Document ID: 1876624 Page 1 of 1

2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes | Specifications
| Document ID: 1876624

Fastener Tightening Specifications

Specification
Application Metric English
Brake Caliper Bleeder Valve 10 N·m 89 lb in
Brake Caliper Bracket Bolt - Front 185 N·m 136 lb ft
Brake Caliper Bracket Bolt - Rear 120 N·m 89 lb ft
Brake Caliper Guide Pin Bolt - Front 27 N·m 20 lb ft
Brake Caliper Guide Pin Bolt - Rear 27 N·m 20 lb ft
Brake Hose Fitting Bolt - Front 52 N·m 38 lb ft
Brake Hose Fitting Bolt - Rear 52 N·m 38 lb ft
Brake Rotor Screw 10 N·m 89 lb in

© 2010 General Motors Corporation. All rights reserved.

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Document ID: 1720830 Page 1 of 1

2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes | Specifications
| Document ID: 1720830

Disc Brake Component Specifications

Specification
Application Metric English
Front Brakes
l Brake Pad Lining Minimum Thickness 2.0 mm 0.080 in
l Brake Rotor Diameter 296.00 mm 11.654 in
l Brake Rotor Discard Thickness* 27.4 mm 1.079 in
l Maximum Allowable Lateral Runout 0.06 mm 0.002 in
l Maximum Allowable Scoring 1.50 mm 0.059 in
l Maximum Allowable Thickness Variation 0.025 mm 0.001 in
Rear Brakes
l Brake Pad Lining Minimum Thickness 2.0 mm 0.080 in
l Brake Rotor Diameter 191 mm 7.520 in
l Rotor Discard Thickness * 18.4 mm 0.724 in
l Maximum Allowable Lateral Runout 0.06 mm 0.002 in
l Maximum Allowable Scoring 1.50 mm 0.059 in
l Maximum Allowable Thickness Variation 0.025 mm 0.001 in
* All brake rotors have a discard dimension cast into them. Replace any rotor that does not
meet this specification. After refinishing the rotor, replace any rotor that does not meet the
minimum thickness specifications.

© 2010 General Motors Corporation. All rights reserved.

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2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2167824

Front Disc Brake Pads Replacement

Removal Procedure
Warning: Refer to Brake Dust Warning in the Preface section.

Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support
the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which
may cause damage to the brake hose and in turn may cause a brake fluid leak.

1. Inspect the fluid level in the brake master cylinder reservoir.

2. If the brake fluid level is midway between the maximum-full point and the minimum
allowable level, no brake fluid needs to be removed before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the
minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

6. Remove the lower brake caliper guide pin bolt (1).

© 2010 General Motors Corporation. All rights reserved.

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Hold the brake caliper guide pin stationary when removing the guide pin bolt.

7. Pivot the brake caliper (1) upward and support with heavy mechanics wire or equivalent.
8. Place a block of wood or an old brake pad against the brake caliper pistons.
9. Using a brake pad spreader tool or equivalent, fully seat the caliper pistons in the caliper
bores.

10. Remove the inner brake pad (1) and the outer brake pad (2).

Note the location of the brake pad wear sensor for correct installation.

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11. Remove the upper and lower brake pad shims (1).
12. If installing new brake pads, discard the shims.

Installation Procedure

1. Install the upper and lower brake pad shims (1).

If installing new brake pads, install new shims.

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2. Install the inner brake pad (1) and the outer brake pad (2).

Note the location of the brake pad wear sensor for correct installation.

Caution: Refer to Fastener Caution in the Preface section.

Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end

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wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

3. Pivot the brake caliper into position and install the lower brake caliper guide pin bolt (1).

Hold the brake caliper guide pin stationary when installing the guide pin bolt. Tighten the bolt
to 27 N·m (20 lb ft).

4. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
5. Lower the vehicle.
6. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel
distance.
7. Slowly release the brake pedal.
8. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly
seat the brake caliper pistons and brake pads.
9. Fill the master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir
Filling.
10. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing.

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Document ID: 2167849 Page 1 of 5

2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2167849

Rear Disc Brake Pads Replacement

Removal Procedure
Warning: Refer to Brake Dust Warning in the Preface section.

Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support
the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which
may cause damage to the brake hose and in turn may cause a brake fluid leak.

1. Inspect the fluid level in the brake master cylinder reservoir.

2. If the brake fluid level is midway between the maximum-full point and the minimum
allowable level, no brake fluid needs to be removed before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the
minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

6. Remove the lower brake caliper guide pin bolt (1).

© 2010 General Motors Corporation. All rights reserved.

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Hold the brake caliper guide pin stationary when removing the guide pin bolt.

7. Pivot the brake caliper (1) upward and support with heavy mechanics wire or equivalent.
8. Place a block of wood or an old brake pad against the brake caliper pistons.
9. Using a brake pad spreader tool or equivalent, fully seat the caliper piston in the caliper bore.

10. Remove the outer brake pad (1) and the inner brake pad (2).

Note the location of the brake pad wear sensor for correct installation.

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11. Remove the upper and lower brake pad shims (1).
12. If installing new brake pads, discard the shims.

Installation Procedure

1. Install the upper and lower brake pad shims (1).

If installing new brake pads, install new shims.

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2. Install the outer brake pad (1) and the inner brake pad (2).

Note the location of the brake pad wear sensor for correct installation.

Caution: Refer to Fastener Caution in the Preface section.

Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end

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wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

3. Pivot the brake caliper into position and install the lower brake caliper guide pin bolt (1).

Hold the brake caliper guide pin stationary when installing the guide pin bolt. Tighten the bolt
to 27 N·m (20 lb ft).

4. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
5. Lower the vehicle.
6. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel
distance.
7. Slowly release the brake pedal.
8. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly
seat the brake caliper pistons and brake pads.
9. Fill the master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir
Filling.
10. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing.

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Document ID: 2082996 Page 1 of 1

2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2082996

Brake Pad and Rotor Burnishing

Warning: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not
attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these
precautions could lead to serious personal injury and vehicle damage.

Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking
surfaces are properly prepared after service has been performed on the disc brake system.

This procedure should be performed whenever the disc brake rotors have been refinished or
replaced, and/or whenever the disc brake pads have been replaced.

1. Select a smooth road with little or no traffic.

2. Accelerate the vehicle to 48 km/h (30 mph).

Note: Use care to avoid overheating the brakes while performing this step.

3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow
the brakes to lock.
4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient
cooling periods between stops in order to properly burnish the brake pads and rotors.

© 2010 General Motors Corporation. All rights reserved.

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Document ID: 2167850 Page 1 of 4

2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2167850

Front Brake Caliper Replacement

Removal Procedure
Warning: Refer to Brake Dust Warning in the Preface section.

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

3. Remove the brake hose fitting bolt (1).

4. Remove the brake hose fitting (2) from the brake caliper.

Note: Do not reuse the brake hose fitting gaskets.

5. Remove and discard the brake hose fitting gaskets (3).

6. Cap the brake hose fitting to prevent brake fluid loss and contamination.

© 2010 General Motors Corporation. All rights reserved.

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Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

7. Remove the brake caliper guide pin bolts (1).

Hold the brake caliper guide pins stationary when removing the guide pin bolts.

8. Remove the brake caliper.

Installation Procedure

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Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

1. Install the brake caliper.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the brake caliper guide pin bolts (1).

Hold the brake caliper guide pins stationary when installing the guide pin bolts.

Tighten
Tighten the bolts to 27 N·m (20 lb ft).

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Note: Install new brake hose fitting gaskets.

3. Install new brake hose fitting gaskets (3) to the brake hose fitting.
4. Install the brake hose fitting (2) to the brake caliper.
5. Install the brake hose fitting bolt (1).

Tighten
Tighten the bolt to 52 N·m (38 lb ft).

6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
8. Lower the vehicle.

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2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2167851

Rear Brake Caliper Replacement

Removal Procedure
Warning: Refer to Brake Dust Warning in the Preface section.

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

3. Remove the brake hose fitting bolt (1).

4. Remove the brake hose fitting (2) from the brake caliper.

Note: Do not reuse the brake hose fitting gaskets.

5. Remove and discard the brake hose fitting gaskets (3).

6. Cap the brake hose fitting to prevent brake fluid loss and contamination.

© 2010 General Motors Corporation. All rights reserved.

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Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

7. Remove the brake caliper guide pin bolts (1).

Hold the brake caliper guide pins stationary when removing the guide pin bolts.

8. Remove the brake caliper.

Installation Procedure

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Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

1. Install the brake caliper.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the brake caliper guide pin bolts (1).

Hold the brake caliper guide pins stationary when installing the guide pin bolts.

Tighten
Tighten the bolts to 27 N·m (20 lb ft).

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Note: Install new brake hose fitting gaskets.

3. Install new brake hose fitting gaskets (3) to the brake hose fitting.
4. Install the brake hose fitting (2) to the brake caliper.
5. Install the brake hose fitting bolt (1).

Tighten
Tighten the bolt to 52 N·m (38 lb ft).

6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
8. Lower the vehicle.

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Document ID: 2167857 Page 1 of 3

2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2167857

Front Disc Brake Hardware Replacement

Removal Procedure
Warning: Refer to Brake Dust Warning in the Preface section.

Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support
the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which
may cause damage to the brake hose and in turn may cause a brake fluid leak.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

3. Remove the brake caliper guide pin bolts (1).

Hold the brake caliper guide pins stationary when removing the guide pin bolts.

4. Without disconnecting the brake caliper hose, remove the brake caliper and support with
heavy mechanics wire or equivalent.
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Note: The guide pins are not interchangeable. Note the location of the guide pins.

5. Remove the upper guide pin (1) and seal.

6. Remove the lower guide pin (2) and seal.

Installation Procedure

Note: The guide pins are not interchangeable. Note the location of the guide pins.

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1. Install the brake caliper guide pin seals to the caliper bracket.
2. Apply a light coat of high temperature silicone brake lubricant to the brake caliper guide pins.
3. Install the upper guide pin (1).

Ensure the lip of the seal is fully seated in the groove of the brake caliper guide pin.

4. Install the lower guide pin (2).

Ensure the lip of the seal is fully seated in the groove of the brake caliper guide pin.

Caution: Refer to Fastener Caution in the Preface section.

Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

5. Position the brake caliper to the bracket.

6. Install the brake caliper guide pin bolts (1).

Hold the brake caliper guide pins stationary when installing the guide pin bolts.

Tighten
Tighten the bolts to 27 N·m (20 lb ft).

7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
8. Lower the vehicle.

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Document ID: 2167861 Page 1 of 3

2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2167861

Rear Disc Brake Hardware Replacement

Removal Procedure
Warning: Refer to Brake Dust Warning in the Preface section.

Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support
the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which
may cause damage to the brake hose and in turn may cause a brake fluid leak.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

3. Remove the brake caliper guide pin bolts (1).

Hold the brake caliper guide pins stationary when removing the guide pin bolts.

4. Without disconnecting the brake caliper hose, remove the brake caliper and support with
heavy mechanics wire or equivalent.
© 2010 General Motors Corporation. All rights reserved.

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5. Remove the upper and lower guide pins (1).

6. Remove the upper and lower guide pin seals (2).

Installation Procedure

1. Install the guide pin seals (2) to the caliper bracket.

2. Apply a light coat of high temperature silicone brake lubricant to the brake caliper guide pins.
3. Install the upper and lower guide pins (1).

Ensure the lip of the seals are fully seated in the groove of the brake caliper guide pins.

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Caution: Refer to Fastener Caution in the Preface section.

Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

4. Position the brake caliper to the bracket.

5. Install the brake caliper guide pin bolts (1).

Hold the brake caliper guide pins stationary when installing the guide pin bolts.

Tighten
Tighten the bolts to 27 N·m (20 lb ft).

6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
7. Lower the vehicle.

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2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2167865

Front Brake Caliper Bracket Replacement

Removal Procedure
Warning: Refer to Brake Dust Warning in the Preface section.

Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support
the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which
may cause damage to the brake hose and in turn may cause a brake fluid leak.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

3. Remove the brake caliper guide pin bolts (1).

Hold the brake caliper guide pins stationary when removing the guide pin bolts.

4. Without disconnecting the brake caliper hose, remove the brake caliper and support with
heavy mechanics wire or equivalent.
© 2010 General Motors Corporation. All rights reserved.

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5. Remove the inner brake pad (1).

Note the location of the wear sensor for correct installation.

6. Remove the outer brake pad (2).

7. Remove the brake pad shims (1).

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8. Remove the brake caliper bracket bolts (1).

9. Remove the brake caliper bracket (1).

Installation Procedure

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1. Install the brake caliper bracket (1).

Caution: Refer to Fastener Caution in the Preface section.

2. Install the brake caliper bracket bolts (1).

Tighten
Tighten the bolts to 185 N·m (136 lb ft).

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3. Install the brake pad shims (1).

4. Install the inner brake pad (1).

Note the location of the wear sensor for correct installation.

5. Install the outer brake pad (2).

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Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

6. Position the brake caliper to the bracket.

7. Install the brake caliper guide pin bolts (1).

Hold the brake caliper guide pins stationary when installing the guide pin bolts.

Tighten
Tighten the bolts to 27 N·m (20 lb ft).

8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
9. Lower the vehicle.

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2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2167870

Rear Brake Caliper Bracket Replacement

Removal Procedure
Warning: Refer to Brake Dust Warning in the Preface section.

Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support
the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which
may cause damage to the brake hose and in turn may cause a brake fluid leak.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

3. Remove the brake caliper guide pin bolts (1).

Hold the brake caliper guide pins stationary when removing the guide pin bolts.

4. Without disconnecting the brake caliper hose, remove the brake caliper and support with
heavy mechanics wire©or equivalent.
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5. Remove the outer brake pad (1).

6. Remove the inner brake pad (2).

Note the location of the wear sensor for correct installation.

7. Remove the brake pad shims (1).

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8. Remove the brake caliper bracket bolts (1).

9. Remove the brake caliper bracket (1).

Installation Procedure

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1. Install the brake caliper bracket (1).

Caution: Refer to Fastener Caution in the Preface section.

2. Install the brake caliper bracket bolts (1).

Tighten
Tighten the bolts to 120 N·m (89 lb ft).

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3. Install the brake pad shims (1).

4. Install the outer brake pad (1).

5. Install the inner brake pad (2).

Note the location of the wear sensor for correct installation.

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Note:
• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

6. Position the brake caliper to the bracket.

7. Install the brake caliper guide pin bolts (1).

Hold the brake caliper guide pins stationary when installing the guide pin bolts.

Tighten
Tighten the bolts to 27 N·m (20 lb ft).

8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
9. Lower the vehicle.

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2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2167885

Front Brake Rotor Replacement

Special Tools

• J 41013 Rotor Resurfacing Kit

• J 42450-A Wheel Hub Resurfacing Kit

Removal Procedure
Warning: Refer to Brake Dust Warning in the Preface section.

Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support
the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which
may cause damage to the brake hose and in turn may cause a brake fluid leak.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

3. Remove the brake caliper bracket bolts (1).

4. Without disconnecting the brake caliper hose, remove the brake caliper and bracket assembly
and support with heavy mechanics wire or equivalent.
5. If installing the original brake rotor, mark the relationship of the rotor to the wheel hub.

© 2010 General Motors Corporation. All rights reserved.

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6. Remove the brake rotor screw (1) and the brake rotor.
7. If the brake rotor is to be machined, check the thickness variation measurement. Refer to
Brake Rotor Thickness Variation Measurement.

Installation Procedure
1. If installing a new brake rotor, clean the friction surfaces of the brake rotor with denatured
alcohol.
2. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the
hub/axle flange.
3. Using the J 41013 , thoroughly clean any rust or corrosion from the mating surface of the
rotor to the hub/axle flange.

Caution: Refer to Fastener Caution in the Preface section.

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4. Install the brake rotor.

If installing the original brake rotor, align the rotor to the wheel hub as noted during
removal.

5. Install the brake rotor screw (1).

Tighten
Tighten the screw to 10 N·m (89 lb in).

6. After installing the brake rotor, measure the assembled lateral runout (LRO) of the brake
rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement.
7. If the brake rotor assembled LRO measurement exceeds specification, bring the LRO to
within specification. Refer to Brake Rotor Assembled Lateral Runout Correction.

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8. Position the brake caliper and bracket assembly to the vehicle.

9. Install the brake caliper bracket bolts (1).

Tighten
Tighten the bolts to 185 N·m (136 lb ft).

10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
11. Lower the vehicle.

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2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2167889

Rear Brake Rotor Replacement

Special Tools

• J 41013 Rotor Resurfacing Kit

• J 42450-A Wheel Hub Resurfacing Kit

Removal Procedure
Warning: Refer to Brake Dust Warning in the Preface section.

Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support
the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which
may cause damage to the brake hose and in turn may cause a brake fluid leak.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

3. Remove the brake caliper bracket bolts (1).

4. Without disconnecting the brake caliper hose, remove the brake caliper and bracket assembly
and support with heavy mechanics wire or equivalent.
5. If installing the original brake rotor, mark the relationship of the rotor to the wheel hub.

© 2010 General Motors Corporation. All rights reserved.

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6. Remove the brake rotor screw (1) and the brake rotor.
7. If the brake rotor is difficult to remove, remove the park brake shoe adjuster access plug on
the face of the brake rotor to gain access to the park brake adjuster.

Loosen the park brake shoe adjuster.

8. If the brake rotor is to be machined, check the thickness variation measurement. Refer to
Brake Rotor Thickness Variation Measurement.

Installation Procedure
1. If installing a new brake rotor, clean the friction surfaces of the brake rotor with denatured
alcohol.
2. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the
hub/axle flange.
3. Using the J 41013 , thoroughly clean any rust or corrosion from the mating surface of the
rotor to the hub/axle flange.

Caution: Refer to Fastener Caution in the Preface section.

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4. Install the brake rotor.

If installing the original brake rotor, align the rotor to the wheel hub as noted during
removal.

5. Install the brake rotor screw (1).

Tighten
Tighten the screw to 10 N·m (89 lb in).

6. After installing the brake rotor, measure the assembled lateral runout (LRO) of the brake
rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement.
7. If the brake rotor assembled LRO measurement exceeds specification, bring the LRO to
within specification. Refer to Brake Rotor Assembled Lateral Runout Correction.

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8. Position the brake caliper and bracket assembly to the vehicle.

9. Install the brake caliper bracket bolts (1).

Tighten
Tighten the bolts to 120 N·m (89 lb ft).

10. If necessary, adjust the park brake. Refer to Parking Brake Adjustment.
11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
12. Lower the vehicle.

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2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2167892

Front Brake Shield Replacement

Callout Component Name

Warning: Refer to Brake Dust Warning in the Preface section.

Preliminary Procedures
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation.
3. Remove the brake rotor. Refer to Front Brake Rotor Replacement.
4. Remove the wheel bearing and hub assembly. Refer to Front Wheel Bearing and Hub
Replacement.
1 Front Brake Shield

© 2010 General Motors Corporation. All rights reserved.

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2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2159253

Rear Brake Shield Replacement

Callout Component Name

Warning: Refer to Brake Dust Warning in the Preface section.

Preliminary Procedures
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation.
3. Remove the park brake shoes. Refer to Parking Brake Shoe Replacement.
4. Remove the wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement.
5. Disconnect the park brake cable from the actuator and mounting bracket. Refer to
Parking Brake Rear Cable Replacement.
6. Remove the wheel bearing/hub assembly. Refer to Rear Wheel Bearing and Hub
Replacement.
1 Disc Brake Backing Plate

© 2010 General Motors Corporation. All rights reserved.

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2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2082845

Brake Rotor Assembled Lateral Runout Correction

Note:
• Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral
runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake
pulsation. Refer to Brake Rotor Thickness Variation Measurement.
• Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification
can cause thickness variation to develop in the brake rotor over time, usually between 4 800-
11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement.

Review the following acceptable methods for bringing the brake rotor assembled LRO to within
specifications. Determine which method to use for the specific vehicle being repaired.

• The indexing method of correcting assembled LRO is most effective when the LRO
specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-
0.005 in). Indexing is used to achieve the best possible match of high spots to low spots
between related components. Refer to Brake Rotor Assembled Lateral Runout Correction -
Indexing.
• The correction plate method of correcting assembled LRO involves the addition of a tapered
plate between the brake rotor and the hub/axle flange. The correction plate method can be
used to correct LRO that exceeds the specification by up to 0.23 mm (0.009 in). Refer to
Brake Rotor Assembled Lateral Runout Correction - Correction Plates.
• The on-vehicle brake lathe method is used to bring the LRO to within specifications through
compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled
Lateral Runout Correction - On Vehicle Lathe.

If the assembled LRO cannot be corrected using these methods, then other components must be
suspected as causing and/or contributing to the LRO concern.

© 2010 General Motors Corporation. All rights reserved.

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2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2082847

Brake Rotor Assembled Lateral Runout Correction -

Indexing
Special Tools

• J-39544-KIT Torque-Limiting Socket Set , or equivalent

• J-45101-100 Conical Brake Rotor Washers

Warning: Refer to Brake Dust Warning in the Preface section.

Note:
• Brake rotor thickness variation MUST be checked BEFORE checking for assembled
lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can
cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement.
• Brake rotor assembled LRO exceeding the maximum allowable specification can cause
thickness variation to develop in the brake rotor over time, usually between 4,800-11,
300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout
Measurement.

1. Remove the J-45101-100 washers and the lug nuts that were installed during the assembled
LRO measurement procedure.
2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there
are no foreign particles or debris remaining.
3. Index the brake rotor in a different orientation to the hub/axle flange.
4. Hold the rotor firmly in place against the hub/axle flange and install one of the J-45101-100
washers (1) and one lug nut (2) onto the upper-most wheel stud.
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5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.

6. Install the remaining J-45101-100 washers and lug nuts onto the wheel studs and tighten the
nuts firmly by hand in a star-pattern.
7. Using the J-39544-KIT set , or equivalent, tighten the lug nuts in a star-pattern to
specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and
Installation.
8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Measurement.
9. Compare the amount of change between this measurement and the original measurement.
10. If this measurement is within specifications, proceed to step 14.
11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled
LRO measurement is obtained.
12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than
it was originally.
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable
specification, refer to Brake Rotor Assembled Lateral Runout Correction.
14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress
the brake pedal several times to secure the rotor in place before removing the J-45101-100
washers and the lug nuts.

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2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2082849

Brake Rotor Assembled Lateral Runout Correction -

Correction Plates
Special Tools

• J-39544-KIT Torque-Limiting Socket Set , or equivalent

• J-45101-100 Conical Brake Rotor Washers

Warning: Refer to Brake Dust Warning in the Preface section.

Note:
• Brake rotor thickness variation MUST be checked BEFORE checking for assembled
lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can
cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement.
• Brake rotor assembled LRO exceeding the maximum allowable specification can cause
thickness variation to develop in the brake rotor over time, usually between 4,800-
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11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout

Measurement.

1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor
assembled LRO measurement procedure, to face upward.
2. Remove the J-45101-100 washers and the lug nuts that were installed during the assembled
LRO measurement procedure and/or the indexing correction procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there
are no foreign particles or debris remaining.
4. Select the correction plate, following the manufacturer's instructions, which has a
specification closest to the assembled LRO measurement.

For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm
(0.003 in) correction plate would be used. If the measurement was 0.127 mm (0.005 in), the
0.152 mm (0.006 in) correction plate would be used.

5. Determine the positioning for the correction plate (1) using the high spot mark (3) made
during the brake rotor assembled LRO measurement procedure.

Note:
• Do NOT install used correction plates in an attempt to correct brake rotor assembled
LRO.
• Do NOT stack up, or install more than one correction plate onto one hub/axle flange
location, in an attempt to correct brake rotor assembled LRO.

6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2)
orientated to align with the high spot mark (3), that was positioned to face upward.

7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for
proper orientation to the flange.
8. Hold the rotor firmly in place against the hub/axle flange and install one of the J-45101-100
washers (1) and one lug nut (2) onto the upper-most wheel stud.
9. Continue to hold the rotor secure and tighten the lug nut firmly by hand.

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10. Install the remaining J-45101-100 washers and lug nuts onto the wheel studs and tighten the
nuts firmly by hand in a star-pattern.
11. Using the J-39544-KIT set , or equivalent, tighten the lug nuts in a star-pattern to
specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and
Installation.
12. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Measurement.
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable
specification, refer to Brake Rotor Assembled Lateral Runout Correction.
14. If the brake rotor assembled LRO measurement is within specification, install the brake
caliper and depress the brake pedal several times to secure the rotor in place before
removing the J-45101-100 washers and the lug nuts.

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2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2082851

Brake Rotor Assembled Lateral Runout Correction - On

Vehicle Lathe
Special Tools
J-45101-100 Conical Brake Rotor Washers

Warning: Refer to Brake Dust Warning in the Preface section.

Note:
• Brake rotor thickness variation MUST be checked BEFORE checking for assembled
lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can
cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement.
• Brake rotor assembled LRO exceeding the maximum allowable specification can cause
thickness variation to develop in the brake rotor over time, usually between 4 800-11
300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout
Measurement.

1. Ensure that the caliper and caliper bracket that are already being supported, are clear from
contacting any rotating components, such as the brake rotor.
2. Remove the J-45101-100 washers and the lug nuts that were installed during the assembled
LRO measurement procedure and/or the indexing correction procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there
are no foreign particles or debris remaining.
4. Set up the lathe, following the manufacturer's instructions.
5. Refinish the brake rotor, following the brake lathe manufacturer's instructions.
6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement.
7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish
specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10.
8. After refinishing the brake rotor, use the following procedure in order to obtain the desired
non-directional finish:
8.1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-
directional finish.
8.2. Using moderate pressure, apply the non-directional finish:
• If the lathe is equipped with a non-directional finishing tool, apply the finish with
120-grit aluminum oxide sandpaper.
• If the lathe is not equipped with a non-directional finishing tool, apply the finish with
a sanding block and 150-grit aluminum oxide sandpaper.
8.3. After applying a non-directional finish, clean each friction surface of the brake rotor
with denatured alcohol, or an equivalent approved brake cleaner.
9. Remove the lathe from the vehicle.
10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Measurement.
11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable
specification, refer to Brake Rotor Assembled Lateral Runout Correction.
12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress
the brake pedal several times to secure the rotor in place before removing the J-45101-100
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washers and the lug nuts.

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2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Brakes | Disc Brakes |
Repair Instructions | Document ID: 2082853

Brake Rotor Refinishing

Special Tools

• J-41013 Rotor Resurfacing Kit

• J-42450-A Wheel Hub Resurfacing Kit

Warning: Refer to Brake Dust Warning in the Preface section.

Note:
• The disc brake rotors do not require refinishing as part of routine brake system service. New
disc brake rotors do not require refinishing.
Do not refinish disc brake rotors in an attempt to correct the following conditions:
- Brake system noise - squeal, growl, groan
- Uneven and/or premature disc brake pad wear
- Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface
- Scoring of the disc brake rotor friction surface less than the maximum allowable
specification
• Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to
allow the rotor to be refinished and remain above the minimum allowable thickness after
refinish specification. Refer to Brake Rotor Thickness Measurement.
Disc brake rotors should only be refinished if they have adequate thickness to be refinished
and if one or more of the following conditions exist:
- Thickness variation in excess of the maximum allowable specification
- Excessive corrosion/rust and/or pitting
- Cracks and/or heat spots
- Excessive blueing discoloration
- Scoring of the disc brake rotor surface in excess of the maximum allowable specification
• Disc brake rotors may need to be refinished as part of the process for correcting brake rotor
assembled lateral runout (LRO) that exceeds the maximum allowable specification.

Note: If the vehicle is equipped with cross-drilled rotors, use a lathe with positive rake tooling.
This setup requires less cutting pressure, which will result in less vibration, and a better surface
finish. Also, use a vibration dampener when cutting. Otherwise, refinish according to the following
instructions.

Note: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust
or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do
this may result in increased assembled lateral runout (LRO) of the brake rotor, which could
lead to brake pulsation.

1. Using the J-42450-A kit , thoroughly clean any rust or corrosion from the mating surface of
the hub/axle flange.
2. Using the J-41013 kit , thoroughly clean any rust or corrosion from the mating surface and
mounting surface of the brake rotor.
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3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no
foreign particles or debris remaining.
4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions,
ensuring that all mounting attachments and adapters are clean and free of debris.
5. Ensure that any vibration dampening attachments are securely in place.
6. With the brake lathe running, slowly bring in the cutting tools until they just contact the
brake rotor friction surfaces.
7. Observe the witness mark on the brake rotor. If the witness mark extends approximately
three-quarters or more of the way around the brake rotor friction surface on each side, the
brake rotor is properly mounted to the lathe.
8. If the witness mark does not extend three-quarters or more of the way around the brake
rotor, re-mount the rotor to the lathe.
9. Following the brake lathe manufacturer's instructions, refinish the brake rotor.
10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement.
11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish
specification, the brake rotor must be replaced.
12. After refinishing the brake rotor, use the following procedure in order to obtain the desired
non-directional finish:
12.1. Follow the brake lathe manufacturer's recommended speed setting for applying a
non-directional finish.
12.2. Using moderate pressure, apply the non-directional finish:
• If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-
grit aluminum oxide sandpaper.
• If the lathe is not equipped with a non-directional finishing tool, apply the finish with a
sanding block and 150-grit aluminum oxide sandpaper.
12.3. After applying a non-directional finish, clean each friction surface of the brake rotor
with denatured alcohol, or an equivalent approved brake cleaner and wipe each
friction surface using a clean shop towel to remove metal particles remaining from
machining. Repeat the cleaning process if necessary to remove all metal particles.
13. Remove the brake rotor from the brake lathe.
14. Measure the assembled LRO of the brake rotor to ensure optimum performance of the disc
brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement.
15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to
within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction.

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