Brake Lines, Repairing: Instructions

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

-- Remove brake line on the brake caliper or wheel brake cylinder.

-- Be sure to catch any leaking brake fluid and dispose of it correctly.

-- Cut the brake line at a suitable place (straight, easily accessible piece) with the tube cutter -2-.

Fig 1: Disconnecting Brake Line At Appropriate Location With Line Cutter

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-- Remove the piece to be exchanged.

-- Lubricate brake line surface.

-- Pinch the brake line in a set of locking pliers -4- so that 50 mm is sticking out of the plastic jaws.

Fig 2: Brake Line Clamped In Self-Grip Pliers

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-- Install the peeling tool -3- in a power drill and place it on the brake line.

-- Operate the drill at a slow RPM.

-- Remove the coating on the brake line using light pressure.

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

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

-- Remove the locking pliers and push the tube fitting -D- onto the brake line.

Fig 3: Identifying Self-Grip Pliers, Tube Fitting And Brake Line

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-- Push the brake line -B- against the stop -A- inside the flaring tool.

Fig 4: Sliding Brake Line Against Stop In Flaring Tool

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NOTE: Brake line must contact stop when hex socket heat screws are tightened, otherwise the flanged head will not be formed correctly.

-- Pretension the brake line inside the flaring unit until the brake line can no longer be moved.

-- Fold up stop -A-.

-- Tighten the hex socket head bolts diagonally using a long reach special wrench -C-.

-- Turn the spindle all the way in the flange unit.

Fig 5: Identifying Turning Spindle To Stop In Flaring Tool

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-- Turn the spindle back.

-- Loosen the hex socket head bolts diagonally.

-- Remove the brake line from the flange unit.

-- Check and clean the brake line and the flared head.

Briefly rinse the part of the brake line remaining in the vehicle:

-- Connect the Brake Charger/Bleeder Unit VAS5234, place the bleeder container hose on the flared head of the brake line and run the Brake Charger/Bleeder Unit VAS5234 briefly until some brake fluid runs through.

-- Clean the brake line with compressed air.

-- Join brake lines with connecting piece -E-.

Fig 6: Identifying Brake Lines Joined With Connecting Piece

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-- Install the brake line.

-- Bleed the brake system. Refer to DESCRIPTION AND OPERATION .