Installation; Disc Brake Caliper Adapter - Front Removal - Chrysler PT Cruiser Service & Repair Manual

PT
DISC BRAKE CALIPER - REAR (Continued)
(6) Using a hammer and Installer, Special Tool
C-4689, and Handle, Special Tool C-4171, drive the
boot into the counterbore of the caliper (Fig. 61).
Fig. 61 Installing Dust Boot In Caliper Counterbore
1 - HAMMER
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4689
4 - CALIPER
(7) Install the brake shoes (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES

- INSTALLATION).

(8) Reinstall the caliper on the vehicle and bleed
the brakes as necessary. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- 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. 14) (Fig.
15).(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL
- DESCRIPTION - DISC BRAKES (REAR))
NOTE: Step (1) below is only required when install-
ing the disc brake caliper after new brake shoes
have been installed.
(1) Completely retract the caliper piston back into
piston bore of the caliper.
(2) Lubricate both adapter caliper slide abutments
with a liberal amount of Mopar Multipurpose Lubri-
cant, or an equivalent.
CAUTION: Use care when installing the caliper
assembly onto adapter so the guide pin bushings
and sleeves do not get damaged by the mounting
bosses on adapter.
(3) Starting with the lower end, carefully lower the
caliper and brake shoes over the brake rotor and
catch the caliper's bottom edge behind the caliper
slide abutment (Fig. 48). Rotate the top of the caliper
into mounting position on the adapter.
CAUTION: Extreme caution should be taken not to
cross thread the caliper guide pin bolts when they
are installed.
(4) Carefully install the caliper guide pin bolts
(Fig. 47), then tighten them to a torque of 22 N·m
(192 in. lbs.).
(5) Install the banjo bolt connecting the brake hose
to the brake caliper (Fig. 46). Install NEW washers.
Place one fitting washer on each side of the hose fit-
ting as the banjo bolt is guided through the fitting.
Thread the banjo bolt into the caliper and tighten it
to a torque of 24 N·m (210 in. lbs.).
(6) Install the tire and wheel assembly. Tighten
the wheel mounting nuts to a torque of 135 N·m (100
ft. lbs.).
(7) Lower the vehicle.
(8) Remove the brake pedal holding tool.
(9) Bleed the caliper as necessary. (Refer to 5 -
BRAKES - STANDARD PROCEDURE)
(10) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
seat the brake shoes.
DISC BRAKE CALIPER
ADAPTER - FRONT
REMOVAL
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING)(Refer to 5 - BRAKES - CAUTION).
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
BRAKES - BASE 5 - 33