Installation

BRAKE (FRONT): FRONT BRAKE: INSTALLATION

INSTALLATION

1. INSTALL FRONT DISC





(a) Align the matchmarks of the disc and axle hub, and install the disc.
NOTE: When replacing the disc with a new one, select the installation position where the front disc has minimal runout.

2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING





(a) Install the disc brake cylinder mounting to the steering knuckle with the 2 bolts.
Torque: 107 Nm (1089 kgf-cm, 79 ft-lbf)
3. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT





(a) Apply lithium soap base glycol grease to 2 new front disc brake bushing dust boots.
(b) Install the 2 front disc brake bushing dust boots to the disc brake cylinder mounting.
4. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING





(a) Apply lithium soap base glycol grease to a new front disc brake cylinder slide bushing.
(b) Install the front disc brake cylinder slide bushing to the No. 2 front disc brake cylinder slide pin.
5. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN





(a) Apply lithium soap base glycol grease to the No. 1 front disc brake cylinder slide pin and No. 2 front disc brake cylinder slide pin.





(b) Install the No. 1 front disc brake cylinder slide pin and No. 2 front disc brake cylinder slide pin to the cylinder mounting.
6. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE





(a) Install the 2 No. 1 front disc brake pad support plates and 2 No. 2 front disc brake pad support plates to the front disc brake cylinder mounting.
NOTE: Be sure to install each front disc brake pad support plate in the correct position and direction.

7. INSTALL FRONT ANTI-SQUEAL SHIM (for 2ZR-FE)





(a) Apply disc brake shim grease to both sides of each No. 1 anti-squeal shim as shown in the illustration.
(b) Install the No. 1 anti-squeal shim and No. 2 anti-squeal shim to each brake pad.
NOTICE:
- When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
- Install the shims in the correct positions and directions.
- Apply disc brake grease to the area that contacts the anti-squeal shims.
- Disc brake grease can seep out slightly from the area where the anti-squeal shim is installed.
- Make sure that disc brake grease is not applied onto the lining surface.

8. INSTALL FRONT ANTI-SQUEAL SHIM (for 2AZ-FE)





(a) Apply disc brake grease to both sides of each No. 2 anti-squeal shim as shown in the illustration.
(b) Install the pad wear indicator, No. 1 anti-squeal shim and No. 2 anti-squeal shim to each brake pad.
NOTICE:
- When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
- Install the pad wear indicators and shims in the correct positions and directions.
- Apply disc brake grease to the area that contacts the anti-squeal shims.
- Disc brake grease can seep out slightly from the area where the anti-squeal shim is installed.
- Make sure that disc brake grease is not applied onto the lining surface.

9. INSTALL FRONT DISC BRAKE PAD





(a) Install the 2 front disc brake pads to the disc brake cylinder mounting.
NOTE: There should be no oil or grease on the friction surfaces of the disc brake pads or the front disc.

10. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY





(a) Hold the front disc brake cylinder slide pin, and install the front disc brake cylinder assembly to the front disc brake cylinder mounting with the 2 bolts.
Torque: 34 Nm (347 kgf-cm, 25 ft-lbf)
11. CONNECT FRONT FLEXIBLE HOSE





(a) Connect the front flexible hose to the front disc brake cylinder assembly with the union bolt and a new gasket.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
HINT: Install the flexible hose lock securely into the lock hole in the disc brake cylinder.

12. FILL RESERVOIR WITH BRAKE FLUID Service and Repair
13. BLEED BRAKE LINE Service and Repair
14. INSPECT FOR FLUID LEAK
15. INSPECT FLUID LEVEL Testing and Inspection
16. INSTALL FRONT WHEEL
Torque: 103 Nm (1050 kgf-cm, 76 ft-lbf)