Brake Pipe Replacement

BRAKE PIPE REPLACEMENT

^ TOOLS REQUIRED
- SA91108NE Universal Tube Bender
- SA9193BR Brake Pipe Flaring Kit

IMPORTANT: All brake pipes are serviced with original equipment pipes except for the right front and underbody brake pipes.

ISO/DIN FLARE

CAUTION: ALWAYS USE DOUBLE WALLED STEEL BRAKE PIPE WHEN REPLACING BRAKE PIPES. THE USE OF ANY OTHER PIPE IS NOT RECOMMENDED AND MAY CAUSE BRAKE SYSTEM FAILURE. CAREFULLY ROUTE AND RETAIN REPLACEMENT BRAKE PIPES. ALWAYS USE THE CORRECT FASTENERS AND THE ORIGINAL LOCATION FOR REPLACEMENT BRAKE PIPES. FAILURE TO PROPERLY ROUTE AND RETAIN BRAKE PIPES MAY CAUSE DAMAGE TO THE BRAKE PIPES AND CAUSE BRAKE SYSTEM FAILURE.

Right Front Brake Pipe





Underbody Brake Pipes





Brake Pipes-to-Union





1. Obtain recommended pipe and fittings of correct size. Outside diameter of pipe is used to specify size. Saturn uses 4.75 mm (0.187 inch) brake pipe.
2. Remove brake pipe to be repaired from vehicle.
3. Cut section to be replaced from brake pipe using an appropriate saw. Do not use a tube cutter to cut new pipe; the end must be flat and square to produce a good flare.
4. Determine length of pipe required for repair by measuring section to be replaced with a string adding 3.2 mm (1/8 inch) for each flare.
5. Cut new pipe using an appropriate saw. Do not use a tube cutter to cut new pipe; the end must be flat and square to produce a good flare.
6. Remove burrs from inside and outside diameters of cut pipe using a deburring tool.
7. Install required fittings.
8. Clamp Brake Pipe Flaring Kit SA9193BR (or equivalent) securely in a vice.
9. Install handle into operating cam.





10. Loosen die clamp screw and rotate locking plate to expose die carrier opening.
11. Select required die set (4.75 mm DIN) and install in carrier with full side of either half facing clamp screw and counter bore of both halves facing punch turret.





12. Insert prepared pipe through rear of die and push forward until end of pipe is flush with face of die.





13. Make sure that rear of both halves of the die rest against hexagon die stops. Rotate locking plate to fully closed position and clamp die firmly by tightening clamp screw.





14. Select appropriate Operation 1 (OP. 1) punch by rotating punch turret until correct size (4.75 mm DIN) points towards the open end of pipe to be flared.





15. Pull operating handle against resistance of pipe to create flare and return handle to original position.
16. Release clamp screw and rotate locking plate to open position.
17. Remove die set and pipe and separate by gently tapping both halves on a bench.
18. Inspect pipe flare for correct shape, size and any flaws.
19. Repeat procedure (steps 6 through 18) for pipe being repaired.





20. Bend pipe using an approved pipe bending tool such as Universal Tube Bender SA91108NE (or equivalent), using the section to be replaced as a guide.
21. Install new repaired pipe to old pipe using a female union.
Torque: Female Repair Union-to-Vehicle Fitting: 18 Nm (13 ft. lbs.)
22. Install repaired pipe assembly into vehicle.
Torque: Brake Pipe Fitting Connection: 18 Nm (13 ft. lbs.)
23. Bleed brake system.