Recommended replacement interval for the part category Repair Kit, brake caliper : 50000 km

Important!

This replacement procedure can be used for:
MERCEDES-BENZ 190 (W201) E 1.8 (201.018), MERCEDES-BENZ 190 (W201) 2.0 (201.022), MERCEDES-BENZ 190 (W201) E 2.0 (201.024), MERCEDES-BENZ 190 (W201) E 2.0 (201.024), MERCEDES-BENZ 190 (W201) 2.0 (201.023), MERCEDES-BENZ 190 (W201) 2.0 (201.023), MERCEDES-BENZ 190 (W201) E 2.0, MERCEDES-BENZ 190 (W201) E 2.0 (201.024), MERCEDES-BENZ 190 (W201) E 2.3, MERCEDES-BENZ 190 (W201) E 2.3 (201.028), MERCEDES-BENZ 190 (W201) E 2.6, MERCEDES-BENZ 190 (W201) D 2.0 (201.122), MERCEDES-BENZ 190 (W201) D 2.0 (201.122), MERCEDES-BENZ 190 (W201) D 2.5 (201.126), MERCEDES-BENZ 190 (W201) D 2.5 (201.126), MERCEDES-BENZ 190 (W201) Turbo-D 2.5 (201.128), MERCEDES-BENZ 190 (W201) Turbo-D 2.5 (201.128), MERCEDES-BENZ 190 (W201) E 2.6 (201.029), MERCEDES-BENZ 190 (W201) E 2.0, MERCEDES-BENZ 190 (W201) 2.3, MERCEDES-BENZ 190 (W201) 2.3 E, MERCEDES-BENZ 190 (W201) 2.6 … View more

The steps may slightly vary depending on the car design.

How to change front brake caliper repair kit on MERCEDES W201 [TUTORIAL AUTODOC]

All the parts you need to replace – Brake Caliper Repair Kit for 190 (W201) and other MERCEDES-BENZ models

Repair Kit, brake caliper

        Repair Kit, brake caliper for 190 (W201) Petrol (109 hp)
      
        Repair Kit, brake caliper for 190 (W201) Petrol (90 hp)
      
        Repair Kit, brake caliper for 190 (W201) Petrol (113 hp)
      
        Repair Kit, brake caliper for 190 (W201) Petrol (116 hp)
      
        Repair Kit, brake caliper for 190 (W201) Petrol (102 hp)
      
        Repair Kit, brake caliper for 190 (W201) Petrol (105 hp)
      
        Repair Kit, brake caliper for 190 (W201) Petrol (118 hp)
      
        Repair Kit, brake caliper for 190 (W201) Petrol (122 hp)
      
        Repair Kit, brake caliper for 190 (W201) Petrol (132 hp)

Replacement: brake caliper repair kit – Mercedes W201. Tools you'll need:

                        Wire brush
                      
                        WD-40 spray
                      
                        All-purpose cleaning spray
                      
                        Dielectric grease
                      
                        Brake cleaner
                      
                        Ceramic grease
                      
                        Brake caliper guide pins grease
                      
                        Torque wrench
                      
                        Combination spanner #10
                      
                        Combination spanner #13
                      
                        Combination spanner #14
                      
                        Combination spanner #15
                      
                        Drive socket # 10
                      
                        Drive socket # 13
                      
                        Drive socket # 19
                      
                        Wheel impact socket #17
                      
                        Ratchet wrench
                      
                        Tap wrench
                      
                        Brake hose clip
                      
                        Brake bleeder kit
                      
                        Brake caliper wind back tool
                      
                        Flat screwdriver
                      
                        Wheel chock

Buy tools

Replacement: brake caliper repair kit – Mercedes W201. AUTODOC experts recommend:

The replacement procedure is identical for the left and right brake calipers on the same axle.
All work should be done with the engine stopped.

Replacement: brake caliper repair kit – Mercedes W201. Take the following steps:

Step 1

Open the bonnet.
Step 2

Unscrew the brake fluid reservoir cap.
Step 3

Secure the wheels with chocks.

Step 4

Loosen the wheel bolts. Use wheel impact socket #17. Use a tap wrench.
Step 5

Raise the car.

Replacement: brake caliper repair kit – Mercedes W201. Tip:
If you are using a jack, make sure it rests on a flat surface without any unevenness.Be sure to additionally secure the car with jack stands.
Step 6

Unscrew the wheel bolts.

AUTODOC recommends:
To avoid injury, hold up the wheel when unscrewing the bolts.
Step 7

Remove the wheel.
Step 8

Detach the connector of the brake pad wear sensor.
Step 9

Clean the fastener of the brake pad wear sensor connector. Use a wire brush. Use WD-40 spray.
Step 10

Unscrew the fastener of the brake pad wear sensor connector. Use a combination spanner #10.
Step 11

Remove the fastening bolt.
Step 12

Detach the connector of the brake pad wear sensor.

Step 13

Clean the mounting seat of the brake hose on the brake caliper. Use a wire brush. Use WD-40 spray.
Step 14

Clamp the brake hose off using a brake hose clamp.
Step 15

Loosen the brake hose fastener. Use a combination spanner #14.
Step 16

Clean the brake caliper fasteners. Use a wire brush. Use WD-40 spray.
Step 17

Unscrew the brake caliper fasteners. Use a combination spanner #15. Use a combination spanner #13.
Step 18

Remove the fastening bolts.
Step 19

Remove the brake caliper.
Step 20

Remove the brake pads.
Step 21

Unscrew the brake hose from the brake caliper.
Step 22

Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
Step 23

Unscrew the brake caliper bracket fasteners. Use a drive socket #19. Use a ratchet wrench.
Step 24

Remove the fastening bolts.
Step 25

Remove the brake caliper bracket.
Step 26

Clean the area where the brake hose connects to the caliper. Use a wire brush. Use all-purpose cleaning spray.
Step 27

Remove the protective plate covering the dust boot of the caliper piston. Use a flat screwdriver.
Step 28

Remove the piston from the brake caliper housing.
Step 29

Remove the dust boot of the brake caliper piston.
Step 30

Remove the caliper piston O-ring. Use a flat screwdriver.
Step 31

Undo the brake bleeder screw. Use a drive socket #10. Use a ratchet wrench.
Step 32

Clean the mounting seats of the piston and related components. Use a wire brush. Use all-purpose cleaning spray.
Step 33

Install a new caliper piston O-ring.
Step 34

Install a new caliper piston dust boot.
Step 35

Install a new caliper piston.

Replacement: brake caliper repair kit – Mercedes W201. AUTODOC recommends:
Treat the piston and its mounting seat with brake fluid to prevent scoring on the cylinder walls during installation.
Step 36

Install the protective plate of the caliper piston dust boot.
Step 37

Press in the brake caliper piston. Use brake caliper wind back tool.
Step 38

Tighten the brake bleeder screw.
Step 39

Clean the brake caliper bracket of dirt and dust. Use a wire brush. Use all-purpose cleaning spray.
Step 40

Remove the brake caliper guide pins.
Step 41

Clean the guide pins and their seats on the brake caliper bracket. Use a wire brush. Use all-purpose cleaning spray.
Step 42

Treat the brake caliper guide pins. Use the brake caliper guide pin grease.
Step 43

Install the new boots of the brake caliper guide pins.
Step 44

Install the brake caliper guide pins.
Step 45

Install the brake caliper bracket.
Step 46

Install the fastening bolts.
Step 47

Tighten the brake caliper bracket fasteners. Use a drive socket #19. Use a torque wrench. Tighten it to 115 Nm torque.
Step 48

Screw the brake hose into the caliper.
Step 49

Install the brake pads.
Step 50

Install the brake caliper and fasten it.
Step 51

Install the fastening bolts.
Step 52

Tighten the brake caliper fasteners. Use a combination spanner #15. Use a drive socket #13. Use a torque wrench. Tighten it to 35 Nm torque.
Step 53

Tighten the fastener connecting the brake pipe to the brake caliper. Use a combination spanner #14. Use a torque wrench. Tighten it to 18 Nm torque.
Step 54

Connect the brake bleeder kit to the brake bleeder screw.
Step 55

Remove the brake hose clamp.

Step 56

Bleed the brake system.
Step 57

Tighten the bleeder screw. Use a combination spanner #10.
Step 58

Disconnect the brake bleeder kit.
Step 59

Tighten the brake caliper bleed screw. Use a drive socket #10. Use a torque wrench. Tighten it to 8 Nm torque.
Step 60

Attach the brake caliper bleed screw cap.
Step 61

Install the brake pad wear sensor connector.

Step 62

Install the fastening bolt.
Step 63

Screw in the fastener of the brake pad wear sensor connector. Use a combination spanner #10.
Step 64

Treat the brake pad wear sensor plug. Use dielectric grease.
Step 65

Attach the connector of the brake pad wear sensor.
Step 66

Treat the surface where the brake disc contacts the wheel rim. Use ceramic grease.
Step 67

Clean the brake disk surface. Use a brake cleaner.
Step 68

Install the wheel.

AUTODOC recommends:
Warning! To avoid injury, hold the wheel while screwing in the fastening bolts on the car. Mercedes W201
Step 69

Screw in the wheel bolts. Use wheel impact socket #17. Use a ratchet wrench.
Step 70

Lower the car and working in a cross order, tighten the wheel bolts. Use wheel impact socket #17. Use a torque wrench. Tighten it to 110 Nm torque.
Step 71

Remove the jacks and chocks.

Replacement: brake caliper repair kit – Mercedes W201. Tip from AUTODOC:
Check the brake fluid level in the expansion tank and top up if necessary.
Step 72

Tighten the brake fluid reservoir cap.
Step 73

Close the bonnet.

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