Orlando

Front Brake Calliper Replacement

Special Tools

CH-558-10 Vacuum Cap

For equivalent regional tools, refer to Special Tools .

Warning: Refer to Brake Dust Warning in the Preface section.

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Warning: Use of eye goggles is necessary to prevent personal injury.

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.



4. Remove the brake fluid reservoir cap and install CH-558-10 vacuum cap (1) to prevent fluid loss and contamination.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
6. Remove the tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .



7. Remove the brake hose-to-calliper bolt (3) from the brake calliper.
8. Remove the brake hose (2) from the brake calliper.

Remove and discard the copper brake hose washers. These washers may be stuck to the brake calliper and/or the brake hose end.

9. Cap or plug the opening in the brake calliper and the brake hose to prevent fluid loss and contamination.
10. Remove the brake calliper guide pin bolts (1).
11. Remove the brake calliper from the calliper bracket.
12. Inspect the brake calliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

•	Restricted calliper guide pin movement

•	Looseness in the brake calliper mounting bracket

•	Seized or binding calliper guide pins

•	Split or torn boots

13. If any of the conditions listed are found, the brake calliper guide pins and/or boots require replacement.

1. Install the brake calliper to the brake calliper bracket.




Note: Do not reuse the brake hose washers.

2. Install NEW copper brake hose washers (1) to the brake hose-to-calliper bolt and to the brake hose.

Caution: Refer to Fastener Caution in the Preface section.




3. Install the brake calliper guide pin bolts (1) and tighten to 28 N·m (21 lb ft).
4. Remove the caps or plugs from the brake calliper opening and the brake hose.
5. Install the brake hose (2) to the calliper.
6. Install brake hose-to-calliper bolt (3) to the calliper and tighten to 40 N·m (30 lb ft).
7. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .
8. Install the tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .
9. Lower the vehicle.



10. Remove the CH-558-10 vacuum cap (1) and install brake fluid reservoir cap.
11. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
12. Slowly release the brake pedal.
13. Wait 15 seconds, then repeat steps 10 and 11 until a firm brake pedal is obtained. This will properly seat the brake calliper piston and brake pads.