Important!
This replacement procedure can be used for:
MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194), MERCEDES-BENZ VITO Box (638) 112 CDI 2.2 (638.094), MERCEDES-BENZ V-Class (W638/2) V 200 CDI (638.294)

The steps may slightly vary depending on the car design.

How to replace front brake pads on MERCEDES-BENZ VITO 1 (W638) [TUTORIAL AUTODOC]

Required tools:
Required tools:
Wire brush
WD-40 spray
Brake cleaner
Anti-squeal paste
Copper grease
Drive socket # 13
Wheel impact socket #17
Brake caliper wind back tool
Ratchet wrench
Torque wrench
Flat Screwdriver
Crow bar
Wheel chock
AUTODOC recommends:
  • Perform the replacement of brake pads in complete set for each axis. This provides effective braking.
  • The replacement procedure is identical for all brake pads on the same axle.
  • All work should be done with the engine stopped.
Carry out replacement in the following order:
  1. How to change Brake Pads on Mercedes W638 Minibus 1996 - free PDF and video manuals
    How to replace MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194) 1997 Brake Pads - step-by-step manuals and video guides
    Step 1.1
    Open the bonnet.
    Step 1.2
    Unscrew the brake fluid reservoir cap.
  2. Mercedes W638 Minibus 108 CDI 2.2 (638.194) 1998 Brake Pads replacement: free workshop manuals
    Step 2
    Secure the wheels with chocks.
  3. Changing Brake Pads on MERCEDES-BENZ VITO Bus (638) 110 CDI 2.2 (638.194) 1999 by yourself
    Step 3
    Loosen the wheel mounting bolts.Use wheel impact socket #17.
  4. How to remove MERCEDES-BENZ VITO 108 D 2.3 (638.164) 2000 Brake Pads - online easy-to-follow instructions
    Step 4
    Raise the front of the car and secure on supports.
  5. How to replace Brake Pads on MERCEDES-BENZ VITO Bus (638) 2001: download PDF manuals and video instructions
    Step 5
    Unscrew the wheel bolts.
    AUTODOC recommends:
    To avoid injury, hold up the wheel when unscrewing the bolts.
  6. How hard is it to do yourself: Brake Pads replacement on Mercedes W638 Minibus 113 2.0 (638.114, 638.194) 2002 - download illustrated guide
    Step 6
    Remove the wheel.
  7. Need to know how to renew Brake Pads on MERCEDES-BENZ VITO ? This free workshop manual will help you to do it yourself
    Step 7
    Spread the brake pads.Use a crowbar.
  8. Changing of Brake Pads on Mercedes W638 Minibus 1996 won't be an issue if you follow this illustrated step-by-step guide
    Step 8
    Clean the brake caliper fasteners. Use a wire brush.Use WD-40 spray.
  9. MERCEDES-BENZ VITO 108 CDI 2.2 (638.194) Brake Pads replacement: online guides and video tutorials
    Step 9
    Unscrew the brake caliper fastening.Use a drive socket #13.Use a ratchet wrench.
  10. Replacing Brake Pads on Mercedes W638 Minibus 1998 112 CDI 2.2 (638.194) by yourself
    Step 10
    Remove the brake caliper.
    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. Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.
  11. VITO Bus (638) 108 D 2.3 (638.164) 1999 Brake Pads DIY replacement workshop manual
    Step 11
    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. How to change Brake Pads on MERCEDES-BENZ VITO Bus (638) 2000 - tips and tricks
    Step 12
    Remove the brake pads.
    AUTODOC recommends:
    Measure the brake disc thickness. Upon reaching the wear limit the part must be replaced.
  13. Step-by-step recommendations for DIY replacement Mercedes W638 Minibus 2001 108 D 2.3 (638.164) Brake Pads
    Step 13
    Clean the brake caliper bracket from dirt and dust.Use a wire brush.Use a brake cleaner.
    AUTODOC recommends:
    After applying the spray, wait a few minutes.
  14. DIY replacement of Brake Pads on MERCEDES-BENZ VITO Bus (638) 110 TD 2.3 (638.174) 2002 is not an issue anymore with our step-by-step tutorial
    Step 14
    Treat the brake caliper piston.Use WD-40 spray.
  15. How to change Brake Pads on Mercedes W638 Minibus 1996 - free PDF and video manuals
    Step 15
    Press in the brake caliper piston.Use brake caliper wind back tool.
  16. How to replace MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194) 1997 Brake Pads - step-by-step manuals and video guides
    Step 16
    Treat the brake caliper bracket where it contacts the brake pads.Use anti-squeal paste.
    AUTODOC recommends:
    Make sure the disc surface is clean before installing the pads.
  17. Mercedes W638 Minibus 108 CDI 2.2 (638.194) 1998 Brake Pads replacement: free workshop manuals
    Step 17
    Install new brake pads.
    AUTODOC recommends:
    Make sure the pads are installed with linings facing the disc.
  18. Changing Brake Pads on MERCEDES-BENZ VITO Bus (638) 110 CDI 2.2 (638.194) 1999 by yourself
    Step 18
    Install the brake caliper and fix it.Use a drive socket #13.Use a torque wrench.Tighten it to 35 Nm torque.
  19. How to remove MERCEDES-BENZ VITO 108 D 2.3 (638.164) 2000 Brake Pads - online easy-to-follow instructions
    Step 19
    Connect the brake pad wear sensor plug.
  20. How to replace Brake Pads on MERCEDES-BENZ VITO Bus (638) 2001: download PDF manuals and video instructions
    Step 20
    Clean the brake disk surface.Use a brake cleaner.
    AUTODOC recommends:
    After applying the spray, wait a few minutes.
    Step 21
    Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
  21. How hard is it to do yourself: Brake Pads replacement on Mercedes W638 Minibus 113 2.0 (638.114, 638.194) 2002 - download illustrated guide
    Step 22
    Install the wheel.
    AUTODOC recommends:
    To avoid injury, hold up the wheel when screwing in the fastening bolts.
  22. Need to know how to renew Brake Pads on MERCEDES-BENZ VITO ? This free workshop manual will help you to do it yourself
    Step 23
    Screw in the wheel bolts.Use wheel impact socket #17.
  23. Changing of Brake Pads on Mercedes W638 Minibus 1996 won't be an issue if you follow this illustrated step-by-step guide
    Step 24
    Lower the car and working in a cross order, tighten the wheel bolts.Use a torque wrench.Tighten it to 120 Nm torque.
  24. MERCEDES-BENZ VITO 108 CDI 2.2 (638.194) Brake Pads replacement: online guides and video tutorials
    Step 25
    Remove the jacks and chocks.
    AUTODOC recommends:
    Check the brake fluid level in the expansion tank and refill if necessary.
  25. Replacing Brake Pads on Mercedes W638 Minibus 1998 112 CDI 2.2 (638.194) by yourself
    Step 26
    Tighten the brake fluid reservoir cap.
    AUTODOC recommends:
    Without starting the engine, press the brake pedal several times until you feel significant resistance.
  26. VITO Bus (638) 108 D 2.3 (638.164) 1999 Brake Pads DIY replacement workshop manual
    Step 27
    Close the hood.
    AUTODOC recommends:
    Slow down smoothly for first 150-200 km after the brake pads replacement. Avoid unneccessary and sharp braking to a stop.
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