Reassembly

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

REASSEMBLY

1. INSTALL FRONT DISC
(a) for Type B:
(1) Check the identification mark to determine the installation side.






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NOTICE:
Correctly install the front disc by checking the mark "R" or "L" engraved on the back of it.






(a) Aligning 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 a light layer of lithium soap base glycol grease to the entire circumference of a new piston seal.
(b) Install the piston seal to the front disc brake cylinder assembly.

4. INSTALL FRONT DISC BRAKE PISTON





(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of a new cylinder boot.
(b) Install the cylinder boot to the front disc brake piston.
(c) Apply a light layer of lithium soap base glycol grease to the contact surfaces of the front disc brake piston, and install it to the front disc brake cylinder assembly.

NOTE:
Do not install the piston forcibly into the front disc brake cylinder assembly.

5. INSTALL CYLINDER BOOT





(a) Install the cylinder boot to the front 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 a light layer of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bushing dust boots.

HINT:
Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to each front disc brake bushing dust boot.





(c) Using a socket wrench (21 mm) and a hammer, install the 2 bushing dust boots to the front disc brake cylinder mounting LH.

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 a light layer of lithium soap base glycol grease to the sliding part and the seal surface of the No. 2 front disc brake cylinder slide pin.
(b) Install the No. 2 front disc brake cylinder slide pin to the cylinder mounting LH.
NOTE:
Insert the No. 2 front disc brake cylinder slide pin into the cylinder mounting LH lower side.

9. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING





(a) Apply a light layer of lithium soap base glycol grease to the contact surface of the front disc brake cylinder slide pin.
(b) Install the front disc brake cylinder slide bushing to the front disc brake cylinder slide pin.
10. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN





(a) Apply a light layer of lithium soap base glycol grease to the sliding part and the seal surface of the front disc brake cylinder slide pin.
(b) Install the front disc brake cylinder slide pin to the cylinder mounting LH.
NOTE:
Insert the slide pin into the cylinder mounting LH upper side.

11. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) for Type A:






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(1) Install the 2 front No. 1 disc brake pad support plates and 2 front No. 2 disc brake pad support plates to the front disc brake cylinder mounting.

NOTICE:
Be sure to install each front disc brake pad support plate to the correct position and direction.

(b) for Type B:





Text in Illustration






(1) Install the front No. 1 disc brake pad support plate and front No. 2 disc brake pad support plate to the front disc brake cylinder mounting.

NOTICE:
Be sure to install each front disc brake pad support plate to the correct position and direction.


12. INSTALL ANTI-SQUEAL SHIMS AND PAD WEAR INDICATOR PLATES
(a) for Type A:
(1) Apply disc brake grease between the front No. 1 anti-squeal shim and front No. 2 anti-squeal shim.






Text in Illustration






NOTICE:
- When replacing worn pads, the front anti-squeal shims must be replaced together with the pads.
- Apply disc brake grease to the area that contacts the front anti-squeal shims.
- Make sure that disc brake grease is not applied onto the lining surface.

(2) Install the front No. 1 anti-squeal shim and front No. 2 anti-squeal shim to each front disc brake pad.

NOTICE:
Disc brake grease can come out slightly from the area where the front anti-squeal shims are installed.
- Install the front anti-squeal shims in the correct positions and directions.
- There should be no oil or grease on the friction surfaces of the pads and disc.

(b) for Type B:
(1) Apply disc brake grease to both sides of the front No. 1 anti-squeal shim.






Text in Illustration






NOTICE:
- When replacing worn pads, the front anti-squeal shims must be replaced together with the pads.
- Apply disc brake grease to the area that contacts the front anti-squeal shims.
- Make sure that disc brake grease is not applied onto the lining surface.

(2) Install the front No. 1 anti-squeal shim and front No. 2 anti-squeal shim to each front disc brake pad.

NOTICE:
- Disc brake grease can come out slightly from the area where the front anti-squeal shims are installed.
- Install the front anti-squeal shims in the correct positions and directions.
- There should be no oil or grease on the friction surfaces of the pads and disc.
- Install the front anti-squeal shim with attention to the direction of the grooves on the front disc brake pads.
- The front disc brake pads of the same part number are used for the inner and outer.
- The RH side pad is symmetrical to the LH side pad.
- Correctly install the front disc brake pads by checking the mark "R" or "L" engraved on the back of them.






(c) Install the pad wear indicator plate to each pad.

NOTICE:
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.