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

MODEL 205 

Fig 1: Master Brake Cylinder Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	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 on repairs to brake system		AH42.00-P-0003-01A
	Notes on externally invisible brake fluid loss		AH42.10-P-9406-02V
	Brake fluid notes		AH42.50-P-0001-01A
	Remove/install
1	Eliminate vacuum in BAS brake booster (A7/7)	To do this, press the brake pedal several times with the engine switched off.
2	Remove brake fluid reservoir		AR42.10-P-0301LW
3	Clean master brake cylinder (1) in area of brake line (2) connections	Before opening the hydraulic system the area around the separation point should be cleaned thoroughly. Otherwise minute particles of dirt in the hydraulic components can result in malfunctions and total failure of the hydraulic system. Only use clean, lint free rags and cleaner free of mineral oil. Do not use any compressed-air for cleaning when the brake system is open.
		Assembly cleaner	*BR00.45-Z-1028-04A
4	Label brake lines (2) according to connections
5	Detach brake lines (2) from master brake cylinder (1)	Seal connection fittings at master brake cylinder (1). Foreign objects can otherwise enter the master brake cylinder (1) and cause damage.
		Retaining screw, brake line to master brake cylinder	*BA42.10-P-1003-04O
		Box wrench bit	Figure
		Record plug	Figure
6	Unscrew nut (3) and nut (arrow)	Nut, brake master cylinder to brake booster	*BA42.10-P-1001-05L
7	Guide master brake cylinder (1) out in the direction of the arrow under the strut (4) out of BAS brake booster (A7/7) and remove towards the back	Collect brake fluid which runs out with an absorbent rag. Otherwise damage can occur to the vehicle paint. Do not tilt the master brake cylinder (1); pull it forward and in a straight line out of the BAS brake booster (A7/7). Otherwise the push rod will be pressed out of its axial position. Replace seal between master brake cylinder (1) and BAS brake booster (A7/7).
8	Install in the reverse order
9	Bleed brake system		AR42.10-P-0010LW
	Check
10	Check brake system for leaks		AR42.10-P-0015LW
11	Carry out brake test on the test stand
	Brake test		AP42.00-P-4290BA

MASTER BRAKE CYLINDER

Number	Designation		MODEL 205
BA42.10-P-1001-05L	Nut, brake master cylinder to brake booster	Nm	21

BRAKE LINES, BRAKE HOSES

Number	Designation			MODEL 205 (except 205.086/087/286/287/387/487)	MODEL 205.086/087/286/287/387/487
BA42.10-P-1003-04O	Retaining screw, brake line to master brake cylinder	Ø 4.75 mm	Nm	18	18
		Ø 6.00 mm	Nm	18	18
		Ø 8.00 mm	Nm	24	24

Fig 2: Identifying Box Wrench Bit (000 589 75 03 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	Adolf Wurth GmbH & Co. KG