GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Sunfire 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Front Brake Hose Replacement

Removal Procedure

    Object Number: 161526 Size: SH
  1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the tire and the wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  3. Clean dirt, grease, and other foreign material from the hoses and brake pipe fitting.

    4. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination.

  4. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose, then cap or plug the brake pipe fitting end.
  5. Remove the retaining nut and retaining clip from the front brake hose.
  6. Remove the retaining bolt and the bracket of the front brake hose.

    7. Object Number: 156274 Size: SH
  7. Remove the brake hose bolt from the Brake caliper.
  8. Remove and discard the two copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  9. Remove the front brake hose from the vehicle.

Installation Procedure

    Object Number: 156274 Size: SH
  1. Install NEW copper gaskets to the front brake hose.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the front brake hose to the caliper.

    3. Tighten
    Tighten the retaining bolt to 50 N·m (37 lb ft).


    Object Number: 161526 Size: SH
  3. Install the retaining clip to the front brake hose.

    4. Important: Make sure the brake hose is not twisted. Make sure the brake hose is not in contact with any suspension components.

  4. Connect the front brake pipe to the front brake hose.

    5. Tighten
    Tighten the front brake pipe to 20 N·m (15 lb ft).

  5. Bleed the brake hydraulic system. Refer to Hydraulic Brake System Bleeding .
  6. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  7. Lower the vehicle.