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

MODEL 204 

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

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
	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 the left engine intake air duct	Engine 156
3	Unhook switchover valve (Y58/1) from bracket (1) and place to one side with lines connected	Engine 271, 272
	Clean
4	Clean hydraulic unit (A7/3) in the area of the connections of the brake lines (3)	Cleaner from package	*BR00.45-Z-1028-04A
5	Separate electrical connector (2) from control unit (N30/4)	Observe notes on separation, 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-0820-02CW
6	Detach heat shield from hydraulic unit (A7/3)	Engine 156
7	Unclip cable tie from bracket (4)
8	Unclip electrical line from holder (4)	Model 204.9
9	Mark brake lines (3) for corresponding connection
10	Detach brake lines (3) from hydraulic unit (A7/3)	Seal brake lines (3) and connections on the hydraulic unit (A7/3) in order to prevent the ingress of foreign objects. Pay attention to stress/chafe-free routing of brake lines (3).
			*BA42.10-P-1004-04L
			Figure
			Figure
			Fig 5
			Fig 3
11	Remove hydraulic unit (A7/3) and bracket (4) upwards from rubber plug	Check rubber plugs fro damage and correct seat and replace if necessary.
12	Undo screw (5) and remove bracket (4)	When installing a new hydraulic unit (A7/3)
			*BA42.45-P-1001-01M
13	Install in the reverse order
14	Use STAR DIAGNOSIS to update control unit (N30/4) software
15	Bleed brake system		AR42.10-P-0010CW
	Checking
16	Read out fault memory with STAR DIAGNOSIS and erase if necessary

ELECTRONIC STABILITY PROGRAM (ESP)

Number	Designation			Model 204
BA42.45-P-1001-01M	Bolt, traction system hydraulic unit to bracket	M8	Nm	16
		M10	Nm	-

BRAKE LINES, BRAKE HOSES

Number	Designation			Model 204
BA42.10-P-1004-04L	Union nut, brake line to hydraulic unit	Ø4.75	Nm	18
		Ø6	Nm	18
		Ø8	Nm	24

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 Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

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