PT Cruiser L4-2.4L Turbo VIN 8 (2005)
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. 16) (Fig. 17).
NOTE: Step (1) below is only required when installing 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 Lubricant, 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. 45). 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. 44), then tighten them to a torque of 22 Nm (192 inch lbs.).
5. Install the banjo bolt connecting the brake hose to the brake caliper (Fig. 43). Install NEW washers. Place one fitting washer 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 24 Nm (210 inch lbs.).
6. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.).
7. Lower the vehicle.
8. Remove the brake pedal holding tool.
9. Bleed the caliper as necessary.
10. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes.
