Peugeot 308: Removing - refitting : Brake hoses

ESSENTIAL : Observe the safety and cleanliness recommendations .

ESSENTIAL : All personnel carrying out work on a vehicle fitted with traction batteries must have received specific electric vehicle training and be authorised to work on these vehicles (observe the regulations in force in the respective country).

ESSENTIAL : All personnel working on vehicles with a fuel cell stack must have completed the STELLANTIS training courses required to work on these vehicles (observe the regulations in force in the respective country).

1. Replacement of parts in all cases

Description	Quantity
Brake hose (Banjo type union)	1 (Per side)

2. Tooling

Workshop equipment :

• A pedal press
• A plastic receptacle
• A bleed pipe

Tool	Reference	Description
	[1367-A] (*)	4 mm feeler gauge
	[0194-2E] (*)	Set of plugs
(*) Use standard workshop equipment if the special tool is not available

3. Preliminary operations

CAUTION : The brake hoses must not be under any tension (kinking and/or twisting).

Raise and chock the vehicle at mid-height (Front wheels suspended).

Remove the wheel (Repair zone).

Place a bleed pipe on the slave cylinder of the brake hose to be removed.

Dip the pipe in the receptacle.

Open the bleeder.

Place the pedal press on the brake pedal in order to prevent the discharge of any brake fluid when disconnecting the brake pipes.

Close the bleeder.

Remove and drain the pipe and the receptacle.

4. Removing the front brake hose

4.1. Front brake hose not fixed on the damper body

Uncouple the front brake hose (1) (In "c").

Plug the brake pipe ; Using the tool [0194-2E].

Release the front brake hose (1) from its support (In "a").

Uncouple the front brake hose (1) (In "b").

Plug the openings of the brake hose (1) and of the brake caliper ; Using the tool [0194-2E].

Remove the front brake hose (1).

4.2. Front brake hose bolted on the damper body with a standard union on the brake caliper

Uncouple the front brake hose (3) (In "e").

Plug the brake pipe ; Using the tool [0194-2E].

Release the front brake hose (3) from its support (In "d").

Remove the bolt (2).

Uncouple the front brake hose (3) (In "f").

Plug the openings of the brake hose (3) and of the brake caliper ; Using the tool [0194-2E].

Remove the front brake hose (3).

4.3. Front brake hose bolted on the damper body with a BANJO union on the brake caliper

CAUTION : Never separate the front brake hose from its support (In "j") :Risk of serious damage to the front brake hose.

Uncouple the front brake hose (5) (In "h").

Plug the brake pipe ; Using the tool [0194-2E].

Release the front brake hose (5) from its support (In "g").

Remove the bolt (4).

Uncouple the front brake hose (5) (In "k").

Plug the openings of the brake hose (5) and of the brake caliper ; Using the tool [0194-2E].

Remove the front brake hose (5).

4.4. Front brake hose clipped on the damper body

Uncouple the front brake hose (6) (In "l").

Plug the brake pipe ; Using the tool [0194-2E].

Release the front brake hose (6) from its support (In "m").

Uncouple the front brake hose (6) (In "n").

Plug the hydraulic unit unions ; Using the tool [0194-2E].

Remove the front brake hose (6).

4.5. Front brake hose fixed on a support (Front wheel speed sensor and electrical harness sold together)

CAUTION : Never separate the front brake hose from its support (In "p") :Risk of serious damage to the front brake hose.

Remove the bolt (9).

Unclip the front wheel speed sensor electrical harness (In "q").

Move aside the wheel speed sensor (8).

Remove the bolts (10).

Move aside the bracket (7).

Uncouple the front brake hose (11) (at "r", "s").

Remove the brake hose (11) and support (7) assembly .

4.6. Front brake hose fixed on a support (Front wheel speed sensor and electrical harness sold separately)

CAUTION : Never separate the front brake hose from its support (In "t") :Risk of serious damage to the front brake hose.

Disconnect the connector (In "v").

Unclip the front wheel speed sensor electrical harness (In "u").

Remove the bolts (12).

Move aside the bracket (13).

Uncouple the front brake hose (14) (At "w" and "x").

Remove the brake hose (14) and support (13) assembly .

5. Removing the rear brake hose

5.1. Rear brake hose without intermediate support

Remove the LH and RH under-body protections (depending on equipment).

Uncouple the rear brake hose (16) (In "z").

Plug the brake pipe ; Using the tool [0194-2E].

Loosen the union (In "y").

Plug the brake pipe ; Using the tool [0194-2E].

CAUTION : Do not damage the fuel tank(left-hand side).

Remove :

• The retaining clip (15)
• The rear brake hose (16)

5.2. Rear brake hose with intermediate support (Without motorised brake caliper)

Remove :

• The LH and RH under-body protections (depending on equipment)
• The bolt (18)

Release the rear brake hose (17) from its support.

Uncouple the rear brake hose (17) (In "aa").

Plug the brake pipe ; Using the tool [0194-2E].

Release the rear brake hose (17) (In "ab").

Uncouple the rear brake hose (17) (In "ac").

Plug the brake pipe ; Using the tool [0194-2E].

Remove the rear brake hose (17).

5.3. Rear brake hose with intermediate support (With motorised brake caliper)

Remove :

• The LH and RH under-body protections (depending on equipment)
• Nut (20)

Uncouple the rear brake hose (19) (In "ad").

Plug the brake pipe ; Using the tool [0194-2E].

Release the rear brake hose (19) (In "ae").

Release the rear brake hose (19) from its support.

Uncouple the rear brake hose (19) (In "af").

Plug the brake pipe ; Using the tool [0194-2E].

Remove the rear brake hose (19).

5.4. Rear brake hose (On the rear suspension arm) (With motorised brake caliper)

Uncouple the rear brake hose (21) (In "ag").

Plug the brake pipe ; Using the tool [0194-2E].

Remove the bolt (22).

Unclip :

• The rear brake hose (21) (In "ah")
• The rear brake hose (21) (In "aj")

Uncouple the rear brake hose (21) (In "ak").

Plug the brake pipe ; Using the tool [0194-2E].

Remove the rear brake hose (21).

6. Refitting the front brake hose

CAUTION : Observe the braking system tightening torques.

6.1. Front brake hose not fixed on the damper body

Remove the tool [0194-2E].

Refit the front brake hose (1).

Couple the front brake hose (1) on the brake caliper (In "b").

Engage the front brake hose (1) in its support (In "a").

Remove the tool [0194-2E].

Couple the front brake hose (1) to the rigid brake pipe (In "c").

6.2. Front brake hose bolted on the damper body with a standard union on the brake caliper

Remove the tool [0194-2E].

Refit the front brake hose (3).

Couple the front brake hose (3) on the brake caliper (In "f").

Refit the bolt (2).

Engage the front brake hose (3) in its support (In "d").

Remove the tool [0194-2E].

Couple the front brake hose (3) to the rigid brake pipe (In "e").

6.3. Front brake hose bolted on the damper body with a BANJO union on the brake caliper

Remove the tool [0194-2E].

Fit the new front brake hose (5).

Couple the front brake hose (5) on the brake caliper (In "k").

Refit the bolt (4).

Engage the front brake hose (5) in its support (In "g").

Remove the tool [0194-2E].

Couple the front brake hose (5) to the rigid brake pipe (In "h").

6.4. Front brake hose bolted on the damper body with a BANJO union on the brake caliper (Assembly BREMBO)

CAUTION : Position the shim [1367-A] (4 mm thick) between the bolt (23) and the brake hose (5) to guarantee the 4 mm clearance.

Remove the tool [0194-2E].

Fit the new front brake hose (5).

Tighten the bolt (24), keeping a 4 mm clearance between the bolt (23) and the brake hose (5).

Refit the bolt (4).

Engage the front brake hose (5) in its support (In "g").

Remove the tool [0194-2E].

Couple the front brake hose (5) to the rigid brake pipe (In "h").

6.5. Front brake hose clipped on the damper body

CAUTION : After the operation, check that the front brake hose (6) is secured in its housing on the damper body (In "m").

Remove the tool [0194-2E].

Refit the front brake hose (6).

Couple the front brake hose (6) on the brake caliper (In "n").

Engage the front brake hose (6) in its support (In "m").

Remove the tool [0194-2E].

Couple the front brake hose (6) to the rigid brake pipe (In "l").

6.6. Front brake hose fixed on a support (Front wheel speed sensor and electrical harness sold together)

Refit the brake hose (11) and support (7) assembly .

Couple up the front brake hose (11) (At "r" and "s").

Refit :

• The bolts (10)
• The wheel speed sensor (8)
• The bolt (9)

Clip the front wheel speed sensor electrical harness (In "q").

6.7. Front brake hose fixed on a support (Front wheel speed sensor and electrical harness sold separately)

Refit the brake hose (14) and support (13) assembly .

Couple up the front brake hose (14) (At "w" and "x").

Refit the bolts (12).

Clip the front wheel speed sensor electrical harness (In "u").

Reconnect the connector (In "v").

7. Refitting the rear brake hose

CAUTION : Observe the braking system tightening torques.

7.1. Rear brake hose without intermediate support

Remove the tool [0194-2E].

Refit the rear brake hose (16).

Couple the rear brake hose (16) (In "y") (without tightening).

Refit the fixing clip (15).

Tighten the union (In "y").

Couple the rear brake hose (16) (In "z").

Refit the LH and RH under-body protections (according to equipment).

7.2. Rear brake hose with intermediate support (Without motorised brake caliper)

Remove the tool [0194-2E].

Refit the rear brake hose (17).

Couple the rear brake hose (17) (In "ac").

Secure the rear brake hose (17) (In "ab").

Couple the rear brake hose (17) (In "aa").

Engage the rear brake hose (17) in its support.

Refit :

• The bolt (18)
• The LH and RH under-body protections (depending on equipment)

7.3. Rear brake hose with intermediate support (With motorised brake caliper)

Remove the tool [0194-2E].

Fit the new rear brake hose (19).

Couple the rear brake hose (19) (In "af") (without tightening).

Tighten the union (In "af").

Engage the rear brake hose (19) in its support.

Secure the rear brake hose (19) (In "ae").

Couple the rear brake hose (19) (In "ad").

Refit :

• Nut (20)
• The LH and RH under-body protections (depending on equipment)

7.4. Rear brake hose (On the rear suspension arm) (With motorised brake caliper)

Remove the tool [0194-2E].

Fit the new rear brake hose (21).

Couple the rear brake hose (21) (In "ak") (without tightening).

Tighten the union (In "ak").

Secure the rear brake hose (21) (At "ah" and "aj").

Refit the bolt (22).

Couple the rear brake hose (21) (In "ag").

8. Additional operations

Clean any splashes of fluid from the surrounding area.

Remove the pedal press .

CAUTION : Bleed the braking circuit .

CAUTION : Observe the tightening torques .

Tighten the wheel bolts.

Refit :

• The wheel (Repair zone)
• The vehicle to its wheels