Remove/install Electronic Stability Program (ESP(R)) hydraulic unit

AR42.45-P-0817MCC

Remove/install Electronic Stability Program (ESP(R)) hydraulic unit

26.11.2019

Model

451.3/4

except code 494 (US version)

2

Cap

Shown on MODEL 451.330

1

Hydraulic unit

8

Nuts

13

Brake line

3

Nut

9

Screw

14

Brake line

4

Folding clamp

10

Guide pin

15

Electrical connector

5

Brake line

11

Brake lines

16

Bracket

6

Bracket

12

Brake line

N47-5

ESP control unit

7

Bracket

 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.

AS00.00-Z-0035-01A

 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 handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system

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

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

 

Remove/install

1

Remove transmitter key and mains plug

Model 451.39/49
except code 494 (US version)

2.1

Perform disable for the high-voltage on-board electrical system

Model 451.391/491
except code 494 (US version)

AR54.10-P-1160MEV

 After completing the work, enclose initial startup log together with the power disable enable log with the vehicle file.

2.2

Connect Star Diagnosis and disable high-voltage on-board electrical system

Model 451.390/490
except code 494 (US version)



AD00.00-P-2000-04MCC

 Print the power disable event log and add to the vehicle file.

 Installation: Put the high-voltage on-board electrical system into operation.

3

Remove maintenance flap

4

Unscrew cap (2) of brake fluid expansion reservoir and extract brake fluid

 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

5

Raise vehicle with vehicle lift

6

Remove high-voltage battery

Model 451.391/491
except code 494 (US version)

AR54.10-P-1140MEV

Model 451.390/490 with engine 780.993
except code 494 (US version)

AR54.10-P-1140MEX

7

Remove bulkhead wall

Model 451.40/43/48
except code 494 (US version)

AR61.25-P-6600MCC

8

Unscrew nut (3), open folding clamp (4) using a suitable tool and remove

 Make sure that the brake lines (13, 14) and the electrical lines are installed at the correct position.

9

Unclip brake lines (13, 14) from holder (16)

10

Unclip brake line (5) from holder (6)

11

Loosen nuts (8), unscrew bolts (9) and remove bracket (7)

 Installation: Move guide pin (10) on hydraulic unit (1) into bracket (7).

 Screw/bolt, ESP hydraulic unit bracket to floor panel

*BA42.45-P-1008-01F

12

Support hydraulic unit (1) using telescopic lifter and removal fixture



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

 Removal fixture

*450589026200

13

Check bolted connections of brake lines (11) with the hydraulic unit (1) for color coding

AR42.10-P-0013-05MCC

 Installation: Mark brake lines (11) accordingly.

14

Loosen bolted connections of brake lines (11) with the hydraulic unit (1) and separate

 Collect brake fluid in a suitable container. Seal connections using suitable plugs.

 Installation: Use 12 mm plug-in open end wrench. Do not bend brake lines (11), pay ATTENTION to routing, leaktightness and clearance.

 Brake line to ESP hydraulic unit

*BA42.10-P-1010-04E

If a brake line (11) with red marking has been released, this brake line (11) must be replaced.



Remove/install brake line from the master brake cylinder to the ESP hydraulic unit

AR42.10-P-0034MCC

15

Carefully lower the hydraulic unit (1) until the brake lines (5, 12, 13, 14) are accessible

16

Check color coding of threaded connections of brake lines (5, 12, 13, 14) to hydraulic unit (1)

AR42.10-P-0013-05MCC

 Installation: Mark the brake lines (5, 12, 13, 14) accordingly.

17

Loosen and disconnect threaded connections of brake lines (5, 12, 13, 14) to hydraulic unit (1)

 Make sure that the brake lines (5, 12, 13, 14) are installed at the correct location. Collect brake fluid in a suitable container. Seal connections using suitable plugs.

 Installation: Do not bend the brake lines (5, 12, 13, 14); make sure that they are routed correctly, are leaktight and are clear of other components.

 Brake line to ESP hydraulic unit

*BA42.10-P-1010-04E

 Socket wrench set

*451589000300

18

Unlock retainer of electrical connector (15) and disconnect electrical connector (15) on ESP control unit (N47-5)

19

Remove hydraulic unit (1)

20

Replace brake lines (5, 12, 13, 14)

Only if a brake line (5, 12, 13, 14) with red color coding was released.

Remove/install left front brake line

AR42.10-P-0032MCC

Remove/install right front brake line

AR42.10-P-0033MCC

Remove/install brake line from ESP(R) hydraulic unit to rear axle

AR42.10-P-0035MCC

21

Install in the reverse order

22

Bleed brake system

AR42.10-P-0010MCC

23

Connect STAR DIAGNOSIS, perform swap check and read out fault memory



AD00.00-P-2000-04MCC

 Brake lines, brake hoses

Number

Designation

Model 451.3/4

BA42.10-P-1010-04E

Brake line to ESP hydraulic unit

Nm

16

 Electronic Stability Program (ESP)

Number

Designation

Model 451.3/4

BA42.45-P-1008-01F

Screw/bolt, ESP hydraulic unit bracket to floor panel

Nm

25