Remove/install stepped tandem master brake cylinder - AR42.10-P-0310GZ

MODEL 164, 166 

Fig 1: Identifying Stepped Tandem Master Brake Cylinder Remove/Install Components - Shown On Model 164 (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Stepped Tandem Master Brake Cylinder Remove/Install Components - Shows Model 164 (2 Of 2)

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

2.5.11	Switch off ignition, added	Operation step 1
	Clean the area around the brake line connections on the master brake cylinder, added	Step 8

	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
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
	Notes on externally invisible brake fluid loss		AH42.10-P-9406-02GZ
1	Switch off ignition
2	Push down brake pedal several times	In order to reduce the vacuum in the BAS brake booster.
3	Open engine hood and raise to vertical position	Model 164	AR88.40-P-1000GZ
		Model 166	AR88.40-P-1000GQ
4	Detach rubber seal (1) in the left section area of the partition wall (4)	Model 164
5	Remove bolt (2)	Model 164
6.1	Detach left section of the partition wall (4) from the clips (3)	Model 164
6.2	Remove cover over left suspension strut tower	Model 166
7	Release and disconnect the electrical connector (5) from the brake fluid indicator switch
	Clean
8	Clean the area around the brake line connections on the master brake cylinder (10)	Before opening the brake system, the area around the separation point should be cleaned thoroughly. Even the smallest particles of dirt, introduced into the hydraulic components, can lead to malfunctions and a total failure of the SBC system.
		LU cleaner	*BR00.45-Z-1028-04A
9	Mark brake line (6) relative to the connection on master brake cylinder (10)	Model 164 To prevent a mix-up when installing.
10	Detach brake lines (6) on master brake cylinder (10)	Collect escaping brake fluid using rags and seal connections immediately. Otherwise, escaping brake fluid may damage adjacent components.
			*BA42.10-P-1003-04J
			Fig 3
			Figure
11	Unscrew nuts (7)	Check master brake cylinder (10) on rear primary piston for leakage, replace if necessary.
			*BA42.10-P-1001-05H
12	Pull brake master cylinder (10) off threaded studs and turn slightly to the side.	Do not tilt master brake cylinder (10), instead pull it out straight forwards. Otherwise, the push rod can be pushed out of its axial position and broken out of the retaining lugs on the controller.
13	Detach electrical connector (8) on ESP brake pressure sensor (B34)	Model 164
14	Take out master brake cylinder (10)	Replace O-ring (16).
15	Remove screw (12)		*BA42.10-P-1003-05H
16	Pull brake fluid reservoir (11) out of master brake cylinder (10)	Check condition of stop plug (15), replace if necessary.
17	Remove bolt (13)	Model 164
			*BA42.10-P-1002-05H
18	Remove impact deflector plate (14)	Model 164
19	Remove ESP brake pressure sensor (B34)	Model 164
			*BA42.45-P-1001-01J
20	Install in the reverse order
21	Bleed brake system	Model 164	AR42.10-P-0010GZ
		Model 166	AR42.10-P-0010CW
	Checking
22	Check brake system for leaks		AR42.10-P-0100-01GZ
23	Carry out brake test on the test stand		AP42.00-P-4290BA

BRAKE LINES, BRAKE HOSES

Number	Designation		Model 164.1/8	Model 166
BA42.10-P-1003-04J	Brake pipe to master brake cylinder	Nm	18	18

MASTER BRAKE CYLINDER

Number	Designation		Model 164.1/8	Model 166
BA42.10-P-1001-05H	Nut, brake master cylinder to brake booster	Nm	10	23
BA42.10-P-1002-05H	Bolt, impact deflector plate to master brake cylinder	Nm	14	-
BA42.10-P-1003-05H	Bolt, brake fluid reservoir to master brake cylinder	Nm	4	4

ELECTRONIC STABILITY PROGRAM (ESP)

Number	Designation		Model 164.1/8
BA42.45-P-1001-01J	Brake pressure sensor to master brake cylinder	Nm	35

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

Courtesy of MERCEDES-BENZ USA

Fig 4: 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	LU cleaner	Adolf Wurth GmbH & Co. KG