Removal and Installation of Brake Hose

GENERAL INFORMATION

Brake hoses and lines connect the master brake cylinder with the wheel brake cylinders.

CAUTION

Rigid metal brake lines must be routed only at a workshop (service station), as this requires appropriate qualification. Brake hoses are used as flexible connections between rigid moving brake components, such as calipers, and the vehicle body. If hoses show visible damage, they must be replaced. If the brake fluid reservoir has run completely empty (for example, due to a leak in the system or as a result of bleeding air when brake fluid was not topped up in the empty reservoir), air enters the ABS pump. In this case, for safety reasons, the air must be bled from the system at a workshop using special equipment. If EDS is fitted, an additional adjustment with the tester must be carried out. When installing a new brake hose, the air must also be bled from the system using special equipment. Do not allow brake hoses to come into contact with oil or fuel, and do not paint brake hoses or coat them with underbody anti-corrosion compound.

REMOVAL

CAUTION

Observe the brake fluid handling rules given in the Brake fluid subsection.

PROCEDURE

1. Raise the vehicle and support it on stands.

2. Remove the caliper. Refer to the Brake disc/caliper removal and installation subsection.

3. Disconnect the brake hose from the guide and the clip holder.

4. Disconnect the brake hose from the line and from the caliper. Do not twist the brake hose. If the brake hose at the caliper must be replaced, remove the caliper first.

CAUTION

Wipe up spilled brake fluid with a rag. Close the line connection toward the wheel brake cylinder with a suitable plug.

INSTALLATION

PROCEDURE

1. Install only brake hoses approved by the manufacturer. Install the new hose so that it hangs without twisting, and tighten it to the brake line to 15 N·m.

CAUTION

Secure the hose to the caliper using new sealing rings. Tighten the hose banjo bolt (hollow bolt) to the caliper to 35 N·m.

2. After installation, with the wheels unloaded and the vehicle raised, turn the steering wheel left and right and check that the hose follows all wheel movements without touching adjacent components.

3. Install the caliper. Refer to the Brake disc/caliper removal and installation subsection.

4. Lower the vehicle onto its wheels.

5. With the vehicle standing on the ground, check that the hose follows all wheel movements without touching adjacent components.

CAUTION

Check the following for security:

– Are the brake hose mounting bolts securely tightened? – Is the brake hose secured in its bracket? – Are the bleeder screws tightened? – Is there enough brake fluid in the reservoir? – With the engine running, check the system for leaks. To do this, press the brake pedal with a force of 200 – 300 N (20 – 30 kg) for 10 s. The pedal must not sink. Check all connections for leaks.

6. Bleed the air from the system at a workshop.

7. Check the brake system operation on a road with light traffic.