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

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MODEL 207, 212, 218 

Shown on model 212 

Fig 1: ETS/ASR/ESP Hydraulic Unit Components - Shown On Model 212
G09976586Courtesy of MERCEDES-BENZ USA

Shown on model 218 

Fig 2: ETS/ASR/ESP Hydraulic Unit Components - Shown On Model 218
G09976587Courtesy of MERCEDES-BENZ USA
DANGER Risk of poisoning  from swallowing brake fluid. Risk of injury  from skin and eye contact with brake fluid 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 Notes on repairs to brake system   AH42.00-P-0003-01A
NOTES Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
NOTES Brake fluid notes   AH42.50-P-0001-01A
REMOVINGINSTALLING Remove/install     
1.1 Switch off ignition and remove transmitter key from electronic ignition lock control unit MODEL 207, 212, 218
without CODE 889 (KEYLESS-GO)		  
1.2 Switch off ignition and remove transmitter key or KEYLESS-GO start/stop button from electronic ignition lock control unit MODEL 207, 212, 218
with CODE 889 (KEYLESS-GO)		  
2 Open engine hood MODEL 207, 212, 218  
MODEL 207, 212 AR88.40-P-1000EW
3 Remove the left engine intake air duct MODEL 207 with ENGINE 272, 273, 642
up to model year 2015
MODEL 212 with ENGINE 156, 272, 273, 642
up to model year 2015
MODEL 218 with ENGINE 157, 642
up to model year 2015		  
CLEAN Clean     
4 Clean area surrounding electrical connection (2) and the connections for the brake lines (1) NOTES
Before opening the brake system, thoroughly clean the repair area using clean, lint-free rag and cleaners that do not contain any mineral oils only.
Otherwise, even the smallest particles of dirt introduced into the hydraulic components can lead to malfunctions and a total failure of the brake system.		  
Assembly cleaner *BR00.45-Z-1028-04A 
5 Disconnect electrical connector (2) MODEL 207, 212
up to model year 2014
with CODE 233 (DISTRONIC PLUS)
MODEL 218
up to model year 2015
with CODE 233 (DISTRONIC PLUS)		 AR42.45-P-0820-02EWD 
MODEL 207, 212
as of model year 2014
MODEL 207, 212
up to model year 2014
without CODE 233 (DISTRONIC PLUS)
MODEL 218
as of model year 2015
MODEL 218
up to model year 2015
without CODE 233 (DISTRONIC PLUS)
NOTES
Observe instructions on disconnecting. Otherwise the locking mechanism may be damaged.
NOTES
Do not touch, deform or damage contacts of connector and jack.
Otherwise, the function of the brake system may be impaired.
NOTES
Do not allow any foreign objects, dirt or fluids to enter the jack or connector.
Otherwise, the function of the brake system may be impaired.		 AR42.45-P-0820-02EW 
SPECIAL TOOL MODEL 207, 212
as of model year 2014
MODEL 207, 212
up to model year 2014
without CODE 233 (DISTRONIC PLUS)
MODEL 218
as of model year 2015
MODEL 218
up to model year 2015
without CODE 233 (DISTRONIC PLUS)
Unlocking tool		 Fig 4
6 Remove cable tie (3) from bracket (4) MODEL 212, 218
up to model year 2015
INSTALLATION IMPORTANT Replace cable tie (3).		  
7 Pry line bracket (5) off the bracket (4) MODEL 212, 218
up to model year 2015		  
8 Unclip lines (7) from bracket (4) MODEL 212, 218
up to model year 2015		  
9 Unclip retaining clips (8) from bracket (4) and place electrical wiring harness (6) to one side MODEL 212, 218
up to model year 2015		  
10 Mark brake lines (1) relative to corresponding connection on traction system hydraulic unit (A7/3)    
11 Remove brake lines (1) from traction system hydraulic unit (A7/3) INSTALLATION IMPORTANT Make sure that the routing of the brake lines (1) is unstressed and free of any chafing.  
TORQUE SPECIFICATION Retaining screw, brake line to hydraulic unit *BA42.10-P-1004-04L 
SPECIAL TOOL Box wrench bit Fig 6
SPECIAL TOOL Adapter coupling Fig 5
SPECIAL TOOL Box wrench bit Fig 3
12 Seal brake lines (1) and connections on traction system hydraulic unit (A7/3). NOTES
Carefully seal brake lines (1) and connections on traction system hydraulic unit (A7/3) to avoid any ingress of foreign objects.
Otherwise, the function of the brake system may be impaired.		  
SPECIAL TOOL Record plug Fig 7
13.1 Unscrew nuts (9) and remove traction system hydraulic unit (A7/3) with bracket (4) from body MODEL 212, 218
up to model year 2015		  
TORQUE SPECIFICATION Bolt/nut, bracket for hydraulic unit to body *BA42.45-P-1004-01M 
13.2 Remove traction system hydraulic unit (A7/3) with intermediate bracket (10) from bracket (4) MODEL 207
MODEL 212, 218
as of model year 2015		  
14.1 Remove bracket (4) with intermediate bracket (10) from traction system hydraulic unit (A7/3) MODEL 212, 218
up to model year 2015
When installing a new traction system hydraulic unit (A7/3).		  
TORQUE SPECIFICATION Bolt, traction system hydraulic unit to bracket *BA42.45-P-1001-01M 
14.2 Remove intermediate bracket (10) from traction system hydraulic unit (A7/3) MODEL 207
MODEL 212, 218
as of model year 2015
When installing a new traction system hydraulic unit (A7/3).		  
TORQUE SPECIFICATION Bolt, traction system hydraulic unit to bracket *BA42.45-P-1001-01M 
15 Install in the reverse order    
16 Calibrate the ESP® control unit using the diagnostic system When installing a new traction system hydraulic unit (A7/3).  
REFER TO SELF-DIAGNOSTIC SYSTEMS     AD00.00-P-2000-04A
17 Bleed brake system   AR42.10-P-0010EW
18 Read out and erase fault memory    
REFER TO SELF-DIAGNOSTIC SYSTEMS     AD00.00-P-2000-04A
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 207 MODEL 212 (except 212.076/092/276/292)
BA42.10-P-1004-04L Retaining screw, brake line to hydraulic unit Ø4.75 Nm 18 18
Ø6 Nm 18 18
Ø8 Nm 24 18
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 212.076/092/276/292 MODEL 218 (except 218.376/392/976/992)
BA42.10-P-1004-04L Retaining screw, brake line to hydraulic unit Ø4.75 Nm 18 18
Ø6 Nm 18 18
Ø8 Nm 18 18
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 218.376/392/976/992
BA42.10-P-1004-04L Retaining screw, brake line to hydraulic unit Ø4.75 Nm 18
Ø6 Nm 18
Ø8 Nm 18
ELECTRONIC STABILITY PROGRAM (ESP)

Number Designation MODEL 207 MODEL 212
BA42.45-P-1001-01M Bolt, traction system hydraulic unit to bracket M8 Nm - 16
M10 Nm 16 27
ELECTRONIC STABILITY PROGRAM (ESP)

Number Designation MODEL 218
BA42.45-P-1001-01M Bolt, traction system hydraulic unit to bracket M8 Nm -
M10 Nm 27
ELECTRONIC STABILITY PROGRAM (ESP)

Number Designation MODEL 212 MODEL 218
BA42.45-P-1004-01M Bolt/nut, bracket for hydraulic unit to body Nm 20 20
Fig 3: Identifying Box Wrench Bit (140 589 00 03 00)
G09976588Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Unlocking Tool (000 589 20 63 00)
G09976589Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Adapter Coupling (001 589 00 16 00)
G09976590Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Box Wrench Bit (000 589 75 03 00)
G09976591Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Record Plug (129 589 00 91 00)
G09976592Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner
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