GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 Brakes 🢒 Disc Brakes 🢒 Front Brake Caliper Overhaul

Disassembly Procedure

    Object Number: 893563 Size: SH
  1. Using a small wooden or plastic tool, remove the caliper dust boot seal from the caliper.

    2. Object Number: 893564 Size: SH
  2. Remove the piston from the caliper body by applying low pressure, non-lubricated, compressed air into the caliper inlet hole.

    3. Caution: To prevent bodily injury, make sure to keep fingers or other body parts away from piston during removal.

    Notice: Pad interior of caliper body to provide a protective cushion for piston when it exits the caliper. This will protect piston from surface damage caused from piston/caliper body contact.

    Notice: To prevent damage to caliper body bore, use a small wooden or plastic (not metal) device to extract seal.

  3. Remove the piston seal from the groove in the caliper.
  4. Remove the bleeder valve and the bleeder valve cap from the caliper body.
  5. Clean all parts in clean denatured alcohol. Dry with non-lubricated, low pressure, compressed air. Make sure to blow out all passages in the caliper body and the bleeder valve.

    6. Object Number: 891858 Size: SH
  6. Inspect the piston for scoring, nicks, cracks, wear or corrosion. Replace the piston if any damage is found.
  7. Inspect the caliper body piston bore for scoring, nicks, wear, or corrosion. Crocus cloth can be used to remove light corrosion. If more extensive damage is present, replace the caliper.

    8. Important: Do not hone the caliper bore.

  8. Inspect the seal groove in the caliper bore for nicks or burrs. If present, replace the caliper.

Assembly Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 891959 Size: SH
  1. Install the bleeder valve into the caliper body assembly.

    2. Tighten
    Tighten the caliper bleeder valve to 6 N·m (53 lb in).

    Important: Make sure the seal is not twisted.

  2. Install the bleeder valve cap.
  3. Lubricate the new piston seal with clean brake fluid and install the seal into the caliper seal groove.

    4. Object Number: 891963 Size: SH
  4. Install the caliper dust boot into the caliper. The boot must sit in the caliper groove.
  5. Lubricate the outside diameter of the piston with clean brake fluid.

    6. Important: The inner lip of the piston boot must engage in the groove of the piston.

  6. Install the piston into the caliper body. Push the piston all the way to the bottom of the caliper bore.