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Home >> Pontiac >> 2003 >> Sunfire Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 234 (Disc Brake System) >> Repair Instructions >> Brake Pads 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. Install a large C-clamp (2) over the body of the brake caliper (1), with the C-clamp ends against the rear of the caliper body and against an old inboard brake pad or a wood block installed against the caliper piston.
    Fig 1: Tightening C-Clamp Evenly Until The Caliper Piston Is Compressed Completely Into The Caliper Bore
    GM482002Courtesy of GENERAL MOTORS CORP.
  2. Tighten the C-clamp (2) evenly until the caliper piston is compressed completely into the caliper bore.
  3. Remove the C-clamp and the old brake pad or wood block from the caliper.
  4. 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.
  5. Install the brake pads to the caliper.
    Fig 2: View Of Disc Brake Pads
    GM927124Courtesy of GENERAL MOTORS CORP.
  6. Thoroughly clean the brake pad mating surface on the steering knuckle of any surface debris and/or corrosion.
  7. Apply a thin layer of high temperature silicone brake lubricant to the brake pad mating surface on the steering knuckle.
  8. Install the caliper assembly (2) to the steering knuckle (3).
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  9. Tighten the caliper bolts (1, 4) to the steering knuckle (3).

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

    Fig 3: Identifying Caliper Bolts
    GM142240Courtesy of GENERAL MOTORS CORP.
  10. Remove the wheel nuts securing the rotor to the hub.
  11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  12. Lower the vehicle.
  13. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  14. Slowly release the brake pedal.
  15. 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.
  16. Fill the brake master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
  17. Burnish the pads and rotors. Refer to Burnishing Pads and Rotors .
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