Remove/install brake lines · ar4210s0020e · Mercedes-Benz WIS

AR42.10-S-0020E

Remove/install brake lines

09.03.2020

Model

447, 448

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

1	Retaining screw
2	Brake line
a	F-flange (115°)
d	Line diameter (Ø 4.75 mm)
d2	Flange diameter (Ø 7.1 0.18 mm)
X	Flange height (2.3 0.3 mm)

P42.10-2899-03

 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 447 with engine 780	AS00.00-Z-0035-01A
 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 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
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 447 with engine 780	AH00.00-Z-0300-01A
Topical note	Notes on battery	Model 447 with engine 780	AH54.10-P-0001-01A
Topical note	Notes on repairs to brake system		AH42.00-P-0003-01A
Topical note	Brake fluid notes		AH42.50-P-0001-01A
	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-S-1000E
2	Remove lower engine compartment paneling.		AR61.20-S-1105E
3	Remove splash guard.	Model 447 with code H12 (Auxiliary hot-water heater) except code MX0 (BlueEFFICIENCY package) except code VQ1 (AVANTGARDE) Model 447 with code HZ1 (Auxiliary heater (warm air)) except code MX0 (BlueEFFICIENCY package) except code VQ1 (AVANTGARDE) Model 447 with code MA6 (Emissions category Euro 6b N1 GR.III/N2) except code MX0 (BlueEFFICIENCY package) except code VQ1 (AVANTGARDE) Model 447 with code MB6 (Low-emission vehicle, Euro 6 Gr. 1) except code MX0 (BlueEFFICIENCY package) except code VQ1 (AVANTGARDE)	AR61.30-S-0015E
4	Remove underbody paneling.	Model 447 with engine 651 with code MX0 (BlueEFFICIENCY package) Model 447 with engine 654.9	AR61.30-S-1001E
		Model 447 with engine 622.8	AR61.30-S-1001EH
		* Applies to Europe only
		

		Model 447 with engine 780.701	AR61.30-S-1001F
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.
		 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 partly replaced.
		 Seal connections on vehicle.
		 Collect escaping brake fluid.
		 Commercially available devices/tools Collecting pan
		 Record plug	*129589009100
7.2	Disconnect brake line (2).	If brake line (2) is partly replaced.
		 Seal connections on vehicle.
		 Collect escaping brake fluid.
		 Commercially available devices/tools Collecting pan
		 Flaring tool	*000589209900
		 Record plug	*129589009100
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 Collecting pan
		 Record plug	*129589009100
	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	*000589209900
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.
			AR42.10-S-0027-01E
		 Only use brake lines (2) with F-flanges (115°) (a) as per Deutscher Industrie-Norm (DIN) 74234.
		 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	*000589209900
13	Make flange on brake line (2) remaining in vehicle.	If brake line (2) is partly replaced.
			AR42.10-S-0027-01E
		 Make flange on corresponding sections of remaining brake line (2) depending on separating points.
		 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	*000589209900
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	*000589209900
15	Install new brake line (2).
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
		 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 threaded connection torque.
		 Retaining screw, brake line to brake hose	*BA42.10-N-1002-04D
		 Retaining screw, brake line to hydraulic unit	*BA42.10-N-1003-04D
		 Retaining screw, brake line to master brake cylinder	*BA42.10-N-1004-04D
		 Retaining screw, brake line to brake line threaded collar	*BA42.10-N-1006-04D
		 Box wrench socket	*000589770300
	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 underbody paneling.	Model 447 with engine 651 with code MX0 (BlueEFFICIENCY package) Model 447 with engine 654.9	AR61.30-S-1001E
		Model 447 with engine 622.8	AR61.30-S-1001EH
		* Applies to Europe only
		

		Model 447 with engine 780.701	AR61.30-S-1001F
19	Install splash guard.	Model 447 with code H12 (Auxiliary hot-water heater) except code MX0 (BlueEFFICIENCY package) except code VQ1 (AVANTGARDE) Model 447 with code HZ1 (Auxiliary heater (warm air)) except code MX0 (BlueEFFICIENCY package) except code VQ1 (AVANTGARDE) Model 447 with code MA6 (Emissions category Euro 6b N1 GR.III/N2) except code MX0 (BlueEFFICIENCY package) except code VQ1 (AVANTGARDE) Model 447 with code MB6 (Low-emission vehicle, Euro 6 Gr. 1) except code MX0 (BlueEFFICIENCY package) except code VQ1 (AVANTGARDE)	AR61.30-S-0015E
20	Install lower engine compartment paneling.		AR61.20-S-1105E
21	Bleed brake system.		AR42.10-S-0010E
	Check
 Warning	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-S-0100-01E
23	Perform brake test on test stand.
	Brake test		AP42.00-S-4290E

 Tightening torques for tools

Number	Designation		Model all (CAR, Light transporter)
BA42.00-P-1001-05A	Stamp holder in flanging tool kit (pre-flanging)	Nm	20

 Tightening torques for tools

Number	Designation		Model all (CAR, Light transporter)
BA42.00-P-1002-05A	Stamp holder in flanging tool kit (post-flanging)	Nm	40

 Tightening torques for tools

Number	Designation		Model all (CAR, Light transporter)
BA42.00-P-1003-05A	Screw, clamping plate to flanging tool kit	Nm	15

 Brake lines, brake hoses

Number	Designation		Model 447, 448
BA42.10-N-1002-04D	Retaining screw, brake line to brake hose	Nm	14

 Brake lines, brake hoses

Number	Designation		Model 447, 448
BA42.10-N-1003-04D	Retaining screw, brake line to hydraulic unit	Nm	14

 Brake lines, brake hoses

Number	Designation		Model 447, 448
BA42.10-N-1004-04D	Retaining screw, brake line to master brake cylinder	Nm	14

 Brake lines, brake hoses

Number	Designation		Model 447, 448
BA42.10-N-1006-04D	Retaining screw, brake line to brake line threaded collar	Nm	14

000 589 77 03 00

Box wrench socket

000 589 20 99 00

Flaring tool

129 589 00 91 00

Record plug

Repair materials

Number	Designation	Order number
BR00.45-Z-1011-05A	Cavity preservation (free of solvents), 1 liter	A 000 986 72 70 10
BR00.45-Z-1028-04A	Assembly cleaner	A 000 986 56 01
BR00.45-Z-1055-07A	Zinc dust paint spray can	A 000 986 82 42 09
BR00.45-Z-1078-06A	ATE brake cylinder paste, article no.: 03.99020501.2	ATE, a brand of the Continental Corporation http://www.ATE.de http://www.ATE.de/kataloge/online-kataloge

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