Caliper Overhaul and Assembly: Assembly

WARNING: This page is about a different car, the 2005 Suzuki Reno and 2005 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Do not use a hone or any other procedure to remove material from the caliper bore or the piston.

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.
Inspect the piston and caliper for scoring, nicks, or corrosion. Replace any components which show these conditions.
Install the bleeder valve and the dust cap.
Lubricate a new piston inner seal with brake fluid.
Install the piston inner seal into the groove in the caliper bore.

Fig 1: Installing Piston Inner Seal Into Groove In Caliper Bore
Courtesy of SUZUKI OF AMERICA CORP.
Install the piston dust seal in its groove.
Lubricate the piston with brake fluid.
Push the piston inward until it is properly seated. Make sure that the dust seal is in the correct groove in the piston and the caliper.
Reinstall the caliper. Refer to "CALIPER REMOVAL AND INSTALLATION :".
Bleed the brake system. Refer to "MANUAL BLEEDING THE BRAKES :".

Fig 2: Installing Piston Dust Seal In Its Groove
Courtesy of SUZUKI OF AMERICA CORP.