| TIBURON(GK) >2005 > G 2.7 DOHC > Brake System > Brake System > Front Disc Brake>Repair procedures |

REPLACEMENT
Brake pad removal
1. | Remove the 2 guide pin bolt, remove the caliper assembly from the knuckle and secure it with a wire or some other retaining method.
2. | Remove the pads.
Do not depress the brake pedal while disassembling the pads.
Brake pad inspection
1. | Check the pads for wear or oil contamination and replace, if necessary.
• | The pads for the right and left wheels should be replaced at the same time. Never "drop" or intermix brake pad sets.
• | All four pads must be replaced as a complete set.
• | When replacing the brake pad, check for deformation. When replacing the guide spring, use a new one or the used one after cleaning away foreignmaterial.
2. | Check the pad for damage or deformation.
Brake pad thickness: Standard value: 11mm (0.43 in.) Service limited value: 2mm (0.079 in)
Brake pad installation
1. | Install the pad clips.
2. | Install the pads onto each pad clip.
Position the pad with its pad wear indicator upward on the piston side.
3. | Insert the piston in the cylinder using the Special Tool (09581-11000).
4. | Install the new pads. The shims are attached to the each pad as illustrated.
Be careful so that the disc or pad isn't contaminated by grease.
5. | Install the bolt and tighten to the specified value.
Tightening torque Guide rod bolt: 22~32 Nm (220~320 kgf•cm, 16~24 lbf•ft)
REMOVAL
1. | Remove the wheel and tire.
2. | Disconnect the brake hose.
3. | Remove the cylinder mounting bolt.
4. | Remove cylinder and pads.
5. | Remove the caliper mounting bolts (2EA) from the knuckle.
6. | Remove the caliper.
INSTALLATION
1. | Install the pads and brake cylinder.
2. | Install the brake hose to the caliper.
Bleeder screw tightening torque: 7~13 Nm (70~130 kgf•cm, 5.2~9.6 lbf•ft)
3. | Fill the brake reservoir with brake fluid.
4. | Bleed the system.
DISASSEMBLY
1. | Remove the piston boot.
2. | Remove the piston using compressed air.
1. | Do not put your fingers in front of the piston when using compressed air.
2. | Be careful not to splatter the brake fluid.
3. | Remove the piston seal from the caliper by using a screwdriver.
INSPECTION
1. | Check the caliper for wear, damage, cracks and dust.
2. | Check the piston for dust, damage, cracks and wear on the outer surface.
3. | Check the sleeve and pin for damage and dust.
4. | Check the pad spring and boots for damage.
5. | Check the carrier for damage, dust, wear and cracks.
1. | Do not use sand paper on the piston surface.
2. | All rubber parts must be replaced with new parts.
6. | Inspect the disc by using a calipers and a dial gauge.
Thickness of disc mm (in.) Standard value : 26 (1.024) Service limit : 24.4 (0.961) Runout of the disc mm (in.) : 0.08 (0.003) Difference of thickness : 0.01mm (0.0004 in.)
1. | Using a micrometer, measure the disc thickness at eight positions approximately 10mm from the outer edge of the disc and at 45° intervals. If you substract the minimum of measurements from the maximum, you get the difference of the disc thickness.
2. | When measuring the disc runout, fix a dial gauge approximately 5mm from the outer edge of the disc, and rotate the disc 360°. At this time, if you subtract the minimum of measurements from the maximum, you get the disc runout.
7. | If necessary, replace the brake disc.
REASSEMBLY
1. | Clean all components except the pads and shims with isopropyl alcohol.
2. | Apply rubber grease on the piston seal and install the piston seal in the cylinder.
3. | Assemble the piston and piston boots according to the following procedure.
(1) | Apply rubber grease to the caliper bore, the outside surface of the piston and the piston boot.
(2) | Install the piston boot on the piston as illustrated.
(3) | Insert the piston boot in the inner groove of the caliper and push the piston into the caliper.
4. | Assemble the sliding parts according to the following procedure.
(1) | Apply rubber grease to the outside surface of the sleeve and pin, pin and sleeve bore of the caliper, pin boot and sleeve boot.
(2) | Insert the boot into the groove of the caliper.
5. | Install the pads.
Be careful so that the disc or pad is contaminated by grease
6. | Tighten the brake hose connecting bolt.
Tightening torque | Nm (kgf•cm, lbf•ft)
Sliding pin | 34~44 (350~450, 26~33)
Carrier mounting bolt | 64~74 (650~750, 48~54)
Brake hose mounting oil bolt | 25~29 (250~300, 18~22)
1. | Check that the surface of the pin and bolts is not damaged before tightening.
2. | Bleed the system. Depress the pedal several times and check for fluid leakage from all connecting parts.