Replace Brake Lines - AR42.10-P-0020B

MODEL 117, 156, 166, 172, 176, 204, 205, 207, 212, 216, 217, 218, 221, 222, 231, 242, 246, 251, 292 

Shown on brake line (2) with line diameter 4.75 mm (d) 

	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	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 handling, transport and storage of ceramic brake disks	Model 204, 205, 212, 217, 218, 221, 222, 231 with code B07 (Ceramic brake system)	AH42.10-P-9406-13A
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
	Notes on handling, transport and storage of composite brake disks	Model 205, 217, 222	AH42.10-P-9406-12LF
	Remove
1	Raise vehicle	Model 117, 156, 166, 172, 176, 204, 205, 207, 212, 216, 217, 218, 221, 222, 231, 242, 246, 251, 292
		Model 231	AR00.60-P-1000TX
		Model 216, 221	AR00.60-P-1000SX
		Model 251	AR00.60-P-1000RT
		Model 205	AR00.60-P-1000LW
		Model 217, 222	AR00.60-P-1000LF
		Model 172	AR00.60-P-1000V
		Model 166, 292	AR00.60-P-1000GZ
		Model 117, 156, 176, 242, 246	AR00.60-P-1000AK
2	Clean respective brake line connections	Before opening the hydraulic system, the area surrounding the connecting points should be thoroughly cleaned. 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
3	Remove respective brake line (2) or section of brake line (2)	The brake lines (2) from the master brake cylinder to the hydraulic unit, plastic-coated brake lines (2) and brake lines (2) with a flexible portion must be completely replaced. Partial replacement is only permissible with brake lines (2) with a line diameter of 4.75 mm (d) (wheel line). For brake lines (2) with a line diameter of 4.75 mm (d) (wheel line) two additional connecting points per brake line (2) are permissible.
4	Seal respective connection fittings and brake lines (2)	Record plug	Figure
	Prepare brake line (2) with line diameter of 4.75 mm (d)
5	Match length of new brake line (2) to match old brake line (2)	Two additional separating points per brake line (2) are permissible. Commercially available devices/tools  Pipe cutter
6	Cut new brake line (2) into sections	If required for installation. Commercially available devices/tools  Pipe cutter Two connecting points per new brake line (2) are permissible. The connecting point must be in perfect condition and it must not be soiled.
7	Slide retaining screws (1) onto brake line (2)	Use specified line connectors only.
8	Make flange on brake line (2)	Make F-flange 115° (a) in accordance with DIN 74234. Follow the operating instructions provided by the tool manufacturer. Commercially available devices/tools  Flaring tool for F-flange 115° (a)
9	Match new brake line (2) to course of old brake line (2)	The bending radius must not be less than 13 mm. Commercially available devices/tools  Bending tool
	Install
10	Install new brake line (2) Note on calculation of tightening torque when using insertion or socket tools with various effective lengths	When routing the brake line (2) make sure there is sufficient distance to other components. There must be no stress, kinking and line narrowing. Use specified line connectors only.	AH00.00-P-0015-01CW
		MODEL 217, 222Retaining screw, brake line to brake hose	*BA42.10-P-1001-04N
		Model 205Retaining screw, brake line to brake hose	*BA42.10-P-1001-04O
		Model 117, 156, 172, 176, 204, 207, 212, 218, 231, 242, 246Retaining screw, brake line to brake hose	*BA42.10-P-1001-04L
		Model 216, 221 Retaining screw, brake line to brake hose	*BA42.10-P-1001-04K
		Model 251 Brake line to brake hose	*BA42.10-P-1002-14A
		Model 166, 292 Brake line to brake hose	*BA42.10-P-1002-04J
		Adapter coupling	Fig 1
		Torque tool set	Fig 3
	Check
11	Check surface of new brake line (2) for scratches and paint damage	If required ↓ Repair paint damage. Zinc dust paint spray can	*BR00.45-Z-1055-07A
12	Apply coating of wax to new brake line (2)	Cavity preservation, solvent-free (1 l container)	*BR00.45-Z-1011-05A
13	Bleed brake system	Model 205	AR42.10-P-0010LW
		Model 217, 222	AR42.10-P-0010LF
		Model 231	AR42.10-P-0010RK
		Model 166, 172, 204, 292	AR42.10-P-0010CW
		Model 207, 212, 218	AR42.10-P-0010EW
		Model 117, 156, 176, 242, 246	AR42.10-P-0010NKB
		Model 251	AR42.10-P-0010RT
		Model 216, 222	AR42.10-P-0010SX
	Check
14	Carry out brake test on the test stand
			AP42.00-P-4290BA

Fig 1: Identifying Adapter Coupling (001 589 00 16 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Torque Tool Set (003 589 05 09 00)

Courtesy of MERCEDES-BENZ USA