Test brake system with pressure tester for leaks - AR42.10-P-0015GZ

MODEL 164 

Shown on model 164.1 on left front wheel brake 

Fig 1: Identifying Rotary Knob, Floating Caliper, Pressure Tester And Brake Pedal Winch

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Rotary Knob, Brake Pedal Winch, Brake Pedal And Driver Seat Frame

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Connection diagram and accessories required for pressure test on rear wheel brake 

Fig 3: Identifying Pressure Tester Connection, Bleed Screw, Banjo Bolt And Seals

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Checking
	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
	Brake fluid notes	All models	AH42.50-P-0001-01A
	Notes on externally invisible brake fluid loss	Model 164	AH42.10-P-9406-02GZ
	Notes on repairs to brake system	All models	AH42.00-P-0003-01A
	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
1	Open engine hood and raise to vertical position		AR88.40-P-1000GZ
2	Connect brake fluid changing equipment	Observe manufacturer's operating instructions! Brake fluid changer, see GOTIS http://gotis.aftersales.daimlerchrysler.com
3	Raise vehicle using two-post lift	Half the height. Two-post lift, see GOTIS http://gotis.aftersales.daimlerchrysler.com	AR00.60-P-1000GZ
4	Remove left front wheel or right front wheel	When testing the brake line pressure at the front wheel brake.
	Remove/install wheels, rotate if necessary		AP40.10-P-4050Z
5	Remove bleed screw on a floating brake caliper (2) of the brake circuit to be tested and connect pressure tester (3)	Pressure testers for hydraulic oil systems must not be used for systems with brake fluid otherwise brake fluid is mixed with mineral oil which can cause the brakes to fail! Observe manufacturer's operating instructions in order to prevent erroneous measurement or faulty operation! At the rear wheel brake  a banjo union (11), a banjo bolt (9) as well as three gaskets (10) are to be used for adaptation. The banjo union (11) is to be mounted at the pressure tester connection (12) with a gasket. Unscrew the bleed screw (8) from the corresponding floating brake caliper of the rear wheel brake. Attach the banjo union (11) to the floating brake caliper together with the banjo bolt (9) and the two gaskets in place of the bleed screw (8). The banjo union (11) as well as the banjo bolt (9) are to be obtained as accessories from the manufacturer of the recommended pressure tester  (see the manufacturer information attached to the pressure tester). A range of gaskets (10) is already supplied with the pressure tester. ATE part number of banjo bolt (9): 03.3520-0300.1 ATE part number of banjo union (11): 03.3521-0100.1 Collect escaping brake fluid. Pressure tester
6	Bleed pressure tester (3) using brake fluid changer	Observe manufacturer's operating instructions in order to prevent erroneous measurement or faulty operation! Pressure tester, see GOTIS http://gotis.aftersales.daimlerchrysler.com  Brake fluid changer, see GOTIS http://gotis.aftersales.daimlerchrysler.com
7	Switch off brake fluid changing unit and release pressure	Brake fluid changer, see GOTIS http://gotis.aftersales.daimlerchrysler.com
	High-pressure check
8	Allow the engine to run at moderate speed in neutral and by jerkily releasing the accelerator pedal, produce as high a vacuum as possible in the brake booster.
9	Press down the brake pedal as far as possible, then insert the brake pedal jack (4) and using the knob (1) tighten as far as possible. After a short dwell time of a few seconds, read off and note the measured value of the brake line pressure from high pressure gauge of the pressure tester (3)	Observe manufacturer's operating instructions in order to prevent erroneous measurement or faulty operation! Only use the brake pedal jack in combination with the adapter for the brake pedal jack (6). Insert the brake pedal jack so that its rubber mounting is propped up on the driver seat frame (7) as illustrated (arrow). If the brake pedal jack is inserted differently, there is a danger that components could be damaged and erroneous measurements occur when testing the brake line pressure! Duration of high pressure test:  5 min. Throughout the 5 min duration of the test, the brake line pressure decrease must not amount to more than 5% of the measurement which was read off and noted down at the beginning.
		Brake pedal winch	Fig 4
		Adapter for brake pedal winch Pressure tester, see GOTIS http://gotis.aftersales.daimlerchrysler.com	Fig 5
	Low-pressure testing
10	Switch off the engine and release the brake pedal jack (4). Then press brake pedal several times until vacuum in brake booster is eliminated	Brake pedal winch	Fig 4
		Adapter for brake pedal winch	Fig 5
11	Press down the brake pedal as far as possible and insert the brake pedal jack (4). Then turn back at the knob (1) slowly until a brake line pressure of approx. 3 bar is displayed on the low pressure gauge of the pressure tester (3)	Observe manufacturer's operating instructions in order to prevent erroneous measurement or faulty operation! Only use the brake pedal jack in combination with the adapter for the brake pedal jack (6). Insert the brake pedal jack so that its rubber mounting is propped up on the driver seat frame (7) as illustrated (arrow). If the brake pedal jack is inserted differently, there is a danger that components could be damaged and erroneous measurements occur when testing the brake line pressure! Duration of low pressure test:  2 min. The previously set brake line pressure must not  fall throughout the 2 min duration of the test
		Brake pedal winch	Fig 4
		Adapter for brake pedal winch Pressure tester, see GOTIS http://gotis.aftersales.daimlerchrysler.com	Fig 5
12	Release and remove brake pedal jack (4)	Brake pedal winch	Fig 4
		Adapter for brake pedal winch	Fig 5
13	Detach pressure tester (3) and screw the bleed screw into the floating brake caliper (2) again	Collect escaping brake fluid. Pressure tester, see GOTIS http://gotis.aftersales.daimlerchrysler.com
14	Bleed brake system	After the brake line pressure test only bleed the floating brake caliper to which the pressure tester (3) was connected. Observe manufacturer's operating instructions!	AR42.10-P-0010GZ
			*BA42.10-P-1001-10L
		Brake fluid changer, see GOTIS http://gotis.aftersales.daimlerchrysler.com	*BA42.10-P-1001-12L
15	Mount left front wheel or right front wheel	If a brake line pressure test was carried out on the front wheel brake.
	Remove/install wheels, rotate if necessary		AP40.10-P-4050Z
16	Lower vehicle using two-post lift		AR00.60-P-1000GZ
		Two-post lift, see GOTIS http://gotis.aftersales.daimlerchrysler.com
17	Detach brake fluid changer	Brake fluid changer, see GOTIS http://gotis.aftersales.daimlerchrysler.com
18	Close engine hood		AR88.40-P-1000GZ

Fig 4: Identifying Brake Pedal Winch (000 589 18 31 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Adapter For Brake Pedal Winch (211 589 00 31 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.