GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Aveo 🢒 General Information 🢒 General Information 🢒 Brake Caliper Replacement

Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Mark the position of the front wheels relative to the wheel hubs and remove the wheels. Refer to Tire and Wheel Removal and Installation .

    3. Caution: Refer to Brake Dust Caution in the Preface section.


    Object Number: 1245697 Size: SH
  3. Remove the fitting and the washers that attach the brake hose to the caliper.

    4. Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

    Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

  4. Disconnect the brake hose, and plug the openings in the caliper and the brake hose to prevent fluid loss and contamination.
  5. Remove the caliper mounting bolts from the steering knuckle.
  6. Remove the caliper assembly.

Installation Procedure

    Object Number: 1245696 Size: SH
  1. Ensure the slide pins are lubricated with Silicone Brake Lubricant, GM P/N 89021536, ACDelco P/N 89021537 (Canadian P/N 89021538), or equivalent. If necessary, refer to Front Brake Caliper Overhaul .

    2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1245699 Size: SH
  2. Install the caliper assembly with the mounting bolts.

    3. Tighten
    Tighten the caliper-to-steering knuckle mounting bolts to 95 N·m (70 lb ft).

  3. Install the brake hose to the caliper with the washers and the brake hose inlet fitting.

    4. Tighten
    Tighten the brake hose inlet fitting to 40 N·m (30 lb ft).

  4. Install the front wheels. Refer to Tire and Wheel Removal and Installation .
  5. Lower the vehicle.

    6. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury.

  6. With the engine OFF, gradually apply and release the brake pedal several times in order to position the caliper piston and the pads.
  7. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .