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Remove/install master brake cylinder - AR42.10-P-0300EW

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MODEL 207, 212, 218 

Fig 1: Master Brake Cylinder Remove/Install Components
G09976563Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

10.8.10 Value changed: Nut for strut to suspension strut tower Model 212 *BA62.30-P-1006-02G 
11.8.10 "Perform brake test on test bench" reference changed Test sequence augmented/revised  
REMOVINGINSTALLING Remove/install     
DANGER 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
NOTES Brake fluid notes   AH42.50-P-0001-01A
NOTES Notes on repairs to brake system   AH42.00-P-0003-01A
NOTES Notes on externally invisible brake fluid loss   AH42.10-P-9406-02V
    NOTES In order to prevent paint damage, brake fluid which has escaped must be rinsed off immediately with water  
1 Remove vacuum in brake booster IMPORTANT To do this, press the brake pedal several times with the engine switched off.  
2 Open engine hood Model 207, 212
Model 218		 AR88.40-P-1000EW
3 Remove wiper arms Model 204, 207, 212, 218 AR82.30-P-6100CW
4 Remove water collector (1) Model 207
IMPORTANT Do not disconnect electric feed lines and hoses of windshield washer nozzles.		  
5 Remove strut (2) TORQUE SPECIFICATION Model 212, 218 *BA62.30-P-1006-02G 
TORQUE SPECIFICATION Model 207 *BA62.30-P-1007-02G 
TORQUE SPECIFICATION Model 207 *BA32.25-P-1003-04M 
CLEAN Clean     
6 Clean area around cap for expansion reservoir (3) and remove cap    
7 Suction off brake fluid from the expansion reservoir (3)    
8 Release and disconnect electrical connector (4)    
9 Remove feed hose (5) Vehicles with manual transmission
IMPORTANT Seal feed hose (5).		 AR25.20-P-0100-01V
SPECIAL TOOL Set of stop plugs Figure
10 Remove screw (6)    
11 Detach expansion reservoir (3) from master brake cylinder (7) NOTES Seal the connections on the master brake cylinder (7) in order to avoid the ingress of foreign objects.  
SPECIAL TOOL Set of stop plugs
INSTALLATION IMPORTANT Replace seals (8).		 Figure
12 Pull vacuum line (9) with check valve out of brake booster    
13 Detach brake lines (10) on master brake cylinder (7) IMPORTANT Seal line connections.  
TORQUE SPECIFICATION *BA42.10-P-1003-04L 
SPECIAL TOOL Box wrench bit Figure
SPECIAL TOOL Set of stop plugs Figure
14 Unscrew nuts (11) TORQUE SPECIFICATION *BA42.10-P-1001-05K 
15 Take out master brake cylinder (7) NOTES The master brake cylinder (7) must not  be tilted  , but rather removed straight out the front of the brake booster, as otherwise the thrust rod will be pushed out of its axial location.
INSTALLATION NOTESInstall  new sealing ring (12).		  
16 Install in the reverse order    
17 Bleed brake system   AR42.10-P-0010EW 
INSPECT Checking     
18 Check brake system for leaks   AR42.10-P-0100-01V 
19 Carry out brake test on the test stand   AP42.00-P-4290BA
SUSPENSION STRUTS

Number Designation Model 207 without code 483 Model 207 with code 483
BA32.25-P-1003-04M Suspension strut to body Nm 33 33
SUSPENSION STRUTS

Number Designation Model 212.00/02/04/05/0 72/073/14/15/20/2 2/24/25/272 without code 489 Model 212.00/02/04/05/072/073/14/15/20/22/24/25/272 with code 489, model 212.077/277
BA32.25-P-1003-04M Suspension strut to body Nm 33 33
SUSPENSION STRUTS

Number Designation Model 212.08/09/28/29 without code 489 Model 212.08/09/28/29 with code 489
BA32.25-P-1003-04M Suspension strut to body Nm 33 33
SUSPENSION STRUTS

Number Designation Model 218.30/32/35/373 without code 489 Model 218.30/32/35/373 with code 489, model 218.374
BA32.25-P-1003-04M Suspension strut to body Nm 33 33
SUSPENSION STRUTS

Number Designation Model 218.39 without code 489 Model 218.39 with code 489
BA32.25-P-1003-04M Suspension strut to body Nm 33 33
MASTER BRAKE CYLINDER

Number Designation Model 207 Model 212 Model 218
BA42.10-P-1001-05K Nut, brake master cylinder to brake booster Nm 25 25 25
BRAKE LINES, BRAKE HOSES

Number Designation Model 207 Model 212 Model 218
BA42.10-P-1003-04L Union nut, brake line to master brake cylinder Ø4.75 Nm 18 18 18
Ø6 Nm 18 18 18
Ø8 Nm 24 24 24
FRONT END ASSEMBLY WITH FRONT REINFORCEMENT

Number Designation Model 207.3 Model 207.4
BA62.30-P-1006-02G Nut, strut to suspension strut tower Nm - -
BA62.30-P-1007-02G Nut, strut to firewall Nm 35 35
FRONT END ASSEMBLY WITH FRONT REINFORCEMENT

Number Designation Model 212 Model 218
BA62.30-P-1006-02G Nut, strut to suspension strut tower Nm 30 30
BA62.30-P-1007-02G Nut, strut to firewall Nm - -
Fig 2: Identifying Box Wrench Bit (000 589 75 03 00)
G09976564Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Set Of Stop Plugs (129 589 00 91 00)
G09976565Courtesy of MERCEDES-BENZ USA
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