Brake Line Repair Instructions

Brake Line Repair Instructions

Special tools, testers and auxiliary items required

• Brake Charger/Bleeder Unit (VAS 5234)

- Remove the affected brake line at brake caliper or wheel brake cylinder and collect escaping brake fluid and dispose of it correctly.

- Disconnect brake line at appropriate location (straight, accessible part) with line cutter - 2 -.






- Remove piece to be exchanged.

- Lubricate brake line surface.

- Clamp brake line in self-grip pliers - 4 - so that 50 mm of the plastic clamping jaws show.






- Clamp shearing tool - 3 - in a drill and place it on the brake line.

- Shear coating from the brake line at a slow drill RPM and with light pressure against the line.

The length of the sheared-off portion is determined by the stop in the shearing tool.

- Remove shearing tool from brake line and remove shearing remains.

- Remove self-grip pliers and tube fitting - D - from brake line.






- Slide brake line - B - against stop - A - in flaring tool.






• Brake line must contact stop when hex socket head bolts are tightened, otherwise flared head will not be formed correctly.

- Clamp brake line in flaring tool until it cannot be moved any more. Fold stop - A - up and tighten hex socket head bolts diagonally with angle bolt driver - C -.

- Turn spindle to stop in flaring tool.






- Turn spindle back.

- Loosen hex socket head bolts diagonally.

- Remove brake line from flaring tool, clean and check brake line and flared head.

Briefly rinse part of brake line remaining in vehicle.

- Connect the (VAS 5234) , place the bleeder container hose on the flared head of the brake line and run the (VAS 5234) briefly until some brake fluid runs through.

- Clean the brake line with compressed air.

- Join brake lines with connecting piece - E -.






- Assemble brake line.

- Bleed the brake system. Refer to => [ Hydraulic System, Bleeding ] Hydraulic System, Bleeding.