Recommended replacement interval for the part category Brake disc : 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) 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) E 2.0, 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 disc and pads set on MERCEDES W201 [TUTORIAL AUTODOC]

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

Brake disc

        Brake disc for 190 (W201) Petrol (109 hp)
      
        Brake disc for 190 (W201) Petrol (90 hp)
      
        Brake disc for 190 (W201) Petrol (113 hp)
      
        Brake disc for 190 (W201) Petrol (116 hp)
      
        Brake disc for 190 (W201) Petrol (102 hp)
      
        Brake disc for 190 (W201) Petrol (105 hp)
      
        Brake disc for 190 (W201) Petrol (118 hp)
      
        Brake disc for 190 (W201) Petrol (122 hp)
      
        Brake disc for 190 (W201) Diesel (72 hp)

Replacement: brake discs – Mercedes W201. Tools you'll need:

                        Wire brush
                      
                        Nylon cleaning brush
                      
                        WD-40 spray
                      
                        Brake cleaner
                      
                        Dielectric grease
                      
                        Anti-squeal paste
                      
                        Ceramic grease
                      
                        Torque wrench
                      
                        Combination spanner #13
                      
                        Combination spanner #15
                      
                        Drive socket # 13
                      
                        Drive socket # 19
                      
                        HEX bit No.H5
                      
                        Wheel impact socket #17
                      
                        Ratchet wrench
                      
                        Tap wrench
                      
                        Crow bar
                      
                        Brake caliper wind back tool
                      
                        Wheel chock

Buy tools

Replacement: brake discs – Mercedes W201. AUTODOC experts recommend:

Replace the brake disks on the car Mercedes W201 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.

Carry out replacement in the following order:

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 discs – Mercedes W201. AUTODOC recommends:
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 brake caliper fasteners. Use a wire brush. Use WD-40 spray.
Step 10

Unscrew the brake caliper fasteners. Use a combination spanner #15. Use a combination spanner #13.
Step 11

Detach the brake pad wear sensor wiring harness.
Step 12

Spread the brake pads. Use a crowbar.
Step 13

Remove the fastening bolts.
Step 14

Remove the brake caliper.

Replacement: brake discs – Mercedes W201. Professionals recommend:
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.
Step 15

Remove the brake pads.
Step 16

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

Unscrew the brake caliper bracket fasteners. Use a drive socket #19. Use a ratchet wrench.
Step 18

Remove the fastening bolts.
Step 19

Remove the brake caliper bracket.
Step 20

Clean the brake disc fastener. Use a wire brush. Use WD-40 spray.
Step 21

Unscrew the brake disc fasteners. Use HEX No.H5. Use a ratchet wrench.
Step 22

Remove the fastening bolt.
Step 23

Remove the brake disc.
Step 24

Clean the wheel hub. Use a wire brush.
Step 25

Treat the contacting surface. Use ceramic grease.
Step 26

Install a new brake disc.
Step 27

Install the fastening bolt.
Step 28

Tighten the brake disc fasteners. Use HEX No.H5. Use a torque wrench. Tighten it to 10 Nm torque.
Step 29

Clean the brake caliper bracket of dirt and dust. Use a wire brush. Use a brake cleaner.

AUTODOC recommends:
Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.
Step 30

Install the brake caliper bracket.
Step 31

Install the fastening bolts.
Step 32

Tighten the brake caliper bracket fasteners. Use a drive socket #19. Use a torque wrench. Tighten it to 115 Nm torque.
Step 33

Treat the brake caliper piston. Use a nylon cleaning brush. Use a brake cleaner.
Step 34

Press in the brake caliper piston. Use brake caliper wind back tool.
Step 35

Treat the brake pads in the area where their surface comes into contact with the brake caliper bracket. Use anti-squeal paste.

Replacement: brake discs – Mercedes W201. Tip from AUTODOC:
Make sure the disc surface is clean before installing the pads.
Step 36

Install the brake pads.
Step 37

Install the brake caliper and fasten it.
Step 38

Install the fastening bolts.
Step 39

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 40

Treat the brake pad wear sensor plug. Use dielectric grease.
Step 41

Attach the connector of the brake pad wear sensor.
Step 42

Attach the brake pad wear sensor wiring harness.
Step 43

Treat the surface where the brake disc contacts the wheel rim. Use ceramic grease.
Step 44

Clean the brake disk surface. Use a brake cleaner.
Step 45

Install the wheel.

AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. Mercedes W201
Step 46

Screw in the wheel bolts. Use wheel impact socket #17. Use a ratchet wrench.
Step 47

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 48

Remove the jacks and chocks.

AUTODOC recommends:
Without starting the engine, press the brake pedal several times until you feel significant resistance.Important! Replacement: brake discs – Mercedes W201. Check the brake fluid level in the reservoir and top up if necessary.
Step 49

Tighten the brake fluid reservoir cap.
Step 50

Close the bonnet.

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