Caliper Overhaul Disassembly 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.

Clean all the parts in denatured alcohol or brake fluid. Dry the parts with unlubricated compressed air and blow out all the passages in the housing and the bleeder valve.
Inspect the piston and the caliper for scoring, nicks, and corrosion. Replace the components if these elements are found.
Inspect the caliper bleeder valve.
CAUTION: Do not remove material from the piston or the caliper bore.

Fig 1: Identifying Piston
Courtesy of SUZUKI OF AMERICA CORP.
Lubricate a new piston inner seal.
Install the piston inner seal into the caliper housing groove. Make sure the seal is not twisted.
Install the outer piston dust seal in the groove.
Lubricate the piston with brake fluid.
Push the piston inward until it is properly seated.
Coat the pins with rubber grease and install the boots.

Fig 2: Installing Piston Inner Seal Into Caliper Housing Groove
Courtesy of SUZUKI OF AMERICA CORP.
Install the caliper bleeder valve and the protector.
Tighten

Tighten the caliper bleeder valve to 8 N.m (71 lb-in).
Connect the brake pads and the pad springs.
CAUTION: Make sure the pad springs are properly installed.

Fig 3: Installing Caliper Bleeder Valve And Protector
Courtesy of SUZUKI OF AMERICA CORP.
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).
Install the caliper assembly. Refer to "CALIPER ASSEMBLY REMOVAL AND INSTALLATION :".

Fig 4: Connecting Retaining Frame To Caliper Housing With Guide Pin Bolts
Courtesy of SUZUKI OF AMERICA CORP.