Disassembly Procedure

WARNING: This page is about a different car, the 2010 Pontiac G5 and 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Verify that the lower (small) O-ring of each injector does not remain in the lower manifold in order to reduce the risk of fire and personal injury.
If the O-ring is not removed with the injector, the replacement injector with new O-rings will not seat properly in the injector socket. Improper seating could cause a fuel leak.

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.

NOTE: It will be necessary to fabricate one or more blocks of wood to the following dimensions to be used during this procedure:

Must fabricate 1 block: 19 mm (3/4 in) X 51 mm (2 in) X 51 mm (2 in)
Optional to fabricate 1 block, rather than using an old brake pad: 19 mm (3/4 in) X 51 mm (2 in) X 127 mm (5 in)
Optional to fabricate 1 block to cushion piston removal: 19 mm (3/4 in) X 51 mm (2 in) X 127 mm (5 in)

Remove the brake caliper from the vehicle. Refer to Front Brake Caliper Replacement (With RPO LNF) .
Drain the brake fluid from the brake caliper.
Place the caliper in a vise using plastic vise caps or suitable material to protect the caliper mounting bosses from the vise jaws.

Fig 1: Blocking Piston Bores

Courtesy of GENERAL MOTORS CORP.

Place an old brake pad or the fabricated 127 mm (5 in) long block of wood over 2 adjoining piston bores and secure in place with a non-marring C-clamp.
Place the fabricated 51 mm (2 in) long block of wood over one of the opposing piston bores and secure it in place with a non-marring C-clamp.
Use clean cloths or the other fabricated 127 mm (5 in) long block of wood to pad the interior of caliper housing during removal of the piston.
Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. If the dust boot seal slides out with the piston, remove the dust boot seal from piston and reinstall the seal into the caliper.
Move the fabricated 51 mm (2 in) long block of wood over the emptied piston bore and secure it in place with a non-marring C-clamp.
Move the clean cloths or the other fabricated 127 mm (5 in) long block of wood to pad the interior of caliper housing during the removal of the piston.
Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. If the dust boot seal slides out with the piston, remove the dust boot seal from piston and reinstall the seal into the caliper.
Repeat steps 4 through 10 for the opposite side of the caliper.

Fig 2: Removing Dust Boot Seals

Courtesy of GENERAL MOTORS CORP.

Using care to not scratch or mar the painted surfaces or piston bore, remove all the dust boot seals using a flat-bladed tool. Discard the dust boot seals.

Fig 3: Exploded View Of Caliper

Courtesy of GENERAL MOTORS CORP.

Using wooden or plastic tool, remove the piston seals (5) from the piston bores. Discard the piston seals.
Remove both brake caliper bleeder caps and valves (1, 2).
Remove the caliper from the vise and clean the entire caliper with denatured alcohol, or equivalent.
Dry the caliper piston bores with non-lubricated filtered air. Make sure the external crossover pipe and the internal fluid ports are clean and free of obstructions.
Inspect the caliper cylinder bores and piston seal counter-bores for scratches, cracks, pitting, and/or corrosion.

NOTE: Do NOT clean the caliper piston bores by honing or cleaning with abrasives.

If the caliper piston bores are scratched, cracked, or pitted, or if corrosion cannot be cleaned with denatured alcohol, replace the caliper assembly.