Peugeot 205 Manual

Hydraulic pipes and hoses - renewal
Braking system / Hydraulic pipes and hoses - renewal

Note: Before starting work, refer to the warning at the beginning of Section 2 concerning the dangers of hydraulic fluid.

1 If any pipe or hose is to be renewed, minimise hydraulic fluid loss by removing the master cylinder reservoir cap, placing a piece of plastic film over the reservoir and sealing it with an elastic band. Alternatively, flexible hoses can be sealed, if required, using a proprietary brake hose clamp; metal brake pipe unions can be plugged (if care is taken not to allow dirt into the system) or capped immediately they are disconnected. Place a wad of rag under any union that is to be disconnected, to catch any spilt fluid.

2 If a flexible hose is to be disconnected, unscrew the brake pipe union nut before removing the spring clip which secures the hose to its mounting. Depending upon the make of the particular caliper, the other end of the hose may be connected simply by screwing it into its tapped hole or by using a hollow bolt with banjo end fitting. Use a new copper sealing washer on each side of the banjo union.

3 To unscrew the union nuts, it is preferable to obtain a brake pipe spanner of the correct size; these are available from most large motor accessory shops. Failing this, a close-fitting open-ended spanner will be required, though if the nuts are tight or corroded, their flats may be rounded-off if the spanner slips. In such a case, a self-locking wrench is often the only way to unscrew a stubborn union, but it follows that the pipe and the damaged nuts must be renewed on reassembly. Always clean a union and surrounding area before disconnecting it. If disconnecting a component with more than one union, make a careful note of the connections before disturbing any of them.

4 If a brake pipe is to be renewed, it can be obtained, cut to length and with the union nuts and end flares in place, from Peugeot dealers. All that is then necessary is to bend it to shape, following the line of the original, before fitting it to the car. Alternatively, most motor accessory shops can make up brake pipes from kits, but this requires very careful measurement of the original, to ensure that the replacement is of the correct length. The safest answer is usually to take the original to the shop as a pattern.

5 Before refitting, blow through the new pipe or hose with dry compressed air. Do not overtighten the union nuts. It is not necessary to exercise brute force to obtain a sound joint.

6 If flexible rubber hoses are renewed, ensure that the pipes and hoses are correctly routed, with no kinks or twists, and that they are secured in the clips or brackets provided.

7 After fitting, bleed the hydraulic system as described in Section 2, wash off any spilt fluid, and check carefully for fluid leaks.

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