Front Brake Pad, Brake Caliper & Brake Rotor: Inspection

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT BRAKE CYLINDER AND PISTON
1. Check the cylinder bore and piston for rust and scoring.
  If necessary, replace the disc brake cylinder and piston.
INSPECT PAD LINING THICKNESS
1. Using a ruler, measure the pad lining thickness.
  Standard thickness: 12.0 mm (0.472 in.)
  
  Minimum thickness: 1.0 mm (0.039 in.)
  
  If the pad lining thickness is equal to or less than the minimum thickness, replace the disc brake pad kit.
  
  Fig 1: Measuring Pad Lining Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
1. Make sure that the disc brake pad supports have sufficient rebound, that there is no deformation, cracks or wear, and that all rust and dirt are removed.
  If necessary, replace the disc brake pad support plate.
INSPECT DISC THICKNESS
1. Using a micrometer, measure the disc thickness.
  Standard thickness:
  
  22.0 mm (0.866 in.)
  
  Minimum thickness:
  
  19.0 mm (0.748 in.)
  
  If the disc thickness is less than the minimum, replace the front disc.
  
  Fig 2: Measuring Disc Thickness Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DISC RUNOUT
1. Check the bearing play in the axial direction and check for the axle hub runout (See ON-VEHICLE INSPECTION ).
2. Provisionally fasten the front disc together with the hub nuts.
  Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
3. 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 3: Measuring Disc Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the runout exceeds the maximum value, change the installation positions of the disc and axle to make the minimum runout. If the runout exceeds the maximum even when the installation positions are changed, grind the disc. If the disc thickness is less than the minimum, replace the front disc.