Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 799

5

Brake Lines

⇒ “5.1 Brake Lines, Repairing”, page 127

5.1

Brake Lines, Repairing

⇒ “5.1.1 General Information”, page 127
⇒ “5.1.2 Overview - Flanging Tool”, page 129
⇒ “5.1.3 Instructions”, page 129

5.1.1

General Information

Special tools and workshop equipment required
♦ Brake Line Tool Kit - VAS6056-
♦ Brake Charger/Bleeder Unit - VAS5234-
Flare brake lines with 5 mm outer diameter using Brake Line Tool

Kit - VAS6056- without damaging coating. In this way, brake lines

can be inexpensively partially replaced in certain cases.
Working with Brake Line Kit - VAG1356- is not permitted because

of the coating and diameter of black brake lines.

Note

♦

Do not bend the brake lines more than maximum 90°.

♦

Otherwise the lines will kink or otherwise deform.

♦

From this the diameter of the line will be narrowed.

♦

Disconnect brake lines preferably at underbody.

♦

Position of intermediate pieces should be selected so that they

cannot rub against moving parts.

♦

Do not lubricate spindle, clean only with mineral spirits.

List of Individual Tools

1 - Brake Line Tool Kit - Flang‐

ing Tool - VAS6056/1-

❑ The Brake Line Tool Kit

- Flanging Tool -

VAS6056/1VAS

6056/6- the Clamp Jaws

- VAS6056/6- .

2 - Brake Line Tool Kit - Pipe

Cutter - VAS6056/2-
3 - Brake Line Tool Kit - Brake

Line Scraper - VAS6056/3-

❑ The threaded pins (in

shaft and at sides) are

set and must not be ad‐

justed!

4 - Brake Line Tool Kit - Line

Grips - VAS6056/4-
5 - Brake Line Tool Kit - Pipe

Bending Tool - VAS6056/5-
6 - AF 6 Angle Screwdriver
7 - Brake Line Tool Kit - Set Of

Clamp Jaws - VAS6056/7-

5.1.2

Overview - Flanging Tool

1 - Flanging Tool Upper Sec‐

tion

❑ Remove to change

Clamp Jaws

2 - Hand Grip Mount

❑ Must be removed to

reach the upper section

retaining bolt

3 - Bolt

❑ For flanging tool upper

section

4 - Clamp Jaws Threaded Pins

❑ Center and hold the

clamp jaws

❑ 2 mm inner hex socket

5 - Clamp Jaws

❑ Various
❑ Assembly instructions.

Refer to

⇒ Fig. ““Clamp Jaws In‐

stallation Instructions”“ ,

page 129

Clamp Jaws Installation Instructions
♦ VAS6056/6 (dark) for black brake lines
♦ VAS6056/7 (light) for green brake lines

Note

♦

The arrow on the rounded side of the clamp jaws must point

toward the edge of the housing.

♦

The straight side of the clamp jaws must be installed toward

the spindle, otherwise the flanged head will not be formed cor‐

rectly.

5.1.3

Instructions

– Remove the corresponding brake line on the brake caliper or

wheel brake cylinder.

– Be sure to catch any leaking brake fluid and dispose of it cor‐

rectly.

– Cut the brake line at a suitable place (straight, easily accessi‐

ble piece) with the tube cutter -2-.

– Remove the piece to be exchanged.
– Lubricate brake line surface.

– Clamp the brake line in a set of locking pliers -4- so that 50

mm is sticking out of the plastic jaws.

– Install the peeling tool -3- in a power drill and place it on the

brake line.

– Shear coating from 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 shavings.

– Remove the locking pliers and push the tube fitting -D- onto

the brake line.

– Push the brake line -B- against the stop -A- inside the flaring

tool.

Note

Brake line must contact stop when hex socket heat screws are

tightened, otherwise the flanged head will not be formed correctly.

– Tension the brake line in the flanging tool.
– Push the brake line forward until it can no longer be moved.
– Fold up the stop -A-.
– Tighten the hex socket head bolts diagonally using a long

reach special wrench -C-.