Remove/install brake lines

AR42.10-P-0020C

Remove/install brake lines

06.03.2020

Model

463

as of model year 2019

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 4.75 mm

d2

Flange diameter 7.1  0.18 mm

X

Flange 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

Notes on repairs to brake system

AH42.00-P-0003-01A

Topical note

Brake fluid notes

AH42.50-P-0001-01A



Remove

1

Raise vehicle.

AR00.60-P-1006A

2

Clean respective brake line connections.


Thoroughly clean area around connecting points before opening hydraulic system.
Otherwise, minute dirt particles in the hydraulic component parts result in malfunctions and total failure of the hydraulic system.

 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

3

Remove respective brake line (2) or section of brake line (2).

 Always replace complete brake lines (2) from the master brake cylinder to the hydraulic unit, plastic-coated brake lines (2) and brake lines (2) with a flexible portion.

 Partial replacement is only permissible with brake lines (2) with a line diameter of 4.75 mm (d) (wheel line).
For brake lines (2) with a line diameter of 4.75 mm (d) (wheel line) two additional connecting points per brake line (2) are permissible.

4

Seal respective connection fitting and brake lines (2) using suitable stop plugs.

 Record plug

*129589009100

Prepare brake line (2) with line diameter of 4.75 mm(d)

5

Match length of new brake line (2) using pipe cutter to old brake line (2).

 Two additional separating points per brake line (2) are permissible.

 Commercially available devices/tools
Pipe cutter

6

Cut new brake line (2) using pipe cutter into sections.

If required for installation.

 Commercially available devices/tools
Pipe cutter

 Two connecting points per new brake line (2) are permissible.

 The connecting point must be in perfect condition and it must not be soiled.

7

Slide retaining screws (1) onto brake line (2).

 Use specified line connectors only.

8

Make flange on brake line (2).

 Make F-flange 115° (a) in accordance with DIN 74234.

 Follow the operating instructions provided by the tool manufacturer.

 Commercially available devices/tools
Flaring tool for F-flange 115° (a)

9

Match new brake line (2) using bending tool to route of old brake line (2).

 The bending radius must not be less than 13 mm.

 Commercially available devices/tools
Bending tool



Install

10

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 stress, kinking and line narrowing.

 Use specified line connectors only.

 Model 463
as of model year 2019Brake hose to brake line on front axle fixed caliper

*BA42.10-P-1011-04B

 Model 463
as of model year 2019Union nut, brake line to connecting point

*BA42.10-P-1010-04B

 Model 463
as of model year 2019Brake line to brake hose

*BA42.10-P-1001-04B

 Model 463
as of model year 2019Brake line to ABS/ESP hydraulic unit

*BA42.10-P-1004-04B

 Model 463
as of model year 2019Brake pipe to master brake cylinder

*BA42.10-P-1003-04B

 Adapter coupling

*001589001600

 Torque tool set

*003589050900



Check

11

Check surface of new brake line (2) for damage through scratches and paint damage.

If necessary,



Repair paint damage.

Zinc dust paint spray can

*BR00.45-Z-1055-07A

12

Apply coating of wax to new brake line (2).

Wax for engine compartment (400 ml spray can)

*BR00.45-Z-1018-05A

13

Bleed brake system.

AR42.10-P-0010XG



Check

14

Perform brake test on test stand.

 Brake lines, brake hoses

Number

Designation

Model 463
as of model year 2019

BA42.10-P-1001-04B

Brake line to brake hose

Nm

14

 Brake lines, brake hoses

Number

Designation

Model 463
as of model year 2019

BA42.10-P-1003-04B

Brake pipe to master brake cylinder

Nm

16

 Brake lines, brake hoses

Number

Designation

Model 463
as of model year 2019

BA42.10-P-1004-04B

Brake line to ABS/ESP hydraulic unit

Nm

16

 Brake lines, brake hoses

Number

Designation

Model 463
as of model year 2019

BA42.10-P-1010-04B

Union nut, brake line to connecting point

Nm

14

 Brake lines, brake hoses

Number

Designation

Model 463
as of model year 2019

BA42.10-P-1011-04B

Brake hose to brake line on front axle fixed caliper

Nm

16

Repair materials

Number

Designation

Order number

BR00.45-Z-1018-05A

Wax for engine compartment (400 ml spray can)

A 000 986 33 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