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HOMESERVICE MANUALSCHEVROLET2008HHR LT, 2.4 P, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 373 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSFRONT BRAKE CALIPER OVERHAULASSEMBLY PROCEDURE
2008 Chevrolet HHR LT, 2.4 P, Automatic

Assembly Procedure

2008 Chevrolet HHR LT, 2.4 P, AutomaticSECTION Assembly Procedure
WARNING: This page is about a different car, the 2010 Chevrolet HHR. 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. CAUTION: Refer to Fastener Caution .
  9. Install the bleeder valve to the caliper and tighten 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 .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.