Opel Insignia Owners & Service Manuals

Opel Insignia: Repair Instructions

Front Disc Brake Pads Replacement (J60)

Removal Procedure

WARNING: Brake Dust Warning.

WARNING: Brake Fluid Irritant Warning.

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution

NOTE: Always replace disc brake pads in axle sets.

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

2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed before proceeding.

3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.

4. Raise and support the vehicle.

5. Remove the front tire and wheel assemblies.

6.

Disc Brakes

NOTE: Do NOT install the C-clamp (1) at connection of the front brake hose.

Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard disc brake pad.(1)

7. Using the C-clamp, compress the brake caliper piston fully into the brake caliper bore.(1)

8.

Disc Brakes

NOTE: Do NOT use any air tools to remove or install the brake caliper guide pin bolts. Use hand tools ONLY.

Brake Caliper Guide Pin Bolt(1)- Lower - Remove.

9.

Disc Brakes

Pivot the brake caliper upward and secure with heavy mechanics wire, or equivalent.(1)

10.

Disc Brakes

Front Disc Brake Outer Pad(2) - Remove.

11. Front Disc Brake Inner Pad(1) - Remove.

12.

Disc Brakes

Retainer Spring(1) - Remove and DISCARD.

13.

Disc Brakes

Front Disc Brake Pad Retaining Spring(1) - Remove and DISCARD[2x].

14.

Disc Brakes

NOTE: For the sake of clarity the illustration shows the brake caliper bracket sectioned.

Inspect the brake caliper guide pins (1)for freedom of movement, and inspect the condition of the guide pin boots (2). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

  • Restricted caliper guide pin movement
  • Looseness in the brake caliper mounting bracket
  • Seized or binding caliper guide pins
  • Split or torn boots

15. If a condition exists - Replace damaged components.

16.

Disc Brakes

Inspect the brake caliper piston and brake caliper piston boot (1). Observe the following:

  • Seized or binding piston
  • Boot not correct in piston groove
  • Boot twisted
  • Split or torn boot

17. If a condition exists - Replace damaged components.

Installation Procedure

1. Thoroughly clean the disc brake pad retainer spring contact area and surfaces of the brake caliper bracket of any corrosion and debris.

2.

Disc Brakes

Front Disc Brake Pad Retaining Spring(1) - Install NEW[2x].

3.

Disc Brakes

Retainer Spring(1) - Install NEW.

4.

Disc Brakes

Front Disc Brake Inner Pad(1) - Install.

5. Front Disc Brake Outer Pad(2) - Install.

6.

Disc Brakes

Ensure the brake caliper guide pin seal is fully seated in the groove of the brake caliper guide pin and the guide pin slides freely in caliper bracket bore.

NOTE: The lower brake caliper guide must seat (arrow) correctly in the brake caliper.

7. Pivot the brake caliper to the installed position.

8.

Disc Brakes

CAUTION: Fastener Caution.

Brake Caliper Guide Pin Bolt(1)- Lower - Install and tighten 47 N.m (35 lb ft) [2x].

9. Install the front tire and wheel assemblies. Tire and Wheel Removal and Installation.

10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

11. Slowly release the brake pedal.

12. Repeat steps (11 - 12)until a firm brake pedal is obtained.

This will properly seat the brake caliper pistons and brake pads.

13. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container.

Front Disc Brake Pads Replacement (JQ5)

Removal Procedure

WARNING: Brake Dust Warning. WARNING: Brake Fluid Irritant Warning.

WARNING: Use of eye goggles is necessary to prevent personal injury.

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution

NOTE: Always replace disc brake pads in axle sets.

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

2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.

3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.

4. Remove the front tire and wheel assemblies.

5.

Disc Brakes

Retract the brake caliper pistons.

NOTE: The brake pad spring is tensioned and has to be firmly hold in place when removing the brake pad pins.

6. Remove the brake pad pins (1) using a suitable drift and hammer. Hold on tight the brake pad spring (2) until first brake pad pin (1) has been removed.

7. Brake Pad Spring(2) - Remove.

8.

Disc Brakes

Front Disc Brake Pad(1) - Remove[2x].

Installation Procedure

1. Inspect the brake caliper piston boots for damage or deterioration. Replace the brake caliper piston boots if damaged or deteriorated.

2. Using a suitable spreader tool, carefully push back all 4 front brake caliper pistons until fully seated into brake caliper bores.

3. Clean the brake pad contact surfaces of the brake caliper from any debris or corrosion.

4.

Disc Brakes

Front Disc Brake Pad(1) - Install[2x].

5.

Disc Brakes

Install the brake pad pins (1) together with the brake pad spring (2). Drive the brake pad pins (1) into the brake caliper using a drift until fully seated.

First install one brake pad pin until fully seated. Thereafter insert the spring behind the pin and firmly press and hold brake pad spring into position. Now install second brake pad pin and check spring for correct seat.

6. Install the front tire and wheel assemblies.

7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

8. Slowly release the brake pedal.

9. Repeat steps (7 - 8) until a firm brake pedal is obtained.

This will properly seat the brake caliper pistons and brake pads.

10. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container.

11. Burnish the brake pads and rotors.

FRONT DISC BRAKE PADS REPLACEMENT (J17)

Removal Procedure

WARNING: Brake Dust Warning.

WARNING: Brake Fluid Irritant Warning.

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution

NOTE: Always replace disc brake pads in axle sets.

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

2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed before proceeding.

3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.

4. Raise and support the vehicle.

5. Remove the front tire and wheel assemblies.

6.

Disc Brakes

Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard disc brake pad.(1)

7. Using the C-clamp (1), compress the brake caliper piston fully into the brake caliper bore.

8.

Disc Brakes

Check the complete retraction of brake caliper piston by verifying that the distance a can not be reduced.

9.

Disc Brakes

NOTE: Do NOT use any air tools to remove or install the brake caliper guide pin bolts. Use hand tools ONLY.

Brake Caliper Guide Pin Bolt(1) - Lower - Loosen the bolt, but do NOT remove.

10.

Disc Brakes

Push back the brake caliper (1) by hand.

11. Ensure the gap a is big enough for loosening the inner brake pad.

12.

Disc Brakes

WARNING: Disc brake pads are adhered to the caliper piston using an adhesive patch. The disc brake pads must be separated from the caliper piston.

Do NOT insert the pry tool through bridge window to pry against the piston face. Prying at this location may damage the brake caliper piston. Failure to follow this warning may result in brake system failure and/or personal injury.

Loose the inner brake pad (1) by twisting a screwdriver (4)between inner brake pad (1)and brake caliper (2).

13.

Disc Brakes

NOTE: Do NOT use any air tools to remove or install the brake caliper guide pin bolts. Use hand tools ONLY.

Brake Caliper Guide Pin Bolt (1) - Upper - Remove.

14.

Disc Brakes

Pivot the brake caliper downward and secure with heavy mechanics wire, or equivalent. (1)

15.

Disc Brakes

Front Disc Brake Outer Pad(2) - Remove.

16. Front Disc Brake Inner Pad(1) - Remove.

17.

Disc Brakes

Front Disc Brake Pad Retaining Spring(1) - Remove and DISCARD[2x].

18.

Disc Brakes

NOTE: For the sake of clarity the illustration shows the brake caliper bracket sectioned.

Inspect the brake caliper guide pins (2) for freedom of movement, and inspect the condition of the guide pin boots (1). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

  • Restricted caliper guide pin movement
  • Looseness in the brake caliper mounting bracket
  • Seized or binding caliper guide pins
  • Split or torn boots

19. If a condition exists - Replace damaged components.

20.

Disc Brakes

Inspect the brake caliper piston and brake caliper piston boot (1). Observe the following:

  • Seized or binding piston
  • Boot not correct in piston groove
  • Boot twisted
  • Split or torn boot

21. If a condition exists - Replace damaged components.

Installation Procedure

1. Thoroughly clean the disc brake pad retainer spring contact area and surfaces of the brake caliper bracket of any corrosion and debris.

2.

Disc Brakes

Front Disc Brake Pad Retaining Spring(1) - Install NEW[2x].

3.

Disc Brakes

If installing NEW brake pads, remove the adhesive backing paper from the brake pad insulators.(1)

4.

Disc Brakes

Front Disc Brake Inner Pad(1) - Install.

5. Front Disc Brake Outer Pad(2) - Install.

CAUTION: The phenolic brake caliper piston can be damaged if it contacts the edges of the brake pads upon installation. To avoid phenolic brake caliper piston damage, carefully hold the brake pads against the rotor and do NOT allow the caliper piston to contact the edges of the brake pads while installing the caliper. If the brake caliper piston sustains any damage, the entire caliper will need to be replaced.

6. Ensure the brake caliper guide pin seal is fully seated in the groove of the brake caliper guide pin and the guide pin slides freely in caliper bracket bore.

7. Pivot the brake caliper to the installed position.

8.

Disc Brakes

Brake Caliper Guide Pin Bolt(1)- Upper - Install and tighten 47 N.m (35 lb ft).

9.

Disc Brakes

CAUTION: Fastener Caution.

Brake Caliper Guide Pin Bolt(1) - Lower - Tighten 47 N.m (35 lb ft).

10. Install the front tire and wheel assemblies. Tire and Wheel Removal and Installation.

11. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

12. Slowly release the brake pedal.

13. Repeat steps (11 – 12) until a firm brake pedal is obtained.

This will properly seat the brake caliper pistons and brake pads.

14. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container.

Rear Disc Brake Pads Replacement (GNC)

Removal Procedure

WARNING: Brake Dust Warning. WARNING: Brake Fluid Irritant Warning.

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution.

NOTE: Always replace disc brake pads in axle sets.

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

  • If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed before proceeding.
  • If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.

2. Set the park brake in Service Mode.

Manual Method

  1. Change the transmission gear to neutral or park position.
  2. Press and hold the push button start switch for 10 seconds, with the brake pedal not applied.

    This will place the vehicle in Service Mode (Ignition ON with the engine OFF).

  3. Press brake pedal several times until brake booster vacuum is empty.
  4. Press the brake pedal and press the park brake switch until the orange park brake lamp begins to flash. By keeping the brake pedal applied, release and re-press the park brake switch for approximately 5 seconds.
  5. Release the brake pedal. The orange park brake lamp extinguishes for a moment after which the rear brake calipers are retracting.

Scan Tool Method (only use if manual method fails)

  1. Install the scan tool to the vehicle and perform the rear brake caliper piston retract.

3. Raise and support the vehicle.

4. Remove the rear tire and wheel assemblies.

5.

Disc Brakes

NOTE:

  • Do NOT use any air tools to remove or install the brake caliper guide pin bolts. Use hand tools ONLY.
  • Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolt.(2)

Brake Caliper Guide Pin Bolt(1)- Lower - Remove.

6.

Disc Brakes

Pivot the brake caliper upward and secure with heavy mechanics wire, or equivalent.(1)

7.

Disc Brakes

Rear Disc Brake Pad(2)- Outer - Remove.

8. Rear Disc Brake Pad(1)- Inner - Remove.

9.

Disc Brakes

Rear Brake Shoe Hold Down Spring(1) - Remove and DISCARD[2x].

10.

Disc Brakes

NOTE: For the sake of clarity the illustration shows the rear brake caliper bracket sectioned.

Inspect the brake caliper guide pins (1)for freedom of movement, and inspect the condition of the guide pin boots (2). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

  • Restricted caliper guide pin movement
  • Looseness in the brake caliper mounting bracket
  • Seized or binding caliper guide pins
  • Split or torn boots

11. If a condition exists - Replace damaged components.

12.

Disc Brakes

Inspect the brake caliper piston and brake caliper piston boot (1). Observe the following:

  • Seized or binding piston
  • Boot not correct in piston groove
  • Boot twisted
  • Split or torn boot

13. If a condition exists - Replace damaged components.

Installation Procedure

NOTE: Do NOT rotate the brake caliper piston when retracting.

1. Carefully push the disc brake caliper piston into the caliper bore until fully seated, using a commercial brake caliper piston retracting shop tool.

2. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket of any debris and corrosion.

3.

Disc Brakes

Rear Brake Shoe Hold Down Spring(1) - Install NEW[2x].

4.

Disc Brakes

Rear Disc Brake Pad(1)- Inner - Install.

5. Rear Disc Brake Pad(2)- Outer - Install.

6.

Disc Brakes

Ensure the brake caliper guide pin seal is fully seated in the groove of the brake caliper guide pin and the guide pin slides freely in caliper bracket bore.

7. Pivot the brake caliper to the installed position.(1)

8.

Disc Brakes

CAUTION: Fastener Caution.

NOTE:

  • Do NOT use any air tools to remove or install the brake caliper guide pin bolts. Use hand tools ONLY.
  • Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolt.(2) Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brakes are applied.

Brake Caliper Guide Pin Bolt(1) - Lower - Install and tighten 35 N.m (26 lb ft).

9. Install the rear tire and wheel assemblies. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

11. Slowly release the brake pedal.

12. Repeat steps (11 - 12) until a firm brake pedal is obtained.

This will properly seat the brake caliper pistons and brake pads.

13. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container.

14. Reset the park brake system from Service Mode.

Manual Method

  1. Change the transmission gear to neutral or park position.
  2. Press and hold the push button start switch for 10 seconds, with the brake pedal not applied.

    This will place the vehicle in Service Mode (Ignition ON with the engine OFF).

  3. Press the brake pedal and pull the park brake switch until the orange park brake lamp extinguishes and the rear brake calipers are extending.
  4. Release the brake pedal.

Scan Tool Method (only use if manual method fails)

  1. Install the scan tool to the vehicle and perform the rear brake caliper piston extend.

REAR DISC BRAKE PADS REPLACEMENT (GNQ)

Removal Procedure

WARNING: Brake Dust Warning.

WARNING: Brake Fluid Irritant Warning.

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution.

NOTE: Always replace disc brake pads in axle sets.

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

  • If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed before proceeding.
  • If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.

2. Set the park brake in Service Mode.

Manual Method

  1. Change the transmission gear to neutral or park position.
  2. Press and hold the push button start switch for 10 seconds, with the brake pedal not applied.

    This will place the vehicle in Service Mode (Ignition ON with the engine OFF).

  3. Press brake pedal several times until brake booster vacuum is empty.
  4. Press the brake pedal and press the park brake switch until the orange park brake lamp begins to flash. By keeping the brake pedal applied, release and re-press the park brake switch for approximately 5 seconds.
  5. Release the brake pedal. The orange park brake lamp extinguishes for a moment after which the rear brake calipers are retracting.

Scan Tool Method (only use if manual method fails)

  1. Install the scan tool to the vehicle and perform the rear brake caliper piston retract.

3. Raise and support the vehicle.

4. Remove the rear tire and wheel assemblies. 5.

Disc Brakes

NOTE:

  • Do NOT use any air tools to remove or install the brake caliper guide pin bolts. Use hand tools ONLY.
  • Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolt.(2)

Brake Caliper Guide Pin Bolt(1) - Lower - Remove.

6.

Disc Brakes

Pivot the brake caliper upward and secure with heavy mechanics wire, or equivalent.(1)

7.

Disc Brakes

Rear Disc Brake Pad(1) - Outer - Remove.

8. Rear Disc Brake Pad(2) - Inner - Remove.

9.

Disc Brakes

Rear Brake Shoe Hold Down Spring(1) - Remove and DISCARD[2x].

10.

Disc Brakes

NOTE: For the sake of clarity the illustration shows the rear brake caliper bracket sectioned.

Inspect the brake caliper guide pins (2)for freedom of movement, and inspect the condition of the guide pin boots (1). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

  • Restricted caliper guide pin movement
  • Looseness in the brake caliper mounting bracket
  • Seized or binding caliper guide pins
  • Split or torn boots

11. If a condition exists - Replace damaged components.

12.

Disc Brakes

Inspect the brake caliper piston and brake caliper piston boot (1). Observe the following:

  • Seized or binding piston
  • Boot not correct in piston groove
  • Boot twisted
  • Split or torn boot

13. If a condition exists - Replace damaged components.

Installation Procedure

NOTE: Do NOT rotate the brake caliper piston when retracting.

1. Carefully push the disc brake caliper piston into the caliper bore until fully seated, using a commercial brake caliper piston retracting shop tool.

2. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket of any debris and corrosion.

3.

Disc Brakes

Rear Brake Shoe Hold Down Spring(1) - Install NEW[2x].

4.

Disc Brakes

Rear Disc Brake Pad(2) - Inner - Install.

5. Rear Disc Brake Pad(1) - Outer - Install.

6.

Disc Brakes

Ensure the brake caliper guide pin seal is fully seated in the groove of the brake caliper guide pin and the guide pin slides freely in caliper bracket bore.

7. Pivot the brake caliper to the installed position.(1)

8.

Disc Brakes

CAUTION: Fastener Caution.

NOTE:

  • Do NOT use any air tools to remove or install the brake caliper guide pin bolts. Use hand tools ONLY.
  • Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolt.(2) Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brakes are applied.

Brake Caliper Guide Pin Bolt(1) - Lower - Install and tighten 35N.m (26 lb ft).

9. Install the rear tire and wheel assemblies. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

11. Slowly release the brake pedal.

12. Repeat steps (11 - 12)until a firm brake pedal is obtained.

This will properly seat the brake caliper pistons and brake pads.

13. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container. Brake Master Cylinder Reservoir Filling.

14. Reset the park brake system from Service Mode.

Manual Method

  1. Change the transmission gear to neutral or park position.
  2. Press and hold the push button start switch for 10 seconds, with the brake pedal not applied.

    This will place the vehicle in Service Mode (Ignition ON with the engine OFF).

  3. Press the brake pedal and pull the park brake switch until the orange park brake lamp extinguishes and the rear brake calipers are extending.
  4. Release the brake pedal.

Scan Tool Method (only use if manual method fails)

  1. Install the scan tool to the vehicle and perform the rear brake caliper piston extend.

BRAKE PAD AND ROTOR BURNISHING

WARNING: Road test a vehicle under safe conditions and while obeying all traffic laws.

Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage.

Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system.

This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced.

1. Select a smooth road with little or no traffic.

2. Accelerate the vehicle to 48 km/h (30 mph).

NOTE: Use care to avoid overheating the brakes while performing this step.

3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock.

4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors.

Front Brake Caliper Replacement (JQ5)

Special Tools

EN-45059 Angle Meter

Equivalent regional tools: Special Tools.

WARNING: Brake Dust Warning.

WARNING: Brake Fluid Irritant Warning.

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution.

Removal Procedure

1. Remove the front tire and wheel assembly.

2. Front Disc Brake Pad - Remove.

3.

Disc Brakes

Brake Hose Fitting Bolt(3) - Remove.

4. Front Brake Hose(2) - Remove.

NOTE: The brake hose washers may be stuck to the brake caliper and/or the brake hose end.

5. Front Brake Hose Washer(4) - Remove and DISCARD[2x].

6. Cap the brake caliper inlet port to prevent brake fluid loss and contamination.

7. Cap the brake hose fitting to prevent brake fluid loss and contamination.

8.

Disc Brakes

Front Brake Caliper Bolt(1) - Remove[2x].

9. Front Brake Caliper(3) - Remove.

Installation Procedure

1. Prepare the brake caliper bolts and the caliper threaded holes for assembly:

  • Re-cut the bolt threads.
  • Re-cut the threaded holes.
  • Thoroughly clean the residue from the bolt threads with denatured alcohol or equivalent and allow to dry.
  • Thoroughly clean the residue from the threaded holes with denatured alcohol or equivalent and allow to dry.
  • Apply thread lock agent to 2/3 of the threaded length of the bolts.

2.

Disc Brakes

Front Brake Caliper(3) - Install.

CAUTION: Fastener Caution.

3. Front Brake Caliper Bolt(1) - Install and tighten[2x]

  1. First Pass: 150N.m (111 lb ft)
  2. Final Pass: 15 - 30 degrees - Use the special tool: EN-45059 meter

4.

Disc Brakes

Remove the caps from the brake caliper and the brake hose.

5. Front Brake Hose Washer(4) - Install NEW[2x].

6. Front Brake Hose(2) - Install.

7. Brake Hose Fitting Bolt(3) - Install and hand tighten.

WARNING: Make sure the brake hose is not twisted, tensioned or kinked after installation. With the suspension settled, check that there is no contact with the surrounding components when moving the steering from stop to stop. Failure to comply could result in damage to the brake hose and lead to severe or fatal injuries.

CAUTION: Fastener Caution.

8. Brake Hose Fitting Bolt(3) - Tighten 40 N.m (30 lb ft).

9. Front Disc Brake Pad - Install.

10. Bleed the brake system. 11. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

12. Slowly release the brake pedal.

13. Repeat steps (10 – 11)until a firm brake pedal is obtained.

This will properly seat the brake caliper pistons and brake pads.

14. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container. Brake Master Cylinder Reservoir Filling.

15. Install the front tire and wheel assembly.

FRONT BRAKE CALIPER REPLACEMENT (J60)

Removal Procedure

WARNING: Brake Dust Warning. WARNING: Use of eye goggles is necessary to prevent personal injury. WARNING: Brake Fluid Irritant Warning.

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution.

1. Raise and support the vehicle.

2. Remove the front tire and wheel assembly.

3.

Disc Brakes

Brake Hose Fitting Bolt (1) - Remove.

4. Front Brake Hose(2) - Remove.

NOTE: The front brake hose washers may stuck to the brake caliper and/or the brake hose end.

5. Front Brake Hose Washer(3) - Remove and DISCARD[2x].

6. Cap the brake hose fitting to prevent brake fluid loss and contamination.

7. Cap the brake caliper inlet port to prevent brake fluid loss and contamination.

8.

Disc Brakes

NOTE: Do NOT use any air tools to remove or install the brake caliper guide pin bolts. Use hand tools ONLY.

Brake Caliper Guide Pin Bolt(1) - [2x].

9.

Disc Brakes

Front Brake Caliper (1) - Remove.

10.

Disc Brakes

NOTE: For the sake of clarity the illustration shows the brake caliper bracket sectioned.

Inspect the brake caliper guide pins (2)for freedom of movement, and inspect the condition of the guide pin boots (1). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

  • Restricted caliper guide pin movement
  • Looseness in the brake caliper mounting bracket
  • Seized or binding caliper guide pins
  • Split or torn boots

11. If a condition exists - Replace damaged components.

Installation Procedure

1.

Disc Brakes

Front Brake Caliper (1) - Install.

2.

Disc Brakes

Ensure the 2 front brake caliper guides seat (arrow) correctly in the brake caliper.

3.

Disc Brakes

CAUTION: Fastener Caution.

Brake Caliper Guide Pin Bolt(1) - Install and tighten 47 N.m (35 lb ft) [2x].

4.

Disc Brakes

Remove the cap from the brake hose fitting.

5. Front Brake Hose Washer(3) - Install[2x] - Use NEW seals.

6. Front Brake Hose(2) - Install.

WARNING: Make sure the brake hose is not twisted, tensioned or kinked after installation. With the suspension settled, check that there is no contact with the surrounding components when moving the steering from stop to stop. Failure to comply could result in damage to the brake hose and lead to severe or fatal injuries.

7. Brake Hose Fitting Bolt (1) - Install and tighten 40 N.m (30 lb ft).

8. Bleed the brake system.

9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

10. Slowly release the brake pedal.

11. Repeat steps (9 – 10)until a firm brake pedal is obtained.

This will properly seat the brake caliper pistons and brake pads.

12. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container.

13. Install the front tire and wheel assembly.

Front Brake Caliper Replacement (J17)

Removal Procedure

WARNING: Brake Dust Warning.

WARNING: Use of eye goggles is necessary to prevent personal injury.

WARNING: Brake Fluid Irritant Warning.

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution.

1. Raise and support the vehicle.

2. Remove the front tire and wheel assembly.

3.

Disc Brakes

Brake Hose Fitting Bolt (1) - Remove.

4. Front Brake Hose(2) - Remove.

NOTE: The front brake hose washers may stuck to the brake caliper and/or the brake hose end.

5. Front Brake Hose Washer(3) - Remove and DISCARD[2x].

6. Cap the brake hose fitting to prevent brake fluid loss and contamination.

7. Cap the brake caliper inlet port to prevent brake fluid loss and contamination.

8.

Disc Brakes

NOTE: Do NOT use any air tools to remove or install the brake caliper guide pin bolts. Use hand tools ONLY.

Brake Caliper Guide Pin Bolt(1) - [2x].

9.

Disc Brakes

Front Brake Caliper (1) - Remove.

10.

Disc Brakes

NOTE: For the sake of clarity the illustration shows the brake caliper bracket sectioned.

Inspect the brake caliper guide pins (2) for freedom of movement, and inspect the condition of the guide pin boots (1). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

  • Restricted caliper guide pin movement
  • Looseness in the brake caliper mounting bracket
  • Seized or binding caliper guide pins
  • Split or torn boots

11. If a condition exists - Replace damaged components.

Installation Procedure

1.

Disc Brakes

Front Brake Caliper (1) - Install.

2.

Disc Brakes

Ensure the 2 front brake caliper guides seat (arrow) correctly in the brake caliper.

3.

Disc Brakes

CAUTION: Fastener Caution.

Brake Caliper Guide Pin Bolt(1) - Install and tighten 47 N.m (35 lb ft) [2x].

4.

Disc Brakes

Remove the cap from the brake hose fitting.

5. Front Brake Hose Washer(3) - Install[2x] - Use NEW seals.

6. Front Brake Hose(2) - Install.

WARNING: Make sure the brake hose is not twisted, tensioned or kinked after installation. With the suspension settled, check that there is no contact with the surrounding components when moving the steering from stop to stop. Failure to comply could result in damage to the brake hose and lead to severe or fatal injuries.

7. Brake Hose Fitting Bolt (1) - Install and tighten 40 N.m (30 lb ft).

8. Bleed the brake system.

9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

10. Slowly release the brake pedal.

11. Repeat steps (9 - 10)until a firm brake pedal is obtained.

This will properly seat the brake caliper pistons and brake pads.

12. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container.

13. Install the front tire and wheel assembly.

REAR BRAKE CALIPER REPLACEMENT (GNC)

Removal Procedure

WARNING: Brake Dust Warning.

WARNING: Use of eye goggles is necessary to prevent personal injury.

WARNING: Brake Fluid Irritant Warning.

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution.

1. Set the parking brake in Service Mode.

  1. Install a scan tool.
  2. Turn the ignition ON with the engine OFF.
  3. Select Electronic Brake Control Module.
  4. Select Control Functions.

NOTE: Do NOT apply any brake pressure during this step.

  1. Select Rear Brake Caliper Piston Retract.

2. Raise and support the vehicle.

3. Remove the rear tire and wheel assembly.

4.

Disc Brakes

Brake Hose Fitting Bolt (1) - Remove.

5. Rear Brake Hose(2) - Remove.

NOTE: The rear brake hose washers may stuck to the brake caliper and/or the brake hose end.

6. Rear Brake Hose Washer(3) - Remove and DISCARD[2x].

7. Cap the brake hose fitting to prevent brake fluid loss and contamination.

8. Cap the brake caliper inlet port to prevent brake fluid loss and contamination.

9.

Disc Brakes

NOTE:

  • Do NOT use any air tools to remove or install the brake caliper guide pin bolts. Use hand tools ONLY.
  • Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolt.(2)

Brake Caliper Guide Pin Bolt(1) - [2x].

10.

Disc Brakes

Electrical Connector(2)@Parking Brake Actuator - Disconnect.

11. Rear Brake Caliper(1) - Remove.

12. Parking Brake Actuator Replacement (GNC) Parking Brake Actuator Replacement (GNQ) - Remove.

13.

Disc Brakes

NOTE: For the sake of clarity the illustration shows the rear brake caliper bracket sectioned.

Inspect the brake caliper guide pins (1) for freedom of movement, and inspect the condition of the guide pin boots (2). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

  • Restricted caliper guide pin movement
  • Looseness in the brake caliper mounting bracket
  • Seized or binding caliper guide pins
  • Split or torn boots

14. If a condition exists - Replace damaged components.

Installation Procedure

1. Parking Brake Actuator Replacement (GNC) Parking Brake Actuator Replacement (GNQ) - Install.

2.

Disc Brakes

Rear Brake Caliper(1) - Install.

3. Electrical Connector(2)@Parking Brake Actuator - Connect.

4.

Disc Brakes

CAUTION: Fastener Caution.

NOTE:

  • Do NOT use any air tools to remove or install the brake caliper guide pin bolts. Use hand tools ONLY.
  • Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolt.(2) Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brakes are applied.

Brake Caliper Guide Pin Bolt(1) - Install and tighten 35 N.m (26 lb ft) [2x].

5.

Disc Brakes

Remove the cap from the brake hose fitting.

6. Rear Brake Hose Washer(3) - Install[2x] - Use NEW seals.

7. Rear Brake Hose(2) - Install.

8. Brake Hose Fitting Bolt (1) - Install and tighten 40 N.m (30 lb ft).

9. Bleed the brake system.

10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

11. Slowly release the brake pedal.

12. Repeat steps (9 – 10)until a firm brake pedal is obtained.

This will properly seat the brake caliper pistons and brake pads.

13. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container.

14. Tire and Wheel Removal and Installation - Install.

15. Leave the parking brake Service Mode.

The park brake system calibrates autonomously.

REAR BRAKE CALIPER REPLACEMENT (GNQ)

Removal Procedure

WARNING: Brake Dust Warning.

WARNING: Use of eye goggles is necessary to prevent personal injury.

WARNING: Brake Fluid Irritant Warning.

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution.

1. Raise and support the vehicle.

2. Remove the rear tire and wheel assembly.

3. Parking Brake Actuator Replacement (GNC) Parking Brake Actuator Replacement (GNQ) - Remove.

4.

Disc Brakes

Brake Hose Fitting Bolt (2) - Remove.

5. Rear Brake Hose(3) - Remove.

NOTE: The rear brake hose washers may stuck to the brake caliper and/or the brake hose end.

6. Rear Brake Hose Washer(1) - Remove and DISCARD[2x].

7. Cap the brake hose fitting to prevent brake fluid loss and contamination.

8. Cap the brake caliper inlet port to prevent brake fluid loss and contamination.

9.

Disc Brakes

NOTE:

  • Do NOT use any air tools to remove or install the brake caliper guide pin bolts. Use hand tools ONLY.
  • Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolt.(1)

Brake Caliper Guide Pin Bolt(2) - [2x].

10.

Disc Brakes

Rear Brake Caliper(1) - Remove.

11.

Disc Brakes

NOTE: For the sake of clarity the illustration shows the rear brake caliper bracket sectioned.

Inspect the brake caliper guide pins (2)for freedom of movement, and inspect the condition of the guide pin boots (1). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

  • Restricted caliper guide pin movement
  • Looseness in the brake caliper mounting bracket
  • Seized or binding caliper guide pins
  • Split or torn boots

12. If a condition exists - Replace damaged components.

Installation Procedure

1.

Disc Brakes

Rear Brake Caliper(1) - Install.

2.

Disc Brakes

CAUTION: Fastener Caution.

NOTE:

  • Do NOT use any air tools to remove or install the brake caliper guide pin bolts. Use hand tools ONLY.
  • Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolt.(1)Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brakes are applied.

Brake Caliper Guide Pin Bolt(2) - Install and tighten 35 N.m (26 lb ft) [2x].

3.

Disc Brakes

Remove the cap from the brake hose fitting.

4. Rear Brake Hose Washer(1) - Install[2x] - Use NEW seals.

5. Rear Brake Hose(3) - Install.

6. Brake Hose Fitting Bolt (2) - Install and tighten 40 N.m (30 lb ft).

7. Parking Brake Actuator Replacement (GNC) Parking Brake Actuator Replacement (GNQ) - Install.

8. Bleed the brake system.

9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

10. Slowly release the brake pedal.

11. Repeat steps (9 - 10) until a firm brake pedal is obtained.

This will properly seat the brake caliper pistons and brake pads.

12. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container.

13. Tire and Wheel Removal and Installation - Install.

Front Brake Caliper Overhaul (J60)

Disassembly Procedure

WARNING: Brake Dust Warning.

WARNING: Brake Fluid Irritant Warning.

WARNING: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury.

CAUTION: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged.

1. Front Brake Caliper - Remove.

2.

Disc Brakes

Bleeder Valve (1) and Cap (2) - Remove.

3.

Disc Brakes

NOTE: Direct low-pressure, compressed air through the brake caliper fluid inlet.

Brake Caliper Piston (1) - Remove.

4. Brake Caliper Piston Dust Boot (2) - Remove and DISCARD.

5.

Disc Brakes

NOTE: Use a wooden or plastic tool to remove the seal.

Brake Caliper Piston Seal (1) - Remove and DISCARD.

6. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly.

7. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly.

8. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent.

9. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air.

NOTE: Do NOT use abrasives to clean the brake caliper piston.

10. Inspect the caliper piston for cracks, scoring, and/or damage to the plating. Replace the caliper piston if any of these conditions exist.

11. Inspect the caliper mounting holes for cracks, scoring, pitting, rust and/or excessive corrosion.

Replace the caliper assembly if any of these conditions exist.

Assembly Procedure

1.

Disc Brakes

Lubricate the NEW caliper piston seal with brake fluid from a clean, sealed brake fluid container.

2. Brake Caliper Piston Seal (1) - Install.

3. Apply a thin coat of brake fluid from a clean, sealed brake fluid container to the brake caliper bore.

4.

Disc Brakes

NOTE: Seat the NEW caliper piston dust boot in the groove of the brake caliper piston.

Brake Caliper Piston (1)@ Brake Caliper Piston Dust Boot (2) - Install.

5. Compress the caliper piston to the bottom of the caliper bore.

6. Fully seat the piston dust boot seal into caliper counterbore.

7.

Disc Brakes

CAUTION: Fastener Caution.

Bleeder Valve (1) - Install 10 N.m (89 lb in).

8. Cap (2) - Install.

9. Front Brake Caliper - Install.

FRONT BRAKE CALIPER OVERHAUL (JQ5)

Disassembly Procedure

WARNING: Brake Dust Warning.

WARNING: Brake Fluid Irritant Warning.

WARNING: Use of eye goggles is necessary to prevent personal injury.

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution.

1. Remove the brake caliper from the vehicle.

2.

Disc Brakes

WARNING: Caliper Piston Removing Warning.

CAUTION: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged.

CAUTION: Do not remove the caliper external crossover tube or separate the 2 caliper halves. If the crossover tube and/or the caliper halves are separated, corrosion and damage to the caliper may result.

NOTE: Remove only one side of caliper pistons at a time. Use a wooden block and tie straps to secure the pistons on the non-removal side.

Remove the brake caliper pistons from the caliper bores by carefully directing low pressure compressed air (1) into the caliper through a fluid inlet hole.

3.

Disc Brakes

Remove the piston dust boot seals (3) from the seal counterbores in the caliper. Discard the dust boot seals (3).

4. Remove the bleeder valve caps (1).

5. Remove the bleeder valves (2).

6. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bores, replace the caliper assembly.

7. If light rust or light corrosion are present in the caliper bores, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly.

NOTE: Do not use abrasives to clean the brake caliper pistons.

8. Clean the brake caliper piston bores and seal counterbores, and the caliper pistons (4) with denatured alcohol, or equivalent.

9. Dry the caliper piston bores and counterbores, and the pistons (4) with non-lubricated, filtered, compressed air.

10. Inspect the caliper pistons (4) for cracks, scoring, and/or damage to the plating. Replace the caliper pistons (4) if any of these conditions exist.

11. Inspect the caliper mounting holes for cracks, scoring, pitting, rust, and/or excessive corrosion.

Replace the caliper assembly if any of these conditions exist.

Installation Procedure

1.

Disc Brakes

Lubricate the cleaned caliper pistons (4) with a thin coat of brake fluid from a clean, sealed brake fluid container.

NOTE: Caliper pistons, and piston dust boot seals are of different sizes and are not interchangeable. Use care when reassembling.

2. Install the new caliper piston dust boot seals (3) over the caliper pistons (4) and make sure that the dust boots outer lips seat properly into the pistons grooves.

NOTE: Caliper pistons, and piston dust boot seals are of different sizes and not interchangeable. Use care when reassembling.

3. Install the bottom half of the caliper pistons (4) into the caliper bores.

4. Compress the caliper pistons (4) to the bottom of the caliper bores.

5. Fully seat the caliper piston dust boot seals (3) into the caliper counterbores.

CAUTION: Fastener Caution.

6. Install the bleeder valves (2) to the caliper and tighten them to 17 N.m (13 lb ft).

7. Install the bleeder valve caps (1).

8. Install the brake caliper to the vehicle.

FRONT BRAKE CALIPER BRACKET REPLACEMENT

Special Tools

EN-45059 Angle Meter

Equivalent regional tools: Special Tools.

WARNING: Brake Dust Warning.

Removal Procedure

1. Raise and support the vehicle.

2. Remove the front tire and wheel assembly.

CAUTION: Brake Caliper Supporting to Prevent Hose Damage Caution.

NOTE: Do NOT disconnect the brake hoses from the calipers.

3. Remove the brake caliper assembly and support with heavy mechanics wire.

4. Front Disc Brake Pad & Front Disc Brake Pad Retaining Spring - Remove.

5.

Disc Brakes

NOTE: The upper guide pin has a bevel (arrow).

Front Brake Caliper Guide Pin- Upper(1) - Remove.

6. Front Brake Caliper Guide Pin- Lower(2) - Remove.

7. Front Brake Caliper Guide Pin Seal(3) - Remove[2x].

8.

Disc Brakes

Front Brake Caliper Bracket Bolt(1) - Remove[2x].

9. Front Brake Caliper Bracket(2) - Remove.

Installation Procedure

1. Prepare the brake caliper bracket bolts and the bracket threaded holes for assembly:

  • Re-cut the bolt threads.
  • Re-cut the threaded holes.
  • Thoroughly clean the residue from the bolt threads with denatured alcohol or equivalent and allow to dry.
  • Thoroughly clean the residue from the threaded holes with denatured alcohol or equivalent and allow to dry.
  • Apply thread lock agent to 2/3 of the threaded length of the bolts.

2.

Disc Brakes

Front Brake Caliper Bracket(2) - Install.

CAUTION: Fastener Caution.

3. Front Brake Caliper Bracket Bolt(1) - Install and tighten[2x].

  1. First Pass: 150 N.m (111 lb ft)
  2. Final Pass: 15 - 30 degrees - Use the special tool: EN-45059 meter

4.

Disc Brakes

Front Brake Caliper Guide Pin Seal(3) - Install[2x].

5. Apply a thin coat of special guide pin grease to the guide pins and insert a small amount of this grease into the guide pin holes.

NOTE:

  • The upper guide pin has a bevel (arrow).
  • Ensure the brake caliper guide pin seal is fully seated in the groove of the brake caliper guide pin and the guide pin slides freely in caliper bracket bore.
  • Gently lift the edge of the guide pin seal while pushing the guide pin into the caliper bracket bore to expel any trapped air.

6. Front Brake Caliper Guide Pin- Upper(1) - Install

NOTE:

  • Ensure the brake caliper guide pin seal is fully seated in the groove of the brake caliper guide pin and the guide pin slides freely in caliper bracket bore.
  • Gently lift the edge of the guide pin seal while pushing the guide pin into the caliper bracket bore to expel any trapped air.

7. Front Brake Caliper Guide Pin- Lower(2) - Install.

8. Front Disc Brake Pad & Front Disc Brake Pad Retaining Spring - Install.

9. Front Brake Caliper - Install.

10. Install the front tire and wheel assembly.

Rear Brake Caliper Bracket Replacement (GNC)

Special Tools

EN-45059 Angle Meter

Equivalent regional tools: Special Tools.

WARNING: Brake Dust Warning.

Removal Procedure

1. Raise and support the vehicle.

2. Remove the rear tire and wheel assembly.

CAUTION: Brake Caliper Supporting to Prevent Hose Damage Caution.

NOTE:

  • Do NOT disconnect the brake hoses from the calipers.
  • Do NOT remove the parking brake actuator from the caliper.

3. Remove the brake caliper assembly and support with heavy mechanics wire.

4. Rear Disc Brake Pad & Rear Brake Shoe Hold Down Spring - Remove.

5.

Disc Brakes

NOTE: The upper guide pin has a bushing (arrow).

Rear Brake Caliper Guide Pin- Upper(1) - Remove.

6. Rear Brake Caliper Guide Pin- Lower(2) - Remove.

7. Rear Brake Caliper Guide Pin Boot(3) - Remove[2x].

8.

Disc Brakes

Rear Brake Caliper Bracket Bolt(1, 3) - Remove[2x].

9. Rear Brake Caliper Bracket(2) - Remove.

Installation Procedure

1. Prepare the brake caliper bracket bolts and the bracket threaded holes for assembly:

  • Re-cut the bolt threads.
  • Re-cut the threaded holes.
  • Thoroughly clean the residue from the bolt threads with denatured alcohol or equivalent and allow to dry.
  • Thoroughly clean the residue from the threaded holes with denatured alcohol or equivalent and allow to dry.
  • Apply thread lock agent to 2/3 of the threaded length of the bolts.

2.

Disc Brakes

Rear Brake Caliper Bracket(3) - Install.

CAUTION: Fastener Caution.

3. Rear Brake Caliper Bracket Bolt(1, 3) - Install and tighten[2x]

  1. First Pass: 100 N.m (74 lb ft)
  2. Final Pass: 15 - 30 degrees - Use the special tool: EN-45059 meter

4.

Disc Brakes

Rear Brake Caliper Guide Pin Boot(3) - Install[2x].

5. Apply a thin coat of special guide pin grease to the guide pins and insert a small amount of this grease into the guide pin holes.

NOTE:

  • The upper guide pin has a bushing (arrow).
  • Ensure the brake caliper guide pin seal is fully seated in the groove of the brake caliper guide pin and the guide pin slides freely in caliper bracket bore.
  • Gently lift the edge of the guide pin seal while pushing the guide pin into the caliper bracket bore to expel any trapped air.

6. Rear Brake Caliper Guide Pin- Upper(1) - Install.

NOTE:

  • Ensure the brake caliper guide pin seal is fully seated in the groove of the brake caliper guide pin and the guide pin slides freely in caliper bracket bore.
  • Gently lift the edge of the guide pin seal while pushing the guide pin into the caliper bracket bore to expel any trapped air.

7. Rear Brake Caliper Guide Pin- Lower(2) - Install.

8. Rear Disc Brake Pad & Rear Brake Shoe Hold Down Spring - Install.

9. Rear Brake Caliper - Install.

10. Install the rear tire and wheel assembly.

REAR BRAKE CALIPER BRACKET REPLACEMENT (GNQ)

Special Tools

EN-45059 Angle Meter

Equivalent regional tools:Special Tools.

WARNING: Brake Dust Warning.

Removal Procedure

1. Raise and support the vehicle. 2. Remove the rear tire and wheel assembly.

CAUTION: Brake Caliper Supporting to Prevent Hose Damage Caution.

NOTE:

  • Do NOT disconnect the brake hoses from the calipers.
  • Do NOT remove the parking brake actuator from the caliper.

3. Remove the brake caliper assembly and support with heavy mechanics wire.

4. Rear Disc Brake Pad & Rear Brake Shoe Hold Down Spring - Remove.

5.

Disc Brakes

Rear Brake Caliper Guide Pin- Upper(1) - Remove.

NOTE: The lower guide pin has a bushing (arrow).

6. Rear Brake Caliper Guide Pin- Lower(3) - Remove.

7. Rear Brake Caliper Guide Pin Boot(2) - Remove[2x].

8.

Disc Brakes

Rear Brake Caliper Bracket Bolt(2) - Remove[2x].

9. Rear Brake Caliper Bracket(1) - Remove.

Installation Procedure

1. Prepare the brake caliper bracket bolts and the bracket threaded holes for assembly:

  • Re-cut the bolt threads.
  • Re-cut the threaded holes.
  • Thoroughly clean the residue from the bolt threads with denatured alcohol or equivalent and allow to dry.
  • Thoroughly clean the residue from the threaded holes with denatured alcohol or equivalent and allow to dry.
  • Apply thread lock agent to 2/3 of the threaded length of the bolts.

2.

Disc Brakes

Rear Brake Caliper Bracket(1) - Install.

CAUTION: Fastener Caution.

3. Rear Brake Caliper Bracket Bolt(2) - Install and tighten[2x].

  1. First Pass: 100 N.m (74 lb ft)
  2. Final Pass: 15 - 30 degrees - Use the special tool: EN-45059 meter

4.

Disc Brakes

Rear Brake Caliper Guide Pin Boot(2) - Install[2x].

5. Apply a thin coat of special guide pin grease to the guide pins and insert a small amount of this grease into the guide pin holes.

NOTE:

  • The lower guide pin has a bushing (arrow).
  • Ensure the brake caliper guide pin seal is fully seated in the groove of the brake caliper guide pin and the guide pin slides freely in caliper bracket bore.
  • Gently lift the edge of the guide pin seal while pushing the guide pin into the caliper bracket bore to expel any trapped air.

6. Rear Brake Caliper Guide Pin- Lower(3) - Install.

NOTE:

  • Ensure the brake caliper guide pin seal is fully seated in the groove of the brake caliper guide pin and the guide pin slides freely in caliper bracket bore.
  • Gently lift the edge of the guide pin seal while pushing the guide pin into the caliper bracket bore to expel any trapped air.

7. Rear Brake Caliper Guide Pin- Upper(1) - Install.

8. Rear Disc Brake Pad & Rear Brake Shoe Hold Down Spring - Install.

9. Rear Brake Caliper - Install.

10. Install the rear tire and wheel assembly.

FRONT BRAKE ROTOR REPLACEMENT (JQ5)

Disc Brakes

WARNING: Brake Dust Warning.

Preliminary Procedures

1. Front Disc Brake Pads Replacement (J60)Front Disc Brake Pads Replacement (JQ5)Front Disc Brake Pads Replacement (J17).

CAUTION: Brake Caliper Supporting to Prevent Hose Damage Caution.

NOTE: Do NOT disconnect the brake hoses from the calipers.

2. Remove the brake caliper assembly and support with heavy mechanics wire.

  1. Front Brake Rotor Bolt
    CAUTION: Fastener Caution
    Tighten 9 N.m (80 lb in)
  2. Front Brake Rotor
    Procedure
    1. Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces.
    2. Always replace brake rotors in axle sets. After brake rotor replacement it is essential to replace the brake pads in axle sets.

FRONT BRAKE ROTOR REPLACEMENT (J17, J60)

Disc Brakes

WARNING: Brake Dust Warning

Preliminary Procedures

CAUTION: Brake Caliper Supporting to Prevent Hose Damage Caution

NOTE: Do NOT disconnect the brake hoses from the calipers.

1. Remove the brake caliper assembly and support with heavy mechanics wire. Front Brake Caliper Replacement (JQ5)Front Brake Caliper Replacement (J60)Front Brake Caliper Replacement (J17).

2. Front Disc Brake Pads Replacement (J60)Front Disc Brake Pads Replacement (JQ5)Front Disc Brake Pads Replacement (J17).

3. Front Brake Caliper Bracket Replacement.

  1. Front Brake Rotor Bolt
    CAUTION: Fastener Caution
    Tighten 9 N.m (80 lb in)
  2. Front Brake Rotor
    Procedure
    1. Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces.
    2. Always replace brake rotors in axle sets. After brake rotor replacement it is essential to replace the brake pads in axle sets.

Rear Brake Rotor Replacement

Disc Brakes

WARNING: Brake Dust Warning.

Preliminary Procedures

CAUTION: Brake Caliper Supporting to Prevent Hose Damage Caution

NOTE: Do NOT disconnect the brake hoses from the calipers.

1. Remove the brake caliper assembly and support with heavy mechanics wire. Rear Brake Caliper Replacement (GNC)Rear Brake Caliper Replacement (GNQ).

2. Rear Disc Brake Pads Replacement (GNC)Rear Disc Brake Pads Replacement (GNQ).

3. Rear Brake Caliper Bracket Replacement (GNC)Rear Brake Caliper Bracket Replacement (GNQ).

  1. Rear Brake Rotor Bolt
    CAUTION: Fastener Caution
    Tighten 9N.m (80 lb in)
  2. Rear Brake Rotor
    Procedure
    1. Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces.
    2. Always replace brake rotors in axle sets. After brake rotor replacement it is essential to replace the brake pads in axle sets.

FRONT BRAKE SHIELD REPLACEMENT

Removal Procedure

WARNING: Brake Dust Warning

1. Raise and support the vehicle.

2. Remove the front tire and wheel assembly.

3.

Disc Brakes

Front Wheel Bearing and Hub Assembly(1) - Remove.

4.

Disc Brakes

Front Brake Shield (1) - Remove.

Installation Procedure

1.

Disc Brakes

Front Brake Shield (1) - Install.

2.

Disc Brakes

Front Wheel Bearing and Hub Assembly(1) - Install.

3. Install the front tire and wheel assembly.

REAR BRAKE SHIELD REPLACEMENT

Removal Procedure

WARNING: Brake Dust Warning

1. Raise and support the vehicle.

2. Remove the tire and wheel assembly.

3.

Disc Brakes

Rear Wheel Bearing and Hub Assembly(1)Remove.

4.

Disc Brakes

Rear Brake Shield(1) - Remove

Installation Procedure

1.

Disc Brakes

Rear Brake Shield(1) - Install.

2.

Disc Brakes

Rear Wheel Bearing and Hub Assembly(1) Install.

3. Install the tire and wheel assembly.

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     Fuel and Evaporative Emission Pipe Warning

    WARNING: In order to reduce the risk of fire and personal injury observe the following items: Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes Do not hammer directly on the fuel harness body cl

     Schematic Wiring Diagrams

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