Front Brake Pad, Brake Caliper & Brake Rotor: Installation

INSTALL FRONT DISC
1. Align the matchmarks of the disc and axle hub, and install the front disc.
  NOTE: When replacing the disc with a new one, select the installation position where the front disc has minimal runout.
  
  Fig 1: Identifying Matchmarks On Disc And Axle Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY
1. Install the front disc brake cylinder assembly with the 2 bolts
  Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf)
  
  Fig 2: Locating Front Disc Brake Cylinder Assembly With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DISC BRAKE ANTI-SQUEAL SHIM
1. Apply disc brake grease to the front disc brake anti-squeal shims and front disc brake pads as shown in the illustration
  NOTE: When applying the disc brake grease, use the grease enclosed with a front disc brake pad kit or supplied grease (Part No. 90998-94072) or equivalent.
2. Install the front disc brake anti-squeal shims to each brake pad
NOTE:
- Apply grease to the area that contacts the anti-squeal shims.
- When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
- Install the shims in the correct position and direction.
- The grease can seep out slightly from the area where the anti-squeal shim is installed.
- There should be no oil or grease on the friction surfaces of the pads and the disc.
Fig 3: Applying Disc Brake Grease
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DISC BRAKE PAD
NOTE: Be sure to inspect the front disc when replacing the brake pads with new ones (See INSPECTION ).
1. Install the front disc brake pads to the front disc brake cylinder assembly
  NOTE:
  - The front brake pad with a pad wear indicator must be installed to the outside position.
  - Match the arrow mark on the pad to the forward rotational direction.
  Fig 4: Identifying Pad Wear Indicator And Arrow Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the pad guide tie rod with the bolt.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
  
  Fig 5: Locating Pad Guide Tie Rod With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a pin punch (5 mm) and a hammer, install the pad guide pin (lower) to the front disc brake cylinder assembly
  NOTE:
  - Do not damage the disc brake cylinder surface.
  - Securely engage the ring of the pad guide pin to the front disc brake cylinder assembly.
  Fig 6: Installing Pad Guide Pin To Front Disc Brake Cylinder Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the anti-rattle spring to the front disc brake cylinder assembly.
  
  Fig 7: Identifying Anti-Rattle Spring To Front Disc Brake Cylinder Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Securely install the anti-rattle spring in the correct position and direction.
5. Holding the anti-rattle spring, insert the pad guide pin (upper) to the front disc brake cylinder assembly as shown in the illustration.
  
  Fig 8: Inserting Pad Guide Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a pin punch (5 mm) and a hammer, install the pad guide pin (upper) to the front disc brake cylinder assembly.
NOTE:
- Do not damage the disc brake cylinder surface.
- Securely engage the ring of the pad guide pin to the front disc brake cylinder assembly.
Fig 9: Removing/Installing Pad Guide Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FRONT FLEXIBLE HOSE
1. Connect the front flexible hose to the front disc brake cylinder assembly with the union bolt and a new gasket.
Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)

NOTE: Install the flexible hose lock securely in the lock hole in the disc brake cylinder assembly.
FILL RESERVOIR WITH BRAKE FLUID (See ON-VEHICLE INSPECTION )

Fig 10: Locating Union Bolt And Gasket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
BLEED BRAKE LINE (See ON-VEHICLE INSPECTION )
INSPECT FOR BRAKE FLUID LEAK
INSPECT FLUID LEVEL IN RESERVOIR (See ON-VEHICLE INSPECTION )
INSTALL FRONT WHEEL
Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)