Front Brake Pad, Brake Caliper & Brake Rotor: Reassembly

HINT:

Use the same procedures for the LH side and RH side.
The procedures listed below are for the LH side.

INSTALL FRONT DISC
1. Align matchmarks on the disc and the axle hub. Install the front disc.
  NOTE: When installing a new disc, select the position where the disc has the minimum runout.
INSPECT DISC RUNOUT
1. Check the looseness of the front wheel bearing and runout in the axle hub before inspecting the disc runout (see ON-VEHICLE INSPECTION ).
2. Hold the front disc with the 3 hub nuts.
  Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
3. Holding a dial indicator 10 mm (0.394 in.) away from the outer edge of the front disc, measure the disc runout.
  
  Fig 1: Measuring Disc Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum disc runout: 0.05 mm (0.0020 in.)
  
  NOTE: If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds even when the installation positions are changed or if disc thickness does not exceed the limit, shave the disc. If disc thickness exceeds the limit, replace the disc.
TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
INSTALL PISTON SEAL
1. Apply lithium soap base glycol grease around a new piston seal and install it into the brake cylinder groove securely.
INSTALL FRONT DISC BRAKE PISTON
1. Check the side of the front disc brake piston for any scratch.
  NOTE: Replace the front disc brake piston with a new one if there is any scratch on it.
2. Apply lithium soap base glycol grease to the inside of a new cylinder boot and install it to the front disc brake piston.
  NOTE: Install the cylinder boot securely into the front disc brake piston groove.
  
  Fig 2: Installing Front Disc Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply lithium soap base glycol grease around the front disc brake piston and install it to the front disc brake cylinder.
  NOTE:
  - Do not install the piston forcibly into the front disc brake cylinder.
  - Do not damage the piston tip during installation.
  - Do not push the piston directly using hard or sharp tools.
INSTALL CYLINDER BOOT
1. Install the cylinder boot to the disc brake cylinder groove.
  NOTE: Install the cylinder boot securely into the disc brake cylinder and piston groove.
2. Using a screwdriver, install a new front disc brake piston set ring to the front disc brake cylinder.
  NOTE: Do not damage the cylinder boot.
  
  Fig 3: Installing Cylinder Boot To Disc Brake Cylinder Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002