Campaign - Front/Rear Bumper Under-Ride Guard Rework
FILE:SERVICE: GROUP 00 OF SERVICE INFORMATION BINDER
PARTS: GROUP I OF INFORMATION_PARTS & ACCESSORIES BINDER
Campaign No. 2007070002
September 2007
Revision Date Purpose
B 09/18/07 Update to include vehicles with brush guards
A 08/17/07 Addition of Caution note regarding drilling procedure
- 07/20/07 Initial issue
TO: ALL MERCEDES-BENZ CENTERS
SUBJECT:
MODEL 164
MODEL YEAR 2006
REWORK STAINLESS STEEL UNDER-RIDE GUARDS ON FRONT AND REAR BUMPERS
This Service Campaign has been initiated because DCAG has determined that on affected vehicles corrosion may occur on the threaded fasteners of the front and rear under-ride guards. Dealers will remove the stainless steel under-ride guards and replace the fasteners in all affected vehicles.
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. If necessary, repair the subject vehicle during the vehicle's next service.
^ Please review the entire Service Campaign bulletin and follow the procedure steps 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 9,362 vehicles are affected.
PROCEDURE OVERVIEW
Procedure
NOTE:
Refer to the MSDS (via NetStar or the Parts Assistance Center website) for a complete description of hazards and other important safety information regarding the thread lock and preservation agent used in this procedure.
A. FRONT BUMPER REWORK
1. Remove license plate and frame (D, Figure 1), if installed.
^ Remove brush guard if installed.
2. Remove front stainless steel under-ride guard.
^ Remove bolts (A-C, Figure 1); Discard bolts A and C.
^ Clean under-ride guard thoroughly.
^ Deburr under-ride guard.
3. Drill access holes into front bumper (arrows, Figure 2).
Note - Holes must be:
^ 28 mm in diameter
^ Drilled alternately to the left and right of existing bolt hole
^ Drilled 25 mm from the edge of the existing bolt hole.
CAUTION!
In order to avoid damaging the Parktronic wiring harness (located behind the bumper), stop immediately after drilling through the bumper!
4. Remove spring clip nuts (A, Figure 1) through drilled access holes.
^ Discard spring clip nuts.
5. Cut adhesive strip into three pieces according to cut template.
6. Install adhesive strips (B, Figure 3) on mounting brackets (B, Figures 1 and 4), as shown in Figure 4.
^ Wrap adhesive strip around top of mounting bracket.
^ Puncture adhesive strip in center of bracket hole.
^ Ensure brackets are grease-free prior to reinstallation of stainless steel panel.
7. Reinstall front stainless steel under-ride guard.
^ Replace upper bolts (A, Figure 1) with new stainless steel bolts.
^ Apply a drop of thread lock to tip of stainless steel bolts, as shown in Figure 6.
^ Install a plastic washer on every stainless steel bolt prior to installing bolt.
^ Torque bolts to 7 Nm.
^ Replace clip nuts (A, Figure 1) with new stainless steel clip nuts.
^ Reinstall bolts into holes marked "B" in Figures 1 and 4; torque to 7 Nm.
^ Install plastic rivets into holes marked "C" in Figures 1 and 5.
8. Rework license plate frame.
^ Ensure there is a gap of 3 mm between frame and stainless steel ride guard, as shown in Figure 7.
9. Reinstall license plate and frame (if previously installed).
^ Reinstall brush guard (if previously installed).
B. REAR BUMPER REWORK
1. Remove rear stainless steel under-ride guard.
^ Remove and discard bolts (E-F, Figure 8).
^ Clean under-ride guard thoroughly.
^ Deburr under-ride guard.
2. Cut out section of mounting rail (G), as shown in Figure 9.
Note:
Ensure the mounting rail cannot come into contact with the stainless steel under-ride guard.
^ Reinstall two mounting bolts on mounting rail directly to left and right of cutout in order to secure mounting rail during cutting procedure.
Note:
Failure to secure the mounting rail may result in the rail falling into the bumper, requiring removal of the bumper to retrieve it.
^ Use a cylindrical cutting/grinding bit similar to one shown in Figure 10.
WARNING!
Risk of injury to skin and eyes caused by sparks resulting from cutting the mounting rail. Ensure to wear eye protection and safety gloves during the cutting procedure.
3. Apply suitable corrosion protection to mounting rail cutout, as shown in Figure 9.
Note:
The mounting rail is cathode-dip painted.
4. Remove tow hook check strap (I, Figure 11).
5. Install adhesive strip on edge of check strap cut out, as shown in Figure 12.
^ Start wrapping adhesive strip from outside and wrap around edge of check strap cutout.
^ Ensure edges of cutout are grease-free.
6. Spray preservation agent into upper bolt holes (E, Figures 8 and 13).
7. Reinstall rear stainless steel under-ride guard.
^ Replace bolts (E and F, Figure 8) with new stainless steel bolts.
^ Apply a drop of thread lock to tip of new bolts, as shown in Figure 6.
^ Install a plastic washer on every stainless bolt prior to installing bolt.
^ Torque bolts to 7 Nm.
^ Install new stainless steel nuts and washers into lower holes (F).
^ Secure nuts with a counter wrench while tightening in order to avoid damaging surface of washers.
^ Reinstall tow hook cover (G, Figures 8 and 9).
Parts Information
Note:
^ Please be aware that only the part number(s) referenced in the Campaign Bulletin is 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.
^ Please note that the information in the most current versions of EPC and StarTime supersedes the parts and warranty information in the Campaign Bulletin.
^ The following allowable labor operation should be used when submitting a warranty claim for this repair:
Warranty Information