SPS

Please take a few minutes to read through these instructions in their entirety BEFORE you start to modify your Saturn. Remember: careful planning and preparation will make your install experience educational and painless.

Braided Stainless Steel Brake Hose Kit Preparation

1. Make sure that you have all the parts listed below before you attempt this installation! Contact SPS immediately if you have questions or concerns regarding part quantities or part numbers.

Vehicle Preparation and Support

1. Loosen the lug nuts of the road wheels using a 19mm socket and place the entire vehicle on jackstands. Be sure that the car is firmly supported before going ANY further with this installation!
2. Remove all road wheels.

Flexible Brake Hose Removal

1. Note: before going ANY farther with this install, it is HIGHLY recommended that you completely remove and replace each brake line completely before attempting the replacement of the subsequent line. The recommended sequence is to replace the right rear line first, followed by the left rear, right front, then left front line.
2. Disconnect the flexible brake hose from the drum brake wheel cylinder or caliper body by loosening the yellowish banjo bolt found on the back side of the drum brake wheel cylinder or caliper body using an 11mm socket. Remove the banjo bolt and two copper washers from the hose end. Note: your kit comes with new banjo bolts, washers, and retainer clips (c-clips), so saving these parts is not necessary for re-assembly. However, you may wish to keep the left front retainer clip for use with the new lines. (See installation step 3 below.)
3. Carefully loosen the tube nut connecting the flexible brake line to the rigid brake pipe. It is highly recommended that you use a 12mm tube nut (5-sided) wrench when disconnecting this joint. Note: the left front line will require a 14mm tube nut wrench.
4. Remove the flexible brake hose c-clip from the flexible brake hose fitting at the hard line to flex line interface using a small screwdriver-ish type implement. Prior to removal, make note of the c-clip installation orientation, as the orientation of your new clips will be the same! Retain the stock left front clip as you may decide to re-use it.
5. Remove the flexible brake hose from the vehicle. You may want to place a drip pan beneath the rigid brake pipe tube nut, as brake fluid will most likely be dripping from this line until re-assembly. Do NOT attempt to plug the tube nut opening, as you may introduce contamination into the brake pipe which could be trapped upon re-assembly.
6. FOR LEFT FRONT BRAKE HOSE ONLY: using a 10mm socket (or equivalent), remove the L-shaped body bracket (L-bracket) from the inner fender rail. Note the orientation of the bracket and the location of the anti-rotation tab as you will be installing your new bracket in the same fashion. Keep the M10 bolt handy, as you will be re-using it for the installation of the new L-bracket.

Stainless Steel Brake Hose Installation

1. For the left rear, right rear, and right front hoses, slide the new stainless steel brake hose fitting into the keyed opening in the rear suspension crossmember (rear lines) or the front brake hose metal L-bracket (right front line). Prior to installing the left front hose, be sure to attach your new L-bracket in the same orientation as the original L-bracket. Tighten the original fastener until comfortably snug - do NOT overtighten, as this fastener does not require excessive torque!
2. Finger-start the tube nut from the rigid brake pipe in the stainless steel brake hose fitting.
3. Install one of the included c-clips by pressing firmly to secure the new stainless steel brake hose in the crossmember / L-bracket. Note: installing the supplied copper clip in the left front corner is quite difficult. To improve ease of installation at this corner, you may flatten the supplied copper clip with a vice or a hammer. Or you may re-use the stock clip (see removal step 2 above.)
4. Place one new copper washer over the end of the new banjo bolt. Slide the assembly through the square banjo fitting end of the new stainless steel brake hose and place a second new copper washer on the opposite side of the square banjo fitting.
5. Finger-start the banjo bolt into the drum brake wheel cylinder or caliper body making sure that the fitting block is securely seated against the drum brake wheel cylinder or caliper body.
6. Using an 11mm socket, torque the banjo bolt-to-brake joint to 49 Nm (36 ft-lb).
7. Using a 12mm crowsfoot wrench, torque the tube nut-to-stainless steel brake hose joint to 24 Nm (18 ft-lb). Use a 14mm crowsfoot wrench on the left front corner.
8. While still on jackstands, bleed the entire brake system using a 10mm wrench to remove any air trapped in the system. Note: rear drum brakes require a 8mm wrench for bleeding. For complete bleeding instructions, see How to Bleed Brakes The Right Way.
9. After bleeding be sure to inspect all stainless steel brake hose and rigid pipe joints for signs of leakage. Correct as necessary.

Vehicle Wrap-Up and Road Test

1. Re-install all four road wheels.
2. Raise the entire vehicle and remove jackstands. Torque the lug nuts to 140 Nm (103 ft-lb) using a 19mm socket. Re-install any hubcaps or wheel covers also using a 19mm socket
3. With the vehicle on level ground and with the car NOT running, apply and release the brake pedal several times until all clearances are taken up in the system.
4. Road test the vehicle to confirm proper function of the brakes. USE CAUTION THE FIRST TIME YOU DRIVE YOUR CAR AFTER MODIFICATION TO ENSURE THE PROPER FUNCTION OF ALL VEHICLE SYSTEMS!
5. Enjoy your modified Saturn!