For 1990-2009 cars

## Front Brake Caliper Replacement HSV Maloo

### Removal Procedure

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

Caution: Refer to Brake Dust Caution in the Preface section.

Caution: Refer to Brake Fluid Caution in the Preface section.

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

Notice: When adding fluid to the brake master cylinder reservoir, use only Holden specification number HN 1796 (Super DOT 4/DOT 4 Plus) brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which may result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.

1. Inspect the fluid level in the master cylinder reservoir.

• | If the brake fluid level is midway between the maximum fill level and the minimum allowable level, no brake fluid needs to be removed from the master cylinder reservoir before proceeding.

| Important: DO NOT re-use the removed fluid.

• | If the brake fluid level is higher than midway between the maximum fill level and the minimum allowable level, syphon the brake fluid to the midway point using a hand vacuum pump before proceeding.

2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the front wheels. Refer to Tire and Wheel Removal and Installation .
4. Install 2 wheel nuts (1), in reverse, to opposite wheel studs to retain the brake rotor to the wheel hub.
5. Place a drain tray beneath the brake caliper assembly.

Important: Install a rubber cap or plug on the exposed brake hose end in order to prevent fluid loss and contamination.

Important: Copper brake hose sealing washers become work hardened due to the heat generated with brake applications and will not re-seal. Install NEW copper brake hose sealing washers whenever the brake hose to brake caliper banjo retaining bolt is removed.

Important: To facilitate removal of the brake caliper, the reversed wheel nuts holding the brake rotor in position will need to be loosened and the brake pads fully pushed back against the pistons within the caliper.

6. Remove the brake hose to brake caliper banjo retaining bolt (1) from the brake caliper (4).

Discard the washers.

Discard the bolt.

7. Remove the brake hose (2) from the brake caliper (4).
8. Gently warm the brake caliper to knuckle retaining bolts (3) with a heat gun to soften the micro encapsulated adhesive on the bolts.
9. Remove and discard the brake caliper to knuckle retaining bolts (3) from the brake caliper (4).
10. Remove the brake caliper (4).

### Installation Procedure

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

Notice: When adding fluid to the brake master cylinder reservoir, use only Holden specification number HN 1796 (Super DOT 4/DOT 4 Plus) brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which may result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.

1. Clean the brake caliper mounting surfaces and brake caliper mounting threads using brake clean and a thread chaser (M12x1.5) to remove the remaining adhesive and avoid thread damage during bolt installation.
2. Check the serviceability of the brake pads. Refer to Brake Pad Inspection .

Important: Each inner and outer brake pad should be installed and removed in its original position. To decrease the risk of installing the brake pads in the wrong position, index the brake pads according to their installed position. 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 if required. Refer to Front Disc Brake Pads Replacement .
4. Position the brake caliper assembly over the brake rotor. The brake rotor may need to be moved forward to allow clearance for placement of the caliper.

Notice: Refer to Fastener Notice in the Preface section.

Important: Under no circumstances is an impact wrench to be used on caliper mounting bolts.

5. Install the NEW brake caliper to knuckle retaining bolts (3).

Tighten
Tighten the bolts to 130 Nm (95 lb ft).

Notice: 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.

6. Install the brake hose (2), brake hose to brake caliper banjo retaining bolt (1) and NEW copper brake hose sealing washers to the brake caliper (4).

Tighten
Tighten the bolt to 33 Nm (25 lb ft).

7. Bleed the braking system. Refer to Hydraulic Brake System Bleeding .
8. Remove the two 2 wheel nuts (1) from the wheel studs retaining the brake rotor to the wheel hub.
9. Install the front wheels. Refer to Tire and Wheel Removal and Installation .
10. Lower the vehicle to the ground.
11. With the Ignition Off, gradually apply the brake pedal to approximately 2/3 of its travel distance.
12. Slowly release the brake pedal.
13. Repeat steps 11 and 12 until a firm brake pedal application is obtained. This will correctly seat the brake caliper pistons and brake pads.
14. Fill the master cylinder reservoir to the correct level. Refer to Master Cylinder Reservoir Filling .
15. Burnish (bed in) the brake pads and brake rotors if required. Refer to Brake Pad and Rotor Burnishing .

## Front Brake Caliper Replacement Except HSV Maloo

### Removal Procedure

#### Tools Required

J 23738-A Hand Vacuum Pump.

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

Caution: Refer to Brake Dust Caution in the Preface section.

Caution: Refer to Brake Fluid Caution in the Preface section.

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Adding Fluid to the Brake System Notice in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

1. Inspect the fluid level in the master cylinder reservoir (2).

• | If the brake fluid level is midway between the maximum fill level and the minimum allowable level, no brake fluid needs to be removed from the master cylinder reservoir (2) before proceeding.

| Important: DO NOT completely empty the master cylinder reservoir (2) or remove any brake lines otherwise complete bleeding of the braking system will be necessary.

| Important: DO NOT re use the removed fluid.

• | If the brake fluid level is higher than midway between the maximum fill level and the minimum allowable level, syphon the brake fluid to the midway point using a hand vacuum pump (1) before proceeding.

2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the front wheels. Refer to Tire and Wheel Removal and Installation .
4. Install two wheel nuts (1) in reverse to opposite wheel studs to retain the brake disc to the hub.

Important: Position the ends of the G-clamps against the rear of the brake caliper (2) and against the outboard brake pad (3).

5. Install large G-clamps over the body of the brake caliper (2).
6. Tighten the G-clamps evenly until the brake caliper pistons bottom in each brake caliper bore.
7. Remove the G-clamps from the brake caliper (2).
8. Place a drain tray beneath the brake caliper assembly.
9. Remove the brake hose to brake caliper banjo retaining bolt (4).

Important: Install a rubber cap or plug on the exposed brake hose end in order to prevent fluid loss and contamination.

10. Separate the brake hose to brake caliper banjo retaining bolt (4) from the brake hose (2).

Important: Copper brake hose sealing washers become work hardened due to the heat generated with brake applications and will not reseal. Install NEW copper brake hose sealing washers (3) whenever the brake hose to brake caliper banjo retaining bolt (4) is removed.

11. Remove the two copper brake hose sealing washers (3). The copper brake hose sealing washers (3) may be stuck to the brake caliper (1) and/or the brake hose (2).

Discard the washers.

Important: Bolts with micro-encapsulated thread sealant must be discarded after removal.

Important: Make sure all the bolt holes are thoroughly cleaned and all micro-encapsulated thread sealant is removed.

12. Remove the brake caliper anchor plate to knuckle retaining bolts (5)

Discard the bolts.

Clean the bolt holes.

13. Remove the brake caliper assembly (1).

### Installation Procedure

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

Caution: Refer to Brake Dust Caution in the Preface section.

Caution: Refer to Brake Fluid Caution in the Preface section.

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Adding Fluid to the Brake System Notice in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

Notice: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.

1. Clean the brake caliper anchor plate to steering knuckle mounting surfaces.
2. Check the serviceability of the brake pads. Refer to Brake Pad Inspection .

Important: The brake pads (4) are marked as inner and outer only. Failure to install the brake pads (4) in their correct position will cause the brake pads (4) not to seat correctly in the brake caliper (1).

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 brake caliper assembly over the brake disc.

Notice: Refer to Fastener Notice in the Preface section.

6. Install the NEW brake caliper anchor plate to knuckle retaining bolts (5).

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

Notice: 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 brake hose (2) to brake caliper banjo retaining bolt (4) and NEW copper brake hose sealing washers (3) to the 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 .
9. Remove the 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 apply 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 .