For 1990-2009 cars

Several important factors are frequently overlooked when performing brake service. The following list must be considered and followed when appropriate:

1. Proper machining of brake rotors is not a simple operation. Make sure the brake lathe is well maintained. Keep it clean at all times. Handle attachment hardware with care. Damaged hardware will not machine rotors or drums accurately. Closely inspect the surface finish of machined rotors and drums. Make sure the cutting tips remain in good condition. Use a dial indicator to make sure rotors turn squarely on the brake lathe.
2. Keep all installed brake parts as clean as possible. Make sure to clean machined brake rotors and brake drums with a spray solvent (Saturn Brake and Choke Cleaner P/N 21007432 or equivalent). Always wipe off machined brake rotor surfaces with a lint-free shop towel after cleaning.
3. Thickness variation of rotors due to wear is a major cause of brake pulsation. Using a micrometer, check for excessive thickness variation whenever a customer comments on brake pulsation.

Important: Make sure calipers slide freely on their pins. Make sure brake pads move freely in their brackets.

4. Lateral rotor runout and restricted pads together are the leading cause of uneven brake rotor wear. Therefore, this combination leads directly to brake pulsation.
5. Uniform wheel bolt torque is very important. Uneven torque can distort brake rotors, causing excessive lateral brake rotor runout. A hand-held torque wrench must be used to secure wheel bolts using a crisscross tightening pattern, even when a torque stick and an air-powered impact gun are used.

Notice: Refer to Fastener Notice in the Preface section.

Caution: Different wheel bolts are required for steel and aluminum wheels. If the wrong wheel bolts are used, they may loosen and come off, permitting the wheel to separate from the vehicle. To help avoid personal injury and vehicle damage, always refer to the parts catalog to verify the correct wheel bolt and wheel combination is used.

6. Install the wheel bolts and tighten in a crisscross pattern.

6.1. | Hand tighten all 5 wheel bolts.

6.2. | Use a torque wrench to initially tighten the wheel bolts using a crisscross pattern.

Tighten
Tighten the wheel bolts (initial torque) to 63 N·m (46 lb ft).

6.3. | Use a torque wrench to final tighten the wheel bolts using a crisscross pattern.

Tighten
Tighten the wheel bolts (final torque) to 125 N·m (92 lb ft).

7. After the rotors/drums and the brake pads/shoes have been replaced, proper break-in promotes both longer life and quieter, smoother brake operation.

### Breaking in New Brake Pads and New Brake Shoes

Proper break-in of new brake pads and new brake shoes promotes both longer brake life and quieter, smoother brake operation. To obtain proper break-in, follow this procedure:

From 48-64 km/h (30-40 mph), apply the brakes gently until the vehicle slows nearly to a stop. Accelerate the vehicle back to 48-64 km/h (30-40 mph) and drive long enough for the brakes to cool -- 30-40 seconds. Repeat this process 5 times, each time allowing sufficient time between stops for the brakes to cool.

Complete the break-in procedure by gently slowing the vehicle from 89-32 km/h (55-20 mph) 4 times. Allow 30-40 seconds between stops for the brakes to cool. This break-in procedure will reduce brake noise and increase brake life and performance.