Brake Caliper Replacement - Front

REMOVAL PROCEDURE





1. Raise and suitably support the vehicle.
2. Remove the tire and the wheel.
3. Remove two thirds of the fluid from the master cylinder reservoir.





4. Compress piston into caliper housing bore to provide clearance between linings and rotor.
^ Ensure one end of C-clamp rest on brake hose fitting bolt and the other end against the outer pad.
^ Tighten C-clamp slowly to press piston into caliper housing bore.





5. Remove the following components if the caliper is being serviced or replaced:
^ Remove the front brake hose bolt (3)
^ Remove the front brake hose (1)
^ Remove the front brake hose seals (2)

6. Discard bolt and seals.





7. Remove the guide pin bolts (discard bolts).
8. Remove the caliper from the caliper bracket. Suspend with mechanic's wire if necessary.

IMPORTANT: Do not attempt to pry or pull the brake pad wear sensor out of the brake pad. The brake pad wear sensor must be pushed out of the brake pad.





9. Remove the inner brake pad from the caliper bracket with the brake pad wear sensor.





10. Remove the inner and outer pads (1) from the caliper bracket (2).
11. Inspect the inner and outer pads for wear and maximum taper of 0.15 mm (0.006 inch). Replace with a new brake pad set if they are tapered beyond specification.

INSTALLATION PROCEDURE





1. Ensure the front brake caliper bracket mounting surfaces (1) are clean and lubricated.





2. Install the inner and outer pads (1) into caliper bracket (2), if removed.





3. Install the caliper (1).





4. Install the brake pad wear sensor to the inner brake pad.





5. Connect the brake pad wear sensor harness and retainers to the front suspension strut.
6. Connect the brake pad wear sensor electrical connector.

NOTICE: Refer to Fastener Notice in Service Precautions.

7. Install new guide pin bolts.
^ Tighten guide pin bolts to 30 Nm (22 lb ft).

8. Install the front brake hose if removed.
9. Install new seals if removed.
10. Install a new front brake hose bolt if removed.
^ Tighten the front brake hose bolt to 40 Nm (30 lb ft).

11. Bleed brake hydraulic system.
12. Install the tire and wheel.
13. Lower the vehicle.