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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 Overhaul › Assembly Procedure

Assembly 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: Exploded View Of Brake Caliper
    GM1212583Courtesy of GENERAL MOTORS CORP.
  1. Lubricate the new piston seal (4) with GM approved, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
  2. Install the lubricated, new piston seal (4) into the caliper bore.
  3. Apply a thin coat of GM approved, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container onto the outer surface area of the caliper piston (3).
    4. Fig 2: Identifying Caliper Piston & Piston Dust Boot Seal
    GM777638Courtesy of GENERAL MOTORS CORP.
  4. Install the bottom half of the caliper piston (2) into the caliper bore.
  5. Install the new piston dust boot seal (1) over the caliper piston (2).
  6. Compress the caliper piston (2) to the bottom of the caliper bore.
  7. Fully seat the piston dust boot seal (1) into caliper counterbore.
    8. Fig 3: View Of Dust Boot Retaining Ring
    GM777640Courtesy of GENERAL MOTORS CORP.
  8. Install the retaining ring that secures the dust boot to the caliper housing.
    9. NOTE: Refer to Fastener Notice in Cautions and Notices.
  9. Install the bleeder valve to the caliper.

    Tighten:  Tighten the brake bleeder valve to 11 N.m (97 lb in).

  10. Install the bleeder valve cap.
  11. Install the brake caliper to the vehicle. Refer to Front Brake Caliper Replacement .
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