Lumina V6-204 3.4L DOHC VIN X SFI (1996)
10. Inspect piston assembly for nicks, cracks, wear or corrosion. Replace piston if any damage is found.
11. Inspect piston bore for scoring, nicks, wear or corrosion. Use crocus cloth to polish out light corrosion. Replace caliper if any heavy corrosion is
found. Do not hone caliper bore.
12. Inspect seal groove for nicks or burrs. If found, replace caliper.
13. Inspect boots for cuts, tears or deterioration. If damaged, replace boots.
14. Inspect bolt sleeve and pin sleeve for corrosion or damage. Replace corroded or damaged sleeves. Do not attempt to polish away corrosion.
CALIPER ASSEMBLE
1. Lubricate pin sleeve with silicone grease, then install pin bolts and pin sleeve to caliper support. Torque bolts to 20 ft. lbs.
2. Lubricate sleeve boot with silicone grease, then compress lip on sleeve boot and push it all the way through caliper body assembly until lip
emerges and seals on inboard face of caliper ear.
3. Lubricate push bolt sleeve with silicone grease, then push it in through lip end of boot until boot seats in sleeve groove at other end.
4. Install bolt boot onto caliper body.
5. Install small end of pin boot over pin sleeve until boot seats in pin groove.
6. If removed, position new lever return spring with hook end around stopper pin, then pry other end of spring over lever.
7. Install bleeder valve and bleeder valve cap. Torque bleeder valve to 8 ft. lbs.
8. Lubricate new piston seal with clean brake fluid and install in groove in caliper bore ensuring it is not twisted.
9. Install piston boot onto piston assembly.
10. Lubricate piston assembly with clean brake fluid.
11. Start piston assembly in by hand, then thread into bottom of caliper bore using spanner type tool in slots in end of piston assembly.
12. Ensure outside edge of piston boot is smoothly seated in counterbore of caliper body assembly.
13. Work boot ring into groove near open end of caliper bore using care not to pinch piston boot between boot ring and caliper body.
14. After installing ring, lift inner edge of boot next to piston assembly and press out any trapped air. Boot must lay flat.
15. Install caliper on vehicle as described under Removal/Installation.
