Remove/Install Brake Lines - AR42.10-P-0020C

Model 463 as of model year 2019 

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

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
	Brake fluid notes		AH42.50-P-0001-01A
	Remove
1	Raise vehicle.		AR00.60-P-1006A
2	Clean respective brake line connections.	Thoroughly clean area around connecting points before opening hydraulic system. Otherwise, minute dirt particles in the hydraulic component parts 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).	Always replace complete 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. 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 fitting and brake lines (2) using suitable stop plugs.	Record plug	Fig 2
	Prepare brake line (2) with line diameter of 4.75 mm(d)
5	Match length of new brake line (2) using pipe cutter to 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) using pipe cutter 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) using bending tool to route 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 463 as of model year 2019 Brake hose to brake line on front axle fixed caliper	*BA42.10-P-1011-04B
		Model 463 as of model year 2019 Union nut, brake line to connecting point	*BA42.10-P-1010-04B
		Model 463 as of model year 2019 Brake line to brake hose	*BA42.10-P-1001-04B
		Model 463 as of model year 2019 Brake line to ABS/ESP hydraulic unit	*BA42.10-P-1004-04B
		Model 463 as of model year 2019 Brake pipe to master brake cylinder	*BA42.10-P-1003-04B
		Adapter coupling	Fig 1
		Torque tool set	Fig 3
	Check
11	Check surface of new brake line (2) for damage through scratches and paint damage.	If necessary, ↓ Repair paint damage. Zinc dust paint spray can	*BR00.45-Z-1055-07A
12	Apply coating of wax to new brake line (2).	Wax for engine compartment (400 ml spray can)	*BR00.45-Z-1018-05A
13	Bleed brake system.		AR42.10-P-0010XG
	Check
14	Perform brake test on test stand.

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