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Removing |
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Risk of injury
caused by body parts being jammed or crushed. Risk of injury
to skin and eyes caused by brake fluid spraying out at high pressure when working on the SBC brake system |
Deactivate SBC brake system using STAR DIAGNOSIS. |
AS42.46-Z-0001-01A |
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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 safety glasses when handling brake fluid. |
AS42.50-Z-0001-01A |
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Information on preventing damage to electronic components due to electrostatic discharge |
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AH54.00-P-0001-01A |
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Notes on repairs to brake system |
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AH42.00-P-0003-01A |
| 1 |
Deactivate SBC brake system using STAR DIAGNOSIS. |
The following steps should be run through in STAR DIAGNOSIS:
Select menu item "SBC Sensotronic Brake Control"/"Deactivate 'SBC' system".
Then process all the individual steps from top to bottom. |
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| 2 |
Switch ignition off, remove ignition key (transmitter key) |
On vehicles with code (889) Keyless Go: Press keyless go start/stop button repeatedly until ignition is switched off.
Remove Keyless Go transmitter card or transmitter key from the vehicle and store beyond transmitter range (min. 2 m). |
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| 3.1 |
Remove right-hand intake air duct |
Model 211 with engine 112, 113 except
model 211.076/276, |
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| 3.2 |
Remove air filter housing |
Model 211 with engine 646.9, 647, 648 |
AR09.10-P-1150T |
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Model 211.076/276 |
AR09.10-P-1150SVK |
| 4.1 |
Remove bolt (17) and remove bracket (15s) with electrical SBC wiring harness |
Due to the risk of damage, only cut through the cable strap on the electrical SBC wiring harness when replacing the bracket (15s).
When installing a new SBC hydraulic unit (A7/3), attach the old bracket (15s) to the new SBC hydraulic unit (A7/3) as new SBC hydraulic units (A7/3) are supplied without a bracket (15s).
Installation:
Install new bolt (17).
Installation:
If the thread for bolt (17) in the SBC hydraulic unit (A7/3) is damaged, the bracket (15d) that is to be attached to the pressure reservoir (16) must be used. |
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*BA42.46-P-1005-01A |
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*BA42.46-P-1006-01A |
| 4.2 |
Detach bracket (15d) with electrical SBC wiring harness from pressure reservoir (16) |
Due to the risk of damage, only cut through the cable strap on the electrical SBC wiring harness when replacing the bracket (15d).
When installing a new SBC hydraulic unit (A7/3), attach the old bracket (15d) to the new pressure reservoir (16) as new SBC hydraulic units (A7/3) are supplied without a bracket (15d). |
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*BA42.46-P-1006-01A |
| 5 |
Release and detach connector of electrical SBC wiring harness on SBC control unit (A7/3n1) |
Place connector in a safe place. |
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| 6 |
Detach electrical SBC wiring harness from bracket (15d, 15s) by cutting through cable strap |
Only when replacing the ground wiring harness in the course of replacing the SBC hydraulic unit (A7/3) or when replacing the bracket (15d, 15s).
Cut the cable strap very carefully to avoid damaging the electrical SBC wiring harness!
Installation:
When attaching the electrical SBC wiring harness to the bracket (15d, 15s), always ensure that the electrical SBC wiring harness contacts the bracket (15d, 15s) and is secured there free of tension.
After the electrical SBC wiring harness has been secured, it should no longer be possible to push it in a longitudinal direction toward the bracket (15d, 15s).
Installation:
Always secure the electrical SBC wiring harness to the bracket (15d, 15s) free of tension using cable tie pliers and with a tightening force of 150 N to 170 N.
Observe the various settings on the cable tie pliers for the specified tightening force:
- Panduit cable tie pliers: Setting HVY 5
- Hellermann cable tie pliers: Setting STD 3
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Fig 13 |
| 7 |
Replace ground wiring harness of electrical SBC wiring harness |
Only when installing a new SBC hydraulic unit (A7/3).
Open connector housing of electrical SBC wiring harness and secondary lock of contact strip. Press ground line plug contact out of pin 37 and pin 44 using
blade holder with clamping pliers and
blade MCP 2.8/Fl. 2.8/JPT/SPT. Remove ground lines.
To remove the ground line plug contact from the connector housing solely
using blade holder with clamping pliers and
blade MCP 2.8/Fl. 2,8/JPT/SPT, as otherwise damage may occur to the connector housing, which would then make it necessary to replace the complete electrical SBC wiring harness!
Installation:
Make sure that the longer ground line of the ground line wiring harness is inserted into pin 44 and the shorter ground line into pin 37 of the connector housing.
Installation:
Make sure that there is no contact between the ground point of the vehicle longitudinal member and any water hose or other lines.
IMPORTANT:
Only the ground line of the electrical SBC wiring harness should be connected to the ground point of the vehicle longitudinal member, otherwise the SBC system could malfunction.
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Fig 15 |
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Fig 14 |
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Clean |
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| 8 |
SBC hydraulic unit (A7/3) and area around connecting points should be cleaned thoroughly before SBC system is opened |
Even the smallest particles of dirt, introduced into the hydraulic components, can lead to malfunctions of the SBC system. |
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Cleaner from package |
*BR00.45-Z-1028-04A |
| 9 |
Mark hydraulic lines (1) |
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| 10 |
Detach hydraulic lines (1) from the SBC hydraulic unit (A7/3) |
Seal all hydraulic lines (1) and connections on the SBC hydraulic unit (A7/3) immediately
with stop plugs to prevent air from entering. Air in the SBC system reduces braking power and can lead to malfunctions in the SBC system.
When installing a new SBC hydraulic unit (A7/3), use the stop plugs supplied with the new SBC hydraulic unit (A7/3) to seal the old SBC hydraulic unit (A7/3).
If the SBC hydraulic unit (A7/3) is to be reused, observe the ordering information for stop plugs:
129 589 00 91 06 (7 each)
129 589 00 91 05 (1 each)
Installation:
Observe markings to avoid swapping the hydraulic lines (1)! When routing the hydraulic lines (1), take extra
care to ensure that the hydraulic lines (1) are not resting against other components, are not under stress and are not twisted. When tightening the hydraulic lines (1), always
observe the torque value and make sure that the hydraulic lines (1) are not twisted.
Installation:
The sound level of the SBC system will be louder if the hydraulic lines (1) rest against other components, are under stress or are twisted. |
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Brake fluid notes |
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AH42.50-P-0001-01A |
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*BA42.46-P-1001-01A |
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Figure |
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Figure |
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Figure |
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Figure |
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Figure |
| 11 |
Detach suction hose (2a) from SBC hydraulic unit (A7/3) |
Seal the suction hose (2a) and connection on the SBC hydraulic unit (A7/3) immediately with stop plugs to prevent air entering. Air in the SBC system reduces braking power and can lead to malfunctions in the SBC system. |
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Figure |
| 12 |
Detach return line (3) from SBC hydraulic unit (A7/3) |
Seal the return line (3) and connection on the SBC hydraulic unit (A7/3) immediately with stop plugs to prevent air entering. Air in the SBC system reduces braking power and can lead to malfunctions in the SBC system.
Check the return line (3) for damage (kinks, external damage, etc.) and replace if necessary. |
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| 13 |
Remove SBC hydraulic unit (A7/3) complete with retaining plate (8) |
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| 14 |
Remove bolt (9) and remove retaining plate (8) from SBC hydraulic unit (A7/3) which has been removed. |
When installing a new SBC hydraulic unit (A7/3).
Attach the old retaining plate (8) to the new SBC hydraulic unit (A7/3) because the new SBC hydraulic unit (A7/3) is supplied without retaining plate (8).
Installation:
Install new bolt (9). |
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*BA42.46-P-1004-01A |
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Install |
| 15 |
Install in the reverse order |
Operation steps 14 to 12 |
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| 16 |
Remove stop plugs and attach return line (3) to SBC hydraulic unit (A7/3) |
When routing the return line (3), take extra
care to ensure that it does not rest against other components and is not installed under stress. When tightening the return line (3) it is essential
to maintain the torque and to ensure that the return line (3) is not twisted.
The operating noise of the SBC system will be louder if the return line (3) rests against other components, is under stress or is twisted. |
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*BA42.46-P-1002-01A |
| 17 |
Replace suction hose (2a) |
Only model 211 with intake hose 15.5 mm outside diameter (old version)
Intake hose with 14 mm outside diameter (new version), only replace if damaged.
Observe different variants of intake hose (2a).
- If a pulsation damper was not fitted in the intake hose (2a), install new intake hose (2a) without pulsation damper.
- If a pulsation damper
was fitted in the intake hose (2a), install new intake hose (2a) with pulsation damper.
Never use a screwdriver or pointed, sharp-edged tools to pry off the suction hose (2a), otherwise the suction line (2) will be damaged and air can enter. Immediately seal suction line (2) with stop plugs to prevent air from entering. Air in the SBC system reduces braking power and can lead to malfunctions in the SBC system.
Replace hose clamps!
Mount new suction hose (2a) on suction line (2) losing as little brake fluid as possible. Fill suction hose (2a) with brake fluid before mounting on SBC hydraulic unit (A7/3): ↓
Hold suction hose (2a) as vertical as possible and fill with brake fluid using a small funnel or syringe. The funnel or syringe must be absolutely
clean and must not have come into contact with mineral oil (engine oil etc.) previously.
Push suction hose (2a) on to the intake connection fitting of the SBC hydraulic unit (A7/3) losing as little brake fluid as possible. The intake hose (2a) must be routed unstressed and must not contact the hydraulic lines (1) or return line (3). |
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| 18 |
Install in the reverse order |
Operation steps 10, 9 and 6 to 3 |
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| 19 |
Use water to rinse off any escaped brake fluid |
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| 20 |
Bleed brake system with STAR DIAGNOSIS |
When performing the bleeding operation always observe the instructions in the document "Bleeding brake system using STAR DIAGNOSIS".
The following steps should be run through in STAR DIAGNOSIS:
Select menu item "Initial startup after repair"/"Exchanging the hydraulic unit".
Then process all the individual steps from top to bottom. |
AR42.10-P-0012R |
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Checking |
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| 21 |
Check connecting points of hydraulic lines (1), suction hoses (2a, 2b) and return line (3) for leaks |
Connect filling unit and allow the maximum filling pressure of the filling unit (2.5 to 3.0 bar) to be applied statically for 10 minutes. Then check the connecting points of the hydraulic lines (1), suction hoses (2a, 2b) and return line (3) for leaks.
Even the smallest drops of brake fluid are a sign of leakage!
Warning!
In particular, the connecting points (VA, VB, VC, VD) of the suction hoses (2a, 2b) must be checked very carefully (tissue paper or similar):
- VA: Suction hose connecting point (2b) to expansion reservoir (11),
- VB: Suction hose connecting point (2b) to suction line (2),
- VC: Suction hose connecting point (2a) to suction line (2) and
- VD: Suction hose connecting point (2a) to SBC hydraulic unit (A7/3).
Visual inspection is not enough as even minimal leakage which is not detectable at first glance can lead to malfunctions of the SBC system.
Finish "SBC" diagnosis after leaktightness test. |
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| 22 |
Check fluid level in brake fluid reservoir, and correct if necessary. |
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AP42.10-P-4210Z |
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*BA42.50-P-1001-01D |
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Risk of death
caused by limbs being caught
or crushed
by rotating parts when performing tests on the brake test stand |
Never leave the vehicle unattended on the rollers except in an emergency. Ensure that no one is under the vehicle or near rotating parts during testing. In case of emergency, use the EMERGENCY STOP switch to shut down test stand. |
AS42.00-Z-0001-01A |
| 23 |
Carry out brake test on the test stand |
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AP42.00-P-4290BA |