Remove/install brake disk, brake caliper and brake pads of the front wheel brake - AR42.10-P-0225CV

MODEL 204.0 (except 204.077), 204.2 (except 204.277), 204.3 (except 204.377), 204.9 With split brake caliper support 

Illustrated on model 204.057 

Fig 1: Identifying Brake Caliper And Brake Pads Remove/Install Components - Illustrated On Model 204.057 (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Brake Caliper And Brake Pads Remove/Install Components - Illustrated On Model 204.057 (2 Of 2)

Courtesy of MERCEDES-BENZ USA

	Remove/install
	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
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Unscrew the cap on the brake fluid expansion reservoir and suction off some brake fluid
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
		In order to prevent the expansion reservoir overflowing when pressing back the brake pistons.
2	Remove wheels
			AP40.10-P-4050CW
3	Detach spring (1) from brake caliper (3)
4	Detach brake wear sensor (S10/2) from electrical connection (S10/2x1)	When removing the brake pads (5) on the right-hand side of the vehicle
5	Remove bolts (11) from the brake caliper support (2)	Guide pin, brake caliper to brake caliper support	*BA42.10-P-1004-10J
6	Remove brake caliper (3)	Do not tension or kink brake hose (4). To relieve the load on the brake hose (4), fasten the brake caliper (3) to the vehicle free of tension. Otherwise the brake hose (4) will be damaged. Do not detach brake hose (4). Route brake wear sensor (S10/2) through opening of brake caliper (3).
7	Take out brake pads (5)	Insert inner brake pad (5) with riveted-on spring in brake piston. Detach protective foil from the outer brake pad (5) and glue into the brake caliper (2) (arrow). Only complete sets of brake pads (5) approved by Mercedes-Benz may be installed. Do not apply brake pastes or lubricants to the brake pads (5) and brake calipers (3)! Brake pads (5) are to be disposed of as special waste. The local authorities can provide information regarding whether disposal is also permitted as industrial waste similar to domestic waste.
	Measure
8	Check brake pads (5) and brake disk (7) for condition and measure wear
		Check brake lining thickness	AP42.10-P-4253A
		Inspect condition of brake disks Inspect condition of brake disks.	AP42.10-P-4258CW
9	Check brake caliper (3) and dust boot (8) on brake piston for damage	If damaged, replace brake caliper (3).
10	Check seal boots (9) for damage and correct seat as well as guide sleeve (10) for ease of movement	Assembly cleaner If there are problems: ↓ Remove/install guide sleeve and seal boot	*BR00.45-Z-1028-04A
			AR42.10-P-0225-01CV
11	Press back brake piston using pusher tool (01)	If brake piston is sluggish, replace brake caliper (3).
		Resetting device	Fig 3
	Clean
12	Clean contact surfaces of brake pads (5) on brake caliper (3) and brake caliper support (2)	In the process do not damage the dust boot (8) on the brake piston. Do not use sharp-edged or pointed objects. Otherwise the brake caliper (3) or brake caliper support (2) will be damaged. The adhesive remains on the contact surfaces of the brake pad (5) and brake caliper (3) must be removed completely.
		Assembly cleaner	*BR00.45-Z-1028-04A
13	Pull brake wear sensor (S10/2) out of pad backing plate of brake pad (5)	When removing the brake pads (5) on the right-hand side of the vehicle
	Notes on installing brake wear indicator contact sensors		AH42.10-P-0003-01CW
		Replace defective brake wear sensor (S10/2).
	Only perform steps 14 and 15 when removing/installing the brake caliper (3)
14	Remove bolt (6) and electrical connection (S102x1) from the brake caliper (3)	Bolt, brake pad contact sensor on brake caliper	*BA42.10-P-1002-10J
15	Detach brake hose (4) from brake caliper (3)		AR42.10-P-0013CW
	Only carry out steps 16 and 17 when removing/installing the brake disk (7)
16	Unscrew bolts (12) from the brake caliper support (2) and remove	Self-locking bolt, brake caliper to steering knuckle	*BA42.10-P-1001-10J
17	Remove security bolt (13) on the front wheel hub and remove brake disk (7)	Locking bolt, brake disk of front axle to wheel hub	*BA42.10-P-1002-06H
18	Install in the reverse order
	Risk of accident  when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work.	Before starting the engine, actuate brake pedal several times until pressure is built up and maintained in the brake system.	AS42.50-Z-0002-01A
19	Operate the brake pedal several times until the brake pads (5) abut the brake disks (7)	Firm resistance should be noticeable at the brake pedal.
20	Check fluid level in brake fluid reservoir, and correct if necessary
			AP42.10-P-4210EW
21	Carry out brake test on the test stand
		MODEL 204	AP42.00-P-4290BA

Fig 3: Identifying Resetting Device (000 589 52 43 00)

Courtesy of MERCEDES-BENZ USA