Reassembly

BRAKE: FRONT BRAKE (for 4GR-FSE):

REASSEMBLY

1. INSTALL FRONT DISC
(a) Align the matchmarks, install the front disc.
HINT: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout.

2. TEMPORARILY TIGHTEN BLEEDER PLUG
(a) Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder assembly.
3. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder assembly.
4. INSTALL FRONT DISC BRAKE PISTON






(a) Apply lithium soap base glycol grease to the piston and a new cylinder boot.
(b) Install the cylinder boot to the piston.
(c) Install the piston to the disc brake cylinder assembly.
NOTE: Do not install the piston forcibly in the cylinder assembly.

5. INSTALL CYLINDER BOOT






(a) Install the cylinder boot to the disc brake cylinder assembly.
NOTE: Install the boot securely to the grooves of the cylinder and piston.

(b) Using a screwdriver, install a new set ring.
NOTICE:
- Install the set ring securely to the grooves of the cylinder boot.
- Do not damage the cylinder boot.
HINT: Tape the screwdriver tip before use.

6. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT






(a) Secure the cylinder mounting LH in a vise.
(b) Apply lithium soap base glycol grease to the seal surface of 2 new bushing dust boots.
(c) Using a socket wrench (21 mm) and a hammer, install the 2 bushing dust boots.
7. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
(a) Install 2 new caliper plates No. 1 to the cylinder mounting LH.
(b) Install the cylinder mounting LH with the 2 bolts.
Torque: 78 Nm (799 kgf-cm, 58 ft-lbf)
8. INSTALL NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Apply lithium soap base glycol grease to the sliding part and the seal surface of the cylinder slide pin No. 2.
(b) Install the cylinder slide pin No. 2 to the cylinder mounting LH.
NOTE: Insert the slide pin No. 2 into the cylinder mounting LH lower side.

9. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Apply lithium soap base glycol grease to the sliding part and the seal surface of the cylinder slide pin.
(b) Install the cylinder slide pin to the cylinder mounting LH.
NOTE: Insert the slide pin into the cylinder mounting LH upper side.

10. INSTALL NO. 2 FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the 2 No. 2 front disc brake pad support plates.
11. INSTALL NO. 1 FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the 2 No. 1 front disc brake pad support plates.
12. INSTALL ANTI-SQUEAL SHIMS AND PAD WEAR INDICATOR PLATES
NOTE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads.





(a) Install the 2 No. 1 anti-squeal shims to each pad.
(b) Apply disc brake grease to the front anti-squeal shim.
NOTICE:
- Disc brake grease is applied between anti-squeal shim No.1 and No. 2.
- Disc brake grease can come out slightly from the area where the front anti-squeal shim is installed.
- Make sure that disc brake grease is not applied onto the lining surface.

(c) Install the 2 No. 2 anti-squeal shims to each pad.
(d) Install the 2 pad wear indicator plates to each pad.
NOTE: Install the pad wear indicator plates in the correct positions and directions.

13. INSTALL DISC BRAKE PADS WITH ANTI-SQUEAL SHIMS
(a) Install the 2 pads with pad wear indicator plates to the cylinder mounting.