GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Opel 🢒 1999 🢒 Sintra 🢒 Preface 🢒 Cautions and Notices 🢒 Front Brake Caliper Replacement

Removal Procedure
  1. Use a suction gun in order to remove and DISCARD approximately 33 percent (1/3) of the brake fluid from the master cylinder.
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the tire and wheel.
    4. • For vehicles with steel wheels, refer to Tire and Wheel Removal and Installation in Tires and Wheels.
    • For Chevrolet and Oldsmobile vehicles with aluminum wheels, refer to Tire and Wheel Removal and Installation in Tires and Wheels.
    • For Pontiac and Export vehicles with aluminum wheels, refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  4. Install two nuts to retain the rotor to the hub.

    5. Object Number: 177027 Size: SH
  5. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad.
  6. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor.
  7. If the brake caliper is going to be removed from the vehicle for unit repair (overhaul) or replacement, go to Step 8. If the brake caliper is not being replaced or overhauled, go to Step 13.

    8. Object Number: 176035 Size: SH
  8. Remove the brake hose bolt (1).
  9. Remove the brake hose (2) from the brake caliper.
  10. Remove and discard the two copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end.
  11. Plug the openings in the brake caliper and the brake hose in order to prevent brake fluid loss and contamination.
  12. Clean off any dirt or corrosion on the brake caliper near the brake hose fitting.

    13. Object Number: 180238 Size: SH
  13. Remove the brake caliper bolts (3).

    14. Notice: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses.

  14. Remove the brake caliper (1) from the brake caliper bracket (2).

    15. Object Number: 178630 Size: SH
  15. Use a strap (1) or heavy gage wire in order to support the brake caliper (2).
  16. Inspect the piston boot for the following conditions:
    17. • Cuts
    • Tears
    • Deterioration
    • Replace the piston boot if damage exists. Refer to Front Brake Caliper Overhaul .

    Object Number: 344219 Size: SH
  17. Inspect the brake caliper bolt boots (4) for the following conditions:
    18. • Cuts
    • Tears
    • Deterioration
    • Replace the bolt boots if damage exists. Refer to Front Brake Caliper Bracket Replacement .
  18. Inspect the caliper bolts for corrosion or damage. If corrosion is found on the brake caliper bolt shaft, replace the brake caliper bolt and the brake caliper bolt boot. Do not attempt to polish away the corrosion.

Installation Procedure

    Object Number: 344282 Size: SH
  1. Ensure that the caliper bolt boots (3) are properly installed.

    2. Object Number: 180238 Size: SH
  2. Install the caliper (1) to the caliper bracket (2).

    3. Object Number: 344219 Size: SH
  3. Use silicone grease to lubricate the brake caliper bolt shaft. Do not lubricate the bolt threads.
  4. Use silicone grease to lubricate the brake caliper bolt boots (4) in the caliper bracket (3).

    5. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  5. Install the brake caliper bolts.

    6. Tighten
    Tighten the brake caliper bolts to 85 N·m (63 lb ft).

  6. Use a flat-bladed tool in order to install the caliper bracket boot over the shoulder of the caliper bolt.
  7. Remove the plugs in the brake hose end.

    8. Object Number: 176035 Size: SH

    Important: Install NEW copper brake hose gaskets (3).

  8. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2).
  9. Install the brake hose bolt to the brake caliper.

    10. Tighten
    Tighten the brake hose bolt to 54 N·m (40 lb ft).

  10. Remove the nuts securing the rotor to the hub.
  11. Install the tire and wheel.
    12. • For vehicles with steel wheels, refer to Tire and Wheel Removal and Installation in Tires and Wheels.
    • For Chevrolet and Oldsmobile vehicles with aluminum wheels, refer to Tire and Wheel Removal and Installation in Tires and Wheels.
    • For Pontiac and Export vehicles with aluminum wheels, refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  12. Lower the vehicle.
  13. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
  14. Bleed the brake system if the brake hose was disconnected from the brake caliper. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
  15. Pump the brake pedal (3/4 of a full stroke) as many times as necessary to obtain a firm brake pedal.
  16. Apply approximately 778 N·m (175 lb ft) of force to the brake pedal for ten seconds.
  17. Inspect the brake caliper and hydraulic brake system for brake fluid leaks.