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

WARNING: This page is about a different car, the 2011 Mercedes-Benz C300, 2010 Mercedes-Benz C300, 2009 Mercedes-Benz C300, and 2008 Mercedes-Benz C300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Replacing Brake Lines
G08844034Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER Risk of injury  due to fan starting unexpectedly Do not reach into the rotation or hazard area of the fan. Wear closed and close-fitting work clothes. -
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z-0010-01A
DANGER 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 
NOTES Notes on externally invisible brake fluid loss   AH42.10-P-9406-02V 
NOTES Brake fluid notes   AH42.50-P-0001-01A 
NOTES Notes on repairs to brake system   AH42.00-P-0003-01A 
1 Remove each brake line (2) IMPORTANTInstallation:  Install brake line (2) free of tension and with correct torque on threaded connection.  
TORQUE SPECIFICATION *BA42.10-P-1002-14A 
2 Define length of new brake line (2) to match the old brake line (2) IMPORTANT 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)
IMPORTANT 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 IMPORTANT The constellation of the connecting point must be correct and there must be no soiling.  
    IMPORTANT Use specified cable connectors for installation only.  
4 Make flange on brake line (2) IMPORTANT Before making the flange, fit the union nut (1) to the respective brake line (2).
IMPORTANT On Mercedes-Benz cars only brake lines with an F-flange (a) as per DIN 74234 may be used.
IMPORTANT When making a flange for the brake line, the tool manufacturer specifications must be complied with.
5 Adapt new brake line (2) IMPORTANT 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    
INSPECT Checking     
7 Check surface of brake line (2) IMPORTANT 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-0010CW 
10 Check brake system for leak-tightness   AR42.10-P-0015CW 
11 Carry out brake test on the test stand   AP42.00-P-4290BA 
BRAKE LINES, BRAKE HOSES

Number Designation Model 204
BA42.10-P-1002-14A Brake line to brake hose Nm 16
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
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