FRONT BRAKE PAD, BRAKE CALIPER & BRAKE ROTOR (for 3GR-FSE): Reassembly

INSTALL FRONT DISC
1. 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.
TEMPORARILY TIGHTEN BLEEDER PLUG CAP
INSTALL FRONT DISC BRAKE BLEEDER PLUG
INSTALL PISTON SEAL
1. Apply lithium soap base glycol grease to a new piston seal.
2. Install the piston seal to the disc brake cylinder assembly.
INSTALL FRONT DISC BRAKE PISTON
1. Apply lithium soap base glycol grease to the piston and a new cylinder boot.
2. Install the cylinder boot to the piston.
  
  Fig 1: Installing Cylinder Boot To Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the piston to the disc brake cylinder assembly.
  NOTE: Do not install the piston forcibly in the cylinder assembly.
INSTALL CYLINDER BOOT
1. Install the cylinder boot to the disc brake cylinder assembly.
  NOTE: Install the boot securely to the grooves of the cylinder and piston.
  
  Fig 2: Installing Boot Securely To Grooves Of Cylinder And Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install a new set ring.
  NOTE:
  - Install the set ring securely to the grooves of the cylinder boot.
  - Do not damage the cylinder boot.
  HINT:
  
  Tape the screwdriver tip before use.
INSTALL FRONT DISC BRAKE BUSH DUST BOOT
1. Secure the cylinder mounting LH in a vise.
2. Apply lithium soap base glycol grease to the seal surface of 2 new bush dust boots.
3. Using a socket wrench (21 mm) and a hammer, install the 2 bush dust boots.
  
  Fig 3: Installing Bush Dust Boots
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
1. Install 2 new caliper plate No.1 to the cylinder mounting LH.
2. Install the cylinder mounting LH with the 2 bolts.
  Torque: 78 N*m (799 kgf*cm, 58 ft.*lbf)
INSTALL FRONT DISC BRAKE CYLINDER NO.2 SLIDE PIN
1. Apply lithium soap base glycol grease to the sliding part and the seal surface of the cylinder slide pin No.2.
2. Install the cylinder slide pin No.2 to the cylinder mounting LH.
  NOTE: Insert the slide pin No.2 into the cylinder mounting LH lower side.
INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
1. Apply lithium soap base glycol grease to the sliding part and the seal surface of the cylinder slide pin.
2. Install the cylinder slide pin to the cylinder mounting LH.
  NOTE: Insert the slide pin into the cylinder mounting LH upper side.
INSTALL FRONT DISC BRAKE PAD SUPPORT NO.2 PLATE
INSTALL FRONT DISC BRAKE PAD SUPPORT NO.1 PLATE
INSTALL ANTI- SQUEAL SHIM KIT FRONT
1. Apply disc brake grease to the 2 ant-squeal shims No.1 and install them to each pad.
  NOTE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
2. Install the 2 anti-squeal shims No.2 to each pad.
  NOTE: Install them with attention to the direction of the grooves on the disc brake pads.
  
  HINT:
  - The parts of the same part number are used for the inner and outer pads.
  - The RH side pad is symmetrical to the LH side pad.
  - Correctly install the brake pads by checking the mark, "R" or "L", engraved on the back of the pads.
3. Install the 2 pad wear indicator plates to each pad.
  NOTE: Install the pad wear indicator plates in the correct positions and directions.
  
  Fig 4: Installing Pad Wear Indicator Plates
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DISC BRAKE PAD KIT
1. Install the 2 pads with pad wear indicator plates to the cylinder mounting LH.
  NOTE: Install them with attention to the direction of the grooves on the disc brake pads.