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Home >> Saturn >> 2004 >> Ion Red Line >> Repair and Diagnosis >> External Pages >> Different car >> Section 141 (Disc Brake System) >> Repair Instructions >> Front Brake Caliper Replacement >> Installation Procedure
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Installation Procedure

WARNING: This page is about a different car, the 2007 Saturn Ion Red Line, 2007 Saturn Ion 3, and 2007 Saturn Ion 2. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Locating Brake Caliper Guide Pin Bolts
    GM1385619Courtesy of GENERAL MOTORS CORP.
  1. Install the brake caliper to the brake caliper bracket.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the brake caliper guide pin bolts (1).

    Tighten:  Tighten the bolts to 34 N.m (25 lb ft).

    3. Fig 2: View Of Front Brake Hose
    GM890982Courtesy of GENERAL MOTORS CORP.
  3. Remove the caps or plugs from the brake caliper opening and the brake hose (3).
    4. IMPORTANT: Do not reuse the copper brake hose gaskets.
  4. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3).
  5. Install the brake hose and the brake hose-to-brake caliper bolt to the brake caliper.

    Tighten:  Tighten the bolt to 48 N.m (35 lb ft).

  6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes.
  7. Remove the wheel nuts retaining the brake rotor to the wheel hub.
  8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (4 Lug Wheel) or Tire and Wheel Removal and Installation (5 Lug Wheel) in Tires and Wheels.
  9. Lower the vehicle.
  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. 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 caliper pistons and brake pads.
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