SERVICE MANUAL UPDATE-SEC. 5F BRAKE ROTOR SPECIFICATIONS

SUBJECT: SERVICE MANUAL UPDATE -SECTION 5F - BRAKE ROTOR SPECIFICATIONS

MODELS AFFECTED: 1990-92 LEMANS W/1.6L ENGINE L4 (RPO L73)

Application:

------------ 1990-92 Pontiac Lemans equipped with vented brake rotors and the 1.6L Engine L4 Vin Code 6.

This bulletin is an amendment to the brake rotor specifications found in Section 5F of the 1990-92 Pontiac Lemans Service Manual (S-9010-T) , (S-9110-T) and (S-9210-T) respectively. The following specifications apply to vehicles equipped with vented brake rotors and the 1.6L L4 Vin Code 6 engine.

Brake Rotors

Rotor Diameter 236.00 mm (9.291 in.) Lateral Runout 0.10 mm (0.004 in.) Thickness Variation 0.01 mm (0.0004 in.) Rotor Thickness (New) 20 mm (0.787 in.) Minimum Thickness after Refinish 17 mm (0.669 in.) Discard Thickness 16.4 mm (0.646 in.)

SECTION 5F

SPECIFICATIONS AND SPECIAL TOOLS

GENERAL SPECIFICATIONS

BRAKEPEDALTRAVEL...........................................101.6 mm (4.0") Brake pedal travel maximum with 445 N (100 lbs.) force applied to pedal with ignition "OFF" and vacuum assist depleted. BRAKEDRUMS Inside Diameter...........................................200.00 mm (7.870") Runout......................................................0.10 mm (0.004") Maximum Rebore Diameter...................................201.00 mm (7.900") Discard Diameter..........................................201.60 mm (7.937") BRAKE ROTORS Rotor Diameter............................................236.00 mm (9.291") Lateral Runout..............................................0.10 mm (0.004") Thickness Variation.........................................0.01 mm (0.0004") Rotor Thickness (New)......................................20 mm (0.787") Minimum Thickness after Refinish...........................17 mm (0.669") Discard Thickness..........................................16.4 mm (0.646") MASTER CYLINDER BORE DIAMETER...............................22.2 mm (0.874") CALIPER BORE DIAMETER.......................................17.4 mm (0.685") WHEEL CYLINDER BORE DIAMETER................................17.5 mm (0.689")

TORQUE SPECIFICATIONS

Hollow Bolt, Front Brake Hose...............................40 N.m (30 lb.ft.) Bolt, Front Brake Hose Support Bracket ..................... 8 N.m (71 lb.in.) Front Brake Hose-to-Brake Pipe..............................11 N.m (97 lb.in.) Rear Brake Hose-to-Brake Pipe..............................11 N.m (97 lb.in.) Parking Brake Lever-to-Underbody............................20 N.m (15 lb.ft.) Screws, Parking Brake Switch Attaching......................25 N.m (18 lb.ft.) Bolts, Front Seat Assembly Retaining........................20 N.m (15 lb.ft.) Nut, Brake Pedal Hex ..........................18 N.m (13 lb.ft.) Proportioning Valves-to-Master Cylinder Body................40 N.m (30 lb.ft.) Nuts, Master Cylinder Assembly Mounting.....................18 N.m (13 lb.ft.) Brake Pipe-to-Master Cylinder Proportioning Valve...........11 N.m (97 lb.in.) Bolts, Caliper-to-Steering Knuckle Mounting.................95 N.m (70 lb.ft.) Bolt, Caliper Inlet Fitting.................................25 N.m (18 lb.ft.) Bolts, Caliper Retaining Frame..............................95 N.m (70 lb.ft.) Fasteners, Drum Brake Backing Plate.........................28 N.m (21 lb.ft.) Bolt, Wheel Cylinder Mounting................................9 N.m (80 lb.in.) Nut, Power Brake Booster-to-Support Bracket ................22 N.m (16 lb.ft.) Nut, Support Bracket-to-Dash Panel..........................22 N.m (16 lb.ft.) Nut, Master Cylinder-to-Power Brake Booster.................18 N.m (13 lb.ft.) Union Nut, Vacuum Hose-to-Intake Manifold...................15 N.m (11 lb.ft.) Splash Shield-to-Steering Knuckle............................4 N.m (35 lb.in.)

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.