Campaign - Underbody Cross Brace Inspection/Welding

Campaign No. 2008110010
December 2008

FILE:
SERVICE:
GROUP 00 OF SERVICE INFORMATION BINDER
PARTS:
GROUP I OF INFORMATION _ PARTS & ACCESSORIES BINDER

TO: ALL MERCEDES-BENZ CENTERS

SUBJECT:
Model 204, Model Year 2008

Check Cross Brace Supports, Repair if Necessary

This Service Campaign has been initiated because Daimler AG has determined that a crack may occur at an underbody cross brace support(s) due to irregularities in the forming process. The underbody cross brace supports will be inspected for cracks and the cracks will be welded, if necessary, 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 50 vehicles are affected.

Procedure

A. Inspect Cross Brace Support

1. Loosen left and right underfloor panels to access center cross brace support.

2. Remove cross brace.

NOTE: Torque bolts to 24 Nm. when reinstalling cross brace support.

3. Remove center heat shield.





4. Inspect left and right cross brace supports for crack formation or crease in area shown (Figure 1).

- If crack or distinct crease does not exist: procedure is complete.

- If crack or distinct crease does exist: proceed to Subject B.

B. Repair Cross Brace Support(s)

1. Disconnect battery ground cable (refer to WIS:. AR54.10-P-0003CW).

2. Drill ends of crack or crease using a 1/8 (approx. 3 mm) drill bit.

3. MIG weld crack or crease on cross member brace.

NOTE:
Ensure experienced MIG welder is performing this procedure.

CAUTION:
Observe all safety procedures when welding on vehicle.

4. Paint welded area: Prime and paint welded areas with dull black aerosol paint.

5. Apply preservation agent to repaired area on cross brace.

6. Reassemble in reverse order.

7. Reconnect negative battery cable (refer to WIS:. AR54.10-P-0003CW).





Primary Parts Information

NOTE:
- Please be aware that only the part number(s) referenced in the Campaign Bulletin is/are approved for use to repair the vehicle. Repairs performed using any other part(s) will not have been performed in accordance with the campaign. Accordingly, warranty claims submitted with reference to an improper part number(s) will be denied.
- The following allowable labor operation should be used when submitting a warranty claim for this repair:





Warranty Information