Volkswagen Workshop Service and Repair Manuals

Work instructions –  Unbolt relevant brake line at brake caliper or wheel brake cylinder; catch escaping brake fluid and dispose of this as per regulations.

–  Cut through brake line at a suitable point (straight, freely accessible section) with pipe cutter -2-. –  Remove section to be renewed. –  Degrease brake line surface.

–  Clamp brake line tightly in set of grips -4- so that approx. 50 mm project from plastic jaws. –  Clamp scraper -3- into a drill and position onto brake line. –  At slow drill speed and with gentle pressure on brake line, scrape coating off brake line. Length of scraping is determined by stop in scraper. –  Withdraw scraper from brake line and remove residue from scraping.

–  Remove set of grips and slide union bolt -D- onto brake line.

–  Slide brake line -B- up to stop -A- in flanging tool.   Note Brake line must be positioned against stop when the hexagon socket head bolts are tightened, or the flange will not be formed correctly. –  Tighten brake line in flanging tool until brake line can no longer be moved. Fold up stop -A- and now tighten hexagon socket head bolts diagonally using special wrench -C-.

–  Turn spindle to stop in flanging tool. –  Turn spindle back again. –  Loosen hexagon socket head bolts diagonally. –  Remove brake line from flanging tool, clean and check brake line and flange. Briefly flush the section of brake line remaining in the vehicle: –  Connect brake filling and bleeding unit -VAS 5234-, connect bleeder bottle hose to brake line flange and allow brake filling and bleeding unit -VAS 5234- to run briefly until a little brake fluid has run through. –  Blow out new brake line to be inserted with compressed air.

–  Join brake lines using connector -E-. –  Install brake line. –  Bleed brake system → Chapter.