Repair Procedure

How to use this Service Information .

NOTICE:

Review the Service Precautions before doing repairs or service .

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: Torque, N.m (lbf.ft)

: Replace

: Warning/Caution

: Inspection/Adjustment

*: Learning

: SPL Tool

: Required Removal

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: Torque, N.m (lbf.ft)

: Replace

: Warning/Caution

: Inspection/Adjustment

*: Learning

: SPL Tool

: Required Removal

A.-
Sub-Procedure

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Removal

NOTE: If the brake disc is stuck to the hub, thread two 8 x 1.25 mm bolts (a) into the brake disc to push it away from the hub. Turn each bolt 90 degrees at a time to prevent the brake disc from binding.

Installation

NOTE:
- Brake discs marked with "FNC" on the brake disc hat cannot be refinished and must be replaced if they are out of specifications.
- When replacing the brake disc, use a brake caliper piston compressor to push in the piston before installing the brake caliper.

B.-

Sub-Procedure

Removal

NOTE: Do not remove the brake pads unless you are replacing it. If the brake pads are removed, the adhesive tape cannot be reused and the brake pads must be replaced.

If the outer pad is removed, clean the outer pad adhesive surface of the caliper body.

Figure 1

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Installation

NOTE:

When installing new brake pads, peel the backing paper off the outer brake pad to expose the adhesive on the shim.
Do not touch the adhesive when installing the brake pad.
Keep dirt or other contaminants off the adhesive surface.
Before installing the brake pads, make sure there is no grease on the outer pad support area on the caliper body.

Press the brake caliper piston. (Figure 1)

Figure 2

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Lubricant Specifications (Figure 2)

Position	Type
a	Service Set Grease (KLUBERPASTE HM 96-402)

After Installation

Press the brake pedal several times to make sure the brakes work.
WARNING:

Engagement may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke.
Brake Fluid Level Adjustment.
Start the engine, and press the brake pedal for 10 seconds with 196 N (20 kgf, 44 lbf) of force to set the adhesive on the shim securely to the caliper.

C.-
After Installation
- Brake System Bleeding - Refer to: Conventional Brake System Bleeding (3.5L Engine) or Brake System Inspection and Test (3.5L Engine) or Brake System Inspection and Test (3.0L Engine) or Electric Servo Brake System Bleeding (3.0L Engine)
D.-
Sub-Procedure

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Installation
- Install the clip (a) by aligning the brake hose groove (b).
After Installation
- Brake System Bleeding - Refer to: Conventional Brake System Bleeding (3.5L Engine) or Brake System Inspection and Test (3.5L Engine) or Brake System Inspection and Test (3.0L Engine) or Electric Servo Brake System Bleeding (3.0L Engine)
- Brake Hose and Line Check - Refer to: Brake Hose and Line Inspection (3.0L Engine) or Brake Hose and Line Inspection (3.5L Engine)

E.-

Sub-Procedure

NOTICE:

Each tire pressure sensor contains a lithium anode battery that is not removable. The complete tire pressure sensor should be disposed of according to local battery disposal guidelines or requirements. Improper battery disposal can be harmful to the environment.

NOTE: The images and procedures for removing the tire from the wheel are for reference only. Remove the tire from the wheel according to the procedure listed by your tire changing machine manufacturer.

Figure 1

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Removal

1. Break the bead loose from the wheel.

Tool Details (Figure 1)

Name
a	Tire Changer(Commercially Available)

Installation Directions (Figure 1)

Position	Direction
b	Outside

NOTICE:

Note these items to avoid damaging the tire pressure sensor: (Figure 1)

Do the outside of the wheel first.
Do not position the bead breaker of the tire changer too close to the rim.
Position the wheel as shown.

Specifications

Standard Value
c	90 deg.

Figure 2

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2. Position the wheel so that the tire machine and the tire iron are next to the valve stem (d), and will move away from it when the machine starts. (Figure 2)

Tool Details (Figure 2)

Name
e	Tire Changer(Commercially Available)
f	Tire Iron

Figure 3

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3. Refer to the figure 3.NOTE: Check the tire pressure sensor housing for any cracks, deforms or damages and replace it if necessary.

Figure 4

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4. Cut around the valve bulb (g) to make the removal of the valve assembly easier. (Figure 4)

Tool Details (Figure 4)

Name
h	Diagonal Plier (Commercially Available)

Figure 5

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5. Pull out the valve assembly (i) vertically through the rim hole. (Figure 5)

Tool Details (Figure 5)

Name
k	Valve Stem Puller Tool (Commercially Available)

Figure 6

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Installation

1. Refer to the figure 6.NOTE:

Make sure the sensor housing is fully seated.
Install the TORX screw until the screw head is in contact with the sensor housing.

Figure 7

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2. Insert the tire pressure sensor in the rim hole.

Lubricant Specifications (Figure 7)

Position	Type
m	Mild Soap And Water Solution

Figure 8

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Figure 9

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3. Pull the tire pressure sensor straight through the rim hole perpendicularly to the rim hole.NOTE: Make sure the tire pressure sensor is installed within the angle.

Tool Details (Figure 8)

Name
n	Valve Stem Puller Tool (Commercially Available)

Specifications (Figure 8 and 9)

Specification / Standard Value
o	No Clearance
p	0 10 deg.

Figure 10

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4. Position the wheel so that the tire machine is next to the valve stem (q) and will move away from it when the machine starts. (Figure 10)

Lubricant Specifications (Figure 10)

Position	Type
r	Paste-Type Tire Mounting Lubricant

Tool Details (Figure 10)

Name
s	Tire Changer(Commercially Available)

5. With a dry air source, inflate the tire to seat the tire bead to the rim.

Specifications

Specification
300 kPa (43.5 psi)

NOTE:

Make sure the tire bead is seated on both sides of the rim evenly.

6. Adjust the air pressure to the specifications listed on the door jamb.

After Installation

Tire Pressure Sensor ID Memorization