How to carry out replacement: Brake Discs 112 CDI 2.2 (638.194) Mercedes W638 Minibus
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Change Mercedes W638 Minibus 108 CDI 2.2 (638.194) Brake Discs yourself – manuals and video tutorials

How to change front brake discs on Mercedes Vito W638 – replacement guide

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When to replace the Brake Discs on your MERCEDES-BENZ VITO
Recommended replacement interval for the part category Brake disc : 50000 km
Important!
This replacement procedure can be used for:
MERCEDES-BENZ VITO Bus (638) 108 D 2.3 (638.164), MERCEDES-BENZ VITO Bus (638) 110 TD 2.3 (638.174), MERCEDES-BENZ VITO Bus (638) 113 2.0 (638.114, 638.194), MERCEDES-BENZ VITO Bus (638) 108 CDI 2.2 (638.194), MERCEDES-BENZ VITO Bus (638) 110 CDI 2.2 (638.194) … View more

The steps may slightly vary depending on the car design.

How to change front brake discs / front brake rotors on MERCEDES-BENZ VITO 1 (W638) [AUTODOC]

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Published on: 14/06/2019
4K views
All the parts you need to replace – Brake Discs for VITO Bus (638) and other MERCEDES-BENZ models
Alternative products
How to change Brake disc on Mercedes W638 Minibus 112 CDI 2.2 (638.194) – step-by-step instructions for straightforward car repair Brake disc
Tools
Replacement: brake discs – Mercedes Vito W638. Tools you need:
Wire brush
WD-40 spray
Brake cleaner
Copper grease
Drive socket # 13
Drive socket # 21
Wheel impact socket #17
Brake caliper wind back tool
Ratchet wrench
Torque wrench
Flat Screwdriver
Phillips screwdriver
Impact screwdriver
Tap wrench
Rubber mallet
Crow bar
Wheel chock
Buy tools
Replacement: brake discs – Mercedes Vito W638. AUTODOC experts recommend:
  • Replace the brake disks on the car Mercedes Vito W638 in complete set for each axis. Regardless of the state of components. This will ensure even braking.
  • The replacement procedure is identical for both brake disks on the same axle.
  • When changing the brake discs, always replace the brake pads.
  • Please note: all work on the car – Mercedes Vito W638 – should be done with the engine switched off.
Carry out replacement in the following order:
  1. Step 1
    How to change Brake Discs on Mercedes W638 Minibus 1996 - free PDF and video manuals
    Open the bonnet. Unscrew the brake fluid reservoir cap.
  2. Step 2
    How to replace MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194) 1997 Brake Discs - step-by-step manuals and video guides
    Secure the wheels with chocks.
  3. Step 3
    Mercedes W638 Minibus 108 CDI 2.2 (638.194) 1998 Brake Discs replacement: free workshop manuals
    Loosen the wheel mounting bolts. Use wheel impact socket #17.
  4. Step 4
    Changing Brake Discs on MERCEDES-BENZ VITO Bus (638) 110 CDI 2.2 (638.194) 1999 by yourself
    Raise the front of the car and secure on supports.
  5. Step 5
    How to remove MERCEDES-BENZ VITO 108 D 2.3 (638.164) 2000 Brake Discs - online easy-to-follow instructions
    Unscrew the wheel bolts.
    Replacement: brake discs – Mercedes Vito W638. Tip:
    To avoid injury, hold up the wheel when unscrewing the bolts.
  6. Step 6
    How to replace Brake Discs on MERCEDES-BENZ VITO Bus (638) 2001: download PDF manuals and video instructions
    Remove the wheel.
  7. Step 7
    How hard is it to do yourself: Brake Discs replacement on Mercedes W638 Minibus 113 2.0 (638.114, 638.194) 2002 - download illustrated guide
    Spread the brake pads. Use a crowbar.
  8. Step 8
    Need to know how to renew Brake Discs on MERCEDES-BENZ VITO 2003? This free workshop manual will help you to do it yourself
    Clean the brake caliper fasteners. Use a wire brush. Use WD-40 spray.
  9. Step 9
    Changing of Brake Discs on Mercedes W638 Minibus 1996 won't be an issue if you follow this illustrated step-by-step guide
    Unscrew the brake caliper fastening. Use a drive socket #13. Use a ratchet wrench.
  10. Step 10
    MERCEDES-BENZ VITO 108 CDI 2.2 (638.194) Brake Discs replacement: online guides and video tutorials
    Remove the brake caliper.
    Replacement: brake discs – Mercedes Vito W638. AUTODOC recommends:
    Tie the caliper to the suspension or to the body with a wire without disconnecting from the brake hose to prevent depressurization of the brake system.Make sure that the brake caliper is not hanging on the brake hose.Don't press the brake pedal after the brake caliper has been removed. As a result, the piston can fall out from the brake cylinder, and brake fluid leakage and depressurization of the system may occur.
  11. Step 11
    Replacing Brake Discs on Mercedes W638 Minibus 1998 112 CDI 2.2 (638.194) by yourself
    Disconnect the brake pad wear sensor plug. Use a flat screwdriver.
    Please note!
    Some cars are not equipped with the brake pad wear sensor.
  12. Step 12
    VITO Bus (638) 108 D 2.3 (638.164) 1999 Brake Discs DIY replacement workshop manual
    Remove the brake pads.
  13. Step 13
    How to change Brake Discs on MERCEDES-BENZ VITO Bus (638) 2000 - tips and tricks
    Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
  14. Step 14
    Step-by-step recommendations for DIY replacement Mercedes W638 Minibus 2001 108 D 2.3 (638.164) Brake Discs
    Unscrew the caliper bracket fastening. Use a drive socket #21. Use a tap wrench. Use a ratchet wrench.
  15. Step 15
    DIY replacement of Brake Discs on MERCEDES-BENZ VITO Bus (638) 110 TD 2.3 (638.174) 2002 is not an issue anymore with our step-by-step tutorial
    Remove the caliper bracket.
  16. Step 16
    How to change Brake Discs on Mercedes W638 Minibus 1996 - free PDF and video manuals
    Clean the brake disk surface. Use a wire brush. Use WD-40 spray.
  17. Step 17
    How to replace MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194) 1997 Brake Discs - step-by-step manuals and video guides
    Unscrew the brake disc fastening. Use a Phillips screwdriver. Use an impact screwdriver.
    Replacement: brake discs – Mercedes Vito W638. Tip from AUTODOC experts:
    If necessary, use a rubber mallet.
  18. Step 18
    Mercedes W638 Minibus 108 CDI 2.2 (638.194) 1998 Brake Discs replacement: free workshop manuals
    Remove the brake disc.
  19. Step 19
    Changing Brake Discs on MERCEDES-BENZ VITO Bus (638) 110 CDI 2.2 (638.194) 1999 by yourself
    Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
  20. Step 20
    How to remove MERCEDES-BENZ VITO 108 D 2.3 (638.164) 2000 Brake Discs - online easy-to-follow instructions
    Install the brake disc.
  21. Step 21
    How to replace Brake Discs on MERCEDES-BENZ VITO Bus (638) 2001: download PDF manuals and video instructions
    Tighten the brake disc fastening. Use a Phillips screwdriver. Use a torque wrench. Tighten it to 9 Nm torque.
  22. Step 22
    How hard is it to do yourself: Brake Discs replacement on Mercedes W638 Minibus 113 2.0 (638.114, 638.194) 2002 - download illustrated guide
    Clean the brake disk surface. Use a brake cleaner.
    AUTODOC recommends:
    Replacement: brake discs – Mercedes Vito W638. After applying the spray, wait a few minutes.
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