Remove/install brake lines

AR42.10-P-0020A

Remove/install brake lines

09.03.2020

Model

163, 164, 168, 169, 170, 171, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 245

Model

463

up to model year 2013

except code 979 (Special protection MB Guard)

1

Union nut

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 (Height= 2.3  0.3 mm)

 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

Brake fluid notes

AH42.50-P-0001-01A

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A

1

Remove each brake line (2)

 Installation: Install brake line (2) free of tension and with correct torque on threaded connection.

 Model 163.113 #A as of 289565
Model 163.113 #A up to 289564
Model 163.113 #X as of 754620
Model 163.113 #X up to 754619
Model 163.128/172/174/175
Model 163.136
Model 163.154 #A as of 289565
except USA
Model 163.154 #A up to 289564
Model 163.157
except USA
Model 163.157
USA
Model 170
Model 171
Model 202
Model 203
Model 208
Model 209
Model 210
Model 211
ABR
Model 211
SBC
Model 215
Model 220
Model 230
except code P99 (Special model "AMG Black Series")
Model 230
with code P99 (Special model "AMG Black Series")Brake line to brake hose

*BA42.10-P-1001-04A

 Model 168Brake line to brake hose

*BA42.10-P-1002-04C

 Model 219
ABRUnion nut, brake line to brake hose

*BA42.10-P-1001-04I

 Model 169
Model 245Brake line to brake hose

*BA42.10-P-1003-04H

 Model 164Brake line to brake hose

*BA42.10-P-1002-04J

 Model 463 (except 463.270/271/272/273)
up to model year 2013
except code 979 (Special protection MB Guard)
Model 463.270/271
up to model year 2013
except code 979 (Special protection MB Guard)
Model 463.272/273
up to model year 2013
except code 979 (Special protection MB Guard)Brake line to brake hose

*BA42.10-P-1001-04B

2

Define length of new brake line (2) to match the old brake line (2)

 Two additional connecting points per brake line (2) are permissible for part replacement of a brake line (2):  Only part replacement for brake lines (2) with line diameter of Ø 4.75 mm (wheel line)

 Heater lines (master brake cylinder to hydraulic unit), SBC return lines, plastic-coated lines and lines with flexible part are excluded from the repair.

3

Cut brake line (2) using pipe cutter

 The constellation of the connecting point must be correct and there must be no soiling.

 Use specified cable connectors for installation only.

4

Make flange on brake line (2)

 Before making the flange, fit the union nut (1) to the respective brake line (2).

 On Mercedes-Benz cars only brake lines (2) with an F-flange (a) as per DIN 74234 may be used.

 When making a flange for the brake line (2), the tool manufacturer specifications must be complied with.

Brake line flaring tool gotis://B_42/43.2_04.0

5

Adapt new brake line (2)

 Adapt brake line (2) using bending tool to old configuration.
A bending radius of 13 mm must not be exceeded here. 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



Check

7

Check surface of brake line (2)

 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 (free of solvents), 1 liter

*BR00.45-Z-1011-05A

9

Bleed brake system

Model 170, 202, 208, 210

AR42.10-P-0010A

Model 169.006/007/008/031/032/033/034/090/306/307/308/331/332/333/334
Model 245.207/208/231/232/233/234

AR42.10-P-0010AK

Model WDB168.032, 168.006/007/008/009/031/033/035/109/131/132/133/135

AR42.10-P-0010GC

Model 163.113/128/136/154/157/172/174/175

AR42.10-P-0010GH

Model 164

AR42.10-P-0010GZ

Model 215
Model 220
except code 979 (Special protection MB Guard)
except code Z07 (B7 armoring on special protection version)

AR42.10-P-0010I

Model 220
with code 979 (Special protection MB Guard)
with code Z07 (B7 armoring on special protection version)

AR42.10-P-0010MB

Model 203, 209

AR42.10-P-0010P

Model 211, 219
with Adaptive Brake (ABR)Model 230
with code P99 (Special model "AMG Black Series")

AR42.10-P-0010T

Model 230
except code P99 (Special model "AMG Black Series")

AR42.10-P-0012R

Model 171

AR42.10-P-0010V

Model 463 (except 463.270/271)
up to model year 2013
except code 979 (Special protection MB Guard)

AR42.10-P-0010GG

Model 463.270/271
up to model year 2013
except code 979 (Special protection MB Guard)

AR42.10-P-0010GX

10

Check brake system for leak tightness

Model 463.270/271
up to model year 2013
except code 979 (Special protection MB Guard)

AR42.10-P-0015GX

Model 463 (except 463.270/271)
up to model year 2013
except code 979 (Special protection MB Guard)Disk brakes on front axle

AR42.10-P-0015GG

Model 170, 202, 203, 208, 209, 210

AR42.10-P-0015A

Model 169.006/007/008/031/032/033/034/090/306/307/308/331/332/333/334
Model 245.207/208/231/232/233/234

AR42.10-P-0015AK

Model 168.006/007/008/009/031/032/033/035/109/131/132/133/135

AR42.10-P-0015GC

Model 163.113/128/136/154/157/172/174/175

AR42.10-P-0015GH

Model 215, 220

AR42.10-P-0015I

Model 211, 219with Adaptive Brake (ABR)

AR42.10-P-0015T

Model 171

AR42.10-P-0015V

Model 164

AR42.10-P-0015GZ

11

Carry out brake test on the test stand



Model 163, 164, 168, 169, 170, 171, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 245 (except 245.286)

AP42.00-P-4290BA



Model 463
up to model year 2013
except code 979 (Special protection MB Guard)

AP42.00-P-4290G

 Brake lines, brake hoses

Number

Designation

MODEL 163.113 #A as of 289565, MODEL 163.113 #X as of 754620, MODEL 163.154 #A as of 289565 except USA

MODEL 163.113 #A up to 289564, MODEL 163.113 #X up to 754619, MODEL 163.154 #A up to 289564

BA42.10-P-1001-04A

Brake line to brake hose

Nm

18

18

 Brake lines, brake hoses

Number

Designation

Model 163.128/172/174/175

Model 163.136

BA42.10-P-1001-04A

Brake line to brake hose

Nm

18

18

 Brake lines, brake hoses

Number

Designation

Model 163.157
USA

Model 163.157
except USA

BA42.10-P-1001-04A

Brake line to brake hose

Nm

18

18

 Brake lines, brake hoses

Number

Designation

Model 170

Model 171

BA42.10-P-1001-04A

Brake line to brake hose

Nm

14

16

 Brake lines, brake hoses

Number

Designation

Model 202

Model 203

BA42.10-P-1001-04A

Brake line to brake hose

Nm

14

14

 Brake lines, brake hoses

Number

Designation

Model 208

Model 209

BA42.10-P-1001-04A

Brake line to brake hose

Nm

14

14

 Brake lines, brake hoses

Number

Designation

Model 210

Model 211 with SBC

BA42.10-P-1001-04A

Brake line to brake hose

Nm

14

18

 Brake lines, brake hoses

Number

Designation

Model 211
ABR

Model 215

BA42.10-P-1001-04A

Brake line to brake hose

Nm

18

14

 Brake lines, brake hoses

Number

Designation

Model 220

Model 230 except code P99

BA42.10-P-1001-04A

Brake line to brake hose

Nm

14

14

 Brake lines, brake hoses

Number

Designation

MODEL 230 with Code P99

BA42.10-P-1001-04A

Brake line to brake hose

Nm

14

 Brake lines, brake hoses

Number

Designation

Model 463 (except 463.236/248/270/271/272/273) up to model year 2019,

Model 463.270/271
up to model year 2019

BA42.10-P-1001-04B

Brake line to brake hose

Nm

15

15

 Brake lines, brake hoses

Number

Designation

Model 463.272/273
up to model year 2019

BA42.10-P-1001-04B

Brake line to brake hose

Nm

15

 Brake lines, brake hoses

Number

Designation

Model 219 with SBC

Model 219 with ABR

BA42.10-P-1001-04I

Union nut, brake line to brake hose

Nm

18

18

 Brake lines, brake hoses

Number

Designation

Model 168.007/008/031/033

Model 168.006/009/131

BA42.10-P-1002-04C

Brake line to brake hose

Nm

14

14

 Brake lines, brake hoses

Number

Designation

Model 168.032/035

Model 168.109/132/133/135

BA42.10-P-1002-04C

Brake line to brake hose

Nm

14

14

 Brake lines, brake hoses

Number

Designation

Model 164.1/8

BA42.10-P-1002-04J

Brake line to brake hose

Nm

15

 Brake lines, brake hoses

Number

Designation

Model 169

Model 245

BA42.10-P-1003-04H

Brake line to brake hose

Nm

18

18

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-1055-07A

Zinc dust paint spray can

A 000 986 82 42 09