Checking the condition and replacing brake lines and hoses (Opel Vectra C)

1. The service brake system operates at a fairly high pressure: 2.0-2.5 bar, so metal tubes of the appropriate cross-section are used as brake lines. However, to supply fluid to the moving elements of the suspension and chassis, it is necessary to use hoses that are capable of withstanding the required loads with a certain margin of safety.

2. Every time you perform maintenance, check all elements of the brake system for cracks, signs of damage to the protective shell, traces of fluid leaks, swelling and other damage. Hoses are a critical and most vulnerable component of the brake system, so they must be inspected with the utmost care. If any questionable signs are detected, the suspected hose must be replaced.

Attention: Do not allow brake hoses to come into contact with oil or gasoline, do not paint them, or expose them to special compounds for anti-corrosion protection of the underbody.

3. Over time, during vehicle operation, old brake hoses may swell, reducing their flow area - this complicates the return of brake fluid to the master cylinder and the complete removal of the brake pads from the disk. As a result, the brake mechanisms heat up, which can lead to failure of both the mechanisms themselves and the wheel bearings.

4. Replacement steel and flexible brake lines can always be purchased at branded service stations, as well as in branded automotive accessory stores.

Attention: Do not under any circumstances use any replacement tubes other than branded ones, specially designed for installation in the brake circuit of your vehicle.

5. If it is necessary to replace metal brake lines, it is necessary to contact an Opel service station, since their installation requires a certain skill and qualification; careless handling can lead to bending of the tubes and affect the size of the channel cross-section. Brake lines must be located at a distance of at least 20 mm from moving or vibrating components of the body, suspension or steering gear. When installing, it is necessary to use all standard clamps and line holders.

6. Before replacing the hose, check the brake fluid level in the reservoir and add the required amount if necessary. Remove the corresponding wheel. Prepare plugs to plug the brake lines after disconnecting them and a rag to remove spilled brake fluid.



(Information taken from the website: «opelbook.ru»)

Note: The procedure for replacing the front brake hose is described below. Replacing the rear brake hose is almost identical, with the only difference being that an intermediate hose holder is not provided (see accompanying illustration).

7. To loosen the union nut connections of the flexible hoses with the steel tubes of the hydraulic lines, use special open-end wrenches with a slotted head. After loosening the union nut, remove the locking bracket and release the brake hose from the support bracket (see accompanying illustration) in the wheel arch, - the locking bracket must be installed in place after disconnecting the hose. Immediately close the brake pipe with the prepared plug.



8. Unscrew the hollow bolt (see accompanying illustration) and disconnect the brake hose from the caliper nipple. Remove the old sealing washers - the washers must be replaced during assembly.





9. Release the hose from the intermediate holder on the shock absorber strut (see illustration 4.8), for which use pliers to remove the locking plate.

10. Make sure that the new brake hoses exactly match the dimensions and characteristics of those removed from the vehicle.

11. Fasten the brake hose with new sealing rings to the caliper, tighten the hollow bolt with the required force. Then remove the plug and connect the hose to the metal brake line, tighten the union nut. After that, fasten the hose in the intermediate holder on the shock absorber stand - make sure that the hose does not twist during installation.

12. With the front wheels raised, turn the steering wheel to the right and left - the hose should not interfere with the moving parts of the steering mechanism and should not come into contact with other structural elements.

13. After replacing the hose, be sure to remove air from the brake system using a special device. Check the fluid level in the brake master cylinder reservoir, and make the appropriate adjustments if necessary.

14. Before operating the vehicle, make sure that the brakes are functioning properly.