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2006 Chevrolet Aveo LT

2006 BRAKES Disc Brakes - Aveo

2006 BRAKES Disc Brakes - Aveo

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS Fastener Tightening Specifications Specification Application Brake Hose Inlet Fitting-to-Caliper Bolt Caliper Bleeder Valve Caliper-to-Steering Knuckle Mounting Bolts Retaining Frame-to-Caliper Housing Bolts Rotor-to-Front Wheel Hub Detent Screw Splash Shield-to-Steering Knuckle Screws DISC BRAKE COMPONENT SPECIFICATIONS Disc Brake Component Specifications Specification Application Caliper Piston Minimum Diameter Disc Type Discard Thickness for 236 mm (9.29 in) Diameter Rotor Discard Thickness for 256 mm (10.08 in) Diameter Rotor Maximum Assembled Lateral Runout - Installed Maximum Groove Depth Maximum Lateral Runout - Not Installed Maximum Thickness Variation New Rotor Thickness - 236 mm (9.29 in) Diameter Rotor New Rotor Thickness - 256 mm (10.08 in) Diameter Rotor Rotor Diameter - Larger Size with SACL500 Stamping Rotor Diameter - Smaller Size with SACL485F Stamping Metric 54 mm Ventilated 18 mm 22 mm 0.06 mm 0.40 mm 0.03 mm 0.10 mm 20 mm 24 mm 256 mm 236 mm 0.709 in 0.866 in 0.002 in 0.016 in 0.001 in 0.004 in 0.787 in 0.945 in 10.08 in 9.29 in English 2.12 in Metric 40 N.m 6 N.m 95 N.m 27 N.m 4 N.m 4 N.m English 30 lb ft 53 lb in 70 lb ft 20 lb ft 35 lb in 35 lb in

DIAGNOSTIC INFORMATION AND PROCEDURES


DIAGNOSTIC STARTING POINT - DISC BRAKES Begin the disc brake system diagnosis with Diagnostic Starting Point - Hydraulic Brakes in Hydraulic Brakes. The use of the Diagnostic Starting Point will lead to the identification of the correct procedure for
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

diagnosing the system and where the procedure is located. SYMPTOMS - DISC BRAKES Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom. Brake Action Uneven - Pulls to One Side Brakes Drag Brake System Noise Brake Action Uneven - Pulls to One Side Checks Actions Inoperative Carrier Replace the carrier. Stuck Caliper Piston Repair the caliper piston or replace the caliper assembly, if needed. Brakes Drag Checks Stuck Caliper Piston Brake System Noise Checks Excessive Rotor Run Out Interference of the Dust Cover Loose Caliper Mounting Bolts

Actions Repair the caliper piston or replace the caliper assembly, if needed.

Actions Replace the rotor. Repair the dust cover. Tighten the mounting bolts.

BRAKE ROTOR SURFACE AND WEAR INSPECTION


Inspection Procedure

1. Shift the transaxle into NEUTRAL.

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 1: View of Brake Rotor, Wheel Stud, and Hub Courtesy of GENERAL MOTORS CORP. 2. Use paint in order to mark the relative position of the following components: Brake rotor (1) Wheel Stud (2) Hub (3) 3. Remove the brake rotor. Refer to Brake Rotor Replacement. IMPORTANT: Rust or contaminants on the hub flange or on the brake rotor mating surfaces may cause excessive brake rotor assembled lateral runout (LRO), which could lead to brake pulsation.
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

4. Inspect the mating surfaces of the hub flange and the brake rotor. Ensure the mating surfaces are clean and free from burrs. 5. Clean the brake pad lining contact surfaces of the brake rotor. IMPORTANT: There are 2 different brake rotor sizes available for this vehicle. 6. Measure the diameter of the brake rotor in order to determine which set of specifications apply to the vehicle. 7. Align the marks and install the rotor to the hub flange. NOTE: Refer to Fastener Notice in Cautions and Notices.

8. Install the 2 detent screws in order to retain the rotor to the hub. Tighten: Tighten the detent screws to 4 N.m (35 lb ft).

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 2: Measuring Brake Rotor Thickness Courtesy of GENERAL MOTORS CORP. 9. Use a micrometer in order to measure the thickness of the brake rotor. Measure the thickness of the rotor at 4 or more points equally spaced around the rotor. Position the micrometer the same distance from the outside edge of the rotor, in the brake pad lining contact area. 10. Compare the measurements to the following specifications:
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Specifications: The thickness of a new 236 mm (9.29 in) diameter brake rotor is 20 mm (0.787 in). The discard specification for the 236 mm (9.29 in) diameter brake rotor is 18 mm (0.709 in). The thickness of a new 256 mm (10.08 in) diameter brake rotor is 24 mm (0.945 in). The discard specification for the 256 mm (10.08 in) diameter brake rotor is 22 mm (0.866 in). 11. If the smallest measurement exceeds the discard specification, you may be able to resurface the brake rotor, depending upon the thickness variation and the surface condition. IMPORTANT: Both rotors must have identical surfaces regarding smoothness and scoring depth in order to provide uniform braking on both sides of the vehicle. For this reason, always replace both brake rotors 12. If the smallest measurement is equal to or less than the discard specification, replace both brake rotors. Refer to Brake Rotor Replacement. 13. Calculate the difference between the largest and the smallest thickness measurements in order to determine the amount of thickness variation. 14. Compare the thickness variation measurements to the following specification: Specification: The maximum thickness variation of the rotor is 0.10 mm (0.004 in). IMPORTANT: Brake rotor thickness variation greater than the specification can cause brake pulsation. 15. If the brake rotor thickness variation measurement exceeds the specification, you may be able to resurface the brake rotor, depending upon the surface condition and the assembled lateral runout (LRO). 16. Inspect the braking surfaces of the brake rotor for the following conditions: Heavy rust and/or pitting Cracks and/or heat spots Excessive blue discoloration 17. If the braking surfaces of the brake rotor exhibit one or more of the braking surface conditions, you may be able to resurface the brake rotor, depending upon the depth of the grooves and the LRO. 18. Use a micrometer in order to measure any grooves on the rotor braking surfaces. 19. Compare the groove depth to the following specification: Specification: The maximum groove depth is 0.40 mm (0.016 in). 20. If the groove depth exceeds the specification, or if an excessive amount of scoring is present, you may be able to resurface the brake rotor, depending upon the LRO.

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 3: Measuring and Recording Assembled LRO Of Rotor Courtesy of GENERAL MOTORS CORP. IMPORTANT: Brake rotor LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4800-11300 km (3000-7000 mi). 21. Perform the following steps in order to measure and record the assembled LRO of the rotor: 1. Install the dial indicator to the vehicle. Position the indicator button in the brake rotor friction surface area 10 mm (0.39 in) from the outer edge of the brake rotor. 2. Verify the indicator is at a 90 degree angle to the rotor. 3. Rotate the rotor until the indicator displays the lowest reading. 4. Set the dial to zero. 5. Rotate the rotor until the indicator displays the highest reading.
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

6. Mark the location of the high spot relative to the nearest wheel stud or studs. 7. Measure and record the amount of LRO. 22. Compare the LRO to the following specification: Specification: The maximum allowable LRO is 0.06 mm (0.002 in). 23. If the measurements of the rotor are within the specifications, remove the dial indicator and complete the installation of the rotor and the pads. Refer to Brake Rotor Replacement. IMPORTANT: Accurate control of the rotor tolerances is necessary for proper performance of the disc brakes. Use precision equipment for refinishing the rotor. 24. If the LRO measurement EXCEEDS the specification, refinish the rotor in order to attain true parallelism. 25. Verify the measurements of the rotor are within the specifications. 26. If the measurements of the rotor are within the specifications, complete the installation of the rotor and the pads. Refer to Brake Rotor Replacement. BRAKE PAD INSPECTION 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the front wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 3. Visually check the linings for minimum thickness and wear. IMPORTANT: The minimum thickness of the inner or the outer pad is 7 mm (0.28 inch). 4. 5. 6. 7. Measure the thickness. Install the brake pads in axle sets only. Install the front wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Lower the vehicle

REPAIR INSTRUCTIONS
BRAKE PADS REPLACEMENT - FRONT
Removal Procedure

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 4: View of Caliper Assembly Retaining Frame Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Brake Caliper Notice in Cautions and Notices.

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. To maintain wheel balance, mark the relative positions of the wheel and the hub, and remove the front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. IMPORTANT: It is not necessary to remove the caliper to service the brake shoes. 3. Remove the lower bolt of the caliper assembly retaining frame.
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 5: Removal of Brake Pads Courtesy of GENERAL MOTORS CORP. 4. Pull the caliper piston housing up. CAUTION: Refer to Brake Dust Caution in Cautions and Notices.

5. Remove the brake pads.


Installation Procedure

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 6: View of Brake Pads Courtesy of GENERAL MOTORS CORP. 1. Measure the minimum lining thickness. Refer to Brake Pad Inspection. 2. Install the brake pads into the caliper. 3. Push the piston inward, if necessary.

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 7: View of Caliper Assembly Retaining Frame Courtesy of GENERAL MOTORS CORP. IMPORTANT: Take care not to damage the piston seal when the piston housing is pulled down. NOTE: Refer to Fastener Notice in Cautions and Notices.

4. Pull down the caliper piston housing and secure it to the retaining frame with the lower bolt. Tighten: Tighten the retaining frame-to-caliper housing bolts to 27 N.m (20 lb ft).
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

5. Align the marks that were made before the wheel removal and install the front wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 6. Lower the vehicle. BRAKE CALIPER REPLACEMENT
Removal Procedure

Fig. 8: View of Bolts and Washers That Attach Brake Hose to Caliper Courtesy of GENERAL MOTORS CORP.

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Mark the position of the front wheels relative to the wheel hubs and remove the wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. CAUTION: Refer to Brake Dust Caution in Cautions and Notices.

3. Remove the bolt and the washers that attach the brake hose to the caliper.

Fig. 9: View of Caliper Assembly and Bolts Courtesy of GENERAL MOTORS CORP.
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

CAUTION: Refer to Brake Fluid Caution in Cautions and Notices.

NOTE:

Refer to Brake Caliper Notice in Cautions and Notices.

4. Disconnect the brake hose, and plug the openings in the caliper and the brake hose to prevent fluid loss and contamination. 5. Remove the caliper mounting bolts from the steering knuckle, and remove the caliper assembly.
Installation Procedure

Fig. 10: View of Caliper Assembly and Bolts


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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices.

1. Install the caliper assembly with the mounting bolts. Tighten: Tighten the caliper-to-steering knuckle mounting bolts to 95 N.m (70 lb ft).

Fig. 11: View of Bolts and Washers That Attach Brake Hose to Caliper Courtesy of GENERAL MOTORS CORP. 2. Connect the brake hose.
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Tighten: Tighten the brake hose inlet fitting-to-caliper bolt and washers to 40 N.m (30 lb ft).

Fig. 12: View of Brake Pads Courtesy of GENERAL MOTORS CORP. Install the front wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Lower the vehicle. Fill the master cylinder to the proper level with clean brake fluid. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes. 7. Recheck the fluid level. 3. 4. 5. 6.
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

IMPORTANT: Do not move the vehicle until a firm pedal is obtained, or improper braking action will result. 8. Repeatedly press the brake pedal to bring the pads in contact with the rotor. BRAKE CALIPER OVERHAUL - FRONT
Disassembly Procedure

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 13: View of Caliper Guide Pin That Connects Caliper Piston Housing to Retaining Frame Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Brake Caliper Notice in Cautions and Notices.

1. Remove the caliper assembly. Refer to Brake Caliper Replacement. 2. Remove the caliper guide pin that connects the caliper piston housing to the retaining frame.
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 14: View of Pins and Rubber Boots Courtesy of GENERAL MOTORS CORP. 3. Remove the bleeder valve protector and the bleeder valve. CAUTION: Refer to Brake Dust Caution in Cautions and Notices.
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

4. Pull out the pins and the rubber boots.

Fig. 15: Removing Caliper Piston From Housing Courtesy of GENERAL MOTORS CORP. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury. CAUTION: Do not place fingers in front of the caliper pistons in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury.

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

IMPORTANT: Insert a piece of hardwood into the caliper housing interior when removing the piston. 5. Remove the front pad brake set, including the pad springs, from the caliper. Refer to Brake Pads Replacement - Front. 6. Using compressed air, blow out the piston from the housing. 7. Remove the outer seal.

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 16: Removal of Inner Seal From Caliper Piston Bore Courtesy of GENERAL MOTORS CORP. 8. Remove the inner seal from the caliper piston bore.
Assembly Procedure

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 17: Inspecting Pistons and Caliper Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.

1. Clean all parts in denatured alcohol or brake fluid. Dry the parts with unlubricated compressed air and blow out all passages in the housing and the bleeder valve. 2. Inspect the piston and the caliper for scoring, nicks, and corrosion. Replace components if these elements are found. IMPORTANT: Do not use a hone or any other procedure to remove material from the piston or the caliper bore.
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

3. Inspect the caliper bleeder valve.

Fig. 18: View of Piston Inner Seal Courtesy of GENERAL MOTORS CORP. 4. 5. 6. 7. 8. Lubricate a new piston inner seal. Install the piston inner seal into the caliper housing groove. Make sure the seal is not twisted. Install the outer piston dust seal in the groove. Lubricate the piston with brake fluid. Push the piston into its bore and make sure the dust seal is seated in the piston groove.

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 19: View of Pins and Rubber Boots Courtesy of GENERAL MOTORS CORP. 9. Coat the pins with rubber grease and install the boots.

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 20: Caliper Bleed Valve And Dust Cap Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices.

10. Install the caliper bleeder valve and the dust cap. Tighten: Tighten the caliper bleeder valve to 6 N.m (53 lb in). IMPORTANT: Make sure the pad springs are properly installed.
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

11. Connect the brake pads and the pad springs.

Fig. 21: Installing Caliper Assembly Courtesy of GENERAL MOTORS CORP. 12. Connect the retaining frame to the caliper housing with the guide pin bolts. Tighten: Tighten the retaining frame-to-caliper housing bolts to 27 N.m (20 lb ft).
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

13. Install the caliper assembly. Refer to Brake Caliper Replacement. BRAKE ROTOR REPLACEMENT
Removal Procedure

Fig. 22: View Of Rotor-To-Front Wheel Hub Detent Screw Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Brake Caliper Notice in Cautions and Notices.

IMPORTANT: To guarantee uniform braking on both sides, both rotors must have identical surfaces regarding smoothness and scoring depth. For this reason, always replace both rotors. 1. Remove the caliper assembly without disconnecting the brake hoses. Refer to Brake Caliper Replacement. 2. Remove the caliper bracket. 3. Remove the rotor-to-front wheel hub detent screw from the rotor and the front wheel hub. 4. Pull off the rotor.
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Installation Procedure

Fig. 23: View Of Rotor-To-Front Wheel Hub Detent Screw Courtesy of GENERAL MOTORS CORP. 1. Inspect the rotor. Refer to Brake Rotor Surface and Wear Inspection. NOTE: Refer to Fastener Notice in Cautions and Notices.

2. Install the rotor to the front wheel hub by tightening the detent screw. Tighten: Tighten the rotor-to-front wheel hub detent screw to 4 N.m (35 lb in). 3. Install the caliper bracket. Tighten: Tighten the caliper bracket mounting bolts to 95 N.m (70 lb ft). 4. Install the caliper assembly. Refer to Brake Caliper Replacement. DISC BRAKE SPLASH SHIELD REPLACEMENT - FRONT
Removal Procedure
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 24: View of Rotor Splash Shield Courtesy of GENERAL MOTORS CORP. 1. Remove the rotor. Refer to Brake Rotor Replacement. 2. Remove the screws for the splash shield from the steering knuckle. 3. Remove the splash shield.
Installation Procedure

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 25: View of Rotor Splash Shield Courtesy of GENERAL MOTORS CORP. 1. Install the splash shield. NOTE: Refer to Fastener Notice in Cautions and Notices.

2. Secure the splash shield to the steering knuckle with the screws. Tighten: Tighten the splash shield-to-steering knuckle screws to 4 N.m (35 lb in). 3. Install the rotor. Refer to Brake Rotor Replacement.

DESCRIPTION AND OPERATION


DISC BRAKE SYSTEM DESCRIPTION AND OPERATION

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 26: View of Piston, Rotor, and Pads Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Brake Caliper Notice in Cautions and Notices.

This caliper has a single bore and is mounted to the steering knuckle with two mounting bolts. Hydraulic pressure, created by applying the brake pedal, is converted by the caliper to a stopping force. This force acts equally against the piston (1) and the bottom of the caliper bore to move the piston outward and to slide the caliper inward, resulting in a clamping action on the rotor (2). This clamping action forces the linings against
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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

the rotor, creating friction to stop the vehicle. Replace all components included in the repair kits used to service this caliper. Lubricate the rubber parts with clean brake fluid to ease assembly. Do not use lubricated shop air on brake parts, as damage to the rubber components may result. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. Replace the pads (3) in axle sets only. The torque values specified are for dry, unlubricated fasteners. Perform the service operations on a clean bench, free from all mineral oil materials.
Clearance Calibration

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

Fig. 27: Sectional View of Pads, Piston Seal, and Piston Courtesy of GENERAL MOTORS CORP. When the hydraulic pressure is applied to the piston (3), the piston moves leftward. The piston seal (2) exerts pressure against the piston and moves with the cylinder. However, a part of the piston seal is fixed into a groove within the cylinder. The shape of the seal is distorted toward the direction the piston is moving, as shown in the figure. When the pressure is taken off the brake pedal and the hydraulic pressure is released from the piston, a restoring elastic force is generated at the seal. This force pushes the piston rightward and back to the original position.

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2006 Chevrolet Aveo LT


2006 BRAKES Disc Brakes - Aveo

As the pads (1) wear away and the clearance between the rotor and the pads becomes larger, the piston moves farther. The shape of the seal could then become more distorted. The distortion is limited to the same amount as previously described, because the end of the seal is fixed into the groove in the cylinder. The piston moves farther to cover the distance of clearance. As the piston returns by the same distance, the rubber seal recovers its original shape, and the clearance between the rotor and pads is maintained in original condition

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