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Caliper-Front Disc Brake: Installation

WARNING: This page is about a different car, the 2006 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: When installing new brake components, be sure to use correct parts. Parts designed for BR4 Performance Brake System must not be mixed with other brake systems. These parts, similar in appearance, can be easily identified. (Refer to BRAKES/HYDRAULIC/MECHANICAL - DESCRIPTION - FRONT DISC BRAKES) 
  1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract the piston. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston.
    CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the boots on the caliper guide pins.
    Fig 1: Brake Caliper Mounting
    GC0019679Courtesy of DAIMLERCHRYSLER CORP.
    1 - BRAKE HOSE
    2 - ADAPTER MOUNTING BOLTS
    3 - BANJO BOLT
    4 - CALIPER GUIDE PIN BOLTS
  2. Install the disc brake caliper over the brake pads on the brake caliper adapter. Make sure the springs on the pads do not get caught in the hole formed into the center of the caliper housing.
  3. Align the caliper guide pin bolt holes with the guide pins. Install the caliper guide pin bolts (4) and tighten them to 35 N.m (26 ft. lbs.).
  4. Install the banjo bolt (3) connecting the brake hose (1) to the brake caliper. Install NEW washers on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 24 N.m (210 in. lbs.).
    Fig 2: Tire And Wheel Mounting
    GC0041085Courtesy of DAIMLERCHRYSLER CORP.
  5. Install the tire and wheel assembly (1) (Refer to TIRES/WHEELS - INSTALLATION) . Install and tighten the wheel mounting nuts (3) to 135 N.m (100 ft. lbs.).
  6. Lower the vehicle.
    Fig 3: Brake Pedal Holder
    GC0019697Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove the brake pedal holding tool.
    Fig 4: Bleeding Brakes
    GC0006390Courtesy of DAIMLERCHRYSLER CORP.
  8. Bleed the caliper as necessary. (Refer to BRAKES - STANDARD PROCEDURE) 
  9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes.
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