FRONT BRAKE (for 4WD) > INSTALLATION

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HINT:
  1. Use the same procedures for the LH side and RH side.
  2. The procedures listed below are for the LH side.



1. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH


C111377

  1. Install the cylinder with the 2 bolts.

    Torque:
    122 N*m{ 1,244 kgf*cm , 90 ft.*lbf }



2. CONNECT FRONT NO. 1 WHEEL CYLINDER TUBE LH


C111376

  1. Using SST, connect the tube to the cylinder.

    SST
    09023-00101  

    Torque:
    15.2 N*m{ 155 kgf*cm , 11 ft.*lbf } without SST
    14 N*m{ 143 kgf*cm , 10 ft.*lbf }

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).



3. INSTALL FRONT ANTI SQUEAL SHIM KIT


C111387E01

  1. Apply disc brake grease to both sides of each No. 1 shim.

  1. Install the No. 1 and No. 2 shims to each pad.

    NOTICE:
    1. When replacing worn pads, the shims must be replaced together with the pads.
    2. Install the shims in the correct position and direction.



4. INSTALL FRONT DISC BRAKE PAD

  1. Install the 2 disc brake pads to the cylinder.

    NOTICE:
    There should be no oil or grease on the friction surface of the pads and disc.



5. INSTALL FRONT DISC BRAKE ANTI-RATTLE SPRING


C111375E01

  1. Install the spring.

  1. Hold down the spring and insert the 2 pins.

  1. Install the clip.



6. FILL RESERVOIR WITH BRAKE FLUID


Fluid:
SAE J1703 or FMVSS No. 116 DOT3



C111283E01



7. BLEED AIR FROM MASTER CYLINDER

HINT:
If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.

  1. Using SST, disconnect the 2 brake lines from the master cylinder.

    SST
    09023-00101  



  1. Slowly depress and hold the brake pedal.


    C111284E01

  1. Cover the outer holes with your finger, and release the pedal.

  1. Repeat the 2 previous steps 3 or 4 times.



  1. Using SST, connect the 2 brake lines to the master cylinder.

    SST
    09023-00101  

    Torque:
    15.2 N*m{ 155 kgf*cm , 11 ft.*lbf } without SST
    14 N*m{ 143 kgf*cm , 10 ft.*lbf } with SST


    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

    C111285E01



8. BLEED AIR FROM BRAKE LINE

  1. Remove the bleeder plug cap.

  1. Connect the vinyl tube to the bleeder plugs.

  1. Depress the pedal several times, and then loosen the bleeder plug with the pedal depressed.

  1. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

  1. Repeat the 2 previous steps until all the air in the brake fluid is gone.

  1. Tighten the bleeder plug.

    Torque:
    10.8 N*m{ 110 kgf*cm , 8 ft.*lbf } for front brake
    11 N*m{ 112 kgf*cm , 8 ft.*lbf } for rear brake (2WD)
    10 N*m{ 102 kgf*cm , 7 ft.*lbf } for rear brake (4WD)

  1. Install the cap.



  1. Bleed air from the brake line for each wheel by repeating the above procedures.


    C111286E01



9. BLEED AIR FROM CLUTCH LINE (M/T)


C112661E01

  1. Remove the bleeder plug cap.

  1. Connect the vinyl tube to the bleeder plug.

  1. Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

  1. At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

  1. Repeat the previous 2 steps until all the air in the fluid is completely bled out.

  1. Tighten the bleeder plug.

    Torque:
    11 N*m{ 112 kgf*cm , 8 ft.*lbf }

  1. Install the bleeder plug cap.

  1. Check that all the air has been bled out of the clutch line.



10. CHECK BRAKE FLUID LEVEL IN RESERVOIR


    F052092

  1. Check the fluid level and add fluid if necessary.

    Fluid:
    SAE J1703 or FMVSS No. 116 DOT3

    HINT:
    Add fluid to a level between the reservoir's MIN and MAX lines.



11. CHECK FOR BRAKE FLUID LEAKAGE


12. INSTALL FRONT WHEEL

Torque:
105 N*m{ 1,071 kgf*cm , 77 ft.*lbf }