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

Disassembly Procedure
  1. Remove the caliper assembly. Refer to Brake Caliper Replacement.

    2. Object Number: 1245703 Size: SH
  2. Remove the caliper guide pin that connects the caliper piston housing to the retaining frame.
  3. Remove the bleeder valve protector and the bleeder valve.

    4. Object Number: 1245710 Size: SH
  4. Pull out the pins and the rubber boots.
  5. Remove the front pad brake set, including the pad springs, from the caliper. Refer to Front Disc Brake Pads Replacement.

    6. Object Number: 1245706 Size: SH
  6. Insert a cloth or a piece of hardwood into the caliper housing.

    7. Warning: Wear safety glasses when using compressed air in order to prevent eye injury.

    Warning: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury.

    Caution: Use just enough air pressure to ease the piston out of the bore. You can damage a blown-out piston even with the padding.

  7. Apply compressed air to the caliper brake hose connector hole in order to remove the piston from the caliper.
  8. Remove the outer seal.

    9. Object Number: 1245708 Size: SH
  9. Remove the inner seal from the caliper piston bore.

Inspection Procedure

    Object Number: 1245712 Size: SH
  1. Clean all parts in denatured alcohol or brake fluid.
  2. Use unlubricated compressed air in order to dry the parts and blow out all passages in the housing and the bleeder valve.
  3. Inspect the caliper bleeder valve.

    4. Note: Do not use a hone or any other procedure to remove material from the piston or the caliper bore.

  4. Inspect the piston and the caliper for scoring, nicks, and corrosion. Replace components if necessary.

Assembly Procedure

    Object Number: 1245713 Size: SH
  1. Lubricate a new piston inner seal with brake fluid.
  2. Install the piston inner seal into the caliper housing groove. Ensure the seal is not twisted.
  3. Lubricate the outer piston dust seal with brake fluid.
  4. Install the outer piston dust seal in the groove.
  5. Lubricate the piston with brake fluid.
  6. Push the piston into its bore and ensure the dust seal is seated in the piston groove.

    7. Object Number: 1245710 Size: SH
  7. Coat the pins with Silicone Brake Lubricant, GM P/N 89021536, ACDelco P/N 89021537 (Canadian P/N 89021538), or equivalent, and install the boots.

    8. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1245716 Size: SH
  8. Install the caliper bleeder valve and the dust cap and tighten to 6 N·m (53 lb in).
  9. Install the front pad brake set and the pad springs. Refer to Front Disc Brake Pads Replacement.

    10. Object Number: 1245718 Size: SH
  10. Connect the retaining frame to the caliper housing with the guide pin bolts and tighten to 27 N·m (20 lb ft).
  11. Install the caliper assembly. Refer to Brake Caliper Replacement.