GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Holden 🢒 2009 🢒 Epica 🢒 Brakes 🢒 Disc Brakes 🢒 Front Brake Caliper Overhaul

Disassembly Procedure
  1. Remove the caliper assembly. Refer to Front Brake Caliper Replacement.
  2. Remove the caliper guide pin bolts and the bracket.
  3. Remove the guide pins and the boots.
  4. Remove the front brake pads. Refer to Front Disc Brake Pads Replacement.

    5. Object Number: 1255716 Size: SH
  5. Insert a cloth or a piece of hardwood into the caliper housing.

    6. 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.

  6. Apply unlubricated, compressed air to the caliper brake hose connector hole in order to remove the piston from the caliper.
  7. Remove the outer piston dust seal.
  8. Remove the inner seal from the bore. Avoid scratching the bore.

    9. Object Number: 1255715 Size: SH
  9. Remove the bleeder value dust cap 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 passages in the housing and the bleeder valve.

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

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

Assembly Procedure
  1. Lubricate a new piston inner seal with brake fluid.
  2. Install the piston inner seal into the groove in the caliper bore.
  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. Ensure the dust seal is in the correct groove in the piston and in the caliper.
  7. Coat the slide 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: 1255715 Size: SH
  8. Install the bleeder valve and the protector and tighten to 6 N·m (53 lb in).
  9. Install the front brake pads. Refer to Front Disc Brake Pads Replacement.
  10. Install the bracket and the guide pin bolts and tighten to 27 N·m (20 lb ft).
  11. Install the caliper assembly. Refer to Front Brake Caliper Replacement.