GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 AURA 🢒 Preface 🢒 Dangers, Warnings, and Cautions 🢒 Front Brake Caliper Replacement

Removal Procedure

    Warning: Refer to Brake Dust Warning in the Preface section.

    Warning: Refer to Brake Fluid Irritant Warning in the Preface section.


    Object Number: 891764 Size: SH
  1. Inspect the fluid level in the brake master cylinder reservoir.
  2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
  3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
  6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub.
  7. Install a large C-clamp (1) over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
  8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
  9. Remove the C-clamp from the caliper.

    10. Object Number: 890982 Size: SH
  10. Remove the brake hose-to-caliper bolt (1) from the brake caliper.
  11. Remove the brake hose (3) from the brake caliper.
  12. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3).
  13. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.

    14. Object Number: 891307 Size: SH
  14. Remove the brake caliper guide pin bolts (2).
  15. Remove the brake caliper from the caliper bracket.
  16. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:
    17. • Restricted caliper guide pin movement
    • Looseness in the brake caliper mounting bracket
    • Seized or binding caliper guide pins
    • Split or torn boots
  17. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.

Installation Procedure

    Object Number: 891307 Size: SH
  1. Install the brake caliper to the brake caliper bracket.

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

  2. Install the brake caliper guide pin bolts (2) and tighten to 35 N·m (26 lb ft).

    3. Object Number: 890982 Size: SH
  3. Remove the caps or plugs from the brake caliper opening and the brake hose.

    4. Note: Do not reuse the copper brake hose gaskets.

  4. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3).
  5. Install the brake hose and the brake hose-to-brake caliper bolt to the brake caliper and tighten the bolt to 50 N·m (37 lb ft).
  6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.
  7. Remove the wheel nuts retaining the brake rotor to the wheel hub.
  8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
  9. Lower the vehicle.
  10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  11. Slowly release the brake pedal.
  12. Wait 15 seconds, then repeat steps 10 and 11 until a firm brake pedal is obtained. This will properly seat the brake caliper piston and brake pads.