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

Model 117, 118, 156, 166, 167, 172, 176, 177, 192, 204, 205, 206, 207, 212, 213, 214, 216, 217, 218, 221, 222, 223, 231, 232, 236, 238, 242, 243, 246, 247, 251, 253, 254, 257, 290, 292, 293, 294, 295, 296, 297 

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

Courtesy of MERCEDES-BENZ USA

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
Notice	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Notice	Notes on handling, transport and storage of composite brake disks		AH42.10-P-9406-12LF
Notice	Notes on handling, transport and storage of ceramic brake disks		AH42.10-P-9406-13A
Notice	Brake fluid notes		AH42.50-P-0001-01A
Notice	Notes on repairs to brake system		AH42.00-P-0003-01A
	Notes on safety-relevant components		AH00.00-Z-0019-01A
	Remove
1	Raise vehicle.		AR00.60-P-1006A
2	Expose installation space of the corresponding brake line (2).
3	Clean respective brake line connections.	Thoroughly clean area around connecting points before opening hydraulic system. Otherwise minute dirt particles in the hydraulic component parts 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	Remove respective brake line (2) or section of brake line (2).	Always completely replace brake lines (2) with a line diameter of 5.25 mm from master brake cylinder to hydraulic unit and brake lines (2) with flexible section. A partial replacement is only permissible for brake lines (2) with a line diameter of 4.75 mm (d) or 4.95 mm (wheel line). For brake lines (2) with a line diameter of 4.75 mm (d) or 4.95 mm (wheel line), 2 additional connecting points per brake line (2) are permissible.
5	Seal respective connection fittings and brake lines (2) with suitable stop plugs.	Record plug	Fig 4
	Prepare painted brake line (2) with line diameter of 4.75 mm (d), 4.95 mm and 5.25 mm
6	Match length of new brake line (2) to old brake line (2) with the pipe cutter.	Flaring tool	Fig 2
7	Separate new brake line (2) into sections using pipe cutter.	If required for installation. Not for brake lines (2) with a line diameter of 5.25 mm. 2 connecting points per new brake line (2) are permissible. The connecting point must be in perfect condition and it must not be soiled. Flaring tool	Fig 2
8	Slide retaining screws (1) onto brake line (2).	Use specified line connectors only.
9	Determine diameter of new brake line (2).	Depending on the coating, brake lines (2) with a line diameter of 4.75 mm (d), a line diameter 4.95 mm or a line diameter 5.25 mm are used.
10	Flange brake line (2) (C).	Brake lines (2) with a line diameter of 4.75 mm (d) are flanged (C) without peeling (A) and without pre-flanging (B). Brake lines (2) with a line diameter of 4.95 mm and a line diameter of 5.25 mm must be peeled (A), pre-flanged (B) and flanged (C). Make F-flange 115° (a) in accordance with DIN 74234.	AR42.10-P-0027-01D
		Screw, clamping plate to flanging tool kit	*BA42.00-P-1003-05A
		Stamp holder in flanging tool kit (post-flanging)	*BA42.00-P-1002-05A
		Stamp holder in flanging tool kit (pre-flanging)	*BA42.00-P-1001-05A
		ATE brake cylinder paste, article no.: 03.99020501.2	*BR00.45-Z-1078-06A
		Flaring tool	Fig 2
11	Adapt new brake line (2) with a bending tool so that it follows the routing path of the old brake line (2).	The bending radius must not be less than 13 mm. Flaring tool	Fig 2
	Install
12	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 214 Retaining screw, brake line to threaded socket	*BA42.10-P-1005-04U
		Model 214 Retaining screw, brake line to hydraulic unit	*BA42.10-P-1004-04U
		Model 214 Retaining screw, brake line to master brake cylinder	*BA42.10-P-1003-04U
		Model 214 Retaining screw, brake line to brake hose	*BA42.10-P-1001-04U
		Model 192, 232 Retaining screw, brake line to threaded socket	*BA42.10-P-1004-04T
		Model 192, 232 Retaining screw, brake line to master brake cylinder	*BA42.10-P-1002-04T
		Model 192, 232 Retaining screw, brake line to brake hose	*BA42.10-P-1001-04T
		Model 192, 232 Retaining screw, brake line to hydraulic unit	*BA42.10-P-1003-04T
		Model 294 except code B07 (AMG - ceramic brake system) Model 294 with code B07 (AMG - ceramic brake system) Model 295 except code B07 (AMG - ceramic brake system) Model 295 with code B07 (AMG - ceramic brake system) Model 296 Model 297 except code B07 (AMG - ceramic brake system) Model 297 with code B07 (AMG - ceramic brake system) Retaining screw, brake line to threaded socket	*BA42.10-P-1004-04S
		Model 294 except code B07 (AMG - ceramic brake system) Model 294 with code B07 (AMG - ceramic brake system) Model 295 except code B07 (AMG - ceramic brake system) Model 295 with code B07 (AMG - ceramic brake system) Model 296 Model 297 except code B07 (AMG - ceramic brake system) Model 297 with code B07 (AMG - ceramic brake system) Retaining screw, brake line to brake hose	*BA42.10-P-1003-04S
		Model 294 except code B07 (AMG - ceramic brake system) Model 294 with code B07 (AMG - ceramic brake system) Model 295 except code B07 (AMG - ceramic brake system) Model 295 with code B07 (AMG - ceramic brake system) Model 296 Model 297 except code B07 (AMG - ceramic brake system) Model 297 with code B07 (AMG - ceramic brake system) Retaining screw, brake line to master brake cylinder	*BA42.10-P-1002-04S
		Model 294 except code B07 (AMG - ceramic brake system) Model 294 with code B07 (AMG - ceramic brake system) Model 295 except code B07 (AMG - ceramic brake system) Model 295 with code B07 (AMG - ceramic brake system) Model 296 Model 297 except code B07 (AMG - ceramic brake system) Model 297 with code B07 (AMG - ceramic brake system) Retaining screw, brake line to hydraulic unit	*BA42.10-P-1001-04S
		Model 206 Model 236 Model 254 Retaining screw, brake line to threaded socket	*BA42.10-P-1005-04O
		Model 206 Model 236 Model 254 Retaining screw, brake line to hydraulic unit	*BA42.10-P-1004-04O
		Model 206 Model 236 Model 254 Retaining screw, brake line to master brake cylinder	*BA42.10-P-1003-04O
		Model 206 Model 236 Model 254 Retaining screw, brake line to brake hose	*BA42.10-P-1001-04O
		Model 223 except code Z07 (B7 armoring on special protection version) Model 223 with code Z07 (B7 armoring on special protection version) Retaining screw, brake line to brake hose	*BA42.10-P-1003-04R
		Model 223 except code Z07 (B7 armoring on special protection version) Model 223 with code Z07 (B7 armoring on special protection version) Retaining screw, brake line to threaded socket	*BA42.10-P-1004-04R
		Model 223 except code Z07 (B7 armoring on special protection version) Model 223 with code Z07 (B7 armoring on special protection version) Retaining screw, brake line to master brake cylinder	*BA42.10-P-1002-04R
		Model 223 except code Z07 (B7 armoring on special protection version) Model 223 with code Z07 (B7 armoring on special protection version) Retaining screw, brake line to hydraulic unit	*BA42.10-P-1001-04R
		Model 221 (except 221.074/077/174/177/179) Union nut, brake line to T-piece	*BA42.10-P-1009-04K
		Model 213, 238, 257, 290, 293 Retaining screw, brake line to threaded socket	*BA42.10-P-1005-04P
		Model 213, 238, 257, 290, 293 Retaining screw, brake line to hydraulic unit	*BA42.10-P-1004-04P
		Model 213, 238, 257, 290, 293 Retaining screw, brake line to master brake cylinder	*BA42.10-P-1003-04P
		Model 166, 167, 292 Brake pipe to master brake cylinder	*BA42.10-P-1003-04J
		Model 216, 221 Union nut, brake line to brake caliper	*BA42.10-P-1010-04K
		Model 216, 221 Union nut, brake line to hydraulic unit	*BA42.10-P-1004-04K
		Model 216, 221 Union nut, brake line to master brake cylinder	*BA42.10-P-1003-04K
		Model 205, 253 Retaining screw, brake line to threaded socket	*BA42.10-P-1005-04O
		Model 205, 253 Retaining screw, brake line to hydraulic unit	*BA42.10-P-1004-04O
		Model 205, 253 Retaining screw, brake line to master brake cylinder	*BA42.10-P-1003-04O
		Model 217, 222 Retaining screw, brake line to brake line (connecting point)	*BA42.10-P-1008-04N
		Model 217, 222 Retaining screw, brake line to threaded socket	*BA42.10-P-1005-04N
		Model 217, 222 Retaining screw, brake line to hydraulic unit	*BA42.10-P-1004-04N
		Model 217, 222 Retaining screw, brake line to master brake cylinder	*BA42.10-P-1003-04N
		Model 117, 156, 172, 176, 204, 207, 212, 218, 231, 242, 246 Retaining screw, brake line to threaded socket	*BA42.10-P-1005-04L
		Model 117, 156, 172, 176, 204, 207, 212, 218, 231, 242, 246 Retaining screw, brake line to hydraulic unit	*BA42.10-P-1004-04L
		Model 117, 156, 172, 176, 204, 207, 212, 218, 231, 242, 246 Retaining screw, brake line to master brake cylinder	*BA42.10-P-1003-04L
		Model 118, 177, 243, 247 Retaining screw, brake line to threaded socket	*BA42.10-P-1003-04Q
		Model 118, 177, 243, 247 Retaining screw, brake line to master brake cylinder	*BA42.10-P-1002-04Q
		Model 118, 177, 243, 247 Retaining screw, brake line to hydraulic unit	*BA42.10-P-1001-04Q
		Model 251 Brake pipe to master brake cylinder	*BA42.10-P-1003-14A
		Model 251 Brake line to floating brake caliper	*BA42.10-P-1001-14A
		Model 251 Brake line to brake hose	*BA42.10-P-1002-14A
		Model 213, 238, 257, 290, 293 Retaining screw, brake line to brake hose	*BA42.10-P-1001-04P
		Model 118, 177, 243, 247 Retaining screw, brake line to brake hose	*BA42.10-P-1004-04Q
		Model 217, 222 Retaining screw, brake line to brake hose	*BA42.10-P-1001-04N
		Model 205, 253 Retaining screw, brake line to brake hose	*BA42.10-P-1001-04O
		Model 117, 156, 172, 176, 204, 207, 212, 218, 231, 242, 246 Retaining 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 166, 167, 292 Brake line to brake hose	*BA42.10-P-1002-04J
		Adapter coupling	Fig 1
		Torque tool set	Fig 3
13	Check surface of new brake line (2) for damage from scratches and paint damage.	If there is a problem, ↓ repair the paint damage. Zinc dust paint spray can	*BR00.45-Z-1055-07A
14	Wax all connections of brake lines (2).	Use commercially available wax.
15	Bleed brake system.	Model 192, 232	AR42.10-P-0010SLY
		Model 206 Model 214 Model 236 Model 254	AR42.10-P-0010WT
		Model 223, 294, 295, 296, 297	AR42.10-P-0010S
		Model 167	AR42.10-P-0010ME
		Model 213, 238	AR42.10-P-0010LWE
		Model 257, 290	AR42.10-P-0010FR
		Model 118, 177, 243, 247	AR42.10-P-0010MFA
		Model 205, 253, 293	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, 221	AR42.10-P-0010SX
16	Perform brake test on test stand.
		Model 192, 206, 214, 223, 232, 236, 254	AP42.00-P-4290BS
		Model 117, 118, 156, 166, 167, 172, 176, 177, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 231, 238, 242, 246, 247, 251, 253, 257, 290, 292, 293	AP42.00-P-4290BA
		Model 243, 294, 295, 296, 297	AP42.00-P-4290EQ

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

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Flaring Tool (000 589 20 99 00)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA