Mercedes C-Class

W203 since 2000 of release

Repair and operation of the car



Mercedes-Benz
+ Mercedes-Benz cars of class C (W-203)
+ Operation manual
+ Routine maintenance
+ Engine
+ Cooling system and heating
+ Power supply system and release
+ Engine electric equipment
+ Manual transmission
+ Automatic transmission
+ Coupling and power shafts
- Brake system
   Specifications
   Replacement of blocks of a forward disk brake
   Removal and installation of a forward support
   Replacement of back brake shoes
   Removal and installation of a back support
   Removal and installation of a brake disk
   Check of a brake disk
   Dual main brake cylinder
   Replacement of brake shoes of the parking brake
   Removal and installation of a cable of the drive of the parking brake
   Removal and installation of the switch of a stoplight
   Removal of air from the brake system
   Removal and installation of a brake hose
   Check of the amplifier of a brake
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment







Replacement of blocks of a forward disk brake

Apply the brake shoes recommended by the manufacturer. Address the Section Acquisition of Spare Parts of Introduction.

If brake shoes are used again, then at removal they need to be marked. Shift of brake shoes from outer side on internal and vice versa or from the right wheel on left is not allowed. Surely replace all brake shoes of one axis at the same time, even in case the limit of wear was reached only by one of them.


Removal

 PERFORMANCE ORDER

1. Mark with paint the provision of forward wheels concerning naves. It will allow to establish at assembly the balanced wheel in its former situation. Weaken bolts of fastening of a wheel before a car poddomkrachivaniye. Lift a forward part of the car, put it on supports and remove forward wheels.

Lifting operation and installations of the car on supports is connected with danger! Therefore before carrying out operation study Poddomkrachivaniye's Section and towage of Introduction to the management.


2. Right brake: Take out the plug (1) of the sensor of wear from the socket. At the same time do not pull for a cable (2). Disconnect a wire (3) the wear sensor from holders.

3. Turn out bolts of fastening (4) above and below.

4. Take out a support (1) from a guide of blocks.

5. Fix a support by a tape (2) or a wire on a depreciation rack. At the same time do not disconnect a brake hose. Otherwise after installation it is necessary to delete air from the brake system. You watch that the hose was not tense.

Do not press a brake pedal at the removed support. Otherwise the piston of the brake cylinder will be squeezed out from the case. If the piston was incidentally squeezed out, remove a support and hand over on HUNDRED for assembly.


6. To protection the piston of the brake cylinder from expression by whetstone of a tree (1).

7. Take out brake shoes (2) from a guide.
8. If the removed brake shoes are applied, mark them ("internal", "external"). Thus, they can awaking be established on the former place.


Check

 PERFORMANCE ORDER

1. Clear the surfaces of sliding and the place of landing of brake shoes on the directing wire brush from light metal, and also wipe a brake disk with the rag moistened in alcohol. Do not apply to this purpose mineral solvents or the tool with sharp edges.

Apply to cleaning of a brake only alcohol.

2. Before installation of brake shoes check hand fingers a brake disk for existence of flutes. In the presence of flutes a disk it is possible to pierce (work HUNDRED) if the disk has still sufficient thickness. Otherwise replace a disk.
3. Measure thickness of a brake disk as it is described in the Section Check of a Brake Disk.
4. Check lock brackets, if necessary replace with new.
5. Check an antisplash cover of the piston for existence of damages. Urgently replace the damaged cover since penetration of dirt can lead to violation of tightness of a support. For this purpose it is necessary to sort a support (work HUNDRED).
6. Check whether brake fluid follows from under the piston. If necessary repair a support on HUNDRED or replace it new.
7. Check also protective cover of the directing fingers of a support and in the presence of damages replace.

At big wear of brake shoes check ease of a piston stroke. For this purpose insert wooden whetstone into a support and ask the assistant to press a brake pedal slowly. The piston has to be pressed and squeezed out easily. For check other brake shoe and an opposite support have to be inserted. At a heavy piston stroke replace a support.


8. Right brake: Take out from the socket on a brake shoe the sensor of wear (1). Replace the damaged sensor of wear new. (2) – wear sensor plug.


Installation

 PERFORMANCE ORDER

1. Press the brake piston by means of adaptation. It can be made also by means of whetstone of a tree of strong breed (the hammer handle). At the same time pay special attention to that the piston did not warp and not to damage a protective cover.

By pressing the piston from the brake cylinder in the tank brake fluid is forced out. You watch liquid level in the tank, if necessary suck away liquid from the tank.

Apply a special bottle to suction of liquid for or a plastic bottle which is intended only for storage of brake fluid. Do not apply the bottle intended for drinking water to this purpose! Brake fluid is poisonous and should not be sucked away by a mouth at all. Use for this purpose the special aspirator. After replacement of brake shoes the level of brake fluid in the tank should not exceed the marks MAX since liquid when heating extends. The following liquid gets on the main brake cylinder, destroys its paint and varnish covering and leads to corrosion.

2. Insert brake shoes sideways at an angle into lock brackets on a guide of blocks. If the blocks which were already applied earlier are established you watch that they were established on the former places.

On frictional surfaces of a brake disk and brake shoes there should not be no lubricant or oil.

3. Insert a support on the place into a guide of blocks.
4. Screw the new self-stopped bolts at the top of and in the bottom of a support and tighten their moment 25 Nanometers.
5. Right brake: Enter the wear sensor plug into the socket. Insert a wear sensor wire in holders.
6. Establish into place forward wheels so that the marks put at removal coincided. Previously grease with a thin layer of bearing lubricant the aligning wheel disk belt on a nave. Do not grease bolts of fastening of wheels. Replace rusty bolts. Wrap bolts. Lower the car on wheels and tighten bolts cross-wise the moment of 110 Nanometers.

Several times, strongly press a brake pedal until notable resistance is felt. Thus, brake shoes adjoin to a disk and hold the working position.

7. Check the level of brake fluid in the tank, if necessary add liquid to the mark MAX.
8. New brake shoes carefully earn extra. For this purpose several times slow down the car from the speed of 80 km/h to speed 9. km/h, slightly pressing a brake pedal. Between braking let's a brake be cooled. The first 200 km of the movement do not apply needlessly strong braking of the car.

In some regions brake shoes have to be utilized in a special way. Local authorities provide information on a possibility of utilization of special waste.

Carry out reliability control:

· Whether brake hoses are fixed?
· Whether the brake hose is fixed in the holder?
· Whether unions for removal of air are tightened?
· Whether enough brake fluid is filled in?
· On the working engine check tightness. For this purpose press a brake pedal by effort of 200 - 300 N (20 – 30 kg) during 10 pages. The pedal should not weaken. Check all accessions for tightness.


Brake mechanisms with a motionless support

On some models 4-piston brakes with a motionless support are in front established. In this section only distinction in installation and removal of brakes of such design is described. Security measures and remarks on check are similar to earlier given.

Illustrations have informative character and cannot correspond to completely considered model.


Removal

 PERFORMANCE ORDER

1. Mark with paint the provision of forward wheels concerning naves. It will allow to establish at assembly the balanced wheels in their former situation. Weaken bolts of fastening of a wheel before a car poddomkrachivaniye. Lift a forward part of the car, put it on supports and remove forward wheels.

Lifting operation and installations of the car on supports is connected with danger! Therefore before carrying out operation study Poddomkrachivaniye's Section and towage of Introduction to the management.


2. Disunite the socket (1) of the sensor of wear (2). At the same time do not pull for a cable.

At assembly the wire has to be laid as it is shown on an illustration.

3. Beat out the corresponding drift (3 mm) two pins outside inside from a support. Remove a shaped spring (1).

4. Take out flat-nose pliers or the screw-driver brake shoes. If they rusted, special adaptation is required (for example, HAZET No. 1966-2).
5. If former brake shoes are applied, mark them ("internal", "external"). Thus they can be established on former places.

Do not press a brake pedal at the removed support. Otherwise the piston of the brake cylinder will be squeezed out from the case. If the piston was incidentally squeezed out, remove a support and hand over on HUNDRED for assembly.


Installation

 PERFORMANCE ORDER

1. By means of adaptation squeeze out both pistons. It can be made also by means of the hammer handle.

2. For an exception of a gnash of disk brakes reverse sides of brake shoes, and also lateral faces of the return plate (an arrow on an illustration) can be greased with a thin layer of brake paste (for example, high-temperature copper paste, Plastilube, Liqui Moly LM-36 or LM-508-ASC). Paste should not get on brake shoes or a brake disk at all. If necessary paste it is necessary to remove and wash out immediately places alcohol.

3. Remove the wear sensor from old brake shoes and insert into new blocks. In the presence of damage of the sensor it should be replaced.
4. Insert brake shoes into a support. If the blocks which were in work are established, check that they rose on the former places.
5. Insert a wear sensor cable into the socket on a support. Lay a cable according to its route.
6. Establish a new shaped spring and put new pins by means of a drift. Hammer a drift against the stop.

Surely replace a shaped spring and pins with new.

7. Establish into place forward wheels so that the marks put at removal coincided. Previously grease with a thin layer of bearing lubricant the aligning wheel disk belt on a nave. Do not grease bolts of fastening of wheels. Replace rusty bolts. Wrap bolts. Lower the car on wheels and tighten bolts cross-wise the moment of 110 Nanometers.

Carry out reliability control:

· Whether brake hoses are fixed?
· Whether the brake hose is fixed in the holder?
· Whether unions for removal of air are tightened?
· Whether enough brake fluid is filled in?
· On the working engine check tightness. For this purpose press a brake pedal by effort of 200 - 300 N (20 – 30 kg) during 10 pages. The pedal should not weaken. Check all accessions for tightness.