Cavalier, Sunfire 2001-2005

Brake Caliper

Print

Removal & Installation




CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Siphon 2 / 3 of the brake fluid out of the master cylinder.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Compress the caliper piston back into the caliper bore using a large pair of pliers, C-clamp or special piston retracting tool.
  8.  
  9. If the caliper is to be completely removed from the vehicle for bench service, disconnect and cap the brake line from the caliper. Discard the old washers.
  10.  
  11. Remove the caliper mounting bolts and sleeves.
  12.  
  13. Remove the caliper from the knuckle.
  14.  
  15. Remove the brake pads from the caliper, if caliper is being replaced.
  16.  

To install:

  1. Install the brake pads in the caliper.
  2.  
  3. Install the caliper on the steering knuckle.
  4.  
  5. Install the mounting bolts and sleeves and torque to 38 ft. lbs. (51 Nm).
  6.  
  7. If the caliper brake line was disconnected, uncap and connect the brake hose to the caliper using new copper washers. Torque the bolt to 37 ft. lbs. (50 Nm).
  8.  
  9. Refill the master cylinder and bleed the brake system.
  10.  
  11. Install the tire and wheel assembly and tighten to specification.
  12.  
  13. Verify correct brake operation.
  14.  

  1. Siphon 2 / 3 of the brake fluid out of the master cylinder.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Compress the caliper piston back into the caliper bore using a large pair of pliers, C-clamp or special piston retracting tool.
  6.  
  7. If the caliper is to be completely removed from the vehicle for bench service, disconnect and cap the brake line from the caliper. Discard the old washers.
  8.  
  9. Remove the caliper mounting bolts and sleeves.
  10.  
  11. Remove the caliper from the knuckle.
  12.  
  13. Remove the brake pads from the caliper, if caliper is being replaced.
  14.  

To install:

  1. Install the brake pads in the caliper.
  2.  
  3. Install the caliper on the steering knuckle.
  4.  
  5. Install the mounting bolts and sleeves and torque to 40 ft. lbs. (51 Nm).
  6.  
  7. If the caliper brake line was disconnected, uncap and connect the brake hose to the caliper using new copper washers. Torque the mounting bolt to 35 ft. lbs. (44 Nm).
  8.  
  9. Refill the master cylinder and bleed the brake system.
  10.  
  11. Install the tire and wheel assembly and tighten to specification.
  12.  
  13. Verify correct brake operation.
  14.  

 
label.common.footer.alt.autozoneLogo