PT Cruiser L4-2.4L Turbo VIN G (2004)
4. Position the dust boot over the lower section of the piston.
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 cocking and binding of the piston.
6. Install the piston into the bore carefully pushing it past the piston seal using hand pressure. 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.
7. Reinstall the caliper on the vehicle and bleed the brakes as necessary.
INSTALLATION
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 Nm (26 ft. lbs.).
4. Install the banjo bolt connecting the brake hose 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 a torque of 26 Nm (230 in. lbs. or 19 ft. lbs.).
5. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.).
6. Lower the vehicle.
7. Remove the brake pedal holding tool.
8. Bleed the caliper as necessary.
9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes.
