Replace brake lines - AR42.10-P-0020A

MODEL 209 

Fig 1: Replacing Brake Lines

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of poisoning  caused by swallowing brake fluid. Risk of injury  caused by brake fluid coming into contact with skin and eyes.	Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.	AS42.50-Z-0001-01A
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
1	Remove each brake line (2)	Installation:  Install brake line (2) free of tension and with correct torque on threaded connection.
			*BA42.10-P-1001-04A
2	Define length of new brake line (2) to match the old brake line (2)	Two additional connecting points per brake line (2) are permissible for part replacement of brake line. * Only part replacement for brake lines with line diameter of Ø 4.75 mm (wheel line) Heater lines (master brake cylinder to hydraulic unit), SBC return lines, plastic-coated lines, and lines with flexible part are excluded from the repair.
3	Cut brake line (2) using pipe cutter	The constellation of the connecting point must be correct and there must be no soiling.
		Use specified cable connectors for installation only.
4	Make flange on brake line (2)	Before making the flange, fit the union nut (1) to the respective brake line (2). On Mercedes-Benz cars only brake lines with an F-flange (a) as per DIN 74234 may be used. When making a flange for the brake line, the tool manufacturer specifications must be complied with.
5	Adapt new brake line (2)	Adapt brake line (2) using bending tool to old configuration. A bending tool radius of 13 mm must not be exceeded here. When routing the brake line make sure there is sufficient distance to other components. There must be no kinking and no line narrowing on the brake line.
6	Install in the reverse order
	Checking
7	Check surface of brake line (2)	Check surface of brake line for scratches and paint damage, if necessary touch up any paint damage.
	Zinc dust paint spray can		*BR00.45-Z-1055-07A
8	Thoroughly wax the brake line (2) after mounting it	Cavity preservation, solvent-free (1L container)	*BR00.45-Z-1011-05A
9	Bleed brake system		AR42.10-P-0010P
10	Check brake system for leaktightness		AR42.10-P-0015A
11	Carry out brake test on the test stand		AP42.00-P-4290BA

BRAKE LINES, BRAKE HOSES

Number	Designation		Model 209
BA42.10-P-1001-04A	Brake pipe to brake hose	Nm	14

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1011-05A	Cavity preservation, solvent-free (1L container)	A 000 986 72 70 10
BR00.45-Z-1055-07A	Zinc dust paint spray can	A 000 986 82 42 09