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Old 11-09-2018, 03:38 PM   #1
claybear
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2002 L-Series 2.2L Wagon
Default Brake Line Diagram?

Hi all

I'm making new brake lines for my 2002 LW200 from the firewall back by copying the originals as closely as I can. Unfortunately, I didn't mark which line hooked up to each of the lines on the firewall before I took them out. I may be able to figure it out by finding another L series car and comparing or by tracing from the master cylinder through the ABS box to the firewall connection. But, if anyone has a diagram or could take a picture of the lines at the firewall and note which one goes to the driver rear and which one goes to the passenger rear, I could save some time. Thanks in advance.

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Old 11-09-2018, 08:36 PM   #2
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Default Re: Brake Line Diagram?

The attached from the FSM may assist you. You may need to blow it up a bit to see the individual lines better.

This past summer one brake line going to the rear brakes sprung a pinhole leak. It was heavily rusted around the middle part of the car.

My friend who manages a busy indi repair shop (with 3 lifts) replaced both rear brake lines for me. He had problems duplicating the long line going to the driver side rear brake. That line was originally routed over the fuel tank. He said he could not reach the original brake line clamps without dropping the tank, so he routed the new line around the fuel tank. You could possibly run into this issue.
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File Type: pdf L Series Brake Lines.pdf (32.7 KB, 5 views)

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Old 11-09-2018, 10:55 PM   #3
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Default Re: Brake Line Diagram?

Thanks Greg.

The reason I am replacing the lines is that the fuel pump sprung a leak and I had to drop the tank. When I saw the brake lines I knew I had to replace them and when I started to remove them I knew that I had made the right decision. I've been bending up the long lines tonight. Kind of fun but tricky, as you might imagine. Thanks for the diagram.

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Old 11-10-2018, 12:55 PM   #4
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Default Re: Brake Line Diagram?

Claybear, I'm doing the same thing on my 2002 L200. Nearly had an accident yesterday when one of my brake lines ruptured during hard braking. Fortunately I was able to stop. but had no braking power after that. A friend of my hauled it home for me.

Now I have both rear brake lines removed from the car. Both were severely corroded. Surprised they lasted this long. I'm going to replace them with Nicopp. Hopefully, Advance Auto has new fittings as well. I will need to bypass the old line going to around the fuel tank to the LH rear brake as GregS&L pointed out. I should be able to route the RH brake line nearly the same as the original.

I've never done this before, so I'm taking my time and thinking things through. I'll let you know how it turns out.

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Old 11-11-2018, 07:00 PM   #5
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Default Re: Brake Line Diagram?

Didn't mean to hijack this thread, but I promised an update. I was able to remove (read that "tear out") the old rear brake lines in my L200. Kept 3 of the 4 end fittings, the 4th was corroded beyond use. Made new brake lines out of Nicopp. Although very strenuous, not really too bad. I bled the rear brakes with a pressure bleeder and now I have solid pedal with no leaks. As a precaution, I'm going to bleed the front brakes.

Claybear, I hope your project is going well. I've made a number of repairs over the years, but I've never made my own brake lines. Gotta keep this car going for a little while longer!

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Old 11-12-2018, 06:27 PM   #6
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Default Re: Brake Line Diagram?

I have all the lines bent up and have flared and installed the two that are on the rear trailing arms. All went smoothly so far. I'm still trying to figure out which connector on the firewall goes to the driver side rear by trying to find an port output diagram of the ABS module. Without seeing the internals I just can't tell. I will post pictures as I get the lines in and also when I figure out the correct hookups. I knew I was in too much of a rush when removing them . . .

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Old 11-14-2018, 08:27 PM   #7
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Default Re: Brake Line Diagram?

Quote:
Originally Posted by claybear View Post
I have all the lines bent up and have flared and installed the two that are on the rear trailing arms. All went smoothly so far. I'm still trying to figure out which connector on the firewall goes to the driver side rear by trying to find an port output diagram of the ABS module. Without seeing the internals I just can't tell. I will post pictures as I get the lines in and also when I figure out the correct hookups. I knew I was in too much of a rush when removing them . . .
If you look at your abs module you will se RR and LR. I believe that stands for right rear and left rear.

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Old 11-15-2018, 01:50 AM   #8
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Default Re: Brake Line Diagram?

Quote:
Originally Posted by soulsurvives View Post
If you look at your abs module you will se RR and LR. I believe that stands for right rear and left rear.
You can be confident, soulsurvives! You've correctly identified what RR and LR stand for here. I saw this when working for my father at his service station and in various auto parts catalogs over the years.

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Old 11-16-2018, 02:43 PM   #9
claybear
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Default Re: Brake Line Diagram?

Thank you so much. I should have cleaned off my module and looked a bit harder. Plan on installing the lines tonight.

I've attached a picture of the tools I used for bending the lines and a couple of the lines themselves.
Attached Images
File Type: jpg IMG_2715.jpg (129.7 KB, 5 views)
File Type: jpg IMG_2716.jpg (141.9 KB, 5 views)

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Old 11-17-2018, 12:49 PM   #10
claybear
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Default Re: Brake Line Diagram?

Hey all, need a little help again. Connecting the rear ABS sensors and realized that once again I forgot to note which side goes to the driver's side. Need to see a wiring diagram with wire colors to get it correct. One pair is Red and Black and the other is White and Brown. Anyone have a schematic/diagram?

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