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Home >> Saturn >> 2005 >> Relay AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 211 (Disc Brake System) >> Repair Instructions >> Front Brake Caliper Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Pontiac Montana SV6, 2007 Chevrolet Uplander, and 2007 Buick Terraza. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Ensuring Caliper Bolt Boots Proper Installation
    GM344282Courtesy of GENERAL MOTORS CORP.
  1. Ensure that the caliper bolt boots (3) are properly installed.
    2. Fig 2: Locating Brake Caliper Bolts
    GM695063Courtesy of GENERAL MOTORS CORP.
  2. Install the caliper (1) to the caliper bracket (2).
    3. NOTE: Refer to Fastener Notice .
  3. Install the brake caliper bolts.

    Tighten:  Tighten the bolts to 54 N.m (40 lb ft).

  4. Remove the plugs in the brake hose end.
    5. Fig 3: Identifying Brake Hose & Components
    GM176035Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Install NEW copper brake hose gaskets (3).
  5. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2).
  6. Install the brake hose bolt to the brake caliper.

    Tighten:  Tighten the bolt to 54 N.m (40 lb ft).

  7. Remove the nuts securing the rotor to the hub.
  8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation .
  9. Lower the vehicle.
  10. Fill the master cylinder to the proper level. Refer to Master Cylinder Reservoir Filling .
  11. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) .
  12. Using the J 28662  apply approximately 778 N.m (175 lb ft) of force to the brake pedal for 10 seconds.
  13. Inspect the brake caliper and hydraulic brake system for brake fluid leaks.
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