Front Brake Caliper Disassembly and Reassembly: Reassembly: Caliper

WARNING: This page is about a different car, the 2010 Suzuki Kizashi. However, it is still accessible from the selected car via links, so may be relevant.

Perform the following procedures before installing brake piston to front brake caliper.
1. Check entire periphery of brake piston and inside face of cylinder for rust, corrosion and any other damage. If any fault is found, replace front brake caliper.
2. Apply rubber grease in piston seal set on new piston seal (1) and fit it into groove in caliper cylinder while taking care not to twist it.
  
  Fig 1: Identifying Piston Seal
  Courtesy of SUZUKI OF AMERICA CORP.
3. Apply rubber grease to new cylinder boot (1). And then place lip (2) of cylinder boot onto caliper cylinder (3) of front brake caliper as shown.
  NOTE: Use rubber grease of which viscosity varies very little even at -40°C (-40°F).
  
  Fig 2: Identifying Cylinder Boot And Caliper Cylinder
  Courtesy of SUZUKI OF AMERICA CORP.
4. Install cylinder boot using special tool.
  Special Tool
  1. 09913-75510
  Fig 3: Installing Cylinder Boot
  Courtesy of SUZUKI OF AMERICA CORP.
Expand cylinder boot and install piston (1) into it. Then insert brake piston (1) into caliper cylinder (2) by hand and fit cylinder boot (4) in boot groove (3) on brake piston.
CAUTION: Check that cylinder boot is fitted in boot groove securely all around piston.

Fig 4: Inserting Brake Piston Into Caliper Cylinder
Courtesy of SUZUKI OF AMERICA CORP.
Insert brake piston into caliper cylinder of front brake caliper.
Install bleeder plug to front brake caliper and tighten to specified torque.
Tightening torque

Bleeder plug: 8.0 N.m (0.82 kg-m, 6.0 lbf-ft)