Spark

Front Brake Caliper Replacement

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

Warning: Refer to Brake Fluid Irritant Warning 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-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 the brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .



6. Remove the brake hose-to-calliper bolt (1) from the brake calliper.
7. Remove the brake hose (3) from the brake calliper
8. Remove and discard the 2 copper brake hose washers (2). These washers may be stuck to the brake caliper and/or the brake hose end (3).
9. Cap or plug the opening in the brake calliper and the brake hose to prevent fluid loss and contamination.



10. Remove the brake calliper guide pin bolts (1).
11. Remove the brake calliper from the calliper brackets.
12. Inspect the brake calliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

•	Restricted calliper guide pin movement

•	Looseness in the brake calliper mounting bracket

•	Seized and binding calliper guide pins

•	Split or torn boots

13. If any of the conditions listed are found, the brake calliper guide pins and/or boots require replacement.

1. Install the brake calliper to the brake calliper bracket.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the brake calliper guide pin bolts (1) and tighten to 28 N·m (21 lb ft).



3. Remove the caps or plugs from the brake caliper opening and the brake hose (3).

Note: Do not reuse the copper brake hose washers.

4. Install NEW copper brake hose washers (2) to the brake hose-to-calliper bolt (1) and to the brake hose (3).
5. Install the brake hose (3) and the brake hose-to-calliper bolt (1) to the brake calliper and tighten to 40 N·m (30 lb ft).
6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding : Pressure → Manual .
7. Install the tyre and wheel assembly. Refer to Tire and Wheel Removal and Installation .
8. Lower the vehicle.
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. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake calliper pistons and brake pads.