Front Brake Pad, Brake Caliper & Brake Rotor: Reassembly

1. Align the matchmarks and install the front disc.

Fig 1: Identifying Matchmarks On Disc And Axle Hub

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1. Temporarily install the front disc with hub nuts.

   Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 

2. Using a dial indicator, 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.) 

   Fig 2: Measuring Disc Runout

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3. If the disc runout is greater than the maximum value, check the bearing play in the axial direction and check the axle hub runout (See ON-VEHICLE INSPECTION ). If the bearing looseness and axle hub runout are normal, adjust the disc to find the position where the disc has the minimum runout. When the disc is still unadjustable, grind it on an "On-car" brake lathe. In case the disc is too thin and ungrindable, try with a new disc.

1. Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder sub-assembly.

1. Install the bleeder plug cap to the front disc brake bleeder plug.

1. Apply lithium soap base glycol grease to a new piston seal.
2. Install the piston seal to the disc brake cylinder assembly.

1. Apply lithium soap base glycol grease to the piston and a new cylinder boot.
2. Install the cylinder boot to the piston.

Fig 3: Installing Cylinder Boot To Piston

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1. Install the cylinder boot to the disc brake cylinder assembly.

Fig 4: Installing Cylinder Boot To Disc Brake Cylinder Assembly

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1. Install the cylinder mounting with the 2 bolts.

Torque: 104 N*m (1,060 kgf*cm, 78 ft.*lbf) 

Fig 5: Installing Cylinder Mounting With Bolts

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1. Apply lithium soap base glycol grease to the seal surface of 2 new bushing dust boots.
2. Install the 2 bushing dust boots to the front disc brake cylinder mounting.

Fig 6: Installing Bushing Dust Boots To Front Disc Brake Cylinder Mounting

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1. Apply lithium soap base glycol grease to a new front disc brake cylinder slide bushing.
2. Install the front disc brake cylinder slide bushing to the front disc brake cylinder slide pin No.2.

Fig 7: Applying Lithium Soap Base Glycol Grease To Front Disc Brake Cylinder Slide Bushing

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1. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the slide pin No.2.
2. Install the front disc brake cylinder slide pin No.2 to the bottom side of the cylinder mounting.

1. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the slide pin No.1.
2. Install the front disc brake cylinder slide pin No.1.

Fig 8: Applying Lithium Soap Base Glycol Grease To Sliding Part

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1. Apply disc brake grease to the anti-squeal shims and install them to each pad.
   NOTE:

   • When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
   • Install the shims correctly in the proper positions and directions.
2. Install 2 anti-squeal shims and the pad wear indicator to the inner pad.

1. Install the 2 brake pads with anti-squeal shim to the disc brake cylinder mounting.

Fig 9: Applying Disc Brake Grease To Anti-Squeal Shims

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