Installation - Chrysler PT Cruiser Service & Repair Manual

5 - 26 BRAKES - BASE
DISC BRAKE CALIPER - FRONT (Continued)
NOTE: Never use an old piston seal.
(1) Dip the new piston seal in clean brake fluid
and install it in the groove of the caliper bore (Fig.
42). The seal should be started at one area of the
groove and gently worked around into the groove
using only your clean fingers to seat it.
Fig. 42 New Piston Seal Installation
1 - SEAL
2 - GROOVE
(2) Coat the new piston with clean brake fluid.
(3) Coat the new piston boot with clean brake fluid
leaving a generous amount inside the boot.
(4) Position the dust boot over the lower section of
the piston (Fig. 43).
Fig. 43 Boot Installation
(5) Extend the dust boot below the bottom of the
piston and guide the lip seal into the groove in the
caliper piston bore.
CAUTION: Force applied to the piston to seat it in
the bore must be applied uniformly to avoid cock-
ing and binding of the piston.
(6) Install the piston into the bore carefully push-
ing it past the piston seal using hand pressure (Fig.
44). Push the piston in until it bottoms in the caliper
bore and the dust boot lip seal falls into the groove
near the top of the piston.
Fig. 44 Piston Installation
1 - PISTON GROOVE
(7) Reinstall the caliper on the vehicle and bleed
the brakes as necessary. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPER -

INSTALLATION)

INSTALLATION
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 (Fig. 11) (Fig.
12).(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL
- DESCRIPTION - DISC BRAKES (FRONT))
(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.
(2) Install the disc brake caliper over the brake
shoes on the brake caliper adapter. Make sure the
springs on the shoes 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 and
tighten them to a torque of 35 N·m (26 ft. lbs.) (Fig.
39).
PT