Testing Repairs

2003 Mercedes-Benz SLK320
1998-2004 TRANSMISSION Brakes - Testing & Repair - 170 Chassis
1998-2004 TRANSMISSION
Brakes - Testing & Repair - 170 Chassis
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: BRAKES - HYDRAULIC AND
MECHANICAL SYSTEMS - AR42.00-Z-9170AA
MODEL 170
AR42.10-P-
Bleed brake system MODEL 129, 140, 170, 202, 208, 210
0010A
AR42.10-P-
Replacing brake hoses MODELS 129, 140, 170, 202, 208, 210
0013A
Test brake system with pressure tester MODEL 129, 140, 170, 202, 203, 208, 210, AR42.10-P-
for leaks 209.3 /4 0015A
Removing and installing mechanical AR42.10-P-
MODELS 129, 140, 170, 202, 208, 210
stop lamp switch 0040A
AR42.10-P-
Remove/install front axle brake caliper MODEL 170, 202, 208, 210 ...
0070BM
AR42.10-P-
Remove/install front axle brake caliper MODEL 170, 202, 208, 210 ...
0070DM
Removing and installing rear brake MODELS 129, 140, 170, 202, 208, 210 except AR42.10-P-
caliper CODE (957a) AMG engineering package 0080AM
AR42.10-P-
Repairing fixed caliper on rear axle MODELS 129, 140, 170, 202, 208, 210
0151A
AR42.10-P-
Repairing floating caliper on front axle MODEL 170, 202, 208, 210 ...
0152B
AR42.10-P-
Remove/install brake disc MODEL 129, 140, 170, 202, 208, 210
0220A
AR42.10-P-
Cleaning brake discs with cleaning pads MODEL 129, 140, 170, 202, 208, 210
0260A
Removing and installing stepped tandem AR42.10-P-
MODELS 129, 140, 170, 202, 208, 210
master brake cylinder 0310A
Remove/check/install front axle brake AR42.10-P-
MODEL 170, 202, 208, 210 ...
pads 1600BM
Remove/check/install front axle brake AR42.10-P-
MODEL 170, 202, 208, 210 ...
pads 1600CM
Removing, checking and installing rear AR42.10-P-
MODEL 129, 140, 170, 202, 208, 210
axle brake pads 1700AM
Removing and installing hand brake AR42.20-P-
MODEL 170
lever 0500A
Removing and installing rear brake MODELS 129, 140, 170, 202, 208, 210 AR42.20-P-
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9:08:04 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
control cable 0525A

Removing and installing brake shoes of MODEL 129, 140, 170, 202, 203, 208, AR42.20-P-
parking brake 209.3 /4, 210 0530A
MODEL 129, 170, 202, 203, 208, 210
AR42.20-P-
Adjust parking brake MODEL 140 as from 1.11.93 MODEL 209.3/
0540A
4
Removing and installing front left or AR42.30-P-
MODELS 129, 140, 170, 202, 203, 208, 210
right rpm sensor 0712A
Removing and installing rear axle speed MODEL 170, 202 with CODE (470a) Anti- AR42.30-P-
sensor lock brake system (ABS) 0714A
Removing and installing BAS control MODEL 129, 140 as of 1.12.96, 170, 202 as of AR42.31-P-
module 1.6.97, 208, 210 as of 1.2.97 6001A
Removing and installing BAS MODEL 129, 140 as of 1.12.96, 170, 202 as of AR42.31-P-
diaphragm travel sensor 1.6.97, 208, 210 as of 1.2.97 6002A
Removing and installing ETS/ASR/ESP AR42.40-P-
MODEL 129, 140, 170, 202, 208, 210 ...
hydraulic unit 0816A
Removing and installing ETS/ASR/ESP AR42.40-P-
MODEL 170, 202, 208 ...
hydraulic unit 0816B
Remove/install left or right rear axle MODEL 129, 140, 170, 202, 203, 208, 209, AR42.40-P-
speed sensor 210 ... 0820A
BLEED BRAKE SYSTEM. - AR42.10-P-0010A
MODEL 129, 140, 170, 202, 208, 210
Fig. 1: Bleeding Brake System
MODIFICATION NOTES
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Friday, October 30, 2009 9:08:04 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.
19.10.00 Value changed from 4 to Value in BA42.10-P- *BA42.10-P-1002-03A

7 Nm 1002-03A changed for
models 202.033/093,
208.374, 210.072 with
code 957 (E50 AMG),
210.074/274
Bleeding
Risk of poisoning from Pour brake fluid only into AS42.50-Z-0001-01A
swallowing brake fluid. suitable and appropriately
Risk of injury from marked containers. Wear
brake fluid coming into protective clothing and eye
contact with skin and protection when handling
eyes. brake fluid.
Brake fluid notes AH42.50-P-0001-01A
Notes on repairs to brake AH42.00-P-0003-01A
system
1 Actuate master brake Models 129.076, AR42.10-P-0010-01A
cylinder switchover 140.04/05/06/07
valve (Y61)
Electrical connection set Fig. 6
The switchover valve
(Y61) must be open so that
the annular passage in
master brake cylinder is
bled.
Wiring harness for Model 129.067 with ESP WF58.50-P-4210-01A
actuation of switchover
valve
2 Connect filling and Pay attention to *WE58.40-Z-1001-07A
bleeding device manufacturer's operating
instructions.
Bleeding pressure 2bar
Brake fluid *BF42.10-P-1001-01A
3 Carrying out bleeding Models 129, 140 without AR42.10-P-0010-02A
operation ASR (code 471a), without
ESP (code 472)
Models 129, 140 with ASR
(Code 471a) and ETS as of
1. 6. 94
Models 129.059/064/068
with/without ESP with
engines 112, 113
Model 170
Model 202 without ASR
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(Code 471a) up to 31.5.94

Model 202 with ASR (code
471a) as of 1.6.94
Model 202 with ESP
Model 208
Model 210 without ESP,
model 210 with ESP,
except model 210.072/272
with ESP
Socket wrench Fig. 4
Bleed screw on *BA42.10-P-1002-02A
front axle fixed caliper
front axle floating caliper
Bleed screw on rear *BA42.10-P-1002-01A
axle fixed caliper
Model 129 with ASR AR42.10-P-0010-02B
(Code 471a) up to 31.5.94
axle fixed caliper
Model 140 with ASR (code AR42.10-P-0010-02C
471a) up to 31.5.94
axle fixed caliper
Model 202 with ASR (code AR42.10-P-0010-02D
471a) up to 31.5.94
axle fixed caliper
Models 129.067/076, 140 AR42.10-P-0010-02E
with ESP, model
210.072/272 with ESP
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axle fixed caliper
4 Disconnect filler and Brake fluid *BF42.10-P-1001-01A
bleeder unit, check brake
fluid level and correct if
necessary
FIXED CALIPER AT REAR

Number Designation Model 129.05/06 Model 129.068/ Model 140
0/061/063/ 076
064/066/ 067
BA42.10-P- Bleed screw on NM 7 7 7
1002-01A rear axle fixed
caliper

Number Designation Model 170.435/ Model 170.466 Models 202.01/020/
444/445/ 022/023/024/
447/449/ 465 025/026/029/
078/08/12/13/ 18/19,
202.028 without
ASR
BA42.10-P- Bleed screw on NM 7 7 7
1002-01A rear axle fixed
caliper

Number Designation Models 202.028 Model 208.335/
with ASR, 344/345/347/
202.033/093 348/365/370/
374/435/444/
445/447/448/
465/470
BA42.10-P-1002- Bleed screw on rear NM 7 7
01A axle fixed caliper

Number Designation Models 210.00/01/ Model 210.20/21/ Models
02/03/04/05/06/ 22/23/24/26/ 210.274
070/072/074/08 270/272/28/60/
61/663
BA42.10-P- Bleed screw NM 7 7 7
1002-01A on rear axle
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fixed caliper
FRONT AXLE FIXED CALIPER

Number Designation Model 129 Model 140 Model 202.028
with Code 957
(C 36 AMG)
BA42.10-P- Bleeder screw at NM 7 7 7
1002-02A fixed caliper of
front axle
FRONT AXLE FIXED CALIPER

Number Designation Model Model 210.055 Model 210.072/270/272
208.370/ 470 with Code 957 up to 07.02.99, model
up to 18.01.99 (E 36 AMG) 210.070 up to 07.02.99
except except
BA42.10-P- Bleeder screw NM 7 7 7
1002-02A at fixed caliper
of front axle
FRONT AXLE FLOATING CALIPER

Number Designation Model 170.435/ Model 170.466
444/445/ 447/449/
465
BA42.10-P-1002- Bleed screw on NM 7 7
03A front axle floating
caliper

Number Designation Models Models 202.024/025/02
202.018/020/ 6/029/082/085/
022/023/078/ 086/088/089/ 128/188,
080/081/083/ 202.028 as of 09/95
087/120/121/
122/125/133/
134/180/182/
193/194, 202.028 up
to 08/95
caliper

Number Designation Model 202.033/093, Models 208.335/344/34
208.374, 210.072 5/347/348/365/
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with Code 957 435/444/445/

(E50 AMG), 447/448/465,
210.074/274 208.370/470
caliper

Number Designation Model 208.370/470 Model 210.00/01/
as of 19.01.99, 02/035/037/04/
except 05/06/08/20/21/
22/23/24/26/28/
60/61/663, except model
210.083/283 as of
08.02.00 Model 210.070

caliper

Number Designation Model 210.083/270/ 283
as of 08.02.99, model
210.070 as of 08.02.99
except
BA42.10-P-1002-03A Bleed screw on front axle NM 7
floating caliper
BRAKE FLUID
Number Designation Model 129 Model 140 Model 170
BF42.10-P- Brake fluid Filling quantity Liters approx. 0,45- approx. 0.7- approx. 0,45-
1001-01A 0,6 0.9 0,6
Specifications for Sheet BB00.40-P- BB00.40-P- BB00.40-P-
Operating Fluids 0330-01A 0330-01A 0330-01A
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0331-00A 0331-00A 0331-00A
BRAKE FLUID
BF42.10-P- Brake fluid Filling quantity Liters approx. 0,45- approx. 0,45- approx. 0,45-
1001-01A 0,6 0,6 0,6
Specifications for Sheet BB00.40-P- BB00.40-P- BB00.40-P-
Operating Fluids 0330-01A 0330-01A 0330-01A
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
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0331-00A 0331-00A 0331-00A
Fig. 2: Identifying Electrical Connection Set (201 589 00 99 00)
Fig. 3: Identifying Socket Wrench (140 589 03 09 00)
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1036-13A Handheld tester (HHT) 651 100 01 99
WH58.30-Z-1037-13A Test cable (multiplexer) 651 100 40 99
WORKSHOP EQUIPMENT
WE58.40-Z-1001-07A Brake fluid replacement unit
Risk of poisoning; Risk of injury - AR42.10-P-0010-02A
Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and
eye protection when handling brake fluid.

Number Designation Model 129.05/06 Model Model 140
0/061/063/064/066/067 129.068/076
BA42.10-P- Bleed screw Nm 7 7 7
1002-01A on rear axle
fixed caliper
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Number Designation Model Model Model

170.435/444/445/447/449/465 170.466 202.01/020/022/023/024/
025/026/029/
078/08/12/13/ 18/19,
202.028 without ASR
BA42.10- Bleed Nm 7 7 7
P-1002- screw on
01A rear axle
fixed
caliper

Number Designation Model 202.028 Model 208.335/
with ASR, 344/345/347/
202.033/093 348/365/370/
374/435/444/
445/447/448/
465/470
BA42.10-P-1002- Bleed screw on rear Nm 7 7
01A axle fixed caliper

Number Designation Model Model 210.20/21/ Model
210.00/01/02/03/04/05/06/ 22/23/24/26/270/272/28/60/61/663 210.274
070/072/074/08
BA42.10- Bleed Nm 7 7 7
P-1002- screw on
01A rear axle
fixed
caliper
FRONT AXLE FIXED BRAKE CALIPER

with Code 957
(C 36 AMG)
BA42.10-P- Bleed screw at Nm 7 7 7
1002-02A front axle fixed
brake caliper

Number Designation Model Model Model 210.072/270/272
208.370/470 up 210.055 with up to 07.02.99, model
to 18.01.99 Code 957 (E 210.070 up to 07.02.99
except 36 AMG) except
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1002-02A front axle
fixed brake
caliper

Number Designation Model 170.435/444/445/447/449/465 Model 170.466
BA42.10-P- Bleed screw on Nm 7 7
1002-03A front axle
floating caliper

Number Designation Model 202.018/020/ Model 202.024/025/02
022/023/078/ 6/029/082/085/
080/081/083/ 086/088/089/ 128/188,
087/120/121/ 202.028 as of 09/95
122/125/133/
134/180/182/
193/194, 202.028 up
to 08/95
BA42.10-P-1002- Bleed screw on Nm 7 7
caliper

Number Designation Model 202.033/093, Model 208.335/344/34
208.374, 210.072 5/347/348/365/
with code 957 (E50 435/444/445/
AMG), 210.074/274 447/448/465,
208.370/470
caliper

from 19.01.99, 02/035/037/04/
except 05/06/08/20/21/
22/23/24/26/28/
60/61/663, except model
210.083/283 as of
08.02.00 Model 210.070

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caliper

Number Designation Model 210.083/270/ 283
as of 08.02.99, model
210.070 as of 08.02.99
except
BA42.10-P-1002-03A Bleed screw on front axle Nm 7
floating caliper
Fig. 4: Identifying Socket Wrench (140 589 03 09 00)
1. Open bleed screw on brake caliper (1) and, with a pressure of bar applied to the system, continue until
roughly 80 cm 3 of bubble-free brake fluid emerges.
2. Close bleed screw on brake caliper (1).
3. Model 140 only: Open bleed screw (b) on master brake cylinder, allow bubble-free brake fluid to emerge,
then reclose.
4. Repeat bleeding operation at brake calipers (2, 3, 4).
Allow fluid to flow at each brake caliper (2, 3, 4)
until roughly 80 cm3 emerges free of bubbles.
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Fig. 5: Bleeding Brake Caliper
Fig. 6: Identifying Electric Connector Set (201 589 00 99 00)
REPLACING BRAKE HOSES - AR42.10-P-0013A
MODELS 129, 140, 170, 202, 208, 210
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Fig. 7: Identifying Brake Hoses
MODIFICATION NOTES
29.7.99 BA42.10-P-1001-04A
changed from 18 Nm to
14 Nm for model 210
Removing, installing
Risk of injury from skin marked containers. Wear
and eye contact with protective clothing and eye
brake fluid protection when handling
brake fluid.
Notes on brake fluid AH42.50-P-0001-01A
system
Notes on installation of AH42.10-P-9406-01A
brake hoses
1 Unscrew brake line (5) Seal connections
from brake hose (51) immediately with plugs.
Brake fluid reservoir must
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not empty completely.

Box wrench bit Fig. 8
Brake line (5) to *BA42.10-P-1001-04A
brake hose (51)
Brake hose connection at Models 129, 140, 202, 210 BT42.10-P-0001-01A
brake line modified ab 09.95
The two versions are
not interchangeable.
2 Detach brake hose clip Models 140, 202 (front
(51a) from front axle axle)
3 Unscrew brake hose (51) Box wrench Fig. 9
from fixed or floating
caliper
Model 170: Pull out
brake hose through rubber
grommet on bracket.
Installation: Model
210 (front axle): Fasten
cable for wear indicator
onto brake hose (51) with
bracket.
Brake hose to fixed *BA42.10-P-1002-04A
or floating caliper
4 Install in the reverse
order
5 Bleed brake system AR42.10-P-0010A
BRAKE LINES, BRAKE HOSES

Number Designation Model 129 Model 140 Model 202 Model 210
BA42.10-P- Brake line to Nm 14 14 14 14
1001-04A brake hose
BA42.10-P- Brake hose to Nm 18 18 18 18
1002-04A fixed or
floating
caliper

Number Designation Model 170 Model 208
BA42.10-P-1001- Brake line to brake Nm 14 14
04A hose
BA42.10-P-1002- Brake hose to fixed Nm 18 18
04A or floating caliper
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Fig. 8: Identifying Box Wrench Bit (000 589 75 03 00)
Fig. 9: Identifying Box Wrench (000 589 76 03 00)
TEST BRAKE SYSTEM WITH PRESSURE TESTER FOR LEAKS - AR42.10-P-0015A
MODEL 129, 140, 170, 202, 203, 208, 210, 209.3 /4
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Fig. 10: Testing Brake System With Pressure Tester For Leaks
Check
Risk of poisoning caused Pour brake fluid only into AS42.50-Z-0001-01A
by swallowing brake suitable and appropriately
fluid. Risk of injury marked containers. Wear
caused by brake fluid protective clothing and
coming into contact with eye protection when
skin and eyes. handling brake fluid.
Notes on externally AH42.10-P-9406-02A
invisible brake fluid loss
system
Notes on handling brake AH42.50-P-0001-01A
fluid
Risk of death caused by Align vehicle between AS00.00-Z-0010-01A
vehicle slipping or the columns of the lifting
toppling off of the lifting platform and position the
platform. four support plates below
the lifting platform
support points specified
by the vehicle
manufacturer.
1 Lift/jack up vehicle Except model 203, AR00.60-P-1000P
209.3/4
Model 203, 209.3/4
2 Unscrew bleed screw at Pressure testers (051)
brake caliper and connect for hydraulic oil systems
pressure tester (051) must not be used for
systems with brake fluid
otherwise the brake fluid
is mixed with mineral oil
which can lead to failure
of the brake.
Pressure tester *WH58.30-Z-1012-15A
3 Bleed pressure tester *WH58.30-Z-1012-15A
(051).
4.1 Switch off easy entry/exit On vehicles with memory
function for driver seat and multifunction
and steering wheel steering wheel.
Otherwise the driver's
seat and steering wheel
move to a different
position, e.g. when the
driver door is
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opened/closed. The seat

may be damaged when
the brake pedal jack (080)
is installed.
See Operator's Manual
High-pressure check
5 Produce vacuum for the Allow the engine to
brake booster run at moderate speed
and by jerkily releasing
the accelerator pedal,
produce as high a vacuum
as possible.
6 Insert brake pedal jack Protect brake pedal
(080) between the brake and seat against damage.
pedal and seat
Brake pedal jack Fig. 11
7 Depress the brake pedal The pressure loss
as far as possible with the during the test duration of
brake pedal jack (080) 5 minutes must not
and observe the pressure exceed 5 % of the
drop regulated value.
Brake pedal winch Fig. 11
Low-pressure testing
8 Switch off engine and
operate brake pedal until
vacuum is reduced
9 Turn back brake pedal The line pressure must
winch (080) until a line not fall throughout the
pressure of approx. 3 bar duration of the test (2
overpressure is still minutes).
indicated on the pressure
gauge
Brake pedal winch Fig. 11
10 Disconnect pressure *WH58.30-Z-1012-15A
tester (051)
11 Bleed brake system Model 129, 140, 170, AR42.10-P-0010A
202, 208, 210
Model 203, 209.3/4 AR42.10-P-0010P
Only bleed the brake
caliper to which the
pressure tester (051) was
connected.
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with code 957
(C 36 AMG)
brake caliper

Number Designation Model 203.018/ Model 209.372/
065/076/ 087/092/ 375/376/ 377/472/
218/265/ 276/287/ 475/476/ 477
292/718, Model 203
with code 949/950
BA42.10-P-1002- Bleed screw at front Nm 7 7
02A axle fixed brake
caliper

Number Designation Model Model 210.055 Model 210.072/270/272
208.370/ 470 with Code 957 up to 07.02.99, model
up to 18.01.99 (E 36 AMG) 210.070 up to 07.02.99
except except
brake caliper

Number Designation Model 170.435/ Model 170.466
444/445/ 447/449/
465
03A axle floating caliper

Number Designation Model 202.018/020/ Model 202.024/025/02
022/023/078/ 6/029/082/085/
080/081/083/ 086/088/089/ 128/188,
087/120/121/ 202.028 from 09/95
122/125/133/
134/180/182/
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193/194, 202.028 up
to 08/95
BA42.10-P-1002- Bleed screw at Nm 7 7
caliper

Number Designation Model 202.033/093, Models 203 except
208.374, 210.072 203.018/ 065/076/
with code 957 (E50 218/265/ 276/718
AMG), 210.074/274
03A axle floating caliper

Number Designation Model 208.335/344/345 /347/348/365/ Model
435/444/445/ 447/448/465, 208.370/470 208.370/470
from 19.01.99,
except
BA42.10-P- Bleed screw at Nm 7 7
1002-03A front axle
floating caliper

Number Designation Model 209
BA42.10-P-1002-03A Bleed screw at front axle Nm 7
floating caliper

Number Designation Model 210.00/01/ Model 210.083/270/
02/035/037/04/ 283 as of 08.02.99,
05/06/08/20/21/ model 210.070 as of
22/23/24/26/28/ 08.02.99 except
60/61/663, except
model 210.083/283 as
of 08.02.00 Model
210.070
BA42.10-P-1002- Bleed screw at Nm 7 7
caliper
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Fig. 11: Identifying Brake Pedal Winch (000 589 18 31 00)
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1012-15A Pressure tester (hydraulic single / dual circuit brake
systems)
REMOVING AND INSTALLING MECHANICAL STOP LAMP SWITCH - AR42.10-P-0040A
MODELS 129, 140, 170, 202, 208, 210
Fig. 12: Identifying Mechanical Stop Lamp Remove/Install Components
1 Remove cover below Model 129 ra68001290150x
instrument panel
Model 140 ra68001400150x
Model 170 AR68.10-P-1500G
Model 202 AR68.10-P-1500E
Model 208 AR68.10-P-1500K
Model 210 AR68.10-P-1500F
2 Unplug electrical
connector from stop
lamp switch (S9)
3 Press catch (S9b)
4 Turn and pull out stop
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lamp switch (S9), and Installation: Pull

adjust actuating pin (S9a) all
the way out.
Fully depress brake
pedal (24), insert stop
lamp switch (S9) and
turn until catch (S9b)
engages. The actuating
travel distance is set
automatically.
order
REMOVING AND INSTALLING FRONT BRAKE CALIPER - AR42.10-P-0070
Removing and installing front brake caliper - AR42.10-P-0070BM
MODEL 202.024 /025 /026 /029 /082 /085 /086 /088 /089 /128 /188
MODEL 170.435 /444 /445 /447 /449 /465, 208.335 /344 /345 /347 /348 /365 /435 /444 /445 /447 /448 /465,
210.00 /01 /02 /035 /037 /04 /053 /06 /081 /082, 210.083 up to 7.2.99, 210.20 /21 /22 /23 /24 /26 /282, 210.283
up to 7.2.99, 210.60 /61 /663
MODEL 210.070 with CODE (491) U.S. version with CODE (498) Japanese version with CODE (625)
Australian version
MODEL 208.370 /470 with CODE (491) U.S. version
MODEL 202.028 as of 1.9.95, 210.055 except CODE (957a) AMG engineering package
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Fig. 13: Identifying Front Brake Caliper Remove/Install Components - Model

170.435 /444 /445 /447 /449 /465
Modification notes
29.7.99 Value changed from 18 Value in BA42.10-P- *BA42.10-P-1001-04A
Nm to 14 Nm 1001-04A for model 210
changed.
29.7.99 Value changed from 30 Value in BA42.10-P- *BA42.10-P-1005-03A
Nm to 22 Nm 1005-03A for model 210
changed.
models 170, 202.
Fatal injuries are Align vehicle between the AS00.00-Z-0010-01A
possible if the vehicle columns of the lifting
slips off the lifting platform and position the
platform four support plates at the
lifting platform support
points specified by the
vehicle manufacturer.
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brake fluid.
system
brake hoses
1 Remove front wheels
AP40.10-P-4050Z
2 Disconnect brake hose Seal connections
(51) first from brake line immediately with plugs.
(5) and then from Brake fluid reservoir must
floating caliper (31a) not empty completely.
Box wrench for brake Fig. 8
line
hose
brake hose (51)
Brake hose to *BA42.10-P-1002-04A
floating caliper
Brake hose connection at Models 202, 210 ab 09.95 BT42.10-P-0001-01A
brake line modified The two versions are
3 Unplug contact sensor Depending on number
(S10/1) from brake pad of plug contacts, install
contact sensor connector one or two contact sensors
(S10/1x1) at each wheel.
Arrangement of wear
sensors for:
Lucas floating caliper: on
outer brake pad.
Teves floating caliper: on
inner brake pad.
On model 202
and taxi version as of
09.95 one contact sensor is
installed.
Notes on installing AH42.10-P-0003-01A
contact sensor for brake
lining wear indicator
4 Unscrew brake pad Installation: Replace
contact sensor connector micro-encapsulated bolt
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(S10/1x1) from floating (31e).

caliper (31a)
*BA42.10-P-1005-03A
5 Unscrew bolts (35) Installation: Replace
self-locking bolt.
*BA42.10-P-1001-03A
6 Remove floating caliper
(31a) together with
caliper support
order
9 Check brake system for AR42.10-P-0100-01A
leaks
Front axle floating caliper

Number Designation Model Models 202.024/025/02
170.435/ 6/029/082/085/
444/445/ 086/088/089/ 128/188,
447/449/ 465 202.028 as of 09/95
BA42.10-P- Self-locking Nm 115 115
1001-03A bolt, brake
caliper support
to steering
knuckle
BA42.10-P- Self-locking M6 Nm 8 -
005-03A bolt, brake pad
contact sensor
to floating M8 Nm 22 22
caliper

Number Designation Models Model 210.00/01/
208.335/344/345 /347/348/365/ 02/035/037/04/
435/444/445/ 447/448/465, 05/06/08/20/21/
208.370/470 22/23/24/26/28/
60/61/663, except
model
210.083/283 as of
08.02.00 Model
210.070
BA42.10- Self- Nm 115 115

P-1001- locking
Microsoft
03A bolt, brake

caliper
support to
steering
knuckle
BA42.10- Self- M6 Nm - -
P-1005- locking
03A bolt, brake
pad contact
sensor to M8 Nm 22 22
floating
caliper
Brake lines, brake hoses

04A hose

04A hose
Microsoft
Removing and installing front brake caliper - AR42.10-P-0070DM
MODEL 202.033 /093, 210.072 /074 /274 with CODE (957a) AMG engineering package
MODEL 208.370 /470 as of 19.1.99 except CODE (491) U.S. version
MODEL 210.070 as of 8.2.99 except CODE (491) U.S. version except CODE (498) Japanese version
except CODE (625) Australian version
MODEL 170.466, 208.374, 210.083 /270 /283 as of 8.2.99
Shown on vehicle with CODE (957a) AMG engineering package
Fig. 16: Identifying Front Brake Caliper Remove/Install Components - Model 170.466
Microsoft
Modification notes
29.7.99 BA42.10-P-1001-04A
with model 210 value
changed from 18 Nm to
14 Nm, BA42.10-P-1005-
03A with model 210
value changed from 30
Nm to 22 Nm
and eye contact with protective clothing and
brake fluid eye protection when
handling brake fluid.
system
brake hoses
AP40.10-P-4050Z
2 Disconnect brake hose Seal connections AR42.10-P-0013A
(5) and then from floating Brake fluid reservoir
caliper (31) must not empty
completely.
line
hose
brake hose (51)
Brake hose (51) to *BA42.10-P-1002-04A
floating caliper
3 Detach spring (31d)
(arrows)
4 Unplug contact sensor
(S10/1) from brake pad
contact sensor connector
(S10/1x1)
Microsoft

5 Unscrew brake pad Installation: Replace
contact sensor connector micro-encapsulated bolt
(S10/1x1) from floating (31e).
caliper (31a)
*BA42.10-P-1005-03A
6 Pull covers (31b) off
guide pins (31c)
7 Unscrew guide pins (31c) *BA42.10-P-1004-03A
8 Remove floating caliper Installation : Insert
(31a) together with the inner brake pad into
brake pads piston of floating caliper.
Insert outer brake pad
into guide of frame and
install floating caliper.
order
leaks

Number Designation Model 170.466 Models
202.033/093,
208.374, 210.072
with code 957 (E50
AMG), 210.074/274
BA42.10-P- Guide pin, Nm 25 27
1004-03A floating caliper
to brake caliper
support
BA42.10-P- Self-locking M6 Nm 8 -
contact sensor
caliper

Number Designation Model Model
208.370/470 as of 210.083/270/ 283 as
19.01.99, except of 08.02.99, model
210.070 as of
08.02.99 except
Microsoft
BA42.10-P- Guide pin, Nm 27 27

to brake caliper
support
BA42.10-P- Self-locking M6 Nm - -
contact sensor
caliper

04A hose

04A hose
Microsoft
REMOVING AND INSTALLING REAR BRAKE CALIPER - AR42.10-P-0080AM
MODELS 129, 140, 170, 202, 208, 210 except CODE (957a) AMG engineering package
Fig. 19: Identifying Rear Brake Caliper Remove/Install Components
MODIFICATION NOTES
29.7.99 Tightening torque BA42.10-P-1001-01A BT42.10-P-0001-02A
changed for bolt, fixed changed for models 129, *BA42.10-P-1001-01A
caliper to wheel carrier 170, 208, 210.
(as of 10/97)
29.7.99 Tightening torque BA42.10-P-1001-04A *BA42.10-P-1001-04A
changed, brake line to changed from 18 Nm to
brake hose 14 Nm for model 210
models 202.028 with
ASR, 202.033/093.
Fatal injuries are Align vehicle between the AS00.00-Z-0010-01A
possible if the vehicle columns of the lifting
slips off the lifting platform and position the
platform four support plates at the
lifting platform support
Microsoft
points specified by the

vehicle manufacturer.
brake fluid.
system
brake hoses
AP40.10-P-4050Z
2 Disconnect brake hose Seal connections
(5) and then from fixed Brake fluid reservoir must
caliper (31) not empty completely.
line
hose
brake hose (51)
Brake hose to fixed *BA42.10-P-1002-04A
caliper
Brake hose connection at Models 202, 210 as of BT42.10-P-0001-01A
brake line modified 09.95
The two versions are
3 Unplug right rear brake Installation: Install
pad contact sensor contact sensor (S10/4) in
(S10/4) from brake pad transparent (temperature-
contact sensor connector resistant) version.
(S10/4x1) On model 202.028 with
ASR as of 09/95, the
contact sensor on the rear
fixed caliper is
discontinued.
4 Unscrew rear right brake
Microsoft
pad contact sensor

connector (S10/4x1)
5 Unscrew fixed caliper Installation: Replace
(31) from wheel carrier micro-encapsulated bolts
(35).
*BA42.10-P-1001-01A
order
leaks
REAR AXLE FIXED CALIPER

Number Designation Model 129.05/06 Model 129.068/ Model 140
0/061/063/ 076
064/066/ 067
BA42.10-P- Self-locking Nm 55 55 115
1001-01A bolt, fixed
caliper to wheel
carrier

Number Designation Model 170.435/ Model 170.466 Models 202.01/020/
444/445/ 022/023/024/
447/449/465 025/026/029/
078/08/12/13/ 18/19,
202.028 without
ASR
caliper to
wheel carrier

Number Designation Models 202.028 Model 208.335/
with ASR, 344/345/347/
202.033/093 348/365/370/
374/435/444/
445/447/448/
465/470
BA42.10-P-1001- Self-locking bolt, Nm 55 55
01A fixed caliper to
wheel carrier
Microsoft

Number Designation Model 210.00/01/ Model 210.20/21/ Model
02/03/04/05/06/ 22/23/24/26/ 210.274
070/072/074/08 270/272/28/60/
61/663
caliper to
wheel carrier

BA42.10-P- Brake line to Nm 14 14 14
1001-04A brake hose
BA42.10-P- Brake hose to Nm 18 18 18
1002-04A fixed or floating
caliper

1001-04A brake hose
BA42.10-P- Brake hose to Nm 18 18 18
1002-04A fixed or floating
caliper
Microsoft
REPAIRING FIXED CALIPER ON REAR AXLE - AR42.10-P-0151A
MODELS 129, 140, 170, 202, 208, 210
Fig. 22: Repairing Fixed Caliper On Rear Axle
1 Remove brake pads on fixed
caliper
2 Remove, install rear brake caliper Models 129, 140, 170, AR42.10-P-0080AM
202, 208, 210 except
CODE (957a) AMG
engineering package
Models 202.028 /033, AR42.10-P-0080BM
210.055,
202.093,208.374,
210.074 /274, 210.072
with CODE (957a) AMG
engineering package
Disassemble/assemble
3 Remove and replace heat shields
On fixed caliper with heat
shields.
Microsoft
4 Press off dust caps (45) Pliers

Installation: Use Fig. 23
pliers (026) and
appropriate plate (027).
5 Hold piston (47) in place with Resetting device Fig. 26
resetting device (031) and
carefully press out opposite
piston with compressed air
If piston has rusted
tight, replace fixed
caliper.
Installation: Coat
cylinder bore with brake
fluid.
Put dust cap (45) over
piston (47) and insert
into cylinder bore
together with piston.
Push in piston using both
hands.
Ensure correct
seating.
Check position of
piston (47) using
checking gauge (019).
Checking gauge Fig. 25
If necessary, correct Fig. 24
using pliers (020).
6 Remove piston seal from the Installation: Coat
groove in the cylinder bore new piston seal with
brake fluid.
7 Check and clean piston and
cylinder bore, and replace if
necessary
Notes on damage to piston or AH42.10-P-9406-
cylinder bore on fixed or floating 03A
caliper.
Test values for rear axle *BE42.10-P-1001-
fixed caliper ? 02A
Model 129
Model 140 *BE42.10-P-1001-
02B
Model 170 *BE42.10-P-1001-
02C
Model 202 *BE42.10-P-1001-
Microsoft
02C
Model 208 *BE42.10-P-1001-
02C
Model 210 *BE42.10-P-1001-
02D
8 Assemble in reverse order
9 Press out opposite piston and
repair second half of fixed caliper
TEST VALUES FOR REAR WHEEL FIXED CALIPER

129.058/060/061/063/ 129.058/ 129.067 with
066/067 up to 08/95 063/067 as of ESP (Bendix
(ATE 38) 09/95 Model 42)
129.067 as of
09/95
without ESP
BE42.10-P- 2-piston Housing dia. mm 37.99-38.03 35.99-36.03 41.99-42.03
1001-02A fixed caliper, new
rear axle Slideway mm 62+0.2 62+0.2 62+0.2
width
Brake disc mm 278 290 300
dia.
Brake disk mm 9 10 22
thickness

129.059/064/068 with 129.059/064 129.076
ESP without ESP (Teves)
BE42.10-P- 2-piston Housing dia. mm 41.99-42.03 35.99-36.03 41.99-42.03
1001-02A fixed new
caliper, rear Slideway mm 62+0.2 62+0.2 62+0.2
axle width
dia.
thickness

Number Designation Model 129.07
(Bendix 46)
BE42.10-P-1001- 2-piston fixed Housing dia. new mm 45.99-46.03
02A caliper, rear axle Slideway width mm 62+0.2
Microsoft
Brake disc dia. mm 300

Brake disk thickness mm 22

Number Designation Model Model 140.04/05/06 /07
140.02/03/1 (Bendix 46)
(ATE 40)
BE42.10-P- 2-piston fixed Housing dia. mm 39.99-40.03 45.99-46.03
1001-02B caliper, rear new
axle Slideway mm 62+0.2 62+0.2
width
Brake disc dia. mm 290 300
Brake disk mm 12 22
thickness

Number Designation Model 170 up Model 170 as of
to 02/97 03/97 except
170.466
BE42.10-P-1001- 2-piston fixed Housing dia. new MM 37.98-38.03 35.98...36.03
02C caliper, rear axle Slideway width mm 62+0.2 64 (+0.2)
Brake disk mm 9 9
thickness

Number Designation Models 202.018/ Models
020/022/023/ 202.024/025/026/028/
120/121/122/ 029/078/080/082/
125/133/134 083/085/086/089/128/
202.028 up to 180/182/188/193 as of
08/95 (Teves) 10/96 202.081/087/088
BE42.10-P- 2-piston fixed Housing dia. mm 34.98-35.03 35.99...36.03
1001-02C caliper, rear new
axle Slideway width mm 62+0.2 62 (+0.2)
Brake disk mm 9 9
thickness

Number Designation Model 202.024/025/026/ Model
029/078/080/082/083/ 202.028 with
085/086/089/128/180/ CODE 957
182/188/194 up to 09/96, (C 36 AMG)
Microsoft
model 202.028 as of 09/95 up to 08/95

(Teves)
BE42.10-P- 2-piston fixed Housing dia. mm 37.99-38.03 38
1001-02C caliper, rear new
axle Slideway mm 62+0.2 -
width
Brake disc mm 278 278
dia.
Brake disk mm 9 24
thickness

202.028 with 202.033/093 208.335/
CODE 957 345/347 up
(C 36 AMG) to 03/97
as of 09/95
BE42.10-P- 2-piston Housing dia. mm 36 42 37.98-38.03
1001-02C fixed caliper, new
rear axle Slideway mm - 62 62+0.2
width
dia.
thickness

208.335/344/345 /347/348/435 as 208.365/370/444/ 208.374
of 04/97 445/447/448/
465/470
BE42.10- 2-piston Housing mm 35.98...36.03 35.99...36.03 42
P-1001- fixed dia. new
02C caliper, Slideway mm 64 (+0.2) 62+0.2/64+0.2 62
rear axle width
Brake mm 278 290 300
disc dia.
Brake mm 9 10 22
disk
thickness

Number Designation Model 210.003/004/ Model 210.015/016/
006/007/010/ 025/026/045/
Microsoft
017/020/035/ 037 053/055/061 with

(ATE38)/048/ 061 ESP/063/065/
without ESP/ 062 070/072/081/ 082
(ATE36)/083
BE42.10-P- 2-piston fixed Housing dia. mm 37.99...38.03 35.99...36.03
1001-02D caliper, rear new
axle Slideway mm 62 (+0.2) 62 (+0.2)
width
Brake disk mm 9 10
thickness

Number Designation Model 210.206/210/ Model 210.055
215/216/217/ with code 957
225/226/235/ (E 36 AMG)
237/245/248/
261/262/263/
265/270/272/
281/282/283/
606/610/616
617/663 (ATE 40)
BE42.10-P- 2-piston fixed Housing dia. mm 39.98...40.03 36
1001-02D caliper, rear new
axle Slideway width mm 62 (+0.2) 61.75
Brake disk mm 12 10
thickness

Number Designation Model 210.072/074/274
with code 957 (E 50
AMG)
BE42.10-P-1001- 2-piston fixed Housing dia. new mm 42
02D caliper, rear axle Slideway width mm 62
Brake disc dia. mm 300
Brake disk mm 22
thickness
Microsoft
Fig. 23: Identifying Pliers (000 589 49 37 00)
Fig. 25: Identifying Checking Gauge (000 589 35 23 00)
Fig. 26: Identifying Resetting Device (000 589 52 43 00)
REPAIRING FLOATING CALIPER ON FRONT AXLE - AR42.10-P-0152B
MODEL 202.024 /025 /026 /029 /082 /085 /086 /089 /128 /188
Microsoft
MODEL 170.435 /445 /447, 208.335 /345 /347 /365 /435 /445 /447 /465,
210.00 /01 /02 /035 /037 /04 /053 /06 /08 /20 /21 /22 /23 /24 /26 /28 /60 /61 /663
MODEL 210.070 /270 with CODE (491) U.S. version with CODE (498) Japanese version with CODE
(625) Australian version
MODEL 208.370 /470 with CODE (491) U.S. version
MODEL 202.028 as of 1.9.95, 210.055 except CODE (957a) AMG engineering package
MODEL 202.033 /093, 208.374, 210.074 /274
MODEL 210.072 with CODE (957a) AMG engineering package
Fig. 27: Identifying Floating Caliper Repair Components
1 Removing and Model 202.024 /025 /026 /029 /082 /085 /086 /089 /128 /188 AR4
installing front brake Models 170.435 /445 /447, 208.335 /345 /347 /365 /435 /445 /447 /465, P-
caliper 210.00 /01 /02 /035 /037 /04 /053 /06 /08 /20 /21 /22 /23 /24 /26 /28 /60 /61 /663 0070
Model 210.070 /270
with CODE (491)
with CODE (498)
with CODE (625)
Model 208.370 /470 with CODE (491)
Model 202.028 as of 1.9.95, 210.055 except CODE (957a) AMG engineering
package
Microsoft
Model 208.374
Models 202.033 /093, 210.072 /074 /274 with CODE (957a) AMG engineering AR4
package P-
0070
2 Remove floating
caliper (34) from
caliper support (33)
Disassemble/assemble
3 Carefully press out Install using pliers if necessary. Fig.

piston (47) using
compressed air;
remove piston with
piston rotating pliers if
necessary
Model 202.033/093, model 208.374 and model 210.072 with CODE 957 E
50 AMG 210.074/274 are fitted with a 2-piston floating caliper.
If piston is rusted tight (47), replace floating caliper (34).
Installation: Coat cylinder bore with brake fluid.
4 Remove dust cap (45) Installation: Put dust cap (45) over piston (47) and insert into cylinder bore
from floating caliper together with piston. Push in piston using both hands. Ensure correct seating.
(34) Floating caliper and repair kit must be from same manufacturer.
5 Remove piston seal Installation: Coat new piston seal (50) with brake fluid.
(50) from the groove Floating caliper (34) and repair kit must be from same manufacturer.
in the cylinder bore.
6 Check piston (47) and
cylinder bore of
floating caliper (34),
and replace if
necessary
Notes on damage to AH4
piston or cylinder bore P-94
on fixed or floating 03A
caliper.
Test values for front axle floating caliper *BE
P-10
03A
7 Remove and replace
plastic guide bushings
(34f)
8 Assemble in reverse
order
Test values for front axle floating caliper

Microsoft
170.435/444/445 /447/449 202.024/025/ 202.033/093

026/029/082/
085/086/087/
088/089/128/188,
model 202.028 as
of 09/95 (Teves)
BE42.10-P- Front axle Housing mm 57.00...57.05 57.00...57.05 2 X 44
1001-03A floating dia. new
caliper Slideway mm 110 110 -
width
dia.
thickness

Number Designation Model Models Model
208.335/344/345 /347/348/435 208.365/444/ 208.374
445/447/448/465,
208.370/470
BE42.10- Front Housing mm 57.00...57.05 57.00...57.05 2 X 44
P-1001- axle dia. new
03A floating Slideway mm 110 113 -
caliper width
Brake mm 288 300 334
disc dia.
Brake mm 25 28 32
disk
thickness

Number Designation Models Models 210.015/016/020 Models
210.003/004/ 025/026/045/ 048/053/055/ 210.072 with
006/007/010/ 062/063/065/ 072/081/082/ CODE 957
017/035/037/ 225/226/245/263 (E50 AMG),
206/210/215/ 265/281/282/606 /610/616/617/ 210.074/274
216/217/235/ 663, 210.061/ 261 with ESP,
237/248/262, Model 210.070
210.061/261 (ATE)
without ESP
(ATE)
BE42.10- Front Housing mm 57.00...57.05 57.00...57.05 2 X 44
P-1001- axle dia. new
03A floating Slideway mm 110 113 -
caliper width
Microsoft
Brake mm 288 300 334

disc dia.
Brake mm 25 28 32
disk
thickness
REMOVE/INSTALL BRAKE DISC - AR42.10-P-0220A
MODEL 129, 140, 170, 202, 208, 210
Fig. 29: Identifying Brake Disc Remove/Install Components
Remove/install
Risk of injury Wear safety gloves, protective clothing and safety glasses, if necessary.
to skin and
eyes caused by
handling hot or
glowing
objects.
Microsoft
Notes on
repairs to brake
system
1 Remove
wheels
Remove/install
wheels, rotate
if necessary
2 Release When removing the brake disks (61) on the rear axle
parking brake
Checking
3 Check brake Only replace brake pads and brake disks (61) in complete sets if necessary.
lining thickness
and brake disks
(61)
Check brake
lining thickness
Inspect
condition of
brake disks
4 Remove brake Do not detach brake hose, instead attach brake caliper to vehicle so that it is free of
disk tension. Do not kink or tension brake hose, as otherwise it will be damaged.
At the front
axle:
Model 129, 140,
Model 208.370 /470 up to 18.01.99 except code 491 USA version,
Model 210.070 up to 07.02.99
except code 491 USA version,
except code 498 Japan version,
except code 625 Australia version,
except code 957 AMG engineering package,
Model 210.072 /270 /272 up to 07.02.99
Model 202.024/025 /026 /029 /082 /085 /086 /088/089 /128 /188,
Model 170.435 /444 /445 /447 /449 /465,
Model 208.335 /344 /345 /347 /348 /365 /435 /444 /445 /447 /448/ 465,
Model
210.00 /01 /02 /035 /037 /04 /053 /06 /081 /082 /20 /21 /22 /23 /24 /26 /282 /60 /61 /66
Model 210.083 /283 up to 7.2.99,
Model 210.070 /270
with code 491 USA version,
with code 498 Japan version,
with code 625 Australia version,
Model 208.370 /470 with code 494 USA version,
Model 202.028 as of 1.9.95, 210.055, except code 957 AMG engineering package
Model
202.018 /020 /022 /023 /078 /080 /081 /083 /087 /120 /121 /122 /125 /133 /180 /182 /1
Microsoft
Model 202.028
up to 31.8.95
except code
957
AMG
engineering
package
Model 170.466,
Model 202.033 /093,
Model 208.374,
Model 208.370 /470 as of 19.01.99 except code 494 USA version,
Model 210.072 /074 /274 with code 957 AMG engineering package,
Model 210.070 as of 08.02.99,
except code 494 USA version,
except code 498 Japan version,
except code 625 Australia version,
Model 210.083/270 /283 as of 08.02.99
Model 202.028, 210.055 with code 957 AMG engineering package C 36, E 36
At the rear axle:

Model 129, 140, 170, 208,
Model 202 except 202.028 /033 /093,
Model 210 except code 957 AMG engineering package
Model 202.028 /033 /093,
Model 210.055 /072 /074 /274 with code 957
AMG engineering package
5 Unscrew Installation: Only replace brake disks (61) in pairs. Lightly grease the seat of the
locking bolt brake disk (61) with long-life grease and replace the locking bolt (64).
(64) and
remove brake
disk (61)
Models 129, 140, 202: Ensure that the dowel pin or roll pins (63) are properly seated in
the brake disk (61).
Models 202.033/093, 208.374, 210.072 with code 957 E 50 AMG 210.074/274
The left and right brake disks (61) are different. Identification:
AMG A210 421 1912 right side
AMG A210 421 1812 left side
Model 140 up to 3.9.93
When installing new brake disks on front axle: ?
Pull out roll pins on front wheel hub.
Device for withdrawing roll pins on front wheel hub
Microsoft
Notes on Model 129.067 as of 01.06.1994, 129.076

installation of
brake discs
Modified front Model 129.067 (as of 01.06.94)
axle brake
discs
Front axle Model 210.072 /272 with code 957 AMG engineering package E 50 AMG
brake system,
function
6 Install in the
reverse order
7 Adjust parking Model 129, 140 as of 1.11.93, 170, 202, 208, 210
brake
Model 140 up to 31.10.93
BRAKE DISCS, BRAKE COVER PLATE

BA42.10-P- Locking bolt of Nm 10 10 10
1001-06A rear axle brake
disk
1002-06A front axle brake
disk

1001-06A rear axle brake
disk
1002-06A front axle brake
disk

Number Designation Model 210.2/ 6
BA42.10-P-1001-06A Locking bolt of rear axle Nm 10
brake disk
BA42.10-P-1002-06A Locking bolt of front axle Nm 10
Microsoft
brake disk
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1001-06A Long-life grease A 000 989 63 51
CLEANING BRAKE DISCS WITH CLEANING PADS - AR42.10-P-0260A
MODEL 129, 140, 170, 202, 208, 210
Fig. 30: Identifying Cleaning Pads
Removing,
installing
1 Remove Only fit one axle with cleaning pads at a time
front and
rear brake
pads on
each axle
separately
Front brake pads AR42.10-
Models 202.018 /020 /022 /023 /078 /080/ P-
083 /120 /121 /122 /125 /133 /180 /182/ 193, 202.028 up to 31.8.95 except 1600AM
CODE (957a)
Models 170.435 /445 /447, P-
202.024 /025 /026 /029 /082 /085 /086 /089 /128 /188, 1600BM
208.335 /345 /347 /365 /435 /445 /447 /465 Model 202.028 as of 1.9.95,
210.00 /01 /02 /035 /037 /04 /05 /06 /08 /20 /21 /22 /23 /24 /26 /28 /60 /61 /663
except CODE (957a AMG engineering package
MODEL 210.070
with CODE (491)
with CODE (498)
Microsoft
with CODE (625)

Model 208.370 /470 with CODE (491)
Model 202.033 /093 P-
Model 210.072 with CODE (957a) AMG-Technik-Paket 1600CM
E 50 AMG
Model 210.074 /274
Model 208.374
Models 129, 140, 210.072/270/272 P-
Model 210.072 except CODE 957a AMG engineering package 1600DM
Model 208.370 /470 except CODE (491)
Model 210.070
except CODE (498)
except CODE (625)
except CODE (491)
Model 202.028, 210.055 with CODE (957a) P-
AMG engineering package 1600EM
Rear brake pads AR42.10-
Models 129, 140, 170, 202, 208, 210 P-
1700AM
2 Install Cleaning pads only available with two securing bolts.
cleaning
pads (050)
on each
axle
separately,
either front
or rear
Fig. 31
Models 129, 210.072/270/272
Model 210.072 except CODE 957a AMG engineering package
Model 208.370 /470 except CODE (491)
Model 210.070
except CODE (498)
except CODE (625)
except CODE (491)
front
Fig. 32
Models
202.018 /020 /022 /023 /078 /080 /083 /120 /121 /122 /125 /133 /180 /182 /193,
202.028 up to 31.9.95 except CODE (957a)
front
Microsoft
Fig. 37
Models 170.435 /445 /447,
202.024 /025 /026 /029 /082 /085 /086 /089 /128 /188,
208.335 /345 /347 /365 /435 /445 /447 /465
Model 202.028 as of 1.9.95,
210.00 /01 /02 /035 /037 /04 /05 /06 /08 /20 /21 /22 /23 /24 /26 /28 /60 /61 /663
except CODE (957a) AMG engineering package
Model 210.070
with CODE (491)
with CODE (498)
with CODE (625)
Model 208.370 /470 with CODE (491)
front
Models 129, 170, 202, 208, 210 only with two holding pins at the fixed Fig. 35
caliper at rear .
Model 140 with 2-piston fixed caliper at front . Fig. 33
Model 140 with 4-piston fixed caliper at front. Fig. 34
Model 140 at rear . Fig. 36
3 Drive Do not use a roller or chassis dynamometer to clean brake discs.
vehicle at a The braking effect is greatly reduced by the cleaning pads.
speed of
approx. 30
km/h for a
distance of
300 meters
depressing
brake
pedal
slightly
several
times.
4 Install in
reverse
sequence
Fig. 31: Identifying Cleaning Pad (129 589 00 28 00)
Microsoft
Microsoft
REMOVING AND INSTALLING STEPPED TANDEM MASTER BRAKE CYLINDER - AR42.10-P-

0310A
MODELS 129, 140, 170, 202, 208, 210
Fig. 38: Identifying Stepped Tandem Master Brake Cylinder Remove/Install Components
Microsoft
Figure Item etc. Work instructions

brake fluid.
system
The switchover master Models 129.076,
brake cylinder must not 140.04/05/06/07
be repaired
Do not tilt the tandem
master brake cylinder,
but pull it straight out
towards the front,
otherwise the thrust rod
is forced out of its axial
position and may break
away from the retaining
lugs on the master
control unit
Notes if loss of brake AH42.10-P-9406-02A
fluid is not visible
externally
Detach electronic Model 170.435
accelerator by
unscrewing two nuts on
the accelerator pedal
bracket
Box wrench for brake Width across flats 11 Fig. 8
lines
After installation Bleed brake system AR42.10-P-0010A
1 Tandem master brake
cylinder
2 Brake lines *BA42.10-P-1003-04A
3 Brake lines *BA42.10-P-1003-04A
9 Reservoir plug Check and replace if
necessary
16 Brake booster
17 Sealing ring Replace sealing ring.
19 Nuts, tandem master *BA42.10-P-1001-05A
brake cylinder to brake
Microsoft
booster
20 Pre-bleed master brake Model 140
cylinder at bleed screw
Y61 Master brake cylinder
switchover valve

1003-04A master brake
cylinder

1003-04A master brake
cylinder
MASTER BRAKE CYLINDER

BA42.10-P- Nut, master Nm 20 20 20
1001-05A brake cylinder to
brake booster
MASTER BRAKE CYLINDER

BA42.10-P- Nut, master Nm 20 20 20
1001-05A brake cylinder to
brake booster
REMOVE/CHECK/INSTALL FRONT AXLE BRAKE PADS - AR42.10-P-1600
Remove/check/install front axle brake pads - AR42.10-P-1600BM
Microsoft
MODEL 170.435 /444 /445 /447 /449 /465, 202.024 /025 /026 /029 /082 /085 /086 /088 /089 /128 /188,
208.335 /344 /345 /347 /348 /365 /435 /444 /445 /447 /448 /465
MODEL 202.028 as of 1.9.95, 210.00 /01 /02 /035 /037 /04 /05 /06 /081 /082, 210.083 up to 7.2.99,
210.20 /21 /22 /23 /24 /26 /282, 210.283 up to 7.2.99, 210.60 /61 /663 except CODE (957) AMG engineering
package
MODEL 210.070 with CODE (491) USA version with CODE (498) Japan version with CODE (625)
Australia version
MODEL 208.370 /470 with CODE (491) USA version
Fig. 40: Identifying Front Axle Brake Pads Remove/Install Components - Model
170.435 /444 /445 /447 /449 /465
Remove/install
Risk of poisoning Only pour brake fluid into suitable AS42.50-Z-0001-01A
caused by swallowing and appropriately marked
brake fluid. Risk of containers. Wear protective
injury caused by brake clothing and eye protection when
fluid coming into handling brake fluid.
contact with skin and
eyes
Risk of injury to skin Wear safety gloves, protective AS00.00-Z-0002-01A
and eyes caused by clothing and safety glasses, if
handling hot or necessary.
glowing objects.
Notes on repairs to AH42.00-P-0003-01A
brake system
Microsoft

Notes on self-locking AH00.00-N-0001-01A
nuts and bolts
1 Unscrew the cap on the In order to prevent the
brake fluid expansion expansion reservoir overflowing
reservoir and suction when pressing back the brake
off some brake fluid pistons.
2 Remove the front
wheels
Remove/install wheels, AP40.10-P-4050Z
rotate if necessary
3 Detach springs (31d)
4 Remove brake pad Installation: Replace defective
contact sensors contact sensors.
brake pad wear sensor
contact sensors
5 Detach covers (31b) *BA42.10-P-1004-
and remove guide pins 03A
(31c)
6 Remove floating brake Attach floating caliper (31a) to
caliper (31a) together vehicle so that it is free of tension.
with inner brake pad Do not kink or tension brake hose,
(31g) as otherwise it will be damaged.
7 Remove brake pads Brake pads (31g) must be
(31g) disposed of as special waste. The
local authorities can provide
information regarding whether
disposal is also permitted as
industrial waste similar to
domestic waste.
Installation: Only the brake
pads (31g) approved by
Mercedes-Benz may be built-in as
a set. Install brake pads (31g)
without grease. Insert inner brake
pad (31g) with spring riveted on
(arrow) into brake piston, insert
outer brake pad (31g) into brake
caliper support (33).
Checking
8 Check brake lining Only replace brake pads (31g)
thickness and brake and brake disks in complete sets if
disks necessary.
Inspect condition of AP42.10-P-4258AM
Microsoft
brake disks
Check brake lining If the brake pads (31g) have AP42.10-P-4253A
thickness worn down to beyond the wear
limit, the bar between the sealing
groove and dust cap may be
damaged; therefore:
?
Check brake system for leaks with AR42.10-P-0015A
pressure tester.
9 Check floating caliper If floating brake caliper (31a)
(31a) for leaks and dust is leaky or dust boot (47) is
boot (47) for signs of damaged or not seated correctly:
damage and correct ?
seating Repair floating caliper:
Except model 170.444 /449, AR42.10-P-0152B
202.088, 208.344 /248 /444 /448
Model 170.444 /449,
Model 202.088,
Model 208.344 /248 /444 /448
10 Press back brake piston If the brake pads (31g) for
using pusher tool several brake calipers are
(031) removed, their brake pistons must
be secured beforehand using
wedges against falling out. If the
brake piston is difficult to move: ?
Repair floating caliper:
Except model 170.444 /449, AR42.10-P-0152B
202.088, 208.344 /248 /444 /448
Model 170.444 /449,
Model 202.088,
Model 208.344 /248 /444 /448
Fig. 26
Fig. 42
Clean
11 Clean contact surfaces Do not damage dust boot (47).
of brake pads (31g) at
floating caliper (31a)
and brake caliper
support (33)
Fig. 43
order
Risk of accident when Before starting engine, actuate AS42.50-Z-0002-01A
commissioning the brake pedal several times until the
vehicle due to a lack of pressure is built up and
Microsoft
braking effect when maintained in the brake system.

the service brake is
operated for the first
time after repair work.
13 Operate the brake A firm resistance must be
pedal several times noticeable at the brake pedal.
until the brake pads
(31g) make contact
with the brake disks
14 Inspect fluid level in
expansion reservoir,
adjust to correct level
if necessary
Brake system - inspect AP42.10-P-4210Z
fluid level

Number Designation Model 170.435/444/445/447/449/465 Model
202.024/025/02
6/029/082/085/
086/088/089/
128/188, 202.028
from 09/95
BA42.10-P- Guide pins, Nm 25 25
to caliper
support

Number Designation Model Model
208.335/344/345 /347/348/365/ 210.00/01/02/035/037/04/05/06/08/20/21/
435/444/445/ 447/448/465, 22/23/24/26/28/ 60/61/663, except
208.370/470 Model 210.083/283 as of 08.02.00
Model 210.070
BA42.10- Guide Nm 25 25
P-1004- pins,
03A floating
caliper to
caliper
support
Microsoft
Fig. 41: Identifying Pusher Tool (000 589 52 43 00)
Fig. 42: Identifying Wedge (601 589 07 63 00)
Fig. 43: Identifying Caliper Brush (000 589 26 68 00)
Remove/check/install front axle brake pads - AR42.10-P-1600CM
MODEL 170.466, 202.033 /093
MODEL 208.374
MODEL 210.072 with CODE (957) AMG engineering package E 50 AMG
MODEL 210.083 as of 8.2.99, 210.074, 210.270 as of 8.2.99, 210.274, 210.283 as of 8.2.99
MODEL 208.370 /470 as of 19.1.99 except CODE (491) USA version
MODEL 210.070 as of 8.2.99 except CODE (491) USA version except CODE (498) Japan version except
CODE (625) Australia version
Microsoft
Fig. 44: Identifying Front Axle Brake Pads Remove/Install Components - Model 170.466
Remove/install
Risk of poisoning caused Only pour brake fluid AS42.50-Z-0001-01A
by swallowing brake into suitable and
fluid. Risk of injury appropriately marked
caused by brake fluid containers. Wear
coming into contact with protective clothing and
skin and eyes eye protection when
Risk of injury to skin and Wear safety gloves, AS00.00-Z-0002-01A
eyes caused by handling protective clothing and
hot or glowing objects. safety glasses, if
necessary.
system
Notes on self-locking nuts AH00.00-N-0001-01A
and bolts
brake fluid expansion expansion reservoir
reservoir and suction off overflowing when
some brake fluid pressing back the brake
pistons.
2 Remove the front wheels
rotate if necessary
3 Detach springs (31d)
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4 Remove brake pad contact Installation: Replace

sensors defective contact sensors.
Notes on installing brake AH42.10-P-0003-01A
pad wear sensor contact
sensors
5 Detach covers (31b) and *BA42.10-P-1004-03A
remove guide pins (31c)
6 Remove floating brake Attach floating caliper
caliper (31a) together with (31a) to vehicle so that it
inner brake pad (31g) is free of tension. Do not
kink or tension brake
hose, as otherwise it will
be damaged.
7 Remove brake pads (31g) Brake pads (31g) must
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.
Installation: Only the
brake pads (31g)
approved by Mercedes-
Benz may be built-in as a
set. Install brake pads
(31g) without grease.
Insert inner brake pad
(31g) with spring riveted
on into brake piston,
insert outer brake pad
(31g) into brake caliper
support (33).
Checking
8 Check brake lining Only replace brake
thickness and brake disks pads (31g) and brake
disks in complete sets if
necessary.
Inspect condition of brake AP42.10-P-4258AM
disks
Check brake lining If the brake pads (31g) AP42.10-P-4253A
thickness have worn down to
beyond the wear limit,
the bar between the
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sealing groove and dust

cap may be damaged;
therefore:
?
Check brake system for AR42.10-P-0015A
leaks with pressure tester.
9 Check floating caliper If floating brake
(31a) for leaks and dust caliper (31a) is leaky or
boot (47) for signs of dust boot (47) is damaged
damage and correct or not seated correctly:
seating ?
Except model 170.466, AR42.10-P-0152B
except model
208.370/470 as of
19.1.99
without code 491 USA
version, except model
210.270 as of 8.2.99,
except model 210.070 as
of 8.2.99 without code
491 USA version,
without code 498 Japan
version,
without code 625
Australia version
Model 170.466, model
208.370/470 as of
19.1.99 without code
491 USA version, model
210.270 as of 8.2.99,
model 210.070 as of
8.2.99 without code 491
USA version, without
code 498 Japan version,
without code 625
Australia version
10 Press back brake piston If the brake pads (31g)
using pusher tool (031) for several brake calipers
are removed, their brake
pistons must be secured
beforehand using
wedges against falling
out. If the brake piston is
difficult to move: ?
Microsoft
Except model 170.466, AR42.10-P-0152B

except model
208.370/470 as of
USA version, except
model 210.270 as of
8.2.99, except model
210.070 as of 8.2.99
without code 491 USA
version, without code 498
Japan version, without
code 625 Australia
version
Model 170.466, model
208.370/470 as of
19.1.99 without code
491 USA version, model
210.270 as of 8.2.99,
model 210.070 as of
USA version, without
code 498 Japan version,
without code 625
Australia version
Fig. 26
Fig. 42
Clean
11 Clean contact surfaces of Do not damage dust
brake pads (31g) at boot (47).
floating caliper (31a) and
brake caliper support (33)
Fig. 43
12 Install in the reverse order
Risk of accident when Before starting engine, AS42.50-Z-0002-01A
commissioning the actuate brake pedal
vehicle due to a lack of several times until the
braking effect when the pressure is built up and
service brake is operated maintained in the brake
for the first time after system.
repair work.
13 Operate the brake pedal A firm resistance must
several times until the be noticeable at the brake
brake pads (31g) make pedal.
contact with the brake
disks
14 Inspect fluid level in
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expansion reservoir,
adjust to correct level if
necessary
fluid level

Number Designation Model 170.466 Model 202.033/093,
208.374, 210.072
with code 957 (E50
AMG), 210.074/274
BA42.10-P-1004- Guide pins, floating Nm 25 27
03A caliper to caliper
support

from 19.01.99, 283 as of 08.02.99,
except model 210.070 as of
08.02.99 except
BA42.10-P-1004- Guide pins, floating Nm 27 27

03A caliper to caliper
support

Number Designation Model 210.072/074/272/274
BA42.10-P-1004-03A Guide pins, floating Nm 25
caliper to caliper
support
Fig. 45: Identifying Pusher Tool (000 589 52 43 00)
Microsoft
Fig. 47: Identifying Brake Caliper Brush (000 589 26 68 00)
REMOVING, CHECKING AND INSTALLING REAR AXLE BRAKE PADS - AR42.10-P-1700AM
MODEL 129, 140, 170, 202, 208, 210
Fig. 48: Identifying Rear Axle Brake Pads Remove/Install Components (With Two Retaining Pins)
Fixed brake caliper with two retaining pins (41) on rear axle
Microsoft
Fig. 49: Identifying Rear Axle Brake Pads Remove/Install Components (With One Retaining Pin)
Fixed brake caliper with one retaining pin (41) on rear axle
Remove/install
Risk of poisoning caused Only pour brake fluid into AS42.50-Z-0001-01A
by swallowing brake suitable and appropriately
fluid. Risk of injury marked containers. Wear
caused by brake fluid protective clothing and
coming into contact with eye protection when
skin and eyes handling brake fluid.
Risk of injury to skin and Wear safety gloves, AS00.00-Z-0002-01A
eyes caused by handling protective clothing and
hot or glowing objects. safety glasses, if
necessary.
system
brake fluid expansion expansion reservoir
reservoir and suction off overflowing when the
some brake fluid brake pistons (47) are
pushed back.
2 Remove rear wheels.
rotate if necessary
3 Remove brake pad Installation: Replace
contact sensor defective brake pad
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contact sensor.
Notes on installing brake AH42.10-P-0003-01A
pad wear sensor contact
sensors
4 Using punch (035) Installation: Hammer
hammer out retaining pins in retaining pins (41) as
(41) and remove retaining far as the stop.
springs
5 Pull brake pads (43) out In order to avoid
of brake caliper (31) damage, insert a wedge
between the lever (034)
and brake caliper (31)
when pressing out seized
brake pads (43) .
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.
Installation: Only sets
of brake pads (43)
approved by Mercedes-
Benz may be installed.
Install brake pads (43)
with peripheral damping
(a and c) ungreased. On
brake pads (43) without
peripheral damping on the
side surfaces (arrows)
coat with some brake pad
paste.
Fig. 50
Brake pad paste *BR00.45-Z-1003-06A
Checking
6 Check brake pad Replace brake pads
thickness and brake disks (43) and brake disks in
sets if necessary.
Inspect condition of brake AP42.10-P-4258AM
disks
Check brake lining If the brake pads (43) AP42.10-P-4253A
thickness have worn down to
Microsoft
beyond the wear limit, the

web between the sealing
groove and dust cap may
be damaged; therefore:
?
Check brake system for AR42.10-P-0015A
leaks with pressure tester.
7 Press back brake piston Do not bend heat
(47) using resetting shield. If brake pads (43)
device (031) have been removed from
several brake calipers
(31), their brake pistons
(47) must be secured
beforehand with wedges
to prevent them from
falling out .
Do not fit the
pusher tool (031) to the
brake disk, but push back
the opposite brake pistons
(47) simultaneously. If
brake pistons (47) are
sluggish:
?
Repair brake caliper (31). AR42.10-P-0151A
Fig. 26
Fig. 42
Clean
8 Clean contact surfaces of brake caliper brush
brake pads (43) using (030) Do not damage
boots of brake pistons
(47).
Fig. 43
Risk of accident when Before starting engine, AS42.50-Z-0002-01A
commissioning the actuate brake pedal
vehicle due to a lack of several times until the
braking effect when the pressure is built up and
service brake is operated maintained in the brake
for the first time after system.
repair work.
10 Operate the brake pedal A firm resistance must
several times until the be noticeable at the brake
brake pads (43) contact pedal.
the brake disks
Microsoft
Checking
11 Check brake fluid level,
correct if necessary
fluid level
Fig. 50: Identifying Lever (123 589 13 33 00)
Fig. 51: Identifying Brake Caliper Brush (000 589 26 68 00)
Fig. 52: Identifying Resetting Device (000 589 52 43 00)
Microsoft
REPAIR MATERIALS
BR00.45-Z-1003-06A Brake pad paste A 001 989 10 51
REMOVING AND INSTALLING HAND BRAKE LEVER - AR42.20-P-0500A
MODEL 170
Fig. 54: Identifying Hand Brake Lever Remove/Install Components
1 Detach return spring (94)
2 Slacken adjusting screw (89)
3 Unscrew self-locking stud bolt
(93) at intermediate lever and front Installation :
Microsoft
hand brake cable. Replace self-locking bolt (93).

Pull rubber handle (75a) off hand Rubber handle can only be removed from hand
4 brake lever with great force (suction). If necessary
brake lever (75)
cut open with a suitable tool.
AR68.20-P-
5 Remove cover on shift lever (111)
2310G
AR68.20-P-
6 Remove rear center console (115)
2020G
Remove contact switch for hand
7
brake indicator lamp.
Unscrew bolts (72) and pull out *BA42.20-P-
8
hand brake lever (75) forwards. 1003-01A
AR42.20-P-
10 Adjusting parking brake
0540A
Parking brake
Number Designation Model 170
BA42.20-P-1003-01A Bolt, hand brake lever to center tunnel Nm 20
REMOVING AND INSTALLING REAR BRAKE CONTROL CABLE - AR42.20-P-0525A
MODELS 129, 140, 170, 202, 208, 210
Fig. 55: Identifying Rear Brake Control Cable Remove/Install Components
Microsoft
1 Remove brake shoes of AR42.20-P-0530A

parking brake
2 Detach return spring (94) Models 129, 140, 170,
202, 208, 210
3 Slacken adjusting screw Models 129, 170
(89)
4 Detach front brake cable Models 140, 170, 202,
(85) from intermediate 208, 210
lever (91) Models 129, 170
Installation: Replace
self-locking bolt (93).
5 Detach brake cables (86)
from equalizer arm (92)
6 Detach brake cables (86) Models 129, 140
from frame floor
Models 170, 202, 208, Fig. 56
210:
Use snap-release tool
(043).
The brake cable can
also be removed by
breaking the clamping
ring (84). To install,
insert a new clamping
ring in the groove in the
brake cable.
7 Unscrew self-locking bolt Installation: Replace
(98) on wheel carrier. self-locking bolt (98).
*BA42.20-P-1002-01A
8 Remove brake control
cable (86)
order
PARKING BRAKE
1002-01A bolt, brake cable
to rear wheel
carrier
PARKING BRAKE
Microsoft
1002-01A bolt, brake cable

to rear wheel
carrier
Fig. 56: Identifying Snap-Release Tool (129 589 11 63 00)
REMOVING AND INSTALLING BRAKE SHOES OF PARKING BRAKE - AR42.20-P-0530A
MODEL 129, 140, 170, 202, 203, 208, 209.3 /4, 210
Models 129, 140 as of 1.11.93, 170, 202, 203, 208, 209, 210
Fig. 57: Identifying Brake Shoes Of Parking Brake Remove/Install Components
MODEL 140 up to 31.10.93
Microsoft
Fig. 58: Identifying Brake Shoes Of Parking Brake Remove/Install Components -- Model 140 Up To
31.10.93
MODIFICATION NOTES
12.12.02 Safety information on AS00.00-Z-0010-01A
lifting platform,
incorporated for the first
time
12.12.02 Check version of pedal Step 12 BT42.20-P-0510-01A
assembly, included for
the first time
Remove/Install
Risk of death . Death Align vehicle between AS00.00-Z-0010-01A
may result if vehicle slips the columns of the
or topples from the lifting hydraulic hoist and
platform. position the four support
plates below the hoist
support points specified
by the vehicle
manufacturer.
1 Remove rear wheels.
rotate if necessary
2 Remove brake discs on Model Series 129, 140, AR42.10-P-0220A
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rear axle 170, 202, 208, 210

Model 203, 209 AR42.10-P-0220P
3.1 Cover panel in main floor Models 202, 203, 209,
under the rear seat cushion 208, 210
3.2 Remove heat shield of Models 129, 140
exhaust system.
4.1 Preloading automatic Model 140 AR42.20-P-0520-01A
cable slack adjuster
Models 202, 208, 210 AR42.20-P-0520-01B
4.2 Release adjustable slack See: Remove/install
adjuster rear brake cable: ?
Model 129, 170 AR42.20-P-0525A
Model 203, 209 AR42.20-P-0525P
5 Unhook retracting spring Installation: Pay
(111) using extraction and attention to correct seat
insertion tool (041) of retracting spring
(111)!
Removal and Fig. 59
installation tool
6 Unhook retaining springs Installation: Pay
(107) using installation attention to correct seat
tool (040) of retaining springs
(107).
Installation tool Fig. 60
7 Remove brake shoes (103) If the brake shoes
over rear axle shaft flange (103) are burnt, the brake
(68) shoes (103), retracting
springs (111, 112) and
retaining springs (107)
should be replaced. On
vehicles with internally
ventilated brake disks the
brake disks must also be
replaced.
Models 129, 140 as of
1.11.93, 170, 202, 203,
208, 209, 210:
Installation: Turn
back the adjusting
mechanism (105) and
insert in the two brake
shoes (103) so that the
adjuster (c) points in the
direction of travel.
Model 140 up to
Microsoft
31.10.93
Installation: Turn
back the adjusting
mechanism (105) and
insert in the two brake
shoes (103) so that the
flat on the adjusting
screw (e) points upwards.
On the left side the
adjusting screw (e) must
point in the direction of
travel and on the right
side towards the back.
8 Detach return spring (112) Models 129, 140 as of
1.11.93, 170, 202, 203,
208, 209, 210:
Coat thread of thrust
piece (104) and
cylindrical part of
adjusting wheel (c) with
MB long-term grease.
Model 140 up to
31.10.93
Coat the thread of the
bolt (b) and adjuster (c)
with MB long-term
grease.
Installation: The
retracting spring (112)
must be under the bolt
(b). Pay attention to
correct seating of the
return spring (112)!
Long-life grease *BR00.45-Z-1001-06A
9 Remove expanding lock Coat all bearing and
(109) slide surfaces on the
expanding lock (109)
with MB long-term
grease.
Long-life grease *BR00.45-Z-1001-06A
11.1 Release automatic slack Model 140, 202, 208, AR42.20-P-0520-02A
adjuster 210
11.2 Load adjustable slack Model 129, 170
adjuster
Inspect
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12 Check version of pedal

assembly
Parking brake pedal BT42.20-P-0510-01A
assembly modified
13 Adjusting parking brake Models 129, 140 as of AR42.20-P-0540A
1.11.93, 170, 202, 203,
208, 209, 210
Model 140 up to AR42.20-P-0540B
31.10.93
Fig. 59: Identifying Removal And Installation Tool (116 589 01 62 00)
Fig. 60: Identifying Installation Tool (112 589 09 61 00)
REPAIR MATERIALS
ADJUST PARKING BRAKE - AR42.20-P-0540A
MODEL 129, 170, 202, 203, 208, 210
MODEL 140 as from 1.11.93
MODEL 209.3/ 4
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Fig. 61: Identifying Parking Brake Adjustment Components
MODIFICATION NOTES
23.8.05 Clearance adjustment Step 7
value changed to 8 teeth
Check
Risk of death caused by Align vehicle between AS00.00-Z-0010-01A
vehicle slipping or the columns of the and
toppling off of the lifting position the four support
platform. plates below the lifting
platform support points
specified by the vehicle
manufacturer.
1.1 Check version of pedal Except model 170
assembly
Parking brake pedal BT42.20-P-0510-01A
assembly modified
2.1 Operate parking brake Except model 170
pedal and check pedal
travel of parking brake
pedal
If the pedal travel is
not within the tolerance
range: ?
Adjusting parking brake.
Actuating force on *BE42.20-P-1001-01C
parking brake pedal
Notches through which *BE42.20-P-1002-01C
the parking brake pedal
must be depressed
2.2 Operate parking brake Model 170
lever and check travel of Adjust parking brake,
the parking brake lever if the parking brake lever
can be pulled up by more
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than 3 notches without

any adequate braking
effect taking place.
Remove
3 Raise vehicle at rear
4.1 Slacken adjusting screw Models 129, 170
(89)
5 Undo a wheel bolt at the Light alloy wheels
left and right rear wheel must be removed due to
the risk of damage.
rotate if necessary
Adjust
6 Use screwdriver to rotate Actuation direction for
adjusting wheel (105) applying the brake shoes:
until the brake shoes abut Right side: Turn the
the parking brake drum adjusting wheel (105)
and the rear wheel or from the bottom upwards.
brake disk can no longer Left side: Turn the
be turned by hand. adjusting wheel (105)
from the top downwards.
Adjusting mechanism for Type 140 BT42.20-P-9311-01A
parking brake modified
7 Turn back adjusting When loosening the
wheel (105) until the adjusting wheels (105)
wheel or brake disk is ensure that both sides are
able to rotate completely turned back by the same
freely by hand number of teeth (8 teeth).
8.1 Turn in adjusting screw Model 129, 170
(89) until the brake cables
no longer sag
Check
9.1 Operate parking brake Except model 170
pedal several times and
check pedal travel of the
parking brake pedal, then
release the parking brake
Actuating force on *BE42.20-P-1001-01C
parking brake pedal
Notches through which *BE42.20-P-1002-01C
the parking brake pedal
must be depressed
9.2 Operate parking brake Model 170
lever several times, check Turn in adjusting
parking brake lever
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travel, and then release screw (89) until the

the parking brake parking brake lever can
be actuated by one tooth
with an average force
application of approx. 90
to 120 Nm.
10 Check for unobstructed
movement of rear wheels
or brake disks
Install
11 Fit wheel bolts or light
alloy wheels
rotate if necessary.
ADJUSTMENT VALUES FOR PARKING BRAKE

Number Designation Model 129, Pedal Model 129, Pedal
assembly with assembly with
pulled notch pushed notch
BE42.20-P-1001- Actuating force on N 170 (-50/+70) 170 (-50/+70)
01C parking brake pedal
BE42.20-P-1002- Notches through Quantity 1 5
01C which the parking
See fig. BT42.20-P-0510- BT42.20-P-0510-
brake pedal must be
01A 01A
depressed

See fig. BT42.20-P-0510- BT42.20-P-0510-
brake pedal must be
01A 01A
depressed

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01C which the parking See fig. BT42.20-P-0510- BT42.20-P-0510-

brake pedal must be 01A 01A
depressed

See fig. BT42.20-P-0510- BT42.20-P-0510-
brake pedal must be
01A 01A
depressed

See fig. BT42.20-P-0510- BT42.20-P-0510-
brake pedal must be
01A 01A
depressed

See fig. BT42.20-P-0510- BT42.20-P-0510-
brake pedal must be
01A 01A
depressed

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01C which the parking See fig. BT42.20-P-0510- BT42.20-P-0510-

brake pedal must be 01A 01A
depressed
REMOVING AND INSTALLING FRONT LEFT OR RIGHT RPM SENSOR - AR42.30-P-0712A
MODELS 129, 140, 170, 202, 203, 208, 210
Fig. 62: Identifying Front Left Or Right RPM Sensor Remove/Install Components
MODIFICATION NOTES
3.5.96 Mount for rpm sensor on refer to note, fig. item
front axle modified (L6/1b; L6/2b)
Fig. item, etc. Work instructions

L6/1a, L6/2a Self-locking Allen Replace *BA42.30-P-1001-01A
screws, rpm sensor screws.
L6/1, L6/2 Rpm sensor, front Installation : Inspect
wheel hub rotor for
damage. Ensure
cleanliness of magnetic
tip.
Models 202, 210
Rpm sensors from
Bosch and Teves must
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not be installed together.

Mount for rpm sensor on Model 202 as of 09.95 BT42.30-P-0001-01A
front axle modified
L6/1b, L6/2b Centering sleeve Replace centering
sleeves.
Model 202
as of 9.95
Lightly grease bore in *BR00.45-Z-1001-06A
steering knuckle.
FRONT AXLE RPM SENSOR

Number Designation Model 129 Model 140 Model 170 Model 202 Model 203
BA42.30-P- Self-locking Nm 22 22 22 22 25
1001-01A screw of
front axle
rpm sensor
to steering
knuckle
FRONT AXLE RPM SENSOR

BA42.30-P-1001- Self-locking screw Nm 22 22
01A of front axle rpm
sensor to steering
knuckle
REPAIR MATERIALS
REMOVING AND INSTALLING REAR AXLE SPEED SENSOR - AR42.30-P-0714A
MODEL 170, 202 with CODE (470a) Anti-lock brake system (ABS)
Model 202
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Fig. 63: Identifying Rear Axle Speed Sensor Remove/Install Components - Model 202
Model 170
Fig. 64: Identifying Rear Axle Speed Sensor Remove/Install Components - Model 170

Remove, install cover on Model 202
trunk floor and cover
panel underneath
Remove, install rubber Model 170
grommet from splash
panel on vehicle floor
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L6a Self-locking hexagon Installation: Replace

socket bolt, rear axle bolt.
speed sensor
*BA42.30-P-1002-02A
L6 Rear axle speed sensor Installation: Ensure
that the magnetic blade is
clean.
Check the drive pinion *BE35.31-P-1001-01A
rotor for number of teeth,
damage, dirt and firm
seating on the drive shaft.
TEST VALUES FOR REAR AXLE CENTER ASSEMBLY

Number Designation Models 129, 140, 170,
202, 208, 210 Number
of teeth on drive
pinion rotor
BE35.31-P-1001-01A Ratio i 2.64/2.65/2.68 36
2.73 35
2.82/2.85 34
2.87 33
3.07 31
3.27/3.29 29
3.45/3.46 28
3.54/3.58 27
3.64/3.67/3.70/3.73 26
3.91/3.92 24
4.08 23
REAR AXLE SPEED SENSOR

02A rear axle speed
sensor to rear axle
housing
REMOVING AND INSTALLING BAS CONTROL MODULE - AR42.31-P-6001A
MODEL 129, 140 as of 1.12.96, 170, 202 as of 1.6.97, 208, 210 as of 1.2.97
Shown on model 208
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Fig. 65: Identifying BAS Control Module Remove/Install Components - Shown On Model 208
Shown on model 210
Fig. 66: Identifying BAS Control Module Remove/Install Components - Shown On Model 210
Notes on brake booster AH43.20-P-0001-01A
1 Operate brake pedal The diaphragm travel
several times until sensor sealing ring may
vacuum in brake booster be sucked into the brake
is reduced. booster if vacuum is
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present.
If this happens, the brake
booster must be replaced.
On models 202, 208, 210
with ESP the BAS
control module is
integrated into the ESP
control module
2 Detach vacuum line (8) Only if space is
cramped.
3 Unplug control module
connector (16a)
4 Unplug BAS release
switch / solenoid valve
connector (A7/7x2)
5 Unplug BAS diaphragm
travel sensor connector
(A7/7x1)
6 Pull BAS control module Installation: Ensure
(N48) off bracket proper seating in the
bracket. The control
module must lock with an
audible click
The BAS control
module is parameterized
automatically by the
engine control module
after the engine is started.
order
REMOVING AND INSTALLING BAS DIAPHRAGM TRAVEL SENSOR - AR42.31-P-6002A
MODEL 129, 140 as of 1.12.96, 170, 202 as of 1.6.97, 208, 210 as of 1.2.97
Shown on model 208
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Fig. 67: Identifying BAS Diaphragm Travel Sensor Remove/Install Components - Shown On Model 208
Shown on model 210
Fig. 68: Identifying BAS Diaphragm Travel Sensor Remove/Install Components - Shown On Model 210
MODIFICATION NOTES
1.8.99 Check diaphragm travel New parts are marked
sensor for labeling with a white, yellow or
blue "D" (Figure 1). The
label may be on the side
away from you.
Notes on brake booster AH43.20-P-0001-01A
1 Operate brake pedal The diaphragm travel
several times until sensor sealing ring may
vacuum in brake booster be sucked into the brake
is reduced. booster if vacuum is
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present.
If this happens, the brake
booster must be replaced.
2 Unplug BAS diaphragm
travel sensor connector
(A7/7x1)
3 Remove locking ring Use a suitable tool, e.g.
(16b) angled scriber (arrow).
Installation: Replace
locking ring and ensure
that it is correctly seated.
Different
manufacturers use
different locking rings.
4 Pull out BAS diaphragm Installation: Rub a
travel sensor (A7/7b1) little spirit or soapy water
onto the front of the
diaphragm travel sensor
so that O-ring slides
correctly when inserted.
5 Replace O-ring Installation: Insert O-
ring into groove in brake
booster and ensure that it
is correctly seated.
order
Checking
7 Start engine Operate brake several
times.
8 Switch off engine
9 Check diaphragm travel There must not be any
sensor for leaks air flow noises audible at
the brake booster.
REMOVING AND INSTALLING ETS/ASR/ESP HYDRAULIC UNIT - AR42.40-P-0816
Removing and installing ETS/ASR/ESP hydraulic unit - AR42.40-P-0816A
MODEL 129, 140 as of 1.6.94, 170, 202 as of 1.6.94, 208, 210 with CODE (212a) Electronic traction
support (ETS) with CODE (471a) Acceleration Slip Regulation (ASR)
MODEL 129, 140, 210 with CODE (472a) Electronic Stability Program (ESP)
MODEL 202, 208 with ENGINE 112, 113 with CODE (472a) Electronic Stability Program (ESP)
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Connections on the ESP hydraulic unit (A7/3)
Fig. 69: Identifying Connections On ESP Hydraulic Unit
Connections on the Teves ASR/ETS hydraulic unit (A7/3)
Fig. 70: Identifying Connections On Teves ASR/ETS Hydraulic Unit
Connections on the Bosch ASR V/ETS hydraulic unit (A7/3)
Microsoft
Fig. 71: Identifying Connections On Bosch ASR V/ETS Hydraulic Unit

system
Ignition off
After installation Bleed brake system AR42.10-P-0010A
After installation Read fault memory and AD00.00-P-1000AZ
erase
Hydraulic lines Box wrench bit with Fig. 8
width across flats 11 mm.
Box wrench bit with Fig. 74
(ASR/ETS) *BA42.40-P-1001-01A
(ESP) *BA42.45-P-1003-01A
Models 202, 208 *BA42.45-P-1003-01B
Risk of confusion!
Mark hydraulic lines and
corresponding
connections before
unscrewing.
Microsoft
Seal off hydraulic Fig. 73

lines and connections
with blind plugs.
Installation: Pay
attention to the markings
when screwing on the
hydraulic lines. Do not
misconnect hydraulic
lines. Trace line routing
to the corresponding
wheel if necessary.
A Plastic caps Installation: Install
with the lug at the
bottom.
A7/3 Hydraulic unit (ETS) Model 170: Pull
upwards out of the rubber
plugs.
ACCELERATION SLIP REGULATION (ASR)

BA42.40-P- Brake line to Nm 15 15 15 15
1001-01A ASR / ETS
hydraulic unit

BA42.40-P-1001- Brake line to ASR / Nm 15 15
01A ETS hydraulic unit
ELECTRONIC STABILITY PROGRAM (ESP)

1003-01A ESP hydraulic
unit

Number Designation Model 208 with
engine 111
BA42.45-P-1003- Union nut, brake M10x1 Nm 14
01B line to ESP
hydraulic unit M12X1 Nm 16

Number Designation Model 208 with Model 202 with
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engines 112, 113 engines 112, 113

BA42.45-P- Union nut, brake M10x1 Nm 14 14
1003-01B line to ESP
hydraulic unit M12X1 Nm 16 16
Fig. 73: Identifying Set Of Plugs (129 589 00 91 00)
Removing and installing ETS/ASR/ESP hydraulic unit - AR42.40-P-0816B
MODEL 170 with CODE (472a) Electronic Stability Program (ESP)
MODEL 202, 208 with ENGINE 111 with CODE (472a) Electronic Stability Program (ESP)
MODEL 202 with ENGINE 605, 611 with CODE (472a) Electronic Stability Program (ESP)
Shown on model 170 Traction systems hydraulic unit (A7/3) manufactured by Teves
Microsoft
Fig. 75: Identifying Traction Systems Hydraulic Unit Remove/Install Components - Shown On Model 170
Traction Systems Hydraulic Unit
Shown on model 170
Fig. 76: Identifying Traction Systems Hydraulic Unit Remove/Install Components - Shown On Model 170
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system
1 Switch off ignition
2 Clean top of traction
systems hydraulic unit
(A7/3) near the hydraulic
lines
3 Unscrew hydraulic lines Risk of confusion!
from traction systems Mark hydraulic lines and
hydraulic unit (A7/3) corresponding
connections before
unscrewing.
Seal off hydraulic Fig. 73
lines and connections
with plugs.
Installation: Pay
attention to the markings
when screwing on the
hydraulic lines. Do not
misconnect hydraulic
lines. Trace line routing
to the corresponding
wheel if necessary.
Vehicles with *BA42.45-P-1003-01B
gasoline engine
Vehicles with *BA42.45-P-1001-01C
diesel engine
4 Unplug connector Unclip connector at
(A7/3x1) from traction the bottom on both sides,
systems hydraulic unit fold upwards and
disconnect.
5 Pull out traction systems Installation: Check
hydraulic unit (A7/3) seating and condition of
upwards, carefully rubber grommets and
pushing the hydraulic replace if necessary.
lines to one side
6 Unscrew bracket (13a) Vehicles with *BA42.45-P-1004-01B
from traction systems gasoline engine
hydraulic unit
diesel engine
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7 Unscrew control module Vehicles with *BA42.45-P-1005-01B

(N47) from traction gasoline engine
systems hydraulic unit
and pull off carefully
diesel engine
8 Install in the reverse Rinse off any brake
order fluid spilled on or around
the frame side member
with water.
10 Read fault memory and Fault memory, see
erase Diagnosis Manual,
Chassis, Volume 3.
11 Activate steering angle AR46.10-P-0300-01A
sensor

with engine with engine
111 111
BA42.45-P- Union nut, M10x1 Nm 14 14 14
1003-01B brake line to
ESP hydraulic M12X1 Nm 16 16 16
unit
BA42.45-P- Nut, bracket to Nm 10 10 10
1004-01B ESP hydraulic
unit
BA42.45-P- Nut, control Nm 4 4 4
1005-01B module to ESP
hydraulic unit

Number Designation Type 202 with
Motor 605, 611
BA42.45-P-1001- Union nut, brake M10x1 Nm 14
01C line to ESP
hydraulic unit M12X1 Nm 16
BA42.45-P-1002- Nut, bracket to ESP Nm 10
01C hydraulic unit
BA42.45-P-1003- Nut, control module Nm 4
01C to ESP hydraulic
unit
Microsoft
Fig. 79: Identifying Set Of Plugs (129 589 00 91 00)
REMOVE/INSTALL LEFT OR RIGHT REAR AXLE SPEED SENSOR - AR42.40-P-0820A
MODEL 129, 140 as of 1.6.94, 170, 202 as of 1.6.94, 208, 210 with CODE (471) Acceleration slip
regulation (ASR) with CODE (212) Electronic traction system (ETS)
MODEL 129, 140, 170, 202, 208, 210 with CODE (472) Electronic Stability Program (ESP)
MODEL 203, 209
Shown on model 202
Microsoft
Fig. 80: Identifying Left Or Right Rear Axle Speed Sensor Remove/Install Components

a Self-locking hexagon Installation: Replace
socket bolts, rear axle bolts in order to prevent
speed sensor them from becoming
loose.
Model 129, 140, *BA42.40-P-1002-01A
170, 202, 208, 210,
Model 203, 209 *BA42.30-P-1001-02A
L6/3, L6/4 Left/right rear axle rpm Installation: Check
sensor rotor on wheel hub for
damage. Pay attention to
cleanliness of magnetic
tip.
Lightly grease bore in *BR00.45-Z-1001-06A
wheel carrier.

BA42.40-P- Self-locking Nm 8 8 8 8
1002-01A bolt, rear axle
speed sensor
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REAR AXLE RPM SENSOR

BA42.30-P-1001- Self-locking bolt of Nm 8 8
02A rear axle rpm sensor
to wheel carrier

01A rear axle speed
sensor
REPAIR MATERIALS
Microsoft

Testing Repairs

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2003 Mercedes-Benz SLK320

1998-2004 TRANSMISSION Brakes - Testing & Repair - 170 Chassis

Brakes - Testing & Repair - 170 Chassis

TESTING & REPAIR

control cable 0525A

BLEED BRAKE SYSTEM. - AR42.10-P-0010A

MODEL 129, 140, 170, 202, 208, 210

Fig. 1: Bleeding Brake System

19.10.00 Value changed from 4 to Value in BA42.10-P- *BA42.10-P-1002-03A

(Code 471a) up to 31.5.94

front axle floating caliper

FIXED CALIPER AT REAR

FIXED CALIPER AT REAR

FIXED CALIPER AT REAR

FIXED CALIPER AT REAR

FRONT AXLE FIXED CALIPER

FRONT AXLE FIXED CALIPER

FRONT AXLE FLOATING CALIPER

FRONT AXLE FLOATING CALIPER

FRONT AXLE FLOATING CALIPER

with Code 957 435/444/445/

FRONT AXLE FLOATING CALIPER

BA42.10-P-1002- Bleed screw on NM 7 7

FRONT AXLE FLOATING CALIPER

0331-00A 0331-00A 0331-00A

Fig. 2: Identifying Electrical Connection Set (201 589 00 99 00)

Fig. 3: Identifying Socket Wrench (140 589 03 09 00)

COMMERCIALLY AVAILABLE TOOLS

Risk of poisoning; Risk of injury - AR42.10-P-0010-02A

FIXED CALIPER AT REAR

FIXED CALIPER AT REAR

Number Designation Model Model Model

FIXED CALIPER AT REAR

FIXED CALIPER AT REAR

FRONT AXLE FIXED BRAKE CALIPER

FRONT AXLE FIXED BRAKE CALIPER

BA42.10-P- Bleed screw at Nm 7 7 7

FRONT AXLE FLOATING CALIPER

FRONT AXLE FLOATING CALIPER

FRONT AXLE FLOATING CALIPER

FRONT AXLE FLOATING CALIPER

BA42.10-P-1002- Bleed screw on Nm 7 7

FRONT AXLE FLOATING CALIPER

Fig. 4: Identifying Socket Wrench (140 589 03 09 00)

Allow fluid to flow at each brake caliper (2, 3, 4)

until roughly 80 cm3 emerges free of bubbles.

Fig. 5: Bleeding Brake Caliper

Fig. 6: Identifying Electric Connector Set (201 589 00 99 00)

REPLACING BRAKE HOSES - AR42.10-P-0013A

MODELS 129, 140, 170, 202, 208, 210

Fig. 7: Identifying Brake Hoses

not empty completely.

BRAKE LINES, BRAKE HOSES

BRAKE LINES, BRAKE HOSES

Fig. 8: Identifying Box Wrench Bit (000 589 75 03 00)

Fig. 9: Identifying Box Wrench (000 589 76 03 00)

TEST BRAKE SYSTEM WITH PRESSURE TESTER FOR LEAKS - AR42.10-P-0015A

MODEL 129, 140, 170, 202, 203, 208, 210, 209.3 /4

opened/closed. The seat

Bleed screw on *BA42.10-P-1002-03A

FRONT AXLE FIXED BRAKE CALIPER

FRONT AXLE FIXED BRAKE CALIPER