Disconnect/connect lines on firewall - AR62.00-P-0010-01GR

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

Remove vacuum line (1) from BAS brake booster (A7/7).
On model 463.303/306/336/340/341/346 the vacuum line (1) is located on the opposite side of the BAS brake booster (A7/7).

Connect: Check rubber grommet for damage, replace if necessary. Moisten rubber grommet with solution of soap water.

Illustrated on model 463.248

Fig 1: Identifying BAS Brake Booster
Courtesy of MERCEDES-BENZ USA
Remove cover (2).
Disconnect circuit 30 engine terminal block (X4/30).

Fig 2: Identifying Engine Terminal Block And Cover
Courtesy of MERCEDES-BENZ USA
Extract brake fluid from differential lock expansion reservoir (5).
Remove hose (6) from differential lock expansion reservoir (5).
Seal hose (6) and connection fittings.
Detach vacuum lines (7).
Disconnect electrical connectors (8) from differential lock solenoid valve, longitudinal equalization (Y68), differential lock solenoid valve, rear axle (Y68/1) and differential lock solenoid valve, front axle (Y68/2).
Mark installation position.
Remove bracket (9).

Fig 3: Identifying Differential Lock Expansion Reservoir, Hose, Vacuum Lines & Electrical Connectors
Courtesy of MERCEDES-BENZ USA
Detach cable drum (10) from bracket (9).
Detach refrigerant lines (11, 12) from expansion valve (13).
Connect: Replace O-rings.
Detach refrigerant line (12) from retaining clamps on firewall and move to one side.
Illustrated on model 463.248

Fig 4: Identifying Refrigerant Lines And Expansion Valve
Courtesy of MERCEDES-BENZ USA
Remove hot water hoses (14) from heat exchanger.
Connect: Check hot water hoses (14) for damage, replace if necessary.
Remove lower coolant hose (15) from coolant pipe (16).
Remove coolant pipe (16).
Illustrated on model 463.248

Fig 5: Identifying Hot Water Hoses, Lower Coolant Hose And Coolant Pipe
Courtesy of MERCEDES-BENZ USA
Remove purge line (17) from purge control valve (Y58/1).
Only on model 463.243/244/245/246/247/248/249/250/254/270/271.

Connect: Use new hose clamps.
Disconnect electrical plug connector (18) on purge switchover valve (Y58/1)
Only on model 463.243/244/245/246/247/248/249/250/254/270/271.
Remove purge control valve (Y58/1) from bracket.
Only on model 463.243/244/245/246/247/248/249/250/254/270/271.

Illustrated on model 463.248

Fig 6: Identifying Purge Control Valve, Electrical Plug Connector And Purge Line
Courtesy of MERCEDES-BENZ USA
Disconnect transmission output speed connector (X22/22) and front axle differential lock connector (function indicator), 2 poles (X62/18) from interior wiring harness and pull out of engine compartment.

Fig 7: Identifying Transmission Output Speed Connector And Front Axle Differential Lock Connector
Courtesy of MERCEDES-BENZ USA
Loosen cable tie (arrows) from firewall.
Remove clamp (19) from underfloor.
Install in the reverse order.
Illustrated on model 463.248

Fig 8: Locating Cable Ties And Clamps
Courtesy of MERCEDES-BENZ USA