Contents: Removal ↓ Installation ↓
The brake system pipes connect the master cylinder to the four wheel brake cylinders.
Please note: Rigid metal brake lines must be installed at a service station, as professional installation requires some experience.
High-pressure brake hoses create flexible connections between the stationary parts of the vehicle and the moving parts, such as the brake calipers. If noticeable damage is detected, the hoses must be replaced. Old brake hoses can swell. In this case, the brake fluid cannot flow from the wheel brake cylinder back to the expansion tank and the wheel brake overheats. If the corresponding bleed valve on the wheel brake cylinder then opens and the wheel no longer locks, this indicates that the brake hose is defective.
Safety instructions for vehicles with ABS If a new brake hose has been installed or one chamber of the brake fluid expansion reservoir has become completely empty (for example, as a result of a leak in the brake system or the chamber was not replenished in a timely manner when filling the system with brake fluid), then air enters the system and reaches the ABS hydraulic pump. In this case, the air must be removed from the brake system at a service station using a device for removing air. If the car is equipped with the EDS system, it is necessary to additionally perform its basic adjustment using a diagnostic device.
Caution: Brake hoses must not come into contact with oil or fuel, and must not be coated with varnish or anti-corrosion agent to protect the underbody.
Removal
Caution: Follow the instructions for handling brake fluid given in the previous chapter.
Safety note: There is a risk of accident when lifting the vehicle! Please read the section "Lifting a car".
Raise the car onto jack stands.
Detach the brake hose from the holder.
First, you need to disconnect the brake hose where it connects to the brake pipe, and then unscrew it from the brake caliper. The brake hose should not twist.
Caution: Collect leaking brake fluid with a rag. If necessary, insert a plug into the hole in the brake pipe leading to the master cylinder.
Installation
Install only brake hoses approved by the factory. Route the new brake hose so that it hangs without twisting. Tighten the hose on both sides to 15 Nm.
Note: Brake hose if required(depends on the brake caliper design), screw it to the brake caliper with new sealing rings. Tighten the connecting bolt (hollow) at the brake caliper to a torque of 38 Nm.
After installation with unloaded wheels (the car is lifted) check the mobility of the brake hoses when turning the steering wheel from lock to lock and make sure that the hoses do not touch anything.
Attention: Finally, remove air from the hydraulic drive of the brake system using an air removal device (at a service station).
Lower the car.
With the vehicle parked, check to see if the hoses are tracking all wheel movements and make sure the hoses are not catching on anything.
Attention, perform a safety compliance check:
- Are the brake hoses tightly tightened?
- Is the brake hose in the holder?
- Are the air bleed valves tightened?
- Is there enough fluid in the brake system?
- With the engine running, perform a leak test. To do this, apply a force of 200 to 300 N to the brake pedal for approximately 10 seconds (from 20 to 30 kg). Do not loosen the brake pedal. Check all connections for leaks.
Finally, perform several braking tests on a street with little traffic.
The original material is available on the portal: vwmanual
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