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

MODEL 163, 164, 168, 169, 170, 171, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 245 

MODEL 461, 463 

Fig 1: Identifying Flange Specifications

Courtesy of MERCEDES-BENZ USA

	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
1	Remove each brake line (2)	Installation:  Install brake line (2) free of tension and with correct torque on threaded connection.
		Model 163, 170, 171, 202, 203, 208, 209, 210, 211, 215, 220, 230	*BA42.10-P-1001-04A
		Model 168	*BA42.10-P-1002-04C
		Model 219	*BA42.10-P-1001-04I
		Model 169, 245	*BA42.10-P-1003-04H
		Model 164	*BA42.10-P-1002-04J
		Model 461, 463	*BA42.10-P-1001-04B
2	Define length of new brake line (2) to match the old brake line (2)	Only two additional connecting points per brake line (2) are permissible for brake line (2) part replacement: Only part replacement for brake lines (2) with line diameter of Ø 4.75 mm (wheel line) 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	The constellation of the connecting point must be correct and there must be no soiling. Use specified cable connectors for installation only.
4	Make flange on brake line (2)	Before making the flange, fit the union nut (1) to the respective brake line (2). On Mercedes-Benz cars only brake lines (2) with an F-flange (a) as per DIN 74234 may be used. When making a flange for the brake line (2), the tool manufacturer specifications must be complied with.
5	Adapt new brake line (2)	Adapt brake line (2) using bending tool to old configuration. A bending radius of 13 mm must not be exceeded here. When routing the brake line (2) make sure there is sufficient distance to other components. There must be no kinking and no line narrowing on the brake line (2).
6	Install in the reverse order
	Checking
7	Check surface of brake line (2)	Check surface of brake line (2) for scratches and paint damage, if necessary touch up any paint damage with textured paint.
		Textured paint	*BR00.45-Z-1023-07A
8	Thoroughly wax the brake line (2) after mounting it	Cavity preservation	*BR00.45-Z-1011-05A
9	Bleed brake system
		Model 170, 202, 208, 210	AR42.10-P-0010A
		Model 169.006 /007 /008 /031 /032 /033 /034 /090 /306 /307 /308 /331 /332 /333 /334 Model 245.207/ 208/ 231/ 232/ 233/ 234	AR42.10-P-0010AK
		Model 168.006 /007 /008 /009 /031, WDB168.032, 9BM168.032, 168.033 /035 /109 /131 /132 /133 /135	AR42.10-P-0010GC
		Model 163.113 /128 /136 /154 /157 /172 /174 /175	AR42.10-P-0010GH
		Model 164	AR42.10-P-0010GZ
		Model 215, 220 except model 220 with code (979) Special protection version, with code (Z07) Top protection	AR42.10-P-0010I
		Model 220 with code (979) Special protection version, with code (Z07) Top protection	AR42.10-P-0010MB
		Model 203, 209	AR42.10-P-0010P
		Model 211, 219 with Adaptive Brake (ABR), model 230 with code (P99) "AMG Black Series" special model	AR42.10-P-0010T
		Model 230 without code (P99) Special model "AMG Black Series"	AR42.10-P-0012R
		Model 171	AR42.10-P-0010V
		Model 461, 463 except model 463.270/ 271 and except model 463 with code (979) Special protection version	AR42.10-P-0010GG
		Model 463 with CODE (979) Special protection version	AR42.10-P-0010GS
		Model 463.270 /271	AR42.10-P-0010GX
10	Check brake system for leaktightness
		Model 170, 202, 203, 208, 209, 210	AR42.10-P-0015A
		Model 169.006 /007 /008 /031 /032 /033 /034 /090 /306 /307 /308 /331 /332 /333 /334 Model 245.207/ 208/ 231/ 232/ 233/ 234	AR42.10-P-0015AK
		Model 168.006 /007 /008 /009 /031, WDB168.032, 9BM168.032, 168.033 /035 /109 /131 /132 /133 /135	AR42.10-P-0015GC
		Model 163.113 /128 /136 /154 /157 /172 /174 /175	AR42.10-P-0015GH
		Model 215, 220	AR42.10-P-0015I
		Model 211, 219 with Adaptive Brake (ABR)	AR42.10-P-0015T
		Model 171	AR42.10-P-0015V
		Model 164	AR42.10-P-0015GZ
		Model 461, 463 except model 463.270/ 271 and except model 463 with code (979) Special protection version	AR42.10-P-0015GG
		Model 463.270 /271	AR42.10-P-0015GX
11	Carry out brake test on the test stand	Model 163, 164, 166, 168, 169, 170, 171, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 245 except model 245.286	AP42.00-P-4290BA
		Model 461, 463	AP42.00-P-4290G

Number	Designation		Model 163.113 as of VIN A289565, X754620 163.154 as of VIN A289565 except	Model 163.113 up to VIN A289564, X754619 163.154 up to VIN A289564	Model 163.128/ 172/174/ 175
BA42.10-P-1001-04A	Brake pipe to brake hose	Nm	18	18	18

Number	Designation		Model 163.136	Model 163.154/157	Model 163.157 except	Model 170
BA42.10-P-1001-04A	Brake pipe to brake hose	Nm	18	18	18	14