Campaign - Check/Replace ESP Hydraulic Unit Bracket Weld

Campaign No. 2012080002, September 2012

TO: ALL MERCEDES-BENZ CENTERS

SUBJECT:
Model 906, Model Year 2012
Check ESP Hydraulic Unit Bracket Weld, Replace if Necessary

This Service Campaign has been initiated because Daimler AG (DAG), the manufacturer of Freightliner and Mercedes-Benz Sprinter vehicles, has determined that on certain vehicles, due to a supplier issue, the Electronic Stability Program (ESP) hydraulic unit bracket may not have been properly welded. An authorized Freightliner or Mercedes-Benz Sprinter dealer will check the bracket weld, and if necessary replace the ESP hydraulic unit bracket at the next workshop visit.

Prior to performing this Service Campaign:
^ Please check VMI to determine if the vehicle is involved in the Campaign and if it has been previously repaired.

^ Please review the entire Service Campaign bulletin and follow the repair procedure exactly as described.

Please note that Recall and Service Campaigns do not expire and may also be performed on a vehicle with a vehicle status indicator.

Approximately 3,147 vehicles are affected.





Procedure

Warning!
Risk of poisoning from swallowing brake fluid. Risk of
injury from skin and eye contact with brake fluid.
Only pour brake fluid into suitable and appropriately
marked containers. Wear protective clothing and eye
protection when handling brake fluid (refer also to WIS:
AS42.50-Z-0001-01A).

Caution!
^ For Notes on repairs to brake system refer to WIS:
AH42.00-P-0003-01A.
^ For Notes on brake fluid refer to WIS:

AH42.50-P-0001-01A.

A. Inspect Welds on ESP Hydraulic Unit Bracket

1. Check welding of hydraulic unit bracket (1, Figure 1) using 0.8 mm feeler gauge:

^ If the feeler gauge can pass through (NOT OK):

Proceed to subject B.

Note:

Location of welds (arrows, Figure 2) on bracket (A).

^ If the feeler gauge cannot pass through (OK):
Procedure is complete.

B. Replace ESP Hydraulic Unit Bracket

1. Remove lines (3, Figure 1) from master brake cylinder to hydraulic unit (2).

Note:
Plug the lines (3, Figure 1) and threaded holes on the hydraulic unit (2) and master brake cylinder using stop plugs.

2. Unscrew lines (4, Figure 1) from hydraulic unit (2).

Note:

Plug the lines (4, Figure 1) and threaded holes on the hydraulic unit (2) using stop plugs.

3. Release and unplug connector (5, Figure 1) from ESP control unit (N30/4).

4. Unscrew 3 nuts (6, Figure 1) securing hydraulic unit.

Note:
Lower right nut not shown.

5. Remove hydraulic unit (2, Figure 1).

6. Remove hydraulic unit bracket (1, Figure 1).





7. Transfer grommets (arrows, Figure 3) from old hydraulic unit bracket to new bracket (A).

8. Installation is in reverse order.

Note:

^ Torque nuts, hydraulic unit to bracket to: 8 Nm.
^ Torque threaded connection for brake lines on hydraulic unit to: 14 Nm
^ Some vehicles may be equipped with 2 lock nuts and 1 bolt securing hydraulic unit bracket to vehicle.
In this case, reuse mounting bolt and replace 2 lock nuts.

9. Bleed brake system, refer to WIS: AR42.10-D-0010H.

10. Check fluid in reservoir, correct if necessary.

11. Check brake system for leaks, refer to WIS: AR42.10-S-0100-01S.

Note (regarding WIS documents referenced in this Procedure):
Replacement of parts not listed in the parts table of this Procedure are not claimable under this campaign. If replacement of additional part(s) is necessary, check coverage prior to submitting under warranty.





Special Tools





Primary Parts Information







Warranty Information