Campaign - High Pressure Fuel Pump Replacement
FILE:SERVICE: GROUP 00 OF SERVICE INFORMATION BINDER
PARTS: GROUP I OF INFORMATION PARTS & ACCESSORIES BINDER
Campaign No. 2005010011
February 2005
TO: ALL MERCEDES-BENZ CENTERS
SUBJECT:
MODEL 211.026, MODEL YEAR 2005
A. INSPECT HIGH PRESSURE FUEL PUMP AND REPLACE FUEL SYSTEM
COMPONENTS IF NECESSARY (FOR RETAILED VEHICLES)
B. INSPECT HIGH PRESSURE FUEL PUMP AND REPLACE FUEL PUMP
IF NECESSARY (FOR VEHICLES IN DEALER INVENTORY)
This Service Campaign has been initiated because DCAG has determined that due to a supplier quality issue the high pressure diesel pump must be changed on affected vehicles (refer to VIN ranges below). An unfavorable material composition in the pump bearings may lead to a higher wear and tear condition leading to possible damage of the high pressure diesel pump. To eliminate the possibility of damage to the high pressure diesel pump we have decided to replace this part as a preventive measure on all affected vehicles. Diesel high pressure pumps in vehicles that have already been delivered to the customers will be replaced through this service campaign. Further inspection will be conducted on customer vehicles for metal particles in the fuel. Should metal particles be found, a more substantial repair to fuel system components is required and detailed in the below work instructions. Vehicles that have been held in dealer inventory only require the high pressure diesel pump to be replaced prior to customer delivery.
Please review the Effective Serial Number chart located below and if necessary repair the subject vehicles. Please contact retail customers to bring in vehicles to dealer to perform this campaign immediately.
Note:
Replacement of affected high pressure pumps does not require EDAC authorization for this campaign only. Dealer must contact EDAC for authorization for complete fuel system replacement (ensure EDAC case number is included in dealer text field if additional repair work is required).
Prior to performing this Service Campaign:
^ Please check VMI to insure the vehicle is involved and to determine if the vehicle has been previously repaired.
Please review the entire Service Campaign bulletin.
Effective Serial Number Range
Approximately 142 vehicles are affected.
A. INSPECT HIGH PRESSURE FUEL PUMP AND REPLACE FUEL SYSTEM COMPONENTS IF NECESSARY (FOR RETAILED VEHICLES)
Note:
Dealer must contact EDAC for authorization for complete fuel system replacement (ensure EDAC case number is included in dealer text field if additional repair work is required)
Procedure
1. Verify manufacturing date of high pressure pump:
^ Remove 9 bolts securing engine cover (Arrow, Figure 1), remove engine cover.
^ Verify manufacturing date (underlined in Figure 2) of high pressure pump (arrow) using a mirror.
^ If the manufacturing date of the high pressure pump is between November 18, 2004 (04-11-18) and January 18, 2005 (05-01-18), proceed to step 2.
^ If manufacturing date is outside of the date range, reinstall engine cover torque bolts to 9 Nm (end of procedure: refer to Repair 1 of Warranty Information).
2. Check for metal shavings from fuel return line on the high pressure pump:
^ Remove clamp (arrow, Figure 3) from high pressure fuel pump return line (A)
^ Detach return line (A) coming from the fuel line connecting support fitting (B).
WARNING!
Risk of explosion caused fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel. Refer to WIS document: AS47.00-Z-0001-01A.
^ Collect fuel into suitable container (Arrow, Figure 4), making sure to hold on tight to fuel line as fuel is under pressure.
^ Only after previous step is complete, switch on ignition for approx. 10 seconds while holding on to fuel line. You will need to collect the first gush of fuel that comes out.
^ Using a suitable filter (such as a paper towel or coffee filter), check collected fuel for visible metal shavings.
^ If no shavings are found, only replace the high pressure pump as per WIS document: AR 07.02-P-10201. Mark new pump with white dot (see note after step 6) (end of procedure: refer to Repair 2 of Warranty Information).
^ If metal shavings are found, proceed to step 3
3. Replace the following fuel system components (see danger WARNING above):
^ Fuel filter as per WIS Document AR 47.20-P-10701.
^ High pressure fuel pump as per WIS Document AR 07.02-P-10201. Mark new pump with white dot (see note after step 6). Complete rail with high pressure lines as per WIS Document AR 07.16-P-1010T.
^ Injectors and return line as per WIS Document AR 07.16-P-1000T.
^ Fuel tank as per WIS Document AR 47.10-P-41001 and AR 47.10-P-4100MZ. Properly dispose the remaining fuel and fuel tank.
4. Flush fuel lines using hand pump:
^ Remove rear seat, remove fuel pump access cover (arrow, Figure 5).
^ Flush the fuel lines by forcing fuel through in the normal direction of flow using a (special tool) hand pump (Arrow, Figure 6). Special tool: W210 589 00 71 00
5. Reassemble in reverse order.
6. Connect SDS. Determine the injectors IMA (Injector Quantity Compensation) coding and code under the following menu items: Control Unit/Drive/CDI 3/ Control unit adaptation/Injector injection quantity adjustment (as per DTB: P-B-07.03/45) (End of procedure. Refer to Repair 3 of Warranty Information).
Note:
If there is no white dot on new high pressure pump, mark the pump with white color dot, marker or paint pen in front of the threaded sleeve (arrow, Figure 7) of the high pressure line.
Note:
Claiming for sublet reimbursement requires detailed explanation in Dealer text field. The following allowable labor operation should be used when submitting a warranty claim for this repair:
Parts and Warranty Information (FOR RETAILED VEHICLES)
Special Tools
Workshop Equipment
B. INSPECT HIGH PRESSURE FUEL PUMP AND REPLACE FUEL PUMP NECESSARY (FOR VEHICLES IN DEALER INVENTORY)
Note:
If vehicle has been driven (e.g., loaner, demo) above mileage accrued in normal vehicle logistics (moved on lot, driven on/off car carrier) dealer must contact EDAC for authorization for complete fuel system replacement (ensure EDAC case number is included in dealer text field if additional repair work is required).
Procedure
1. Verify manufacturing date of high pressure pump:
^ Remove bolts securing engine cover (Arrow, Figure 8), remove engine cover.
^ Verify manufacturing date (underlined in Figure 9) of high pressure pump (arrow) using a mirror.
^ If the manufacture date of the high pressure pump is between November 18, 2004 (04-11-18) and January 18, 2005 (05-01-18), proceed to step 2.
^ If manufacturing date is outside of the date range, reinstall engine cover torque bolts to 9 Nm (end of procedure: refer to Repair 4 of Warranty Information).
2. Replace the high pressure pump as per WIS document: AR 07.02-P-10201. Mark new pump with white dot (see note after step 6) (end of procedure: refer to Repair 5 of Warranty Information).
Note:
The following allowable labor operation should be used when submitting a warranty claim for this repair:
Parts and Warranty Information (FOR VEHICLES IN DEALER INVENTORY)