Brake Pipe, Hydraulic Unit / Front Wheel / Junction
Brake pipe from hydraulic unit/front wheel/junction, replacing
Preparation
Disconnect the battery lead
See VCC-104452.
Preparations when replacing brake pipes (applies to all brake pipes)
Switch off the ignition. Collect the brake fluid
See Replacing the front brake calipers.
Removing the integrated relay/fusebox
- Remove the nut for the positive cables
- lilt the cable terminals away from the screw
- remove both the screws.
Remove:
- Remove the integrated relay/fusebox from the bracket
- lift up the box at the front (1). Press the box (2) to the side. Then angle the box out of the bracket (3).
Brake pipe left front, replacing Clean around the brake pipe on the ABS hydraulic modulator. Remove the brake pipe from the ABS hydraulic modulator and the clips
Blow clean around the brake pipe using compressed air.
Place paper under the ABS hydraulic modulator as protection against brake fluid spillage.
Remove:
- the brake pipe from the ABS hydraulic modulator
- the brake pipe from its clips and holder. Open the holder.
Note: Do not damage the ABS line.
Remove the brake pipe from the car
Raise the car
Separate the brake pipe and the brake hose at the bracket.
Counterhold the brake hose so that it does not twist.
Remove the brake pipe from the car.
Install the new brake pipe
Note: The new brake pipe must be bent into the correct shape when installing. This is important otherwise the pipe may be subject to stresses when it is in place.
Tighten pipes on brake hose to 17 Nm
Check that the hose is not twisted.
Install the brake pipe in the ABS hydraulic modulator
Install:
- the brake pipe in the ABS hydraulic modulator. Tighten to 17 Nm
- the pipe in its holder. Open the holder
- the ABS line in its clips on the brake pipe
- the integrated relay/fusebox.
- the Air Cleaner (ACL) housing.
Brake pipe right front, replacing
Clean around the brake pipe on the ABS hydraulic modulator.
Remove the brake pipe from the ABS hydraulic modulator and holder
Open the holder.
Remove the brake pipe from the car
Raise the car. Remove:
- the screws for the front cross member (1)
- the pipe from the bracket, left-hand side (2)
- the cross member. Remove the brake pipe from its clips.
Separate the brake pipe and brake hose at the bracket (3).
Counterhold the brake hose so that it does not twist.
Remove the brake pipe from the car.
Install the new brake pipe
Note: The new brake pipe must be bent into the correct shape when installing. This is important otherwise the pipe may be subject to stresses when it is in place.
Install:
- the brake pipe between the ABS hydraulic modulator and the bracket, left-hand side (1)
- the brake pipe in its clips in the front cross member (2)
- the front cross member with the screws.
Tighten the cross member. Tighten to 25 Nm.
Install the ABS line in its clips.
Lower the car.
Tighten brake pipes on brake hose to 17 Nm.
Install the brake pipe in the ABS hydraulic modulator
Tighten to 17 Nm.
Install:
- the brake pipe in its holder. Open the holder
- the integrated relay/fusebox.
- the Air Cleaner (ACL) housing.
Front-rear brake pipe to the rear junctions, replacing
Clean around the brake pipe on the ABS hydraulic modulator. Remove the brake pipe from the ABS hydraulic modulator and holder
Open the holder.
Remove the brake pipe from its clips by the side member
Straighten the brake pipe by the ABS hydraulic modulator.
Note: The new brake pipe must be bent into the correct shape when installing. This is important otherwise the pipe may be subject to stresses when it is in place.
Remove the brake pipe from its clips
Raise the car
Remove the left front wheel.
Remove the screw from the bracket for the brake pipe and brake hose.
Remove the holder from the brake pipes.
Clean the brake pipe and joint nipple.
Separate the brake pipe at the joint nipple. Counterhold the joint nipple.
Remove the brake pipe from its clips.
Cut the brake pipe at the bracket. Leave the pipe that has been cut in place as a guide for installation of the new brake pipe.
Install the new brake pipe
Remove the cut-off brake pipe. Install the new one.
Tighten the brake pipe in the joint nipple. Tighten to 22 Nm.
Secure the brake pipe in its clips in the body floor.
Bend and adjust the brake pipe so that it aligns with the hydraulic unit.
Installing the brake pipe, continued
Install:
- the brake pipe in the ABS hydraulic modulator. Tighten to 17 Nm
- the brake pipe in its clips at the bracket. Adjust the pipe as necessary
- the clip holder on the brake pipes by the side member - the bracket. Tighten to 12 Nm.
Note: The brake pipes must not be in contact with each other or the car body.
Check for leakage. Check that the ABS lines are correctly secured in their clips.
Install the wheel
See Installing wheels.
Install the integrated relay/fusebox and the connector for the ABS unit
Hydraulic unit, replacing.
Install the Air Cleaner (ACL) housing
Brake pipe master cylinder/ABS unit, replacing.
Fill and bleed the brake system
See Brake system bleeding (using bleeding unit).