For 1990-2009 cars

## Brake Caliper Replacement Front

### Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the tire and the wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
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 in). 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: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

7. Install new guide pin bolts.

Tighten
Tighten guide pin bolts to 30 N·m (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
Tighten the front brake hose bolt to 40 N·m (30 lb ft).

11. Bleed brake hydraulic system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
12. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and wheel.
13. Lower the vehicle.

## Brake Caliper Replacement Rear

### Removal Procedure

1. Remove one-third of the brake fluid from the master cylinder reservoir.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.

Important: Use only minimal effort to manipulate the pistons. Ensure to use slow gradual force as the cylinders are so small.

4. Use a screwdriver to gently pry between the rotor and each brake pad to bottom each piston in its bore.
5. Use a punch to drive the rear brake caliper retaining pins (1) out of the rear brake caliper from the outside inward.
6. Remove the rear brake caliper spring retainer (2).
7. Remove the brake pads.
8. Remove the rear brake caliper pipe (1).
9. Remove the rear brake caliper bolts (2).
10. Remove the rear brake caliper from the rotor.

### Installation Procedure

1. Install the caliper onto the rotor.
2. Install the rear brake caliper bolts (2).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Tighten
Tighten the rear brake caliper bolts (2) to 80 N·m (59 lb ft).

3. Install the rear brake caliper pipe (1) to the caliper.

Tighten
Tighten the brake pipe fitting to 16 N·m (12 lb ft).

4. Install the brake pads.
5. Perform the following steps to install the rear brake caliper retaining pins:

5.1. | Use a punch to drive the first pin (2) into the caliper. Ensure the pin (2) inserts through the holes in the brake pads.

5.2. | Install the rear brake caliper spring retainer (1).

5.3. | Install the second pin (2). Ensure the pin (2) inserts through the holes in the brake pads.

6. Bleed the brake hydraulic system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
8. Lower the vehicle.

Important: It is important that new braking surfaces be broken in or burnished after brake pads are installed and/or after rotors are refinished. Avoid overheating the brakes.

9. Make 20 stops from 48 km/h (30 mph) using medium to firm brake pedal pressure to burnish the brake rotors.