Remove/install ETS/ASR/ESP(R) hydraulic unit

AR42.40-P-0816MFA

Remove/install ETS/ASR/ESP(R) hydraulic unit

06.03.2020

Model

118, 177, 247

Modification notes

15.01.2020

Document completely revised.

Shown on model 177 with engine 260 (engine removed)

1

Hydraulic unit

6

Bracket

5

Nuts

N30/4

Electronic Stability Program control unit

Shown on model 177 with engine 282 with code ME08 (Hybrid drive 75-84 KW VARIANT (INCLUDING PLUG-IN))

1

Hydraulic unit

6

Bracket

8

Elastomer bearing

5

Nuts

7

Brake lines

N30/4

Electronic Stability Program control unit

 Danger

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.Model 177, 247 with engine 282
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))

AS00.00-Z-0035-01A

 Danger

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

 Caution

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

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

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

Model 177, 247 with engine 282
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))

AH00.00-Z-0300-01A

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A

Topical note

Brake fluid notes

AH42.50-P-0001-01A

Topical note

Notes on externally invisible brake fluid loss

AH42.10-P-9406-02A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Notes on safety-relevant components

AH00.00-Z-0019-01A



Remove

1

Disconnect ground line of on-board electrical system battery (G1).

AR54.10-P-0003MFA

2.1

Remove the coolant expansion reservoir.

Model 177, 247 with engine 282
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))

AR08.50-P-2478MFH

2.2

Remove heat shield for firewall far enough until hydraulic unit (1) is accessible.

Model 118 with engine 282
Model 118, 177, 247 with engine 139
Model 118, 177, 247 with engine 260
Model 118, 177, 247 with engine 608
Model 118, 177, 247 with engine 654
Model 177, 247 with engine 282
except code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))

Model 118, 177, 247 with engine 260

AR49.10-P-0001MFC

Model 118 with engine 282
Model 177, 247 with engine 282
except code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))

AR49.10-P-0001MFD

Model 118, 177, 247 with engine 608

AR49.10-P-0001MFE

Model 118, 177, 247 with engine 654

AR49.10-P-0001MFF

Model 118, 177, 247 with engine 139

AR49.10-P-0001MFG

3

Clean hydraulic unit (1).


Before opening the hydraulic unit (1), the area around the separation points must be thoroughly cleaned.
Otherwise minute dirt particles in the hydraulic components will result in malfunctions and total failure of the hydraulic unit (1).

 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

Release and disconnect electrical connector at ESP® control unit (N30/4).

AR42.45-P-0001-01MFA

5

Cover painted surfaces in the repair area.


Protect painted surfaces from brake fluid.
Otherwise damage will be caused by escaping brake fluid.

6

Mark brake lines (7) relative to hydraulic unit (1).

7

Remove brake lines (7) from hydraulic unit (1).


Do not kink or crush brake lines (7).
Otherwise the brake lines (7) will be damaged.

 Adapter coupling

*001589001600

 Box wrench bit

*140589000300

8

Seal brake lines (7) using suitable stop plugs.


Seal brake lines (7).
Otherwise foreign objects can enter and cause damage to the hydraulic unit (1).

 Record plug

*129589009100

9

Seal connections of hydraulic unit (1) using suitable stop plugs.


Seal connections on hydraulic unit (1).
Otherwise foreign objects can enter and cause damage to the hydraulic unit (1).

 Record plug

*129589009100

10

Loosen nuts (5).

11

Remove hydraulic unit (1) from holder (6).



Check

12

Check elastomer bearing (8) for damage.

If damage is visible:



Replace holder (6).

 Nut, hydraulic unit bracket to body

*BA42.45-P-1002-01Q

13

Check elastomer bearings on hydraulic unit (1) for damage.

If damage is visible,



Replace hydraulic unit (1).



Install

14

Coat elastomer bearing (8) and elastomer bearings on hydraulic unit (1) with lubricant.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

15

Attach hydraulic unit (1) to holder (6).

 Note installation position of hydraulic unit (1) in holder (6).

16

Tighten nuts (5).

 Mounting for hydraulic unit to holder

*BA42.45-P-1001-01Q

17.1

Remove stop plugs from connections of hydraulic unit (1).

If hydraulic unit (1) is to be reused.

 Record plug

*129589009100

17.2

Remove screw plugs from connections of hydraulic unit (1).

If the hydraulic unit (1) is to be replaced.

18

Remove stop plugs from brake lines (7).

 Record plug

*129589009100

19

Position brake lines (7) on hydraulic unit (1).


Route brake lines (7) free of tension and chafing.
Otherwise the brake lines (7) will be damaged.

 Observe markings.

20

Attach brake lines (7) to hydraulic unit (1).

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 Retaining screw, brake line to hydraulic unit

*BA42.10-P-1001-04Q

 Adapter coupling

*001589001600

 Box wrench bit

*140589000300

21

Connect and lock electrical connector at Electronic Stability Program control unit (N30/4).

AR42.45-P-0001-01MFA

22

Remove covers from painted surfaces.

23.1

Install coolant expansion reservoir.

Model 177, 247 with engine 282
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))

AR08.50-P-2478MFH

23.2

Attach heat shield for firewall.

Model 118 with engine 282
Model 118, 177, 247 with engine 139
Model 118, 177, 247 with engine 260
Model 118, 177, 247 with engine 608
Model 118, 177, 247 with engine 654
Model 177, 247 with engine 282
except code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))

Model 118, 177, 247 with engine 260

AR49.10-P-0001MFC

Model 118 with engine 282
Model 177, 247 with engine 282
except code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))

AR49.10-P-0001MFD

Model 118, 177, 247 with engine 608

AR49.10-P-0001MFE

Model 118, 177, 247 with engine 654

AR49.10-P-0001MFF

Model 118, 177, 247 with engine 139

AR49.10-P-0001MFG

24

Attach ground line of the on-board electrical system battery (G1).

AR54.10-P-0003MFA

25

Bleed brake system.

AR42.10-P-0010MFA

26

Perform commissioning of Electronic Stability Program control unit (N30/4) using diagnostic system.



AD00.00-P-2000-06MFA



Check

27

Perform brake test on test stand.



AP42.00-P-4290BA

 Brake lines

Number

Designation

Model 118

Model 177

BA42.10-P-1001-04Q

Retaining screw, brake line to hydraulic unit

Nm

16

16

 Brake lines

Number

Designation

Model 247

BA42.10-P-1001-04Q

Retaining screw, brake line to hydraulic unit

Nm

16

 Electronic Stability Program (ESP)

Number

Designation

Model 118

Model 177

BA42.45-P-1001-01Q

Mounting for hydraulic unit to holder

Nm

8

8

 Electronic Stability Program (ESP)

Number

Designation

Model 243, 247

BA42.45-P-1001-01Q

Mounting for hydraulic unit to holder

Nm

8

 Electronic Stability Program (ESP)

Number

Designation

Model 118

Model 177

BA42.45-P-1002-01Q

Nut, hydraulic unit bracket to body

M6

Nm

10

10

 Electronic Stability Program (ESP)

Number

Designation

Model 243, 247

BA42.45-P-1002-01Q

Nut, hydraulic unit bracket to body

M6

Nm

10

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01