Front Disc Brake Caliper Disassembly and Reassembly: Reassembly

WARNING: This page is about a different car, the 2011 Suzuki SX4. However, it is still accessible from the selected car via links, so may be relevant.

Assemble parts in reverse order of disassembly, observing the following instructions.

CAUTION: Failure to take proper precautions when assembling the brake caliper can result in brake system failure, which could lead to an accident.

Clean each part before installation using the same brake fluid as that in the master cylinder reservoir. Never use any other brake fluid or volatile solvent.
Before installing the piston seal and cylinder boot to the cylinder, apply rubber grease included in the piston seal set or brake fluid to them.
Fit a new piston seal, securely into the groove of the cylinder making sure that it is not twisted.

NOTE: If you do not bleed air from the brake system after replacement of a brake pipe or hose, brake system performance may be affected. Be sure to bleed the brake system referring to AIR BLEEDING OF BRAKE SYSTEM after replacement of a brake pipe or hose.

Before installing caliper to carrier, install slide pins with rubber grease included in slide pin/boot set applied into caliper carrier hole and check for its smooth movement in thrust direction.

Fig 1: Installing Slide Pins With Rubber Grease

Courtesy of SUZUKI OF AMERICA CORP.

Check all around piston for rust, corrosion and any other damage. If it is found faulty, replace piston or brake caliper.

Fig 2: Identifying Piston

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Install piston seal, boot and piston to caliper referring to the following instructions.

Replace with a new piston seal (1) at every overhaul. After applying rubber grease included in piston seal set or brake fluid, fit piston seal (1) into groove in cylinder taking care not to twist it.

Fig 3: Identifying Piston Seal
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Before inserting piston (1) into cylinder, apply rubber grease included in piston seal set or brake fluid to new boot (a) and install it onto piston as shown.

Fig 4: Installing Piston Seal Onto Piston
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Fit boot as it is in figure into boot groove in cylinder with fingers.

Fig 5: Fitting Boot Into Boot Groove In Cylinder
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Insert piston into cylinder by hand and fit boot in boot groove in piston.
NOTE: Check that boot is fitted in boot groove securely all around piston and cylinder.

Fig 6: Inserting Piston Into Cylinder
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To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not take it all out.
NOTE: Boot's face (1) should be at the same level from cylinder's face (2) all around.
Insert piston into cylinder by hand.

Fig 7: Identifying Boot Face And Cylinder Face
Courtesy of SUZUKI OF AMERICA CORP.