GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Optra 🢒 General Information 🢒 General Information 🢒 Front Brake Caliper Overhaul

Disassembly Procedure

    Object Number: 1289979 Size: SH
  1. Remove the caliper assembly. Refer to Front Brake Caliper Replacement .
  2. Remove the caliper guide pin that connects the caliper piston housing to the retaining frame.

    3. Object Number: 1289996 Size: SH
  3. Pull out the pins and the rubber boots.
  4. Remove the front pad brake set, including the pad springs from the caliper. Refer to Front Disc Brake Pads Replacement .

    5. Object Number: 1290011 Size: SH
  5. Insert a cloth or a piece of hardwood into the caliper housing.

    6. Caution: Wear safety glasses when using compressed air in order to prevent eye injury.

    Caution: 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.

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

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

    8. Object Number: 1290027 Size: SH
  8. Remove the inner seal.

    9. Object Number: 1290029 Size: SH
  9. Remove the bleeder valve protector and the bleeder valve.

Inspection Procedure

    Object Number: 1290030 Size: SH
  1. Clean all the parts in denatured alcohol or brake fluid.
  2. Dry the parts with unlubricated compressed air and blow out all the passages in the housing and the bleeder valve.

    3. Important: Do not remove material from the piston or the caliper bore.

  3. Inspect the piston and the caliper for scoring, nicks, and corrosion. Replace the components if these elements are found.
  4. Inspect the caliper bleeder valve.

Assembly Procedure

    Object Number: 1290032 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 inward until the piston is properly seated.

    7. Object Number: 1289996 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. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1290029 Size: SH
  8. Install the caliper bleeder valve and the protector.

    9. Tighten
    Tighten the caliper bleeder valve to 8 N·m (71 lb in).

    Important: Make sure the pad springs are properly installed.

  9. Install the brake pads and the pad springs. Refer to Front Disc Brake Pads Replacement .

    10. Object Number: 1289979 Size: SH
  10. Connect the retaining frame to the caliper housing with the guide pin bolts.

    11. Tighten
    Tighten the retaining frame-to-caliper housing bolts to 27 N·m (20 lb ft).

  11. Install the caliper assembly. Refer to Front Brake Caliper Replacement .