Metro, Prizm 2000-2002

Brake Caliper

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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. Siphon a sufficient quantity of brake fluid from the master cylinder reservoir to prevent the brake fluid from overflowing the master cylinder when removing or installing the calipers. This is necessary, as the piston must be forced into the cylinder bore to provide sufficient clearance to install the caliper.
  2.  
  3. Remove the wheel and tire assembly.
  4.  
  5. Install 2 lug nuts finger tight to hold the disc in place.
  6.  
  7. Disconnect the brake hose fitting at the caliper and discard the 2 copper washers. Use a pan to catch any spilled fluid and immediately plug the disconnected hose.
  8.  
  9. Remove the 2 caliper mounting bolts and then remove the caliper from the mounting bracket.
  10.  

To install:

  1. Use a caliper compressor, a C-clamp or large pair of pliers to slowly press the caliper piston back into the caliper.
  2.  
  3. Apply a thin, even coating of anti-seize compound to the sliding surfaces. Don't use grease or spray lubricants; they will not hold up under the extreme temperatures generated by the brakes.
  4.  
  5. Install the caliper assembly to the mounting plate.
  6.  
  7. Install caliper mounting bolts and torque to 22 ft. lbs. (30 Nm).
  8.  
  9. Install the brake hose to the caliper using 2 new copper washers. Torque the bolt to 17 ft. lbs. (23 Nm).
  10.  
  11. Bleed the brake system.
  12.  
  13. Remove the 2 lugs holding the disc in place and install the wheel and tire assembly.
  14.  
  15. Check the level of the brake fluid in the master cylinder reservoir; it should be at least to the middle of the reservoir.
  16.  


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. Siphon a sufficient quantity of brake fluid from the master cylinder reservoir to prevent the brake fluid from overflowing the master cylinder when removing or installing the calipers. This is necessary, as the piston must be forced into the cylinder bore to provide sufficient clearance to install the caliper.
  2.  
  3. Remove the wheel and tire assembly.
  4.  
  5. Install 2 lug nuts finger tight to hold the brake rotor in place.
  6.  
  7. Disconnect the brake hose at the caliper and discard the 2 copper washers. Use a pan to catch any spilled fluid and immediately plug the disconnected hose.
  8.  
  9. Remove the 2 caliper mounting bolts and then remove the caliper from the mounting bracket.
  10.  

To install:

Click image to see an enlarged view

Fig. Using a large C-clamp to compress the piston back into the caliper bore

  1. Use a caliper compressor, a C-clamp or large pair of pliers to slowly press the caliper piston back into the caliper.
  2.  
  3. Apply a thin, even coating of anti-seize compound to the sliding surfaces. Don't use grease or spray lubricants; they will not hold up under the extreme temperatures generated by the brakes.
  4.  
  5. Install the caliper assembly to the mounting plate.
  6.  
  7. Install the caliper mounting bolts and torque to 25 ft. lbs. (34 Nm).
  8.  
  9. Install the brake hose to the caliper using 2 new copper washers. Torque the brake hose bolt to 22 ft. lbs. (30 Nm).
  10.  
  11. Bleed the brake system.
  12.  
  13. Remove the 2 lugs holding the disc in place and install the wheel.
  14.  
  15. Check the level of the brake fluid in the master cylinder reservoir; it should be at least to the middle of the reservoir.
  16.  

 
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