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Home >> Pontiac >> 2003 >> Sunfire Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 234 (Disc Brake System) >> Repair Instructions >> Brake Caliper Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the caliper bushings and install the caliper bolts to the caliper. Refer to Disc Brake Hardware Replacement .
    IMPORTANT: The outer brake pad must be mounted with the leading edge of the wear sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position.
  2. Install the brake pads to the caliper.
    Fig 1: View Of Disc Brake Pads
    GM927124Courtesy of GENERAL MOTORS CORP.
  3. Thoroughly clean the brake pad mating surface on the steering knuckle of any surface debris and/or corrosion.
  4. Apply a thin layer of high temperature silicone brake lubricant to the brake pad mating surface on the steering knuckle.
  5. Install the caliper assembly to the steering knuckle.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Tighten the caliper bolts to the steering knuckle.

    Tighten:  Tighten the bolts to 51 N.m (38 lb ft).

  7. Remove the caps or plugs from the opening in the brake caliper and the brake hose.
    IMPORTANT: Install NEW copper brake hose gaskets (2).
  8. Assemble the NEW copper brake hose gaskets (2), and the brake hose bolt (1), to the brake hose (3).
    Fig 2: Exploded View Of Brake Hose Fittings
    GM927122Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  9. Install the brake hose-to-brake caliper bolt to the brake caliper.

    Tighten:  Tighten the bolt to 50 N.m (37 lb ft).

  10. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes.
  11. Remove the wheel nuts securing the rotor to the hub.
  12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  13. Lower the vehicle.
  14. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  15. Slowly release the brake pedal.
  16. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
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