Remove/Install Brake Lines - Ar42.10-D-0020TS

Model 907 

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

	Risk of death  when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.	AS00.00-Z-0035-01A
	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 accident  when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work.	Before starting the engine, actuate brake pedal several times until pressure is built up and maintained in the brake system.	AS42.50-Z-0002-01A
	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
	General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment		AH00.00-Z-0300-01A
	Notes on battery		AH54.10-P-0001-01A
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
	General information on malfunctions in the brake system		AH42.30-N-2007-01A
	Notes on inspecting corrosion on brake lines		AH42.50-Z-0002-01A
	Remove
1	Raise vehicle.		AR00.60-D-1000-04TS
	Special instructions for lifting and supporting vehicle		AH00.60-N-0100-01TS
2	Remove lower engine compartment paneling.	Model 907 with code XM1 (Noise reduction)	AR61.20-D-1105TS
3	Remove underbody paneling.	Model 907 with code XM1 (Noise reduction)	AR61.30-D-1001TS
4	Remove underfloor paneling from high-voltage battery module.	* Applies to Europe only	AR61.30-D-1002TE
5	Define length of new brake line (2) to match old brake line (2).	If brake line (2) is partly replaced. The separating points must be in perfect condition. Malfunctions may occur otherwise. Select separating points at an easily accessible point or remove brake line (2) if access is difficult. Malfunctions may occur otherwise. The lines of the master brake cylinder to the hydraulic unit, plastic-coated lines and lines with flexible component are excluded from the repair. Two additional separating points per brake line (2) are permissible for partial replacement of a brake line (2).
	Clean
6	Clean repair area thoroughly.	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. Otherwise, there may be malfunctions to and total failure of the hydraulic system. Clean brake line (2), brake line connections and immediate surrounding area on vehicle. Assembly cleaner	*BR00.45-Z-1028-04A
	Remove
7.1	Remove brake line (2).	If brake line (2) is completely replaced. Seal connections on vehicle. Collect escaping brake fluid. Commercially available devices/tools  Collection bowl Record plug	Fig 3
7.2	Disconnect brake line (2).	If brake line (2) is partly replaced. Seal connection on vehicle. Collect escaping brake fluid. Commercially available devices/tools  Collection bowl Flaring tool	Fig 2
		Record plug	Fig 3
8	Remove remaining piece of old brake line (2).	If brake line (2) is partly replaced. Seal connection on vehicle. Collect escaping brake fluid. Commercially available devices/tools  Collection bowl Record plug	Fig 3
	Install
9	Determine line diameter (d) of new brake line (2).	If brake line (2) is partly replaced.
10	Match length of new brake line (2) to old brake line (2) with the pipe cutter.	If brake line (2) is partly replaced. Flaring tool	Fig 2
11	Slide retaining screws (1) onto brake line (2).	If brake line (2) is partly replaced. Use specified threaded collars only.
12	Flange on new brake line (2).	If brake line (2) is partly replaced. Only use brake lines (2) with F-flanges (115°) (a) as per Deutscher Industrie-Norm (DIN) 74234.	AR42.10-S-0027-01E
		Stamp holder in flanging tool kit (pre-flanging)	*BA42.00-P-1001-05A
		Stamp holder in flanging tool kit (post-flanging)	*BA42.00-P-1002-05A
		Screw, clamping plate to flanging tool kit	*BA42.00-P-1003-05A
		ATE brake cylinder paste, article no.: 03.99020501.2	*BR00.45-Z-1078-06A
		Assembly cleaner	*BR00.45-Z-1028-04A
		Flaring tool	Fig 2
13	Make flange on brake line (2) remaining in vehicle.	If brake line (2) is partly replaced. Make flange on corresponding sections of remaining brake line (2) depending on separating points.	AR42.10-S-0027-01E
		Stamp holder in flanging tool kit (pre-flanging)	*BA42.00-P-1001-05A
		Stamp holder in flanging tool kit (post-flanging)	*BA42.00-P-1002-05A
		Screw, clamping plate to flanging tool kit	*BA42.00-P-1003-05A
		ATE brake cylinder paste, article no.: 03.99020501.2	*BR00.45-Z-1078-06A
		Assembly cleaner	*BR00.45-Z-1028-04A
		Flaring tool	Fig 2
14	Adapt new brake line (2).	If brake line (2) is partly replaced. Adapt brake line (2) according to old path using bending tool. A bending radius of 13 mm must not be dropped below. Damage and malfunctions can otherwise occur. Flaring tool	Fig 2
15	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 kinking and no line narrowing on the brake line (2). Damage and malfunctions can otherwise occur. Install brake line (2) free of tension and with correct torque on threaded connection.	AH00.00-P-0015-01CW
		Retaining screw, brake line to brake hose	*BA42.10-N-1001-14TS
		Retaining screw, brake line to hydraulic unit	*BA42.10-N-1003-14TS
		Retaining screw, brake line to master brake cylinder	*BA42.10-N-1004-14TS
		Retaining screw, brake line to brake line threaded socket	*BA42.10-N-1005-14TS
		Box wrench socket	Fig 1
	Check
16	Check surface of brake line (2) for signs of scratches and paint damage.	If necessary, ↓ Repair any scratches or paint damage. Zinc dust paint spray can	*BR00.45-Z-1055-07A
	Install
17	Apply preservation agent thoroughly to brake line (2) after installation.	Cavity preservation (free of solvents), 1 liter	*BR00.45-Z-1011-05A
18	Install underfloor paneling on high-voltage battery module.	* Applies to Europe only	AR61.30-D-1002TE
19	Install underbody paneling.	Model 907 with code XM1 (Noise reduction)	AR61.30-D-1001TS
20	Install lower engine compartment paneling.	Model 907 with code XM1 (Noise reduction)	AR61.20-D-1105TS
21	Bleed brake system.		AR42.10-D-0010TS
	Check
	Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
22	Check brake system for leaks.		AR42.10-D-0100-01TS
23	Perform brake test on test stand.
	Brake test		AP42.00-D-4290TS

TIGHTENING TORQUES FOR TOOLS

TIGHTENING TORQUES FOR TOOLS

TIGHTENING TORQUES FOR TOOLS

BRAKE LINES, BRAKE HOSES

BRAKE LINES, BRAKE HOSES

BRAKE LINES, BRAKE HOSES

BRAKE LINES, BRAKE HOSES

Fig 1: Box Wrench Socket (000 589 77 03 00)

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

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