Remove/install ETS/ASR/ESP hydraulic unit - AR42.40-P-0816SX

MODEL 216.### 1#

MODEL 221.### 1#

Fig 1: Identifying ETS/ASR/ESP Hydraulic Unit Components

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

29.10.08

Value changed: Union nut, brake line to hydraulic unit

*BA42.10-P-1004-04K

	Remove/install
	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
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
1	Switch off ignition
2	Remove right engine intake air duct (1)	Except engine 642
3	Detach electrical connector from coolant expansion reservoir (2) and place coolant expansion reservoir (2) to one side with lines connected
4	Unhook power steering expansion reservoir and place to one side with the connected lines	Vehicles with electrohydraulic power steering (EHPS) Release power steering expansion reservoir, remove upwards and set aside with connected lines.
	Clean
5	Clean the hydraulic unit (A7/3) in the area of the brake line connections	Cleaner from package	*BR00.45-Z-1028-04A
6	Separate electrical connector (3) from control unit (N47-5)	Observe notes, otherwise damage to the locking mechanism can occur! In order to avoid damage and malfunctions, do not touch, deform or damage contacts of connector and jack! Do not allow any foreign objects, dirt fluids to enter the jack or connector!	AR42.45-P-0820-02T
7	Mark brake lines (4) for corresponding connection
8	Detach brake lines (4) from hydraulic unit (A7/3)	Seal brake lines (4) and connections on the hydraulic unit (A7/3) in order to prevent the ingress of foreign objects. Installation: Pay attention to stress/chafe-free routing of brake lines (4).
			*BA42.10-P-1004-04K
			Fig 6
			Fig 2
			Fig 4
			Fig 5
			Fig 3
9	Remove hydraulic unit (A7/3) with bracket (5) upwards out of the rubber plugs	Check rubber plugs fro damage and correct seat and replace if necessary.
10	Unscrew bolt (6) and remove bracket (5)	When replacing the hydraulic unit (A7/3)
			*BA42.45-P-1001-01L
11	Install in the reverse order
12	Carry out software update of control unit (N47-5) using STAR DIAGNOSIS
13	Bleed brake system		AR42.10-P-0010SX
	Checking
14	Read out fault memory and erase if necessary
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A

ELECTRONIC STABILITY PROGRAM (ESP)

Number	Designation		Model 216	Model 221
BA42.45-P-1001-01L	Bolt, traction system hydraulic unit to bracket	Nm	18	20

BRAKE LINES, BRAKE HOSES

Number	Designation		Model 216 except 216.374/377/379	Model 216.374/377/379
BA42.10-P-1004-04K	Union nut, brake line to hydraulic unit	Nm	17	17

BRAKE LINES, BRAKE HOSES

Number	Designation		Model 221 except 221.074/077/174/ 177/179	Model 221.074/077/174 /177/179
BA42.10-P-1004-04K	Union nut, brake line to hydraulic unit	Nm	17	17

Fig 2: Identifying Box Wrench Bit (000 589 75 03 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Box Wrench Bit (140 589 00 03 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Torque Wrench (001 589 87 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Plug-In Joint Adapter (001 589 00 16 00)

Courtesy of MERCEDES-BENZ USA

Fig 6: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Cleaner from package	Adolf Wurth GmbH&Co. KG Reinhold-Wurth-Str. 12-17 74653 Kunzelsau-Gaisbach Germany Tel. +49 7940 15-0 Fax +49 7940 15-1000 www.wuerth.de