(a) Apply lithium soap base glycol grease to a new front disc brake cylinder slide bush.
(b) Install the front disc brake cylinder slide bush to the front disc brake cylinder slide pin No. 2.
11. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN






(a) Apply the lithium soap base glycol grease to the sliding part and the seal surface of the slide pin No. 2.
(b) Install the front disc brake cylinder slide pin No. 2 to the bottom side of the cylinder mounting LH.
(c) Apply the lithium soap base glycol grease to the sliding part and the seal surface of the slide pin.
(d) Install the front disc brake cylinder slide pin.
12. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the front disc brake pad support plate (No. 1) and the front disc brake pad support plate (No. 2) to the front disc brake cylinder mounting LH.
13. INSTALL ANTI SQUEAL SHIM KIT FRONT






(a) Apply disc brake grease to the anti squeal shims and install them to each pad.

NOTICE:
- When replacing worn pads, the anti squeal shims must be replaced together with the pads.
- Install the shims correctly of which positions and directions.

(b) Install the pad wear indicator to the inner pad.
NOTE: Install the pad wear indicator correctly of which positions and directions.

14. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Install the 2 brake pads with the anti squeal shims to the disc brake cylinder mounting LH.
NOTE: There should be no oil or grease on the friction surface of the pads and the disc.