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Home >> Pontiac >> 2009 >> G8 Base >> Repair and Diagnosis >> External Pages >> Different car >> Section 51 (Disc Brake System) >> Repair Instructions >> Front Brake Caliper Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2008 Pontiac G8. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Refer to Safety Glasses Caution .
    CAUTION: Refer to Vehicle Lifting Caution .
    CAUTION: Refer to Brake Dust Caution .
    CAUTION: Refer to Brake Fluid Caution .
    CAUTION: Refer to Brake Fluid Irritant Caution .
    NOTE: Refer to Adding Fluid to the Brake System Notice .
    NOTE: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
    NOTE: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.
  1. Clean the front brake caliper anchor plate mounting surfaces to the front steering knuckle.
  2. Check the serviceability of the brake pads. Refer to Brake Pad Inspection .
    3. IMPORTANT: The brake pads are marked as inner and outer only. Failure to install the brake pads in their correct position will cause the brake pads not to seat correctly in the brake caliper.
  3. Install the existing or NEW brake pads as required.
  4. Press the inner brake pad by using a suitable tool to make sure the brake caliper pistons bottom in each brake caliper bore.
  5. Position the front brake caliper assembly over the front brake disc.
    6. Fig 1: Identifying Brake Caliper Anchor Plate To Knuckle Retaining Bolts
    GM1943448Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  6. Install the NEW front brake caliper anchor plate to front steering knuckle retaining bolts (5).

    Tighten:  Tighten the bolts to 60 Nm +120° (44 lb ft +120°).

    7. NOTE: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.
    IMPORTANT: Install NEW copper brake hose sealing washers (3).
  7. Install the front brake hose (2) to brake caliper banjo retaining bolt (4) and NEW copper brake hose sealing washers (3) to the front brake caliper (1).

    Tighten:  Tighten the banjo bolt to 35 Nm (25 lb ft).

  8. Bleed the braking system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) .
  9. Remove the two wheel nuts retaining the brake disc to the hub.
  10. Install the front wheels. Refer to Tire and Wheel Removal and Installation .
  11. Lower the vehicle to the ground.
  12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  13. Slowly release the brake pedal.
  14. Repeat steps  12 and  13 until a firm brake pedal is obtained. This will correctly seat the brake caliper pistons and brake pads.
  15. Fill the master cylinder reservoir to the correct level. Refer to Master Cylinder Reservoir Filling .
  16. Burnish (bed in) the brake pads and brake discs if required. Refer to Brake Pad and Rotor Burnishing .
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