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Replace brake lines - AR42.10-P-0020B

WARNING: This page does not describe the selected car, but rather 33 other vehicles, including the 2016 Mercedes-Benz E63 S AMG, 2016 Mercedes-Benz E400, 2016 Mercedes-Benz E350, 2016 Mercedes-Benz E300, and 2016 Mercedes-Benz E250. However, it is still accessible from the selected car via links, so may be relevant.

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
G09976537Courtesy of MERCEDES-BENZ USA
DANGER 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
DANGER 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
DANGER 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 Notes on externally invisible brake fluid loss   AH42.10-P-9406-02V
NOTES Brake fluid notes   AH42.50-P-0001-01A
NOTES Notes on repairs to brake system   AH42.00-P-0003-01A
REMOVINGINSTALLING Remove/install     
1 Remove each brake line (2) INSTALLATION IMPORTANT Install brake line (2) free of tension and with correct torque on threaded connection.  
TORQUE SPECIFICATION MODEL 217, 222 *BA42.10-P-1001-04N 
TORQUE SPECIFICATION MODEL 205 *BA42.10-P-1001-04O 
TORQUE SPECIFICATION
MODEL 117, 156, 172, 176, 204, 207, 212, 218, 231, 242, 246		 *BA42.10-P-1001-04L 
TORQUE SPECIFICATION
MODEL 216, 221		 *BA42.10-P-1001-04K 
TORQUE SPECIFICATION
MODEL 251		 *BA42.10-P-1002-14A 
TORQUE SPECIFICATION
MODEL 166		 *BA42.10-P-1002-04J 
2 Define length of new brake line (2) to match the old brake line (2) IMPORTANT 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).
IMPORTANT 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 IMPORTANT The connecting point must be in perfect condition and it must not be soiled.
INSTALLATION IMPORTANT Use specified line connectors only.		  
4 Make flange on brake line (2) IMPORTANT Before making the flange, fit the union nut (1) to the respective brake line (2).
IMPORTANT On Mercedes-Benz cars only brake lines (2) with an F-flange (a) as per DIN 74234 may be used.
IMPORTANT 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) IMPORTANT Adapt the brake lines (2) to the old configuration using a bending tool. A bending radius of 13 mm must not be exceeded here.
INSTALLATION IMPORTANT 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    
INSPECT Check     
7 Check surface of brake line (2) IMPORTANT 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 leak tightness 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    
REFER TO MAINTENANCE     AP42.00-P-4290BA
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 216 (except 216.374/377/379) MODEL 216.374/377/379
BA42.10-P-1001-04K Union nut, brake line to brake hose Nm 17 17
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 221 (except 221.074/077/174/177/179) MODEL 221.074/077/174/177/179
BA42.10-P-1001-04K Union nut, brake line to brake hose Nm 17 17
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 117 MODEL 156
BA42.10-P-1001-04L Retaining screw, brake line to brake hose Nm 16 16
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 172 MODEL 176
BA42.10-P-1001-04L Retaining screw, brake line to brake hose Nm 16 16
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 204 MODEL 207
BA42.10-P-1001-04L Retaining screw, brake line to brake hose Nm 16 16
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 212 (except 212.076/092/276/292) MODEL 212.076/092/276/292
BA42.10-P-1001-04L Retaining screw, brake line to brake hose Nm 16 16
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 218 (except 218.376/392/976/992) MODEL 218.376/392/976/992
BA42.10-P-1001-04L Retaining screw, brake line to brake hose Nm 16 16
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 231 MODEL 242
BA42.10-P-1001-04L Retaining screw, brake line to brake hose Nm 16 16
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 246
BA42.10-P-1001-04L Retaining screw, brake line to brake hose Nm 16
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 217 except AMG MODEL 217 AMG
BA42.10-P-1001-04N Retaining screw, brake line to brake hose Nm 16 16
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 222 (except 222.077/177/178/179) MODEL 222.077/177/178/179
BA42.10-P-1001-04N Retaining screw, brake line to brake hose Nm 16 16
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 205 (except 205.086/087/286/287/387/487) MODEL 205.086/087/286/287/387/487
BA42.10-P-1001-04O Retaining screw, brake line to brake hose Nm 16 16
BRAKE LINES, BRAKE HOSES

Number Designation MODEL 166
BA42.10-P-1002-04J Brake line to brake hose Nm 14
BRAKE HOSES, BRAKE LINES

Number Designation MODEL 251
BA42.10-P-1002-14A Brake line to brake hose Nm 16
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1011-05A Cavity preservation, solvent-free (1 container) A 000 986 72 70 10
BR00.45-Z-1055-07A Zinc dust paint spray can A 000 986 82 42 09
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