Brakes Page D-1

Page D-1

Section D

Brakes

ATTENTION

HSV vehicles are equipped with a Supplemental Restraint System (SRS). An SRS consists of seat belt pre-

tensioners (fitted to all front seats), a d river’s-side air bag, a passeng er’s-side air bag and right and left h and

side air bags. Refer to CAUTIONS, Section 12M, of the Holden WL Service Information before performing any

service operation on or around SRS components, the steering mechanism or wiring. Failure to follow the

CAUTIONS could result in personal injury or unnecessary SRS system repairs.

1 Purpose...................................................................................................................................................2

2 Brakes......................................................................................................................................................3

2.1 General Information............................................................................................................................................... 3

2.2 Service Operations................................................................................................................................................ 4

Pad Replacement................................................................................................................................................... 4

Calliper Overhaul................................................................................................................................................... 4

Brake Discs ............................................................................................................................................................ 5

2.3 Service Parts.......................................................................................................................................................... 6

Front Callipers........................................................................................................................................................ 6

Rear Callipers......................................................................................................................................................... 7

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1 Purpose

The purpose of this section is to provide information on the Brake Systems fitted to HSV WL model. Details are given

where differences occur between the HSV models and standard Holden models. A series of instruction drawings

describe the design changes and indicate specific part numbers, fitting instructions and relevant notes for vehicle

servicing.

NOTE

If specific technical data on a HSV model is not

contained in this supplement, obtain data for that

model from Section 5A Service and Park Brakin g

Systems of the WL Service Information.

References are made throughout this section to

Holden Service Information to assist in providing

information for specific service operations.

When hoisting (or jacking) HSV models,

ensure that the lifting h ead o f th e hoist lifts on

the chassis before the arm of the hoist

contacts the side-skirt

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2 Brakes

2.1 General Information

Brake systems fitted to HSV WL model employ the vacuum boosted, four-wheel-disc concept operating through a

tandem master cylinder. T his tandem arra ng e ment prov ides separ ate brak i ng s ystems to the front and rear wheels which

in turn, provides adequate bra king (to the front or rear wheels) if a fault occurs in either system. HSV WL model is also

equipped with the BOSCH Anti-lock Braki ng System (ABS) as standard. Inspection, replacement and testing of the ABS

must be carried out in accordance with the procedures detailed in the relevant Holden Service Information.

Whenever any component of the ABS is

disturbed during service operations, it is vital

that the complete ABS is checked using the

procedure detailed in the relevant Holden

Service Information.

Model Premium Performance

GRANGE --- S

Table D-1 Brake System

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2.2 Service Operations

Although HSV brake systems have different fittings and components, the general service principles are the same as

those which apply to Holden standard brake systems. The important differences between Holden brake systems and

HSV systems are the component parts and the specified wear limits for those parts. Drawings of specific HSV brake

systems and component part numbers are included in this section and wear limits have also been specified where

required.

Pad Replacement

Refer to appropriate dra wings in this section or in Holden Service Information. Ensure that the follo wing important notes

are observed and replace brake pads in accordance with the procedures in the Holden WL Series Service Information.

Important Notes On Brake P ad Replacement

• Do not remove mounting brackets unless damaged or for disc servicing.

• Pads should be replaced if there is less than 3mm of lining material r emaining or if pads are damaged.

• Pads must be replaced as a full set of 4. Ensure pad material is correct specificati on. Do not mix pad material front

to rear. Use genuine HSV replacement parts to ensure correct pad material is used.

• Before fitting new pads check that all pads are fitted with insulati ng material.

When replacing pads in Perfo rmance brakes, ensure that shims and spring are fully clipped into position so that the y are

clear of the rotor. Carefully lower the body over the pads and bracket ensuring the pa ds are engaged with spring so that

they are free to slide. Ensure Piston Boot is not caught between the Piston and the inn er pad. Fit new guide bolt through

the lower hole and tighten to a torque of 30-34 Nm.

Calliper Overhaul

Refer to appropriate dra wings in this section or in Holden Service Information. Ensure that the follo wing important notes

are observed and overhaul callipers as detailed in Section 5A Service and Park Braking Systems of the WL series

Service Information.

Notes On Calliper Overhaul

• Do not remove the mounting brackets unless damaged or for disc servicin g.

• Remove the pistons by directing light air pressure into the brake h ose port, and progressively increase until piston

is forced out of bore .

Caution is necessary to avoid physical

injury—Piston may be ejected with

considerable force due to air pressure. Use

packing to prevent piston damaging body of

calliper.

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Brake Discs

Refer to appropriate dra wings in this section or in Holden S ervice Information. Ensure tha t important notes are o bserved

and overhaul discs as detaile d in Section 5A Service and Park Braking S ystems.

Do not remove mounting bracket from the

brake calliper unless the bracket requires

service. It is critical for safety that the bolts

holding the mounting bracket to the calliper if

removed, are correctly reinstalled.

Refer Drawing No. 04I-030003 for assembly

requirements.

Brake Disc Wear Limits.

The minimum thickness for discs fitted to standard Holden brakes is cast in the hub of the disc and is specified in

Section 5A Service and Park Braking S ystems in the Holden Service Info rmation. T he minimum th ickne ss for brake dis cs

fitted to HSV brake systems is stamped into the ed ge of the disc. For information, the new and minim um thicknesses of

discs used in HSV brake systems are tabulated be low.

Disc Location New Thickness Minimum Thickness

FRONT

REAR

32.0 mm

18.0 mm

30.0 mm

16.0 mm

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2.3 Service Parts

It is essential that genuine replacement parts be fitted to HSV brake assemblies. This is particularly important when

replacing brake pads because of the various types of lining material used. Complete brake assemblies, front and rear

discs, callipers and attachm ent parts have also been identif ied as replacement parts and t hese items are available from

HSV. These parts are listed in the follo wing paragraphs or referenced in enclosed drawings.

Front Callipers

05A-970730 FRONT HYDRAULIC REPAIR KIT COMPRISING

2 OFF SEALING RINGS

2 OFF PISTON BOOT

1 OFF BLEED SCREW PROTECTION COVER

2 OFF GUIDE PIN BOOT

05A-030702 FRONT CALLIPER HOUSING ASSEMBLY RH COMPRISING

1 OFF CALLIPER BODY RH

1 OFF ABUTMENT BODY

2 OFF PAD ABUTMENT SHIM

2 OFF SEALING RING

2 OFF PISTON BOOT

2 OFF PISTON

1 OFF BLEED SCREW PROTECTOR COVER

1 OFF BLEED SCREW

1 OFF ANTI RATTLE SPRING

2 OFF GUIDE PIN BOOT

2 OFF GUIDE PIN

2 OFF GUIDE PIN BOLT

05A-030701 FRONT CALLIPER HOUSING ASSEMBLY LH COMPRISING

1 OFF CALLIPER BODY RH

1 OFF ABUTMENT BODY

2 OFF PAD ABUTMENT SHIM

2 OFF SEALING RING

2 OFF PISTON BOOT

2 OFF PISTON

1 OFF BLEED SCREW PROTECTOR COVER

1 OFF BLEED SCREW

1 OFF ANTI RATTLE SPRING

2 OFF GUIDE PIN BOOT

2 OFF GUIDE PIN

2 OFF GUIDE PIN BOLT

05A-970733 PISTON BRAKE

05A-970734 BLEED SCREW

05A-970735 PAD ABUTM ENT SHIM

05A-970736 ANTI RATTLE SPRING

05A-970737 GUIDE PIN

05A-970738 GUIDE PIN BOLT

05A-990704 BRAKE PAD KIT JBI NF42 COMPRISING

2 OFF OUTER PAD ASSEMBLY JBI NF42

2 OFF INNER PAD ASSEMBLY JBI NF42

4 OFF GUIDE PIN BOLT

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Rear Callipers

Servicing procedures and servicing kits for the WL Performance Rear Caliper are exactly the same as for the standard

WL Holden Rear Caliper. T herefore, when servicing the WL rear caliper, refer to the procedures in the

Section 5A Service and Park Braking Systems.

HSV Performance Rear Calipers use uniq ue brake pads, with a thinner pad to suit HSV’s wider ventilated disc.

05B-020710 REAR CALLIPER HOUSING ASSY RH COMPRISING

1 OFF CALLIPER BODY

1 OFF SEALING RING

1 OFF CALLIPER PISTON

1 OFF DUSTBOOT

1 OFF BLEED SCREW

1 OFF BLEED SCREW DUST CAP

05B-020709 REAR CALLIPER HOUSING ASSY LH COMPRISING

1 OFF CALLIPER BODY

1 OFF SEALING RING

1 OFF CALLIPER PISTON

1 OFF DUSTBOOT

1 OFF BLEED SCREW

1 OFF BLEED SCREW DUST CAP

05B-970704 REAR BRAKE PAD KIT (BM962) COMPRISING

4 OFF BRAKE PAD (BM962)

4 OFF RETAINING BOLTS

Brakes Page D-8

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advanced automotive design and engineering

RELEASE

REVISION RECORD

SYM

DATE

INSTRUCTION DRAWING.

advanced automotive design and engineering

SIGNATURES ON

ISSUE DATED

ORIGINAL APPROVAL

AUTH'YCK.

DR.

APPR

L.H

D.P

22.04.03

APPR

CK.

DR.

MODEL :

DWG.

DATE:

REFERENCE :

PARTNO.

04I-030003

NAME

PERFORMANCE BRAKE

SYSTEM - FRONT

SIZE

11.07.02 ECN. O1186.03

M.B

MAJOR ASSEMBLIES

1. 05A-970705/6

2. 05A-970701

3. 05F-970701/2

CALIPER ASM FRT. RH/LH

DISC FRONT PERFORMANCE

HOSE FRONT RH/LH

COMPONENTS / SERVICE PARTS

4. ABUTMENT BRACKET

5. PAD ABUTMENT SHIM

6. OUTER PAD ASM

7. INNER PAD ASM

8. BLEED SCREW COVER

9. BLEED SCREW

10. ANTI RATTLE SPRING

11. GUIDE PIN BOOT

12. CALIPER BODY

13. SEALING RING

14. PISTON BOOT

15. GUIDE PIN BOLT

16. GUIDE PIN

17. PISTON

32-37Nm

180 - 190 Nm

80-90NmTHEN 45° TURN

412-14NmTHEN 90° TURN

APPLYLOCTITE 243

BEFORE INSTALLATION

Brakes Page D-9

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RELEASE

REVISION RECORD

SYM

DATE

INSTRUCTION DRAWING.

SIGNATURES ON

ISSUE DATED

ORIGINAL APPROVAL

AUTH'YCK.

DR.

APPR

D.P

16.09.04

APPR

CK.

DR.

MODEL :

DWG

DATE:

REFERENCE :

PARTNO.

04I-040009

NAME

PERFORMANCE BRAKE

SYSTEM - REAR

SIZE

30-34Nm

32-37Nm

12-14Nm

APPLYLOCTITE 243

BEFORE INSTALLATION

MAJOR ASSEMBLIES

1. 05B-020709/10

2. 05B-000701

3. 05F-970703

CALIPER ASM RR RH/LH

DISC REAR PERFORMANCE

HOSE REAR BRAKE PERFORMANCE

470 - 100 Nm