Overhaul

DISASSEMBLY
1. Remove the front disc brake caliper assembly and lining from the vehicle.

2. Apply air pressure to the fluid port in the front disc brake caliper with Rubber-Tipped Air Gun 100-DO09 or equivalent to remove the caliper piston.

NOTE: Place a cloth over the caliper piston before applying air pressure to prevent damage to the caliper piston.

3. Inspect caliper pistons and replace if scoring, nicks, corrosion or signs of wear are present.
4. Remove the dust boot from the front disc brake caliper assembly and discard.
5. Remove the rubber piston seal from the caliper piston and discard.
6. Inspect caliper bores and seal grooves. Replace front disc brake caliper if either bore is badly scored or corroded around the seal groove area.
7. Remove bleeder cap and wheel cylinder bleeder screw.
8. Clean all parts with isopropyl alcohol.
9. Dry with filtered, unlubricated compressed air, blowing out all passages in front disc brake caliper and wheel cylinder bleeder screw.

ASSEMBLY
1. Install wheel cylinder bleeder screw and tighten to 15 Nm (11 ft. lbs.).
2. Apply a film of clean brake fluid to the new caliper piston seal and install it in the cylinder bore. Make sure seal does not become twisted but is firmly seated in the groove.
3. Install a new dust boot by setting the flange squarely in the outer groove of the caliper bore.
4. Coat caliper piston with brake fluid and install caliper piston in the cylinder bore. Use a wood block or other flat stock when installing caliper piston back into piston bore. Make sure caliper piston is not cocked. Spread the dust boot over the caliper piston as it is installed. Seat dust boot in piston groove.
5. Install the brake lining and front disc brake caliper over the front disc brake rotor.