Page 345 of 2490
I
nstallation
R
emove housing from carrier.
11
.
NOTE: The inner brake pad is fitt ed with a clip which secures
the pad into the caliper piston.
Remove and discard brake pa ds. (See Caution above).
12
.
Remove brake carrier from vertical link.
Re
move bolts.
R
emove carrier.
13. Remove brake dust and clean caliper mating surfaces. See
Warning above.
1. Install
caliper carrier to vertical link.
Al
ign carrier to vertical link .
Install and tigh
ten bolts to 140 Nm.
2. Install brake pads in to caliper housing. (See Caution above).
1. Remove plug from port and slowly retract piston into caliper housing.
Page 346 of 2490

2.
Remove paper backing from pads to reveal adhesive
shim. Install brake pads, insert clip located on back of
inner pad into caliper piston.
3. Inst al
l caliper housing to caliper carrier.
Align hou
s
ing to carrier.
1. Install and tighten guide pins to 25-30 Nm.
2. Install dust covers.
3. Install anti-rattle spring.
4. NOTE : Th
e brake hose must only be installed with the vehicle's
body supported and the suspension hanging.
Install and tighten brake hose to caliper housing to 10-14 Nm.
5. NO
TE: Make sure the brake
hose does not twist when
tightening the hose lock-nut.
Connect brake hose to brake tube.
1. Position hose thread through bracket.
2. Install and tighten locking nut. Refer to Specifications, section 206-03.
3. Install and tighten brake- tube union nut. Refer to
Specifications, section 206-03.
6. Remove special tool from brake pedal.
7. Fit wheels. Refer to section 204-04.
8. NOTE: Make sure the brake hose is routed correctly.
Remove stands and lower vehicl e. Refer to section 100-02.
9. Bleed brake hydraulic system. See operation 70.25.03.
Page 347 of 2490

Front Disc Brake - Brake CaliperVehicles With: High Performance Brakes
Re
moval and Installation
Remov
al
S
pecial Tool(s)
Brake Pedal
Hold Tool
JDS 9013
1. WARNING: BRAKE DUST, IF INHALED CAN DAMAGE
YOUR HEALTH. ALWAYS REMOVE BRAKE DUST USING A VACUUM
BRUSH. DO NOT USE A COMPRE SSED-AIR LINE TO DISPERSE
BRAKE DUST INTO THE ATMOSPHERE.
• CAUTIONS:
Replacement of nuts and bolts: Various thread-locking
devices are used on nuts and bolts throughout the vehicle. These
devices restrict the number of ti mes a nut or bolt can be used.
See section 100-00 for information.
Remove brake fluid spillage immediately from paint work,
with clean water.
The Brembo caliper is aligned to the brake disc when it is
first installed to the vehicle, therefore, care must be taken not to
disturb this alignment. When removing the caliper; remove the
bolts that secure the anchor bracket to the vertical link only. DO
NOT loosen any other caliper bolts.
Open engine compartment and fit paint work protection covers
to fenders.
2. R
aise vehicle on a four-post lift.
3. Raise front of vehicle and support on stands. Refer to Section
100-02.
4. Remove front wheels. Refe r to operation 74.20.05.
5. NOTE
: The following three pictorial procedures must be
carried-out to minimize brake fl uid loss when disconnecting the
brake hose.
Open Left-Hand-Front and Left-H and-Rear caliper bleed nipples.
Connect
a bleed tube and co
ntainer to the calipers.
O
pen bleed nipples.
6. Depress and hold down brak e pedal at the specified
measurement using the special tool.
Page 348 of 2490
1.
Position tool between
brake pedal and seat frame.
2. Turn the tool wheel unti l the brake pedal is held
60mm down from its released position.
7. Close bleed nipples on both calipers.
Tigh ten bleed n
ipples to 12-16 Nm.
Remove bleed tub
e
s and containers.
8. Disc
onnect brake hose from brake tube.
1. Unscrew brake tube union nut.
2. Remove nut from hose.
3. Remove hose from bracket.
Fit plugs to brake tu
be and hose.
9. Re
lease brake hose from caliper.
R
e
move union bolt.
Remove an
d discard se
aling washers.
Inst
al
l plugs into caliper and hose.
10. Remove brake pads from caliper.
1. Remove 'R' clips.
2. Withdraw pins from caliper.
3. Remove anti-rattle spring.
Page 349 of 2490
I
nstallation
4
. Remove brake pads.
11
.
CAUTION: Only remove the bolts securing the caliper
anchor bracket to the vertical link. Refer to caution above for
more information.
Remove caliper from vertical link.
Re
move bolts.
12
.
Remove brake dust and clean mating surfaces. See Warning
above.
1. Install
caliper to vertical link.
Install and tigh
ten bolts to 180 Nm.
2. CAUTI
ONS:
Retracting the caliper piston may cause the fluid reservoir
to over-flow. Remove brake flui d spillage immediately from paint
work, with clean water.
Note the condition of pins and 'R' clips and replace if
necessary.
Install brake pads into caliper.
Sl
owly retract caliper pistons.
1. Install pads.
Page 350 of 2490
2.
Po
sition anti-rattle spring.
3. Install pins.
4. Install 'R' clips.
3. CAUTIO
N: The brake hose must
only be installed with the
vehicle's body supported and the suspension hanging.
Install brake hose to caliper.
Remove plugs f rom caliper and hose.
Instal
l new sealing washers.
Install and tigh
ten un
ion bolt to 22-26 Nm.
4.
NO
TE: Make sure the brake
hose does not twist when
tightening the hose lock-nut.
Connect brake hose to brake tube. 1. Position hose thread through bracket.
2. Install and tighten locking nut. Refer to Specifications, section 206-03.
3. Install and tighten brake- tube union nut. Refer to
Specifications, section 206-03.
5. Remove special tool from brake pedal.
6. Fit wheels. Refer to operation 74.20.05.
7. NOTE: Make sure the brake hose is routed correctly.
Remove stands and lower vehicl e. Refer to section 100-02.
8. Bleed brake hydraulic system. See operation 70.25.06.
Page 351 of 2490

Front Dis
c Brake - Brake DiscVe
hicles With: Standard Brakes
Re
moval and Installation
Remov
al
• WAR
NINGS:
BRAKE DISCS MUST ALWAYS BE REPLACED IN PAIRS.
BRAKE DUST, IF INHALED CAN DAMAGE YOUR HEALTH. ALWAYS REMOVE BRAKE DUST USING A VACUUM BRUSH.
DO NOT USE A COMPRESSED-AIR LINE TO DI SPERSE BRAKE DUST INTO THE ATMOSPHERE.
CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the
vehicle. These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
1. O
pen engine compartment and in
stall paint work protection
covers to fenders.
2. Raise front of vehicle and suppo rt on stands. See Section 100-
02.
3. Remove front wheels. Re fer to Section 204-04.
4. CAUTI
ON: Remove brake flui
d spillage immediately from
paint work, with clean water.
Loosen brake fluid reservoir-cap.
Position a cloth around the
reservoir to collect any fluid
spillage.
5. CAU
TION: Tie caliper housing aside. Do not allow the
caliper housing to hang on the hydraulic hose, as this will damage
the hose.
Remove caliper housing from caliper carrier.
1. Remove anti-rattle spring.
2. Remove dust covers.
3. Remove guide pins.
Re
move and tie caliper housing aside.
6.
CAUTI
ON: Always install new brake pads, irrespective of
the condition of the original pads, when renewing brake discs.
• NOTE: The inner brake pad is fitted with a clip which secures
the pad into the caliper piston.
Remove brake pads from caliper housing.
Page 352 of 2490
In
stallation
Discard b
rake pads.
7. Re
move brake carrier from vertical link.
Re
mo
ve bolts.
R
e
move carrier.
8. With draw brake disc from
hub.
9. Repeat above procedure to remo ve opposite side brake disc.
10. Remove brake dust from calipers and clean mating surfaces,
see WARNING above.
11. Thoroughly clean the area of the hubs where they mate
against the br ake discs.
1. Install brake disc to hu
b.