Campaign - Starter Wiring Harness Routing
Campaign No. 2006100003, October 2006FILE:
SERVICE: GROUP 00 OF SERVICE INFORMATION BINDER
PARTS: GROUP I OF INFORMATION _ PARTS & ACCESSORIES BINDER
TO: ALL MERCEDES-BENZ CENTERS
SUBJECT:
MODEL 164, MODEL YEAR 2006
INSPECT STARTER WIRING HARNESS; REPAIR OR REPLACE IF NECESSARY
This Service Campaign has been initiated because DCAG has determined that on the affected vehicles (see VIN range below) the starter wiring harness may be routed incorrectly. This routing could lead to chafing of the protective sleeve covering the starter wiring harness. Over time, such chafing has the potential to wear through the protective sleeve and may expose the underlying starter wiring harness to further chafing.
Please review the Effective Serial Number chart located below and if necessary repair the subject vehicles during the vehicle's next service.
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.
Approximately 9,057 vehicles are affected.
Effective Serial Number Range
NOTE:
Every vehicle in the VIN range may not be included in the campaign. VMI must always be checked before performing campaigns to verify that the campaign is required on a specific vehicle. VMI always overrides the bulletin in reference to a specific vehicle's inclusion in a particular campaign. Please also note that Recalls and Service Campaigns do not expire and may also be performed on a vehicle with a vehicle status indicator.
Procedure
A. INSPECT STARTER WIRING HARNESS
1. Remove bottom engine compartment paneling; refer to WIS document AR61.20-P-1105GZ.
2. Check starter wiring harness corrugated tube for damage in the area of the engine support (A, Figure 1).
a. Starter wiring harness corrugated tube not damaged: Carry out Subject B.
b. Starter wiring harness corrugated tube damaged: Carry out Subject C.
c. Corrugated tube and red insulation of starter wiring harness damaged: Carry out Subject D.
B. CORRUGATED TUBE NOT DAMAGED
1. Mount starter wiring harness (A) to oil dipstick guide tube (C) using clip (B) (Figure 2).
2. Retrofit protective cap on right side engine support lower rear screw (A, Figure 3).
C. CORRUGATED TUBE DAMAGED
1. Cut open a new 5 cm long corrugated tube (A) lengthwise and install over existing corrugated tube (B) in the damaged area (Figure 4).
2. Repaint section on engine support if damaged.
3. Fasten the starter wiring harness to the oil dipstick guide tube using clip (Figure 2).
4. Retrofit protective cap on right side engine support lower rear screw (Figure 3).
D. STARTER WIRING HARNESS DAMAGED
New repair method:
The exhaust system does not have to be completely removed.
The existing WIS literature will be adapted.
1. Disconnect ground wire from battery; refer to WIS document AR54.10-P-0003GZ.
2. Remove right catalytic converter; refer to WIS document AR49.10-P-5500GZM
NOTE:
The nuts and bolts referred to in WIS document AR49.10-P-5500GZM DO NOT need to be replaced.
3. Remove starter (A, Figure 5).
- Pry open cable holder (B) and remove cable.
- Remove transmission bracket bolts (D).
- Remove starter heat shield bolts (E); remove heat shield (F).
- Remove starter (A) from transmission bellhousing with wires still attached (Figure 6).
- Remove cap from electrical connection terminal 30 nut (B) and remove nut; remove electrical connection terminal 50 nut (C).
- Remove starter from vehicle.
4. Remove cap (A) and disconnect starter wiring harness (B) from alternator (C). (Figure 7)
5. Lower vehicle and open hood.
6. Cut wire ties and disconnect starter wiring harness (A, Figure 8 & 9).
- Remove bolt (B) at oil dipstick (Figure 8).
- Remove starter wiring harness from clip (C, Figure 8).
- Remove starter wiring harness from clip (B, Figure 9).
- Disconnect starter wiring harness from front prefuse F32 (C, Figure 9).
CAUTION:
Carefully remove starter wiring harness from prefuse to prevent damage to prefuse.
7. Remove starter wiring harness from vehicle; install new wiring harness in reverse order.
- Torque nuts on alternator and starter (A, Figure 7; C, Figure 6) to 15 Nm.
- Secure new harness with cable ties.
8. Assemble in the reverse order.
9. Perform Subject A: Fasten the starter wiring harness to the oil dipstick guide tube using clip (Figure 2), and retrofit protective cap on engine support mounting screw (Figure 3).
10. Repaint section on engine support if damaged.
11. Perform basic programming; refer to WIS document AR00.19-P-0200GZ.
Special Tools
NOTE:
The noted Special Tool is classified as a "K" tool and can be ordered at the discretion of the dealer.
Primary Parts Information
NOTE:
The following secondary part(s) is/are not to be ordered in equal quantities as the primary part(s). therefore do not package or kit campaign parts together since not all vehicles will require these parts.
Secondary 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
Repair 1
Operation:
Starter wiring harness corrugated tube, Check (02-5396)
Clip for starter wiring harness (after check), Install (02-5397)
Repair 2
Operation:
Starter wiring harness corrugated tube, Check (02-5396)
Corrugated tube in damaged area (after check), Install (02-5398)
Clip for starter wiring harness (after check), Install (02-5397)
Repair 3
Operation
Starter wiring harness corrugated tube, Check (02-5396)
Starter wiring harness (after check), Replace (Model 164) (02-5399)
Clip for starter wiring harness (after check), Install (02-5397)