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

MODEL 204.077/277/377 

MODEL 212.074/075/076/077/092/274/275/276/277/292 without CODE B07 (Ceramic brake system) 

MODEL 218.374/375/376/392/974/975/976/992 without CODE B07 (Ceramic brake system) 

Fig 1: Identifying Brake Disk, Brake Caliper And Brake Pads Of Front Wheel Brake Remove/Install Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Brake Disk, Brake Caliper And Brake Pads Of Front Wheel Brake Remove/Install Components (2 Of 2)

Courtesy of MERCEDES-BENZ USA

	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
	Risk of injury  . Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Brake fluid notes		AH42.50-P-0001-01A
	Remove/install
1	Unscrew the cap on the brake fluid expansion reservoir and suction off some brake fluid	In order to prevent the expansion reservoir overflowing when pressing back the brake pistons.
2	Remove the front wheels
		MODEL 204	AP40.10-P-4050CW
		MODEL 212, 218 Turn if necessary.	AP40.10-P-4050EW
	Check
3	Check condition of brake disks (61)
		MODEL 204	AP42.10-P-4258CW
		MODEL 212, 218 Replace brake disks (61) as a set only.	AP42.10-P-4258EW
4	Check brake lining thickness
			AP42.10-P-4253A
		Check to ensure that the brake pads (43) have not worn beyond the permissible wear limit. Otherwise the bar between the sealing groove and the dust cap may be damaged. Replace brake pads (43) as a set only. ↓ Check brake system for leaks using pressure tester:
		MODEL 204	AR42.10-P-0015CW
		MODEL 212, 218	AR42.10-P-0015EW
	Only carry out operation steps 5 to 12 when removing/installing the brake pads (43)
5	Disconnect electrical connector of right front brake wear sensor (S10/2x1)
	Notes on installing brake wear indicator contact sensors		AH42.10-P-0003-01CW
		Only fitted on the right-hand side.
6	Remove bolt (30) and remove support (33) of retaining spring (31d)	Bolt for anti-rattle spring support	*BA42.10-P-1006-10J
7	Drive out retaining pins (41) using punch and remove retaining spring (31d)	Hammer in retaining pins (41) as far as the end stop. Ensure that retaining spring (31d) is correctly seated. Replace retaining pins (41) if necessary.
8	Pull brake pads (43) out of brake caliper (31a)	Brake pads (43) 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. Only complete sets of brake pads (43) approved by Mercedes-Benz may be installed. Do not apply brake pastes or lubricants to the brake pads (43) and brake calipers (31a).
9	Press back brake piston using resetting device	Secure remaining brake pistons to prevent them slipping out. If the brake pistons are sluggish replace brake caliper (31a).
		Resetting device	Figure
		Wedge	Fig 3
	Check
10	Check brake caliper (31a) for leaks and dust boot for damage	MODEL 204	AR42.10-P-0015CW
		MODEL 212, 218 Replace dust boot or brake caliper (31a) if necessary.	AR42.10-P-0015EW
	Clean
11	Clean contact surfaces of brake pads (43) on brake caliper (31a)	Do not use sharp-edged or pointed tools to clean. Otherwise damage may occur if not observed.
		Assembly cleaner	*BR00.45-Z-1028-04A
12	Pull right front brake wear sensor (S10/2) out of pad backing plate of brake pad (43)	Replace the defective right front brake wear sensor (S10/2). Only fitted on the right-hand side.
	Only carry out steps 13 to 17 when removing/installing the brake caliper (31a)
13	Detach brake hose from brake caliper (31a)	MODEL 204	AR42.10-P-0013CW
		MODEL 212, 218 Seal connections immediately. Otherwise damage can be caused by escaping brake fluid.	AR42.10-P-0013EW
		Record plug	Figure
14	Remove screw/bolt (31e) for right front brake wear sensor electrical connector (S10/2x1)	Replace bolt (31e). Only fitted on the right-hand side.
		Bolt, brake wear sensor to brake caliper	*BA42.10-P-1002-10J
15	Remove bolts (35) from steering knuckle and remove brake caliper (31a)	Replace bolts (35).
		Bolt, brake caliper/brake caliper support to steering knuckle	*BA42.10-P-1001-10J
16	Bleed brake system	MODEL 204	AR42.10-P-0010CW
		MODEL 212, 218	AR42.10-P-0010EW
17	Check brake system for leaks		AR42.10-P-0100-01V
	Only carry out steps 18 to 21 when removing/installing the brake disks (61)
18	Remove bolts (35) from steering knuckle and remove brake caliper (31a)	Do not detach the brake hose, but fasten the brake caliper (31a) to the vehicle free of tension. Do not tension or kink brake hose. Otherwise it will be damaged. Replace bolts (35).
19	Remove locking bolts (64) and detach brake disks (61)	Install new locking bolts (64).
		Locking bolt, brake disk of front axle to wheel hub	*BA42.10-P-1002-06H
	Clean
20	Clean contact surfaces and snug fits of brake disks (61)
21	Grease snug fits of brake disks (61) lightly	Paste, hot lubrication 1 kg, DBL 6879.20	*BR00.45-Z-1005-06A
22	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
23	Operate the brake pedal several times until the brake pads (43) abut the brake disks (61)	Firm resistance should be noticeable at the brake pedal.
	Check
24	Inspect fluid level in expansion reservoir, adjust to correct level if necessary
			AP42.10-P-4210EW
25	Carry out brake test on the test stand
			AP42.00-P-4290BA

Fig 3: Identifying Wedge (601 589 07 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Resetting Device (000 589 52 43 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA