Safety Recall - No SRPC1623

Transcription

1 Service News - PC Reference No: SRPC1623 Please file in: Group: 51 Date: 24 October 2016 Version: 2.0 To: Service Managers at Passenger Car Retailers Please advise your Market Area Directors, After Sales Directors and CSU agents (Customer Support Units) of the contents of this letter Safety Recall - No SRPC1623 Title: Check starter transmission alternator wiring harness, rework if necessary Model: 222 with OM642 Codeword: 1607P51C21 Dear Colleague On the above cars produced between October 2014 and April 2016, it is possible that there may not be sufficient clearance between the starter/alternator cable harness and the exhaust system. Should this be the case the harness may overheat and be damaged, which may result in the transmission inadvertently shifting into "Neutral" with no obvious cause while driving. The drivetrain will also have no motive power and the engine may stall. Depending on the traffic situation this may present a risk to the occupants and other road users. In addition to the above, it may not be possible to select the "Park" position. However, the parking brake will remain fully functional. We therefore ask that you check the starter /alternator wiring harness and rework or replace the wiring harness as described on the attached working instructions Models concerned There are 723 affected cars in the UK excluding grey and parallel imports. Model Baumuster Chassis number range S-Class 222 with OM642 As per KDM To minimise customer inconvenience, you should check in the KDM section of EVA whether the car is affected by this or any other campaigns. If any campaigns are outstanding on the car, please arrange for all the required work to be carried out during one workshop visit. Warranty claims will only be accepted for this work carried out on cars within the campaign range. Yours faithfully Sally Jones Customer Services Director Mercedes Benz Cars CIRCULATE TO SERVICE MANAGER PARTS MANAGER SERVICE ADVISER W SHOP S VISOR TECHNICIANS

2 Procedure -2- MBUK will contact the owners of affected cars using DVLA records. If you are unsure whether a particular car should be campaigned, check through the search facility in the KDM section of EVA. For Warranty auditing purposes, please ensure that you have taken supporting data to verify successful repair of the car (eg. print outs/photographs etc) and include these in the job pack to substantiate your claim. Only System or Diagnostic Technicians should undertake Safety Recall work. In the case of this Safety Recall, it is necessary for the System/Diagnostic Technician(s), who will be carrying out the work, to first complete online SABA training, course reference number SRPC1615 Once the training has been successfully completed, the declaration page accompanying this newsletter must be signed and then kept in the car s job pack for auditing purposes. Working instructions All working instructions are to be printed off in colour Check starter - transmission - alternator wiring harness, rework or replace if necessary Model 222 with OM642 Check/test procedure 1. Remove engine cover (A, figure 1) at top and shield (B, figure 1) at firewall. Shield is tightened with two sheet metal screws (C, figure 1). C A B Figure 1

3 2. Check space (D, figure 2) between transmission wiring harness and exhaust system. Minimum distance must be 35 mm! -3- D D Figure 2 a. If minimum distance is less than 35 mm and electrical wiring harness is not damaged: Carry out work procedure A. b. If electrical wiring harness makes contact or is damaged: Carry out work procedure B. c. If minimum distance is 35 mm or more: End measure. The findings from the check/test procedure must be captured in written form on the workshop order and then filed in a tamper-proof manner! Work procedure A Carry out only if wiring harness is not damaged! 1. Pull the electrical wiring harness upward through the bracket on the partition wall until the distance of at least 35 mm to the exhaust system has been reached. Figure 3 2. Install remaining parts again.

4 -4- Work procedure B Carry out only if wiring harness is damaged! Replace starter - transmission - alternator wiring harness. 1. Move selector lever to position "N" and release parking brake. Only required in 4matic vehicles! 2. Disconnect ground line from electric battery. 3. Remove center and rear bottom sections of soundproofing. 4. Detach drive shaft of transfer case to front axle transmission at front axle transmission. Operation step is only required in 4matic vehicles! Heat shield above drive shaft does not have to be removed completely. Push released drive shaft slightly to one side. Screw/bolt, drive shaft to front axle transmission 45 Nm + 95 tightening angle Figure 4 5. Remove shield for electric transmission connection and disconnect connector. Figure 5

5 -5-6. Unscrew bracket (E, figure 6) for electric transmission wiring harness from transmission bell housing. E Figure 6 7. Unscrew electrical connectors (F, figure 7) from starter and unhook wiring harness from bracket (G, figure 7) of transmission bell housing. G F Figure 7 8. Remove right air filter housing.

6 9. Unscrew electrical wiring harness from alternator (H, figure 8) and disconnect connector from preglow relay (J, figure 8). Unhook bracket from wiring harness and separate cable tie (K, figure 8). -6- K J H Figure Disconnect electrical connectors from prefuse box (figure 9) in engine compartment and remove starter - transmission alternator wiring harness. Nut, positive terminal to engine compartment prefuse box M6 8 Nm Nut, positive terminal to engine compartment prefuse box M8 16 Nm Figure 9

7 Removed starter - transmission alternator wiring harness. Figure Assemble in reverse order. Parts supply Parts (if required) can be ordered in the normal manner via Parts Logistics. Part numbers specific to this Service Measure may be removed from both Automatic Ordering or Order Proposals in the RIMS System. This is to limit the amount of unused stock at Retailers and to avoid a Bottleneck Situation in the UK and Germany. Parts will still be available for manual ordering. PLEASE ORDER ONLY SUFFICIENT PARTS TO COMPLETE THE CARS THAT YOU WILL BE RECTIFYING. Quantity Description Part number As required Wiring harness (right-hand drive vehicle) A Cable tie A Screw/bolt (only 4matic) A Removed parts Please dispose of the parts locally once the warranty claim has been paid and the warranty guidelines have been met. Settlement of costs Costs incurred to carry out this work should be submitted via an individual Warranty/Goodwill claim per car. Please ensure that you use the relevant operation number(s) and damage code quoted. Standard texts and flat rates

8 Operation number Text Time Check starter wiring harness 0.3 h Rework starter wiring harness (after check) 0.1 h Replace starter wiring harness (after check) 1.7 h except 4matic Replace starter wiring harness (after check) only 4matic 2.4 h NOTE: -8- WIS/ EVA system may not have records for these Standard Texts and Times. If not it will be necessary to create them in your Autoline DMS system. To do this, follow the instructions located on Network News entitled: Manually creating Repair times and texts records. This can be found in the following location: Business Operations, Systems, User manuals & Instructions Once this has been carried out, they may then be entered directly in the New Product field of the Point of Sale screen. Retailers using other DMS systems will need to contact their supplier. The Operation Codes are Live in EVA. Damage code Text Carry out Safety Recall Prepared by: Geoff Ward / Colin Marsh Telephone No:

9 Declaration -9- I, the undersigned, hereby declare that I have read and understand the contents of the newsletter and attached working instruction for Safety Recall SRPC1623 I have also successfully completed the relevant training course, reference number SRPC1623 Name (please print in block capitals): Job Title (please circle): Diagnostic Technician Systems Technician Signature: Date (dd/mm/yyyy):