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 

Fig 1: Union Nut, Brake Line & Flange

Courtesy of MERCEDES-BENZ USA

	Risk of injury  due to fan starting unexpectedly	Do not reach into the rotation or hazard area of the fan. Wear closed and close-fitting work clothes.	AS20.40-Z-0001-01A
	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 externally invisible brake fluid loss		AH42.10-P-9406-02V
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
	Remove/install
1	Remove each brake line (2)	Install brake line (2) free of tension and with correct torque on threaded connection.
		MODEL 217, 222	*BA42.10-P-1001-04N
		MODEL 205	*BA42.10-P-1001-04O
		MODEL 117, 156, 172, 176, 204, 207, 212, 218, 231, 242, 246	*BA42.10-P-1001-04L
		MODEL 216, 221	*BA42.10-P-1001-04K
		MODEL 251	*BA42.10-P-1002-14A
		MODEL 166	*BA42.10-P-1002-04J
2	Define length of new brake line (2) to match the old brake line (2)	Two additional separating points per brake line (2) are permissible. Partial replacement is only permissible with brake lines (2) with line diameter Ø 4.75 mm (d) (wheel line). Heater lines (master brake cylinder to hydraulic unit), plastic-coated lines and lines with flexible part are excluded from the repair.
3	Cut brake line (2) using pipe cutter	The connecting point must be in perfect condition and it must not be soiled. Use specified line connectors only.
4	Make flange on brake line (2)	Before making the flange, fit the union nut (1) to the respective brake line (2). On Mercedes-Benz cars only brake lines (2) with an F-flange (a) as per DIN 74234 may be used. When making a flange for the brake line (2), the tool manufacturer specifications must be complied with. Brake line flaring tool
5	Adapt new brake line (2)	Adapt the brake lines (2) to the old configuration using a bending tool. A bending radius of 13 mm must not be exceeded here. When routing the brake line (2) make sure there is sufficient distance to other components. There must be no kinking and no line narrowing on the brake line (2).
6	Install in the reverse order
	Check
7	Check surface of brake line (2)	Check surface of brake line (2) for scratches and paint damage, if necessary touch up any paint damage.
		Zinc dust paint spray can	*BR00.45-Z-1055-07A
8	Thoroughly wax the brake line (2) after mounting it	Cavity preservation, solvent-free (1 container)	*BR00.45-Z-1011-05A
9	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	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, MODEL 221	AR42.10-P-0010SX
10	Check brake system for leaktightness	MODEL 205	AR42.10-P-0015LW
		MODEL 166	AR42.10-P-0015GZ
		MODEL 172, 204, 217, 222, 231	AR42.10-P-0015CW
		MODEL 207, 212, 218	AR42.10-P-0015EW
		MODEL 117, 156, 176, 242, 246	AR42.10-P-0015NKB
		MODEL 251	AR42.10-P-0015RT
		MODEL 216, 221	AR42.10-P-0015SX
11	Carry out brake test on the test stand
			AP42.00-P-4290BA