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Home >> Suzuki >> 2004 >> Swift + >> Repair and Diagnosis >> External Pages >> Different car >> Section 41 (Disc Brake System) >> Repair Instructions >> Brake Caliper Overhaul - Front >> Assembly Procedure
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Assembly Procedure

WARNING: This page is about a different car, the 2005 Suzuki Swift +, 2005 Pontiac Wave, and 2005 Chevrolet Aveo. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Inspecting Pistons and Caliper
    GM1245712Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.
  1. Clean all parts in denatured alcohol or brake fluid. Dry the parts with unlubricated compressed air and blow out all passages in the housing and the bleeder valve.
  2. Inspect the piston and the caliper for scoring, nicks, and corrosion. Replace components if these elements are found.
    3. IMPORTANT: Do not use a hone or any other procedure to remove material from the piston or the caliper bore.
  3. Inspect the caliper bleeder valve.
    4. Fig 2: View of Piston Inner Seal
    GM1245713Courtesy of GENERAL MOTORS CORP.
  4. Lubricate a new piston inner seal.
  5. Install the piston inner seal into the caliper housing groove. Make sure the seal is not twisted.
  6. Install the outer piston dust seal in the groove.
  7. Lubricate the piston with brake fluid.
  8. Push the piston into its bore and make sure the dust seal is seated in the piston groove.
    9. Fig 3: View of Pins and Rubber Boots
    GM1245710Courtesy of GENERAL MOTORS CORP.
  9. Coat the pins with rubber grease and install the boots.
    10. Fig 4: Caliper Bleed Valve And Dust Cap
    GM1245716Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  10. Install the caliper bleeder valve and the dust cap.

    Tighten:  Tighten the caliper bleeder valve to 6 N.m (53 lb in).

    11. IMPORTANT: Make sure the pad springs are properly installed.
  11. Connect the brake pads and the pad springs.
    12. Fig 5: Installing Caliper Assembly
    GM1245718Courtesy of GENERAL MOTORS CORP.
  12. Connect the retaining frame to the caliper housing with the guide pin bolts.

    Tighten:  Tighten the retaining frame-to-caliper housing bolts to 27 N.m (20 lb ft).

  13. Install the caliper assembly. Refer to Brake Caliper Replacement .
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