MBenz C230 W203 272 V6-2.5 PDF

Mercedes Benz C230
W203 Chassis - V6 2.5L M272 Engine

Repair Manual
hermelvallem@gmail.com
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Mercedes Benz C 230 (203.052) V6-2.5L (272.920) 2
Vehicle: Application and ID
AH60.00-P-0800-02B Vehicle Identification Number
AH60.00-P-0800-02B Vehicle Identification Number
The vehicle identification number starts and ends with the "Mercedes star" trademark (1, 19) and has 19 punched numbers with a total length of 103
mm
If, in case of repair, the area where the vehicle identification number has been embossed is replaced, it is necessary to punch in the vehicle
identification number at the same point.
This involves a change to the vehicle which is subject to compulsory notification. In the Federal Republic of Germany immediately inform the
vehicle licensing authority in writing.
The vehicle owner is required to complete a certificate for the vehicle licensing authority which indicates that the vehicle identification number has
been re-stamped after completing body repairs.
As prove, the original vehicle identification number cut out of the old part, may also be enclosed.
A vehicle identification number incompletely punched in by the workshop must be crossed out and pinched in correctly in the spare field on the
right crossmember, the right side of the drive shaft tunnel, the rear partition wall or the firewall.
This procedure should be noted additionally in the certificate for the vehicle licensing authority as follows:
"The incorrectly or incompletely punched vehicle identification number was crossed out and the correct vehicle identification number punched in
the spare field."
Export countries must observe their relevant vehicle licensing provisions and legal regulations.
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Vehicle: Technician Safety Information
AH00.00-U-1000-01Z Observe Safety Regulations When the Engine Is Running

AH00.00-U-1000-01Z Observe Safety Regulations When The Engine Is Running
Before performing jobs with engine running apply parking brake.

On vehicles with automatic transmission place selector lever into position P".
On vehicles with manual transmission place shift lever into neutral.
AH00.00-N-0001-01A Notes on Self-Locking Nuts and Bolts
AH00.00-N-0001-01A Notes on self-locking nuts and bolts
Important repair information

Bolts with locking splines, micro-encapsulated bolts and self locking nuts must always be replaced after being used once.
There is an increased risk of injury when unscrewing micro encapsulated bolts due to the sudden breakaway torque.
Before new micro-encapsulated bolts are screwed in, the mating thread must be re-cut in order to remove all the residue of the old bolt locking
compound.
AS54.00-Z-0001-01A Risk Of Death When Touching Components On Vehicles With High-voltage

On-board Electrical System
AS54.00-Z-0001-01A Risk Of Death When Touching Components On Vehicles With High-voltage On-board Electrical System
DANGER: Do not touch components and open lines of the high-voltage on-board electrical system. Persons who are carriers of electronic
implants (e.g. cardiac pacemakers), must not carry out any work on high-voltage on-board electrical systems.
High-voltage on-board electrical system
Voltage values of > 120 volt apply in the entire high-voltage on- board electrical system.
Risk of death caused by electric shock
Burns, fibrillation of the heart or cardiac arrest due to electric shock can occur when touching components of the high-voltage on-board electrical
system. The consequences of an electric shock may also only occur after a few minutes, therefore a doctor should be consulted in every case.
Safety instructions/precautions
- Persons who are carriers of electronic implants (e.g. cardiac pacemakers), must not carry out any work on high-voltage onboard electrical
systems.
- Open lines and components of the high-voltage on-board electrical system must not be touched under any circumstances.
In particular this affects accident vehicles before the high- voltage on-board electrical system is put out of action.
- Work on components of the high-voltage on-board electrical system may only be carried out by persons proven to have taken part in special
qualification measures and who have completed special electrotechnical training and are authorized.
AS54.10-Z-0001-01A Risk Of Explosion From Gas. Risk Of Poisoning And Burns From Swallowing
Battery Electrolyte.
AS54.10-Z-0001-01A Risk Of Explosion From Gas. Risk Of Poisoning And Burns From Swallowing Battery Electrolyte. Risk Of Injury To
Eyes And Skin As Result Of Caustic Burns From Battery Electrolyte Or From Handling Damaged Lead- Acid Batteries.
DANGER: No fire, sparks, naked flames or smoking. Wear acid-resistant gloves, clothing and eye protection. Pour battery electrolyte
only into suitable and appropriately marked containers.
Possible hazards
Risk of explosion
A highly explosive gas mixture is produced when charging lead-acid batteries.
Risk of poisoning
If battery electrolyte is swallowed, this can result in manifestations of poisoning such as headaches, dizziness, stomach pain, respiratory paralysis,
unconsciousness, vomiting and cramps.
Battery electrolyte mist causes caustic burns to the eyes. If swallowed, this can result in caustic burns to the mucous membranes and respiratory
passages.
The absorption of lead in the body can cause damage to blood, nerves and kidneys; in addition, lead compounds are considered to represent a
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reproductive hazard.
Injury hazard
Battery electrolyte contains sulfuric acid which can cause severe caustic burns to skin and eyes. Strict caution is required when leadhandling
damaged lead-acid batteries (removing from vehicle damaged in accident) because of the sharp edges on the fractured housing and direct contact
with the lead plates.
Protective measures/rules of conduct

- Charge lead-acid batteries only in well ventilated areas.
- No fire, sparks, naked flames or smoking.
- Do not place any tool or other conducting objects onto the lead-acid battery (risk of short-circuit).
- Disconnect and remove lead-acid batteries for charging.
- Always disconnect negative terminal first of all; always connect positive terminal first of all.
- Do not switch on the charger until after it has been connected to the terminals; switch it off before disconnecting.
- Keep lead-acid batteries and battery electrolyte away from unauthorized persons.
Pour battery electrolyte only into suitable and appropriately marked containers.
- Always store lead-acid batteries horizontally.
- Ensure the gassing line is properly connected.
- Ensure the gassing line does not have any kinks and is not blocked at any point.
- Pay attention to instructions for use of the particular lead-acid battery and the operating instructions of the vehicle.
- Wear acid-resistant clothing and eye protection with side guards.
First-aid measures
Eye contact
^ Rinse out eyes immediately with plenty of water.
Skin contact
^ Take off moistened clothing.
^ Immediately neutralize acid splashes on skin or clothing with acid converter or soap suds and rinse off with plenty of water.
Inhaling battery electrolyte mist

^ Take the affected person out into the fresh air.
Swallowing battery electrolyte

^ Have the person affected drink plenty of water with the addition of activated charcoal.
As a general rule, the person affected should consult a medical service or doctor after first-aid has been rendered.
Fire protection measures
Suitable extinguishing agents

- CO(2) and dry extinguishing agent
Component Identification
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AS54.10-Z-0001-02A Risk Of Injury Caused By Contact With Battery Gel When Handling
Damaged Lead-Gel Batteries
AS54.10-Z-0001-02A Risk Of Injury Caused By Contact With Battery Gel When Handling Damaged Lead-gel Batteries
DANGER: No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and safety glasses.
Potential risks
Risk of poisoning
If battery gel is swallowed this can cause poisoning symptoms such as headaches, dizziness, stomach aches, respiratory paralysis, unconsciousness,
vomiting, caustic burns and cramps. The absorption of lead in the body can cause damage to blood, nerves and kidneys; in addition, lead
compounds are considered to represent a reproductive hazard.
Risk of injury
Battery electrolyte gel is just as caustic as normal electrolyte fluid and can cause serious caustic burns to the skin and eyes. Strict caution is required
when handling damaged lead-gel batteries (e.g. when removing from a vehicle damaged in an accident) due to the sharp edges on a broken housing
and direct contact with the lead plates.
Safety precautions and rules of conduct

- No fires, sparks, open flames or smoking.
- Keep tools and other conductive objects away from lead-gel batteries (risk of short-circuit).
- Disconnect and remove lead-gel batteries for charging.
- Always disconnect negative terminal before positive terminal connect positive terminal before and always negative terminal.
- Switch on the charging equipment only after connecting to the terminals and switch off the charging equipment before disconnecting from
the terminals.
- Keep lead-gel batteries away from unauthorized persons (especially children).
- Observe the instructions of the particular lead-gel battery and the operator's manual of the vehicle.
- Wear acid-resistant clothing and eye protection with side guards.
- Only fill gel into suitable and appropriately marked containers.
First aid measures
Eye contact
^ Rinse out eyes immediately with plenty of water.
Skin contact
^ Remove affected clothing.
^ Immediately neutralize acid or gel on skin or clothing with acid converter or soap suds and rinse off with plenty of water.
Swallowing battery gel

^ Have the person affected drink plenty of water with the addition of activated charcoal.
As a general rule, always consult a medical service or doctor after first-aid has been rendered.

- CO(2) and dry extinguishing agent
AP00.20-P-0000-02A Safety Notes/Warning Notes
AP00.20-P-0000-02A Safety Notes/warning Notes
Safety information (hazardous situations for persons), warnings (quality of work, property damage).
These notes are identified by the following symbols (logos):
In order to rule out any risk of personal injury, to avoid impairing the reliability and safety of the vehicle, and to prevent damage to the vehicle as a
result of work improperly carried out, these instructions are to be read carefully and complied with in full.
Consequently, it is not possible for Daimler AG to evaluate in the last consequence every situation which might present a risk of injury for the
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operative. It is therefore essential that anyone performing repair work on Mercedes-Benz passenger cars applies his professional expertise in order
to satisfy himself that his own safety is not at risk and that the vehicle will not be impaired in any way, in particular in terms of safety, by the
method of repair selected.
It is therefore expressly pointed out that all work for the operations described must be carried out in compliance with valid directives and
instructions from the responsible local authorities and those relating to health, work safety and environmental protection.
AS00.00-Z-0002-01A Risk Of Injury. Skin Or Eye Injuries May Result When Handling Hot Or
Glowing Objects.
AS00.00-Z-0002-01A Risk Of Injury. Skin Or Eye Injuries May Result When Handling Hot Or Glowing Objects.
DANGER: Wear protective gloves, protective clothing and (where necessary) safety glasses.
Risk of injury
Unprotected contact with hot or glowing objects may cause severe burns to the skin and eyes.
If glowing objects come into contact with water, hot steam or hot splashing water may result in severe skin and eye burns. Severe and possibly
permanent injuries may result if hot or glowing objects come into contact with unprotected skin or eyes.
Fire may result if glowing objects come into contact with flammable materials or substances.
Safety precautions/instructions
- Wear protective clothing, safety glasses and heat-resistant gloves.
- Transport hot or glowing objects using approved equipment only.
- When handling glowing objects, avoid sparks and keep objects away from flammable materials and substances.
First aid measures

- Flush the affected skin areas with plenty of cold water and dress with sterile bandages.
- Consult a doctor without delay.
AS00.00-Z-0004-01A Risk Of Death. Death May Occur If Body Parts Are Drawn Into Rotating
Vehicle Parts.
AS00.00-Z-0004-01A Risk Of Death. Death May Occur If Body Parts Are Drawn Into Rotating Vehicle Parts.
DANGER:
Do not reach into rotating parts. Wear closed and snug-fitting work clothes.
Secure area near rotating vehicle parts against unauthorized access.
Risk of death
Freely rotating parts near the running engine and around the drive train can cause serious injuries.
During all work on rotating driven axles the opposite wheel hub spins in rotation as well. This produces a blind hazard area that must be protected
from unauthorized access.
- Wear closed and snug-fitting work clothes.
- Remove all items of jewelry, such as chains, rings, etc.
- Restrain long hair by wearing an appropriate head cover.
- Set up appropriate shielding (e.g. barrier, safety guard) to secure blind hazard areas against unauthorized access.
AS00.00-Z-0008-01A Risk Of Accident Caused By Vehicle Starting Off On Its Own When Jacked
Up. Risk Of Injury Caused By Rotating
AS00.00-Z-0008-01A Risk Of Accident Caused By Vehicle Starting Off On Its Own When Jacked Up. Risk Of Injury Caused By Rotating
Parts When Working On Running Engine Or Drive Train.
DANGER:
Ensure that jack stands have secure and adequate footing. An authorized person must occupy the driver seat.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.
Potential risks
Risk of accident
caused by vehicle driving off on its own when under operation (e.g. during tests) with engine running and gear engaged. Danger caused by vehicle
falling off the jack stands.
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Risk of injury
Caused by exposed rotating parts next to the running engine and around the drive train which can cause serious injuries. Because the engine heats
up when operating, serious burns can be caused by touching unshielded parts.
- The danger zone of the vehicle may only be entered by persons required to conduct the work. To perform the work, climb into cab.
- Lift the vehicle high enough that the wheels do not touch the ground when operated.
- A person should be sitting in the cab who is acquainted with the operation of the vehicle and who can initiate appropriate measures.
- When jacking up vehicle using the jack stands, make sure they are positioned on solid ground and that they are secure.
- The vehicle must be securely positioned on the surfaces; place a non-slip base on the surface if necessary.
- Wear closed and close-fitting work clothes.
- Remove all jewelry such as chains, rings etc.
- Wear suitable head wear to cover long hair.
- Before commencing any work on the running engine, familiarize yourself with the location of potentially hot parts.
- When carrying out work when the engine is running do not touch any hot and rotating parts.
First aid measures for burns

- Flush the skin areas affected with plenty of cold water and cover skin with sterile burn dressings. Do not apply the dressings tightly, but
rather loosely over the affected skin area. Do not use any frayed dressings (e.g. old dressing material).Do not rub the affected skin areas.
- Consult a physician immediately.
AS00.00-Z-0014-01A Risk of Injury. Rubber Mounts and Bearing Parts Can Suddenly Come Loose
During Installation/Removal and
AS00.00-Z-0014-01A Risk Of Injury. Rubber Mounts And Bearing Parts Can Suddenly Come Loose During Installation/removal And
Shoot Wildly Through The Air.
DANGER: Shield hazard area with suitable catch device (basket, grate box). Also ensure that no unauthorized persons are present in the
hazard area.
Risk of injury
When installing and removing tight transverse control arm mounts, the rubber mounts can be put under extremely high tension. If one of the mounts
is released suddenly it can shoot out of the installation bore hitting and injuring anyone in the immediate area.
- When pressing parts in and out ensure that no one is in the immediate vicinity and therefore in the hazard area except for the person
performing the work.
- Also secure the pressing point (hazard area) with a suitable catch device (basket, grate box).
- When pressing out loosen mount by tapping a number of times with a hammer. Press out in a number of intervals relieving the pressure in
between.
AS00.00-Z-0015-01A Risk of Explosion From Pressurized Spray Cans
AS00.00-Z-0015-01A Risk Of Explosion From Pressurized Spray Cans
DANGER: Protect cans from direct sunlight and temperatures above 50 °C
Risk of explosion
Spray cans (engine compartment preservative, paints, etc.) are pressurized and can explode when heated up to above 50 °C.
- Protect spray cans from the sun's rays or temperatures above 50 °C. After use do not drill or incinerate the spray can.
- Only use in well ventilated areas, wear respiratory protection if necessary.
AS00.00-Z-0021-01A Risk of Death Caused By Coming Into Contact With Components of A 220 V
System
AS00.00-Z-0021-01A Risk Of Death Caused By Coming Into Contact With Components Of A 220 V System
DANGER: Do not touch voltage conducting parts in the 220 V system
Risk of death caused by electric shock
Risk of death caused by coming into contact with electrical parts of the 220 V system. Electric shocks can cause fibrillation of the heart or even
cardiac arrest. It may also take several minutes for the consequences of an electric shock to show themselves; for this reason always contact a
doctor.
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Risk of injury caused by burns
Electric shock or direct body contact with a power source can lead to burns or scalding.
Never connect the 220 V power supply to an outside socket during any repair work.
Do not touch any conductive parts of the 220 V system.
Before beginning any work always:

- Disconnect the 220 V system
- Ensure that the 220 V system cannot be reactivated
- Ensure that no voltage is present
- Ensure that the parts you are working on are grounded and short circuited
All repair work should be performed only by a trained electrician or under the direction and supervision of a trained electrician.
Persons who wear electronic implants (e.g. heart pacemakers) must not carry out any work on such components.
When performing any repair work on the 220 V system, proper insulated protective clothing must be worn and insulated tools and protective
devices must be used as per the safety regulations.
Observe country-specific regulations.
First aid measures
The shocked person must be immediately removed from the electric circuit.
Use protective gloves and a wood board or a wood ladder to push or move the shocked person out of the danger zone.
First attempt to turn off the power.
- Check for breathing. If there is no breathing or insufficient breathing, the preferable action is to perform mouth-to-mouth resuscitation. If
necessary, carry out CPR.
- If victim is unconscious, but breathing, place victim in the recovery position.
- Sterile bandages for burns.
If any of these symptoms occur, consult a physician immediately.

AS00.19-Z-0001-01A Risk of Injury Caused By Burns to Skin and Eyes. Risk of Poisoning Caused
By Inhaling Fumes When Working
AS00.19-Z-0001-01A Risk Of Injury Caused By Burns To Skin And Eyes. Risk Of Poisoning Caused By Inhaling Fumes When Working
With Heat-shrinkable Tubing.
DANGER: Work in well ventilated rooms only. Wear safety glasses with side protection and protective gloves.
Potential risks
Risk of injury
When working with heat-shrinkable tubing, excessive temperatures may cause burns to skin and eye.
Risk of poisoning
When working with heat-shrinkable tubing, vapors may be produced which lead to symptoms of poisoning such as coughing, headaches, dizziness
and nausea. Moreover, irritation may occur to the respiratory paths and eyes.
- Work only in well ventilated rooms.
- Avoid overheating the heat-shrinkable tubing.
- Stop heat-shrinking immediately if the shrink hose becomes blistered or charred or shows other signs of damage.
- Do not inhale the vapors.
- Avoid contact with melted shrink tubing.
- Wear safety glasses with side protection and protective gloves.
First aid measures
When eyes or skin come in contact with melted shrink tubing
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- Flush the affected area immediately with plenty of water for approx. 15 minutes.
- Treat affected areas like burn wounds. Do not remove any burned parts.
- Contact physician or medical service.
When vapor is inhaled:

- Take victim to fresh air.
- Keep victim calm and cover with a blanket.
- Contact physician or medical service.

- Water mist, general-purpose foam, powder, carbon dioxide
- Protective equipment for firefighters (compressed air equipment, oxygen apparatus, chemical resistant protective clothing)
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Vehicle: Vehicle Damage Warnings
AH00.00-N-0005-01A Measures For Preventing Damage to Vehicles or Components When

Performing ARC Welding Work
AH00.00-N-0005-01A Measures For Preventing Damage To Vehicles Or Components When Performing Arc Welding Work
The following measures must be taken before welding in order to prevent damage to various vehicle components:
1. Have fire extinguishers at the ready.

2. The negative terminal of the battery must be disconnected and covered up.
3. In vehicle with airbags the red, 12-pin test connection/plug-in connection must be disconnected no sooner than two seconds after the battery
has been disconnected (risk of unwanted activation).
6. Attach protective shields to prevent flying sparks and radiated heat in endangered areas.
7. Do not touch electronics housings or electrical cables with the welding electrode or the welder's ground connection.
8. If two parts are being welded together, both parts must be attached to the welder's negative clamp.
9. Make direct connection between the electrical welder's ground connection and the part being welded. Ensure that there are no electrically
insulating parts between the ground connection and the welding point.
10. Protect or remove any parts that are sensitive to heat such as plastic cables.
11. Remove electrical cables that are laid in cavities and/or pipelines, covered containers and electrical components from the danger area before
welding.
12. If possible, the points where the welded part is being attached to the vehicle and the ground terminal is attached to the electrical welder must
be bare; remove all traces of paint, corrosion, oil, grease and soiling.
13. The ground terminal of the welder must not be attached to the transmission. The welding current can cause arcing at the bearing points inside
the transmission. The structural changes that this causes lead to premature failure of the equipment.
AP00.20-P-0000-02A Safety Notes/Warning Notes
AP00.20-P-0000-02A Safety Notes/warning Notes
Safety information (hazardous situations for persons), warnings (quality of work, property damage).
These notes are identified by the following symbols (logos):
In order to rule out any risk of personal injury, to avoid impairing the reliability and safety of the vehicle, and to prevent damage to the vehicle as a
result of work improperly carried out, these instructions are to be read carefully and complied with in full.
Consequently, it is not possible for Daimler AG to evaluate in the last consequence every situation which might present a risk of injury for the
operative. It is therefore essential that anyone performing repair work on Mercedes-Benz passenger cars applies his professional expertise in order
to satisfy himself that his own safety is not at risk and that the vehicle will not be impaired in any way, in particular in terms of safety, by the
method of repair selected.
It is therefore expressly pointed out that all work for the operations described must be carried out in compliance with valid directives and
instructions from the responsible local authorities and those relating to health, work safety and environmental protection.
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Vehicle: Initial Inspection and Diagnostic Overview
AP00.20-P-0053BA Check All Visible Parts For Leaks and Damage

AP00.20-P-0053BA Check All Visible Parts For Leaks And Damage
- MODEL 124, 129, 140, 168, 170, 202, 203, 208, 209, 210
- MODEL 211.004 /006 /007 /008 /016 /020 /022 /023 /024 /026 /028 /029 /041 /042 /052 /054 /056 /057 /061 /065 /070 /072 /076 /077 /080
/082 /083 /084 /087 /089 /090 /092 /206 /207 /208 /216 /220 /222 /223 /226 /241 /242 /252 /254 /256 /257 /261 /265 /270 /272 /276 /277 /280
/282 /283 /284 /287 /289 /290 /292 /606 /608 /616 /620
- MODEL 215.373 /374 /375 /378
- MODEL 230.454 /456 /458 /467 /470 /471 /472 /474 /475
- MODEL 220.025 /026 /028 /063 /065 /067 /070 /073 /074 /075 /083 /084 /087 /125 /126 /128 /163 /165 /167 /170 /173 /174 /175 /178 /183
/184 /187 /875 /878
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AR00.10-P-1010A Check Gear Capacity

AR00.10-P-1010A Check Gear Capacity
- MODEL all
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Vehicle: Programming and Relearning
AH54.21-P-0001-03Y Notes on Programming Control Units

AH54.21-P-0001-03Y Notes On Programming Control Units
Program using STAR DIAGNOSIS (Xentry flash)
Xentry Flash: The term Xentry flash is used to designate the Daimler AG standard for programming control units.
In the process a distinction is made between two types of programming:
^ Offline programming with Release CD
^ Offline programming with Special Release CD
Further explanation of terms:

^ Flashing: Programming of control units
^ Software: Control unit software
^ Release CD: Control unit software integrated on Diagnosis Assistance System (DAS) DVD
^ Special Release CD: Special CD which contains software updates
Deliveries and costs
The release CD is integrated into the DAS-DVD and together with the Workshop Information System DVD is delivered monthly by the Daimler
AG. Delivery is free of charge for the case of repair.
Offline programming with Release CD
The control unit software of the Release CD can be installed on the hard disk in the case of the "STAR DIAGNOSIS Compact" diagnosis system.
Installation of the dat in not possible in the case of the "STAR DIAGNOSIS Basic" diagnosis system. In this case, the Release CD must be inserted
into the CD or DVD drive.
^ The information on the Release CD:
- applies to all divisions
- applies to all model series
- applies to all control units
^ The information on the Release CD provides a "basic supply" of control unit software for the vehicle. The current software releases of all
programmable control units are located on the Release-CD. An old software release can therefore be repeatedly replaced (updated) by a new
software release.
^ If a plant service measure requires a change in software release in a programmable control unit, the workshop can carry out this change with
the Release CD.
AH54.21-P-0001-03Z Notes on Programming Control Units
AH54.21-P-0001-03Z Notes On Programming Control Units
Offline programming with Special Release CD
Program using STAR DIAGNOSIS (Xentry flash)
Xentry Flash: The term Xentry flash is used to designate the Daimler AG standard for programming control units. In the process a distinction is
made between two types of programming:
^ Offline programming with Release CD
^ Offline programming with Special Release CD
Further explanation of terms:

^ Flashing: Programming of control units
^ Software: Control unit software
^ Release CD: Control unit software, integrated onto DAS DVD
^ Special Release CD: Special CD which contains software updates

^ The Special Release CD is a special CD which contains software updates
^ The workshop must ask for the Special Release CD at the STAR DIAGNOSIS user help desk and request it via the usual ordering channels
^ Manual redocumentation required in the vehicle documentation system (FDOK)
AH54.21-P-0001-04Z Flow Chart For Off-Line Programming With Special Release CD
AH54.21-P-0001-04Z Flow Chart For Off-line Programming With Special Release CD
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AH54.21-P-0004-01X Notes on SCN Coding of Control Units

AH54.21-P-0004-01X Notes On SCN Coding Of Control Units
The "Software Calibration Number" (SCN) is specified by law in Europe and USA for all control units relevant to exhaust emission as of model
year 2002.
Accordingly the software and coding of such a control unit must be clearly identifiable by means of the SCN. As a number the SCN consists of 16
numbers. The first 10 places correspond to the object number to be coded (mostly object number of control unit software). The next 2 places
designate the manufacturing plant or field organization, in which the vehicle has been coded. The last 4 places are a number of the variants of the
coding string of the vehicle-specific as-built configuration. This number is serially numbered for each newly formed variant.
If special equipment has been installed or removed in the vehicle (e.g. retrofitting a telephone), these retrofit codes must be added to the central
system before requesting the SCN coding data. The appropriate national organization must be contacted (MPC) for this.
AR54.21-P-0013-01X Online SCN Coding
AR54.21-P-0013-01X Online SCN Coding
The following work instructions describe the procedure for the online software calibration number (SCN) coding with Xentry Flash.
Precondition for SCN coding:

^ Networked STAR DIAGNOSIS diagnosis system
^ User ID and password for Xentry flash (user on aftersales platform)
Entry into coding in the Diagnosis Assistance System (DAS)

1. Select control unit.
2. Select menu item "control unit adaptations" or "initial startup". Continue with "F3".
3. Select menu item "SCN coding". Continue with "F3".
4. Select "Online (networked STAR DIAGNOSIS device)" menu item. Continue with "F3".
5. Enter user ID and password into the login screen. Continue with "Log in". After logging in the SCN coding data are automatically queried in
the background and the control unit is then coded.
6. Press "F11" to print out the order log and enclose the repair order.
The order record can also be stored in the Diagnosis Assistance system (DAS). This is done by clicking on "F11", "Print to file", selecting
"printout of test step" and entering a file name. In StarUtilities, the StarPad program can be used to display and printout the order log at the
"Logs" menu item.
7. Continue with "F2".
The SCN coding of the control unit is completed.

AR54.21-P-0013-04X Offline SCN Coding
AR54.21-P-0013-04X Offline SCN Coding
The following work instructions describe the procedure for the online software calibration number (SCN) coding with Xentry Flash. The SCN
coding data are requested by fax through the Star Diagnosis User Help Desk.
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For the Off-line fallback process Daimler ERG reserves the right to invoice 9 EUR per fax query.
Precondition for offline SCN coding:

^ STAR DIAGNOSIS diagnosis system with printer
^ Fax device
The offline SCN coding is broken down into 2 steps:

A. Determine vehicle data for offline SCN coding from vehicle. The vehicle data is used to create the fax form for ordering the SCN coding data
through the Star Diagnosis Help Desk.
B. Perform SCN coding. The coding is performed with the SCN coding data from the Star Diagnosis Help Desk.
A. Determine vehicle data for offline SCN coding from the vehicle.
1. Select control unit in Diagnosis Assistance System (DAS).
2. Select menu item "control unit adaptations" or "initial startup". Continue with "F3".
3. Select menu item "SCN coding". Continue with "F3".
4. Select "Offline (STAR DIAGNOSIS device not-networked)" menu item. Continue with "F3".
5. Confirm note on sequence of SCN coding with "F2".
6. Completely fill out fax form and click "F11" to print out.
If an email address is entered in the fax form, you will be sent the SCN coding data per email. If a fax number is entered in the fax form,
you will be sent the SCN coding data per fax.
7. Send printed out fax form to the given fax no. for the Star Diagnosis Help Desk.
B. Perform SCN coding. The coding is performed with the SCN coding data from the Star Diagnosis Help Desk.
If the SCN coding data are received per email, burn the data to a CD or save the data on a USB removable storage device and identify
accordingly. Unpack the Zip files first when doing so.
8. In the Diagnosis Assistance System (DAS) choose the "Step 2: Perform SCN coding" menu item. Continue with "F3".
9.1 Select keyboard input using "F4".
For SCN coding data per fax.
9.2 Insert CD or connect USB removable storage device.
For SCN coding data per email.
10.1 Enter SCN coding data manually into the DAS.
For SCN coding data per fax.
10.2 Confirm using "F3" and import the data per CD or USB removable storage device.
For SCN coding data per email.
11. Perform SCN coding.
12. Switch ignition on/off.
Control unit specific, refer to specification in DAS.
13. Press "F11" to print out the order log and enclose the repair order.
The order log can also be stored on the DAS. This is done by clicking on "F11", "Print to file", selecting "printout of test step" and
entering a file name. In StarUtilities, the StarPad program can be used to display and printout the order log at the "Logs" menu item.
14. Continue with "F2".
The SCN coding of the control unit is completed. Scrap the CD following successful SCN coding as per the guidelines for theft-relevant
parts (DTR 69/00). The scrapping process is to be documented on the repair order. The data on the USB removable storage device are to
be deleted properly once they have been used.
AR54.21-P-0014-01Y Program Control Unit
AR54.21-P-0014-01Y Program Control Unit
Offline programming with Release CD

1. Start Diagnosis Assistance System (DAS) and select category/vehicle model.
Selection of main menu, systems and select the control unit to be programmed.
3. Select menu item "control unit adaptations".
4. Select menu item "control unit programming".
5. Select menu item "Program control unit using DVD or removable storage device".
6. With new software press the "F3" button and program the control unit.
Display appears if new software is present.
Only perform the following steps, if no communication (communication error) is possible between the Diagnosis Assistance System (DAS) and
control unit.
7. Eliminate the cause of the error message using the test steps in the "error messages" menu.
If the cause of the fault cannot be found or eliminated, please inform the STAR DIAGNOSIS User Help Desk. Replace control unit in
agreement with STAR DIAGNOSIS User Help Desk.
8. If necessary determine the part number of the control unit and replace the control unit.
9. Select menu item "Initial startup with automatic adoption of settings from the old control unit" or "Initial startup without automatic adoption
of the settings from the old control unit" in the main menu. Then select "Repair functions" and carry out "Replace control unit".
4
When installing new control unit
AR54.21-P-0014-01Z Program Control Unit
AR54.21-P-0014-01Z Program Control Unit
Offline programming with special release CD.

1. Start Diagnosis Assistance System (DAS) and select category/vehicle model.
Selection of main menu, systems and select the control unit to be programmed.
3. Select menu item "control unit adaptations".
4. Select menu item "control unit programming".
5. Select "Offline (STAR DIAGNOSIS device not-networked)" menu item.
6. Select menu item "Program control unit using DVD or removable storage device".
7 Insert Special Release CD.
The programming of the control unit now starts automatically.
AR00.19-P-0200P Perform Basic Programming
AR00.19-P-0200P Perform Basic Programming
- MODEL 203, 463.202 /222 /236 /237 /243 /244 /245 /246 /247 /248 /249 /250 /254 /270 /271 /303 /306 /309 /322 /323 /332 /333 /336 /340
/341 /346
AR54.21-P-0014Y Programming Of Control Units

AR54.21-P-0014Y Programming Of Control Units
- MODEL 129.058 /063 /067 /076, 163, 164, 166, 168, 169, 170, 171, 199, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220,
221, 230, 240, 245, 251, 450, 452, 454, 461.302 /304 /305 /331 /332 /333 /334 /340 /342 /343 /344 /345 /346, 463.206 /208 /209 /232 /233
/240 /241 /243 /244 /245 /246 /247 /248 /249 /250 /254 /270 /271 /303 /306 /308 /309 /322 /323 /332 /333 /336 /340 /341 /346 (except,
245.286)
Off-line programming with Release CD
5
AR54.21-P-0014Z Programming Of Control Units

AR54.21-P-0014Z Programming Of Control Units
- MODEL 129.058 /063 /067 /076, 163, 164, 168, 169, 170, 171, 199, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221,
230, 240, 245, 251, 461.302 /304 /305 /331 /332 /333 /334 /340 /342 /343 /344 /345 /346, 463.206 /208 /209 /232 /233 /240 /241 /243 /244
/245 /246 /247 /248 /249 /250 /254 /270 /271 /303 /306 /308 /309 /322 /323 /332 /333 /336 /340 /341 /346 (except, 245.286)
Offline-Programmierung mit Special Release-CD
6
AR54.21-P-0015X SCN Coding Of Control Units

AR54.21-P-0015X SCN Coding Of Control Units
- MODEL 129.058 /063 /067 /076, 163, 164, 166, 168, 169, 170, 171, 199, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220,
221, 230, 240, 245, 251, 450, 452, 454, 461.302 /304 /305 /331 /332 /333 /334 /340 /342 /343 /344 /345 /346, 463.206 /208 /209 /232 /233
/240 /241 /243 /244 /245 /246 /247 /248 /249 /250 /254 /270 /271 /303 /306 /308 /309 /322 /323 /332 /333 /336 /340 /341 /346
7
1
Vehicle: Service and Repair
AH00.00-N-0011-01A Notes on Evaluating Leakages

AH00.00-N-0011-01A Notes On Evaluating Leakages
Before starting repair work due to leakage from a major assembly, the type of leakage present must be carefully checked.
^ Moist areas from which no liquid is dripping or running are no cause for complaint. This is known as "Sweating".
Even with today's levels of sealing technology, this "sweating" cannot be prevented in all cases and has no negative effect on system function. Any
repair work performed will only result in an improved appearance. As such, it cannot be justified.
For a closer inspection, clean the affected area and observe for an appropriate period of time.
^ If the complaint concerns fluid that is visibly dripping or running, then appropriate repairs must be performed to stop this type of leakage.
AH00.00-P-0013-01AK Notes on Removing Adhesive Residues and Foils on Paint and Metal
Surfaces With Surface Conditioning Disks
AH00.00-P-0013-01AK Notes On Removing Adhesive Residues And Foils On Paint And Metal Surfaces With Surface Conditioning Disks
When removing the remaining glue, films, trim strips, etc. using rubber disks, the following points must be remembered:
^ Please use safety glasses and hearing protection
^ Use of surface conditioning disk with hand drill
^ Use a speed of 2000 to 2500 rpm to avoid smearing
^ Only apply slight pressure to the surface that is being repaired using the surface conditioning disk and do not work at the same location for
too long, as otherwise excessive heat generation could damage the sheet metal or the paint
^ Rotational direction of surface conditioning disk opposite to working direction
^ When using on water-based paints, discoloration can occur in individual cases. In this case, perform preliminary tests at hidden locations.
^ Do not use surface conditioning disks on plastics or painted plastic parts such as bumpers
AH00.00-P-0015-01CW Notes on Calculating Tightening Torque When Using Insertion Tool With
Various Effective Lengths.
AH00.00-P-0015-01CW Notes On Calculating Tightening Torque When Using Insertion Tool With Various Effective Lengths.
The working length of the insertion tool (2) plugged onto the torque wrench (1) changes the leverage of the torque wrench (1). This in turn alters
the actual tightening torque. Therefore the tightening torque to be set has to be calculated as a function of the working length of the insertion tool
(2) and the specified tightening torque.
The following formula is used to calculate the torque to be set.
2
AH00.00-P-5000-01A Notes on Avoiding Damage Through Contamination and Foreign Objects

AH00.00-P-5000-01A Notes On Avoiding Damage Through Contamination And Foreign Objects
With each maintenance and repair work to the engine as well as to the ancillary assemblies and detachable parts comes the danger of property
damage caused by contamination and foreign bodies.
These are particularly vulnerable:
- hot film mass air flow sensor,
- turbocharger and compressor,
- all components involved in gas exchange,
- emission control system.
Remove/install
Openings through which contamination or foreign bodies can be brought into the engine, its ancillary assemblies or its detachable parts are to be
plugged immediately with suitable, clean covers, plugs or clean, lint-free rags.
Installation: Leave no covers, plugs or rags for the assembly behind in order to avoid damages and complaints about engine running characteristics.
Before the assembly, check all components for contaminants, remaining foreign bodies and fluid and dispose of them.
Clean
For cleaning, use only clean tools and clean, lint-free rags.
Residues of cleaning agents and removed contaminants must be removed from the engine, ancillary assemblies and detachable parts.
Do not dispose of contaminants using compressed air because components (for example, heating wire of the hot film mass air flow sensor) could
possibly be damaged or contamination could enter the engine, ancillary assemblies and detachable parts unnoticed.
AP00.20-P-0000-06B Special Service Procedures
AP00.20-P-0000-06B Special Service Procedures
Have the brake fluid replaced if more than 2 years have elapsed since the last change; this is best done in the spring.
The coolant should be inspected for correct anticorrosion/ antifreeze concentration before the beginning of, and during the cold season of the year.
Depending on the model series, the coolant has to be replaced every 3 years or 15 years (or after 250,000 km).
Refer to the particular valid service sheet for further additional operations based on kilometers or years.
AH00.00-P-0006-01RM Notes on Threaded Connections With Aluminum Screws/Bolts
AH00.00-P-0006-01RM Notes On Threaded Connections With Aluminum Screws/bolts
Important repair information
For threaded connections with aluminum screws/bolts, the aluminum screws/bolts are generally to be replaced after being used once.
When loosening threaded connections with aluminum screws/bolts, there is a risk of injury caused by the sudden loosening torque.
Before new aluminum screws/bolts are screwed in, the mating thread must be thoroughly cleaned.
1
Engine: Application and ID
AH01.00-P-0001-01D Notes on position of engine number
Shown as example on engine 275

The engine number is located on the upper right transmission flange.
1
Engine: Description and Operation
AP01.00-P-1000ZZ Cleaning and preserving engine and engine compartment
Cleaning and preserving engine and engine compartment
1
Engine: Testing and Inspection
AH01.00-P-0300-01VA General Information on Inspecting Cylinder

AH01.00-P-0300-01VA General information on inspecting cylinder
1. Pressure Gloss Marks, Smoothings
2. Visible Stripes, Friction Marks
3. Ring Shaped Imprints
2
4. Rotary Bright, Reflecting, Polished Upper Surfaces Of Cylinder
5. Roughened Streaks, Rubbing Seizures (+ 6, 7, 8)
AR01.00-P-0200QB Inspecting Cylinders With Light Probe

AR01.00-P-0200QB Inspecting cylinders with a light probe
3
Steps 1 - 8
Steps 9 - 10
4
Special Tools
Commercially available tools
AR01.00-P-1300QB Inspect Cylinders For Leaks

AR01.00-P-1300QB Inspect cylinders for leaks
5
Steps 1 - 9
Steps 10 - 11
Cylinder leakage
6
Special Tools
Commercially Available Tools
AR18.00-P-0025QB Measure Oil Consumption

AR18.00-P-0025QB Measure oil consumption
Steps 1-10
AR18.00-P-1250SX Check Oil Pressure

AR18.00-P-1250SX Check oil pressure
7
Steps 1-10
8
Oil pressure test specifications
Crankcase, timing case cover, end cover
Special Tools
AH01.00-N-1300-02A Determine Loss of Pressure at Cylinder

AH01.00-N-1300-02A Determine loss of pressure at cylinder
If an increased pressure loss was found with the cylinder leak tightness tester, inspect engine by listening at cylinder head gasket, air intake area,
exhaust, oil filler opening and prechamber or spark plug bores of the adjacent cylinder or cylinders.
Check the coolant in the coolant expansion reservoir for the formation of air bubbles.
9
Possible causes for the pressure loss are:
1. Outlet of air through prechamber or spark plug bore of adjacent cylinder or cylinders, air bubbles in coolant expansion reservoir:
pressure loss at cylinder head gasket
2. Outlet of air through air intake area: For inspecting by listening, open throttle valve
pressure loss at inlet valve(s)
3. Outlet of air through exhaust:
pressure loss at exhaust valve(s)
4. Outlet of air through oil filler opening:
pressure loss through pistons and piston rings
It is possible to pinpoint the pressure loss of the relevant cylinder by spraying with engine oil. Engine oil seals off the gap between piston and
cylinder briefly.
If a reduced pressure loss now occurs for a short time, the cause is very likely to be at the pistons, piston rings or cylinder contact surface of the
relevant cylinder.
Determining the cause can be falsified by the position of the piston ring joints. If suspicion exists that the loss of pressure is caused by the
piston ring joints being positioned directly one above the other, fit parts to engine and repeat test after running engine for a short time.
AH01.00-P-0300-01A General Information on Inspecting Cylinder Walls
AH01.00-P-0300-01A General information on inspecting cylinder walls
Pressure gloss marks, smooth spots

Isolated bright areas in the middle of the cylinder barrel or at the cylinder head bolts.
Continue to use crankcase.
10
Visible mottling, friction marks
Visible mottling, friction marks

Starting from reverse area of the upper piston ring tapering downwards.
Traces of dry friction marks which cannot be felt, caused by oil film being washed off by fuel, for example from many cold starts when driving
short distances.
Friction marks occurring mainly around the cylinder head bolts and on the pressure side are not a problem provided that they are smoothed out.
The piston rings are not damaged.
Ring shaped imprints

Visible imprints on cylinder barrel in the upper and lower reverse area of piston rings are not a cause for complaint.
11
Circumferential bright, reflecting, polished upper surfaces of cylinder
Circumferential bright, reflecting, polished upper surfaces of cylinder

Starting from the reverse area of the upper piston ring with measurable, partial cylinder wear.
The cylinder barrel is unusable.
Do not use the crankcase anymore.
Roughened mottling, friction scoring

Starting from first and second piston ring, tapering to an end only in bottom part of cylinder. Progressive signs of friction lead to friction score
marks.
Where these signs of friction are perceptible, the cylinder barrel is unusable.
The piston rings may be damaged.
Continuous individual traces of scratch

Caused by soiling, for example, by the back-pulsation of soot particles from the catalytic converter or exhaust.
Piston seizure
Most of cylinder wall perceptibly roughened over the entire length. Material deposits and perceptible scoring marks on cylinder wall and at
piston skirt.
12
The cylinder barrel is unusable.
Brown coloring of cylinder upper surface.

A brown coloration over large areas of the cylinder barrel is oil varnish and indicates that the engine has been driven at a high temperature level.
Oil varnish above piston ring zone is normal and is not a reason for complaint.
Reuse crankcase provided no impermissible cylinder distortion is present.

AH01.00-P-0300-01VA General Information on Inspecting Cylinder Walls
AH01.00-P-0300-01VA General information on inspecting cylinder walls
General note
If a complaint is made about an engine, for example because of noises, overheating, oil consumption etc., perform a visual inspection of the
mounted cylinder head by inspecting with light probe with an endoscope. The following notes should be helpful in assessing the cylinder barrels
to allow a professional decision to be made about the condition and further use of the crankcase. If this can cannot be assessed with sufficient
security through inspecting with an endoscope then the work "Check compression pressure" and "Check cylinder leakage" must be performed
before removal of the cylinder head as described in the Workshop Information System (WIS).
The results of checking should be documented on a repair order. For deviations from the prescribed wear and tolerance values one should
particularly determine the direction of the leakage while checking the leak tightness of the cylinder (in the direction valve or in the direction of
the crankcase).
In the case of deviating compression pressure values, in particular when not achieving the installation tolerance/new values (measured with a
compression recorder), one should check for indications of a fluid lock (e.g. wet piston crown, wet air filter, water-oil-glycol residues).
Ideal condition
Ideal condition
A matt gray user interface, no honing pattern, a dry cylinder barrel, without polished sections or mirror polished flats.
It is also possible that irregularities can occur which should be individually assessed.
13
Individual score marks up fields of score marks
Individual score marks up fields of score marks

Caused by residual waste or soiling during company, e.g. through back pulsation of particle from the catalytic converter or the exhaust system.

Visible in the upper and lower reversal range of piston rings, are not a reason for complaint.
14
Brown coloring of cylinder upper surface
Brown coloring of cylinder upper surface.

Brown coloration (oil varnish) over large areas of the cylinder barrel indicates that the engine has been driven at a high temperature level. This is
normal and not a cause for complaint.

Individual blank points, e.g. in middle of cylinder or in area of cylinder head bolts. An all-round impression at the piston ring reversing point
above and below.
15
Imprint on valve cooling bore for an 8 and 12 cylinder engine
Optical stripes, friction marks

Starting from the first, second or third piston ring, run out after approx. 30 mm. Traces of dry friction marks which cannot be felt, caused by soot
particles and oil film being washed off by fuel, e.g. from frequent cold starts associated with short-distance driving. These traces of friction
marks which occur principally in area of cylinder head bolts and on pressure side are not a problem provided they are smoothed.
Corrugated wear of the cylinder barrel
Imprint on valve cooling bore for an 8 and 12 cylinder engine

The cooling bore in the crankcase shows a different coloration to the cylinder barrel.
16
Optical stripes, friction marks
Corrugated wear of the cylinder barrel

A washboard type surface structure of the cylinder barrel, partially or all around.

Starting from first, second or third piston ring, tapering to an end only in bottom part of cylinder. Friction marks as described under "Optical
streaks, friction marks", in an advanced for becoming friction eroded areas.
If friction eroded areas are perceptible the cylinder barrel is unusable.
17
Piston seizure, eroded areas on the ring
Piston seizure, eroded areas on the ring

Most of cylinder wall perceptibly roughened over the entire length. Material deposits and perceptible scoring marks on cylinder wall and at
piston skirt.
Cylinder barrel unusable.

AR18.00-P-0025-05QB Determine Oil Consumption
AR18.00-P-0025-05QB Determine oil consumption
Weigh engine oil

1 Allow engine oil to drain in the oil reservoir provided.
When oil filler cap is opened and engine is at operating temperature.
2 Place oil reservoir on a balance and weigh.

3 Note oil mass in kg and kilometer reading for the vehicle.
4 Fill up the engine with the prescribed quantity of engine oil.
5 Fit remaining parts to vehicle
Determine oil consumption

1 Weigh engine oil.
3 Perform measurement run.
4 Weigh engine oil again.
To prevent measurement errors, the new measurement must be carried out at the place of the first oil measurement!

6 Determine differential mass and measurement distance.
Oil consumption over 1000 km:

Differential mass in kg x 1000 km Oil consumption in
Measurement distance in km x 0.85 1000 km
Calculated oil consumption in liters (1) per 1000 km.
1
Engine: Procedures
AH00.00-P-0007-01SF Notes on Bolted Connections With Self Tapping Screws

AH00.00-P-0007-01SF Notes on bolted connections with self tapping screws
General:
Terms:
"Self-tapping" is the generic term and it comprises both "thread-forming" and "thread-cutting". The following covers only thread forming screws
that meet the globally applicable "TAPTITE" standard.
Properties:
Thread forming screws create a screw-in thread in prefabricated core holes via typical conical crests without cutting.
The screw-in threads created by thread forming screws can easily take up screws with a metric ISO thread (standard screw).
Automatic centering during initial manual installation of self-tapping screws is given.
Repair and replacement solutions:

^ It is permissible to reuse an existing or other used thread forming screw.
^ The installation of a new thread forming screw into an already existing screw-in thread is not permissible.
^ It is permissible to replace a thread forming screw with a new or used standard screw. The length of the standard screw must be three threads
(groove tip) shorter than the length of the originally installed thread forming screw.
AH01.10-P-0001-01A Use of Engine No. When Installing Reconditioned Engines and Factory-New
Replacement Engines or Crankcases
AH01.10-P-0001-01A Use of engine no. when installing reconditioned engines and factory-new replacement engines or crankcases
The engine number has a different legal significance in individual countries. In the Federal Republic of Germany, for example, it has been
classified by the legislative authorities since mid-1972 as "insignificant in terms of traffic legislation". It is therefore no longer included in the
vehicle title document and vehicle registration document.
Practically all other countries continue to require the indication of the engine number on motor vehicles which are registered in such countries. In
dealing with international traffic, the authorities proceed on the basis of the provisions of the country in which the vehicle is registered.
In order to avoid any problems on the occasion of vehicle checks or when crossing international frontiers as a result of the lack of or incorrect
engine number, the following directives have to be observed when carrying out repairs.
1. Directives for vehicles which are registered in the Federal Republic of Germany
a) In the case of vehicles for which no engine number is indicated in the vehicle registration document (first registration after approx.
mid-1972), it is not necessary to stamp or revise an engine number if a replacement engine or crankcase of the same type is fitted.
b) If an engine number is indicated in the vehicle registration document, it is possible, if an engine of the same type is fitted, to transfer the
number of the removed component to the new engine, or the appropriate authority (vehicle inspection authority, vehicle registration
authority) should be requested to delete the engine number in the vehicle title document or registration document. The German Federal
Minister of Transport has issued appropriate ministerial orders in Transport Gazette 1973, p. 66.
2. Vehicles which are registered outside of the Federal Republic of Germany

If a reconditioned engine or factory-new replacement engine or crankcase is fitted and this is of the identical type, it is then necessary to adopt
the engine number of the engine removed and to transfer it to the new engine or crankcase.
Note
It is possible in the case of various engines only to stamp the engine number in place when the engine is removed.
For this reason, pay attention to the particular directives stated in Para 3 for the installation of reconditioned engines, crankcases and short
blocks.
3. Special directives
3.1 Installation of factory-new replacement engine of identical type

a) If a factory-new engine is installed and an engine number is required (e.g. vehicle registered outside of the Federal Republic of Germany), the
number of the factory-new engine must be ground off and the number of the originally installed engine of identical type stamped in its place.
b) If the factory-new engine is fitted with an engine type plate (older car engines) and it is necessary to indicate an engine number in the vehicle
documents, in this case take the engine type plate off the engine removed and affix it at the same point on the engine of identical type to be
installed.
2
3.2 Installation of reconditioned engine of identical type

a) The reconditioned engine plate must not be removed either from the reconditioned engine to be installed, nor from the engine removed, if the
latter was a reconditioned engine.
b) If the engine removed is fitted with an Engine type plate (older car engines) and it is necessary to indicate an engine number in the vehicle
documents, the engine type plate then has to be taken off the engine removed and affixed at the same point to the reconditioned engine to be
installed. This plate should be affixed in addition to the reconditioned engine plate.
In the event that a vehicle owner has problems on the occasion of vehicle checks or when crossing international frontiers because of the lack of
an engine number, the workshop in question may in certain circumstances be held liable.
After replacing an engine, the engine number has to be altered in the vehicle maintenance booklet and on the vehicle data cards as well as in the
repair customer file. These documents should clearly show which engine is installed in the vehicle in order to ensure smooth parts service.
In addition, the copy of the vehicle data card which is held at the Parts Department of the relevant Branch or Importer should also be altered.
3.3 Model designation identification of crankcases and short blocks

Crankcases and short blocks available in the parts sector are not provided with an engine model designation identification and also not with an
engine number.
Extract from Transport Gazette 1973 p. 66

(applies only to the Federal Republic of Germany)
Official Gazette of the Federal Minister of Transport
Directive in respect of vehicle title document (VkBI 1972 p. 354)
Bonn, 28 December 1972
StV 2/36.15.17
To make it possible to identify the engine on the occasion of vehicle inspections (e.g. by an inspection authority when a vehicle is taken out of
service or at the Customs on the occasion of importation of vehicle), the workshop carrying out the repairs has to stamp the engine model
designation in the crankcase or the short block in the space provided for the engine number.
Example:
Type Engine model designation
201.024 102.962
Pursuant to the directive relating to the vehicle title document dated 20 June 1972, Part C. No. 9.1, a dash should be inserted at the relevant point
in the place of data which are no longer required in future (e.g. in the case of the "factory number of engine") in those instances where the older
type of title documents are used for the preparation of the vehicle title document.
The question which is now posed is what procedure should be adopted in respect of the vehicle title document or the vehicle registration
document in the event that the factory number of the engine from the past is still entered in the older type of title documents and a replacement
engine with a new number is now installed in the vehicle in question. Following consultation with the competent authorities in the regions, now
provide the following instructions:
1.
In view of the fact that the factory number of the engine is regarded as insignificant in respect of traffic legislation, no change requires to be
made to the vehicle documents. This also does not conflict with section 27 Para 1 StVZO pursuant to which the data in the vehicle title and
registration documents constantly have to reflect actual circumstances. This requirement namely covers only those particulars relating to actual
circumstances which are of significance in terms of traffic legislation. This is no longer the case, however, in respect of the factory number of the
engine.
II.
In order to spare the relevant vehicle owner any misunderstandings or indeed possible disadvantages (e.g. on the occasion of checks when
abroad), recommend proceeding as follows:
In the event that the replacement engine installed has a different number than that entered in the title and registration document, the figures in the
column "engine factory number" shall be deleted and the following endorsement made at a suitable point both in the title as well as in the
registration document:
"Entry of engine factory number no longer necessary".

If the endorsement is made close to the deletion, it is sufficient to state:
"Entry no longer required".

The Federal Minister of Transport
3
Ip. p.
Wagner
AP01.00-P-1000ZZ Cleaning and Preserving Engine and Engine Compartment
AP01.00-P-1000ZZ Cleaning and preserving engine and engine compartment
Cleaning and preserving engine and engine compartment
AR01.00-P-0050-01A Remove Sealant

AR01.00-P-0050-01A Remove sealant
Repair materials
4
1 Wipe off operating fluids and other soiling from sealing surface using rags.
2 Spray Loctite(R) 7200 onto sealing surfaces and leave to work for about 10 to 20 minutes.
Observe manufacturer's processing instructions!
3 Remove loosened silicone sealant with a scraper from sealing surfaces and wipe off with rags.
Do not use any sharp-edged tools or abrasive paper as this will damage the sealing surfaces.
The sealing surfaces must feel even after treatment. The sealing surfaces must not be metallic bright; a thin layer of firmly adhering silicone
sealant must remain (see picture).
4 Absolutely be sure to thoroughly clean the sealing surface with cleaning spray Loctite(R) 7063 and blow off using compressed air.
Fully blow off the cleaning spray Loctite(R) 7063 before applying the new silicone sealant otherwise leaks can occur.
AR01.10-P-0110QB Crank Engine With Starter
AR01.10-P-0110QB Cranking engine using the starter.
5
Step 1 - 6
Special Tools
AR33.10-P-0100-01P Attaching Engine Supporting Frame and Lifting Engine

AR33.10-P-0100-01P Attaching engine supporting frame and lifting engine
- except CODE (P98) Black Series
Special Tools
6
Alternatively the engine lifting device (01) or engine carrier arm (1) can be used.
Put on engine carrier arm

1 Mount engine carrier arm (1) with its supports on the inner folds of the right and left fender (arrows).
In the process ensure that the paint on the two fenders is not damaged.
2 Lift engine by the front lifting eye.
Engine carrier arm, shown on model 203 with engine 111
Engine lifting device, shown on model 209 with engine 272
7
Mount engine lifting device

Observe the manufacturer's assembly specifications and safety information on the engine hoist (01), in order to avoid assembly faults.
1 Mount preassembled engine hoist (01) on the strut towers and longitudinal member.
When mounting ensure that no lines or hoses are pinched and no paint is damaged in the area of the area of the longitudinal member and
suspension strut tower.
2 Adjust the engine hoist (01) and tighten the bolted connections.
3 Detach the hose (1) from the electrical air pump (M33).
Only on vehicles with engine 271, 272, 273.
4 Mount lifting device (01a) on the front engine lifting eye.

5 Tighten clamping bolt (01b) and raise engine.
1
Engine: Removal and Replacement
AR01.10-P-2401QB Remove/Install Engine With Transmission

AR01.10-P-2401QB Remove/install engine with transmission
2
Modification notes
Modification notes
Steps 1-2
3
Steps 3-24
4
Steps 24 (Continued)-41
Step 41 (Continued)
5
Power steering pump
Refrigerant compressor
Clutch actuation
Injectors, injection valves, lines
6
Engine suspension, engine mounts, engine supports
Engine mount, engine support (engine side)
Housing
Transmission oil cooling system
Propeller shaft
7
Special Tools
AR03.30-P-5000QB Remove/Install Retaining Lock For Crankshaft / Ring Gear

AR03.30-P-5000QB Remove/install retaining lock for crankshaft / ring gear
8
Steps 1 - 7
Housing
Housing
Manual Transmission Complete
9
Special Tools
AR01.00-P-2410-02QB Disconnect Engine Wiring Harness

AR01.00-P-2410-02QB Disconnect engine wiring harness
1 Unclip electrical connectors (G3/3x1, G3/4x1, G3/5x1, G3/6x1) and the electrical lines of O2 sensors from retaining clamps.
2 Disconnect the electrical connectors (G3/3x1, G3/4x1, G3/5x1, G3/6x1) of the O2 sensors.
Transmission 722
3.1 Detach heat shield (1) and disconnect plug for automatic transmission (2).
Transmission 716
3.2 Pull plug off backup lamp switch (S16/2).
10
4 Remove dust filter box.

5 Disconnect electrical line of circuit 30 (3a) from battery (G1).
6 Open cover (4) of front backup fuse box (F32).
7 Disconnect the electrical line of circuit 30 (3b) from front prefuse box (F32).
8 Detach the rubber seal (5) from the partition wall.
9 Pull out plastic cover (6) with engine wiring harness and place onto cylinder head cover.
10 Detach ground line (7) from longitudinal member.
11 Disconnect electrical connectors (8, 9).
12 Release plug (10) and disconnect from the ME-SFI [ME] control unit (N3/10).
13 Slacken engine wiring harness and place to one side.
AR01.10-P-2500-01A Position Portable Lifting Platform
AR01.10-P-2500-01A Position portable lifting platform
The lifting platform (01) is variably adjustable in the vehicle longitudinal direction at the adjusting screw (03). The mounting plates (2) guided in
rails are also variably adjustable in the vehicle longitudinal direction and transverse direction at the adjusting screw (04) to the transmission and
11
front axle carrier. The respectively individual mounting plates (2) can be adjusted for height by means of an adjusting rod (05) to the required tilt
of the transmission and front axle carrier.
Ensure that no cables of lines get caught when lowering.
1 Position lifting platform (01) with aggregate mount (02) under the front axle carrier (1).
Take note in doing so of even alignment of the mounting plates (2) on the engine/transmission unit.
2 Fix the whole engine/transmission unit by means of tensioning straps (3) to the mounting plates (2).
1
Variable Valve Timing Actuator: Procedures
AR05.20-P-7201-06VA Loosen/tighten the center valves
Modification notes
Camshaft, camshaft adjustment
Special Tools
Counter hold camshafts at the rear with a Torx(R) screwdriver bit T60 to unfasten and fasten the center valves. Before installing, the center
valves must be lubricated with oil on the contact surfaces with the pulse wheels.
Center valves of right cylinder head

1 Loosen the center valves in the direction of the arrow.
2 Tighten the center valves against the direction of the arrow.
2
Center valves of left cylinder head

3 Loosen the center valves in the direction of the arrow.
4 Tighten the center valves against the direction of the arrow.
1
Variable Valve Timing Actuator: Removal and Replacement
AR05.20-P-7201QB Remove/Install Camshafts

AR05.20-P-7201QB Remove/install camshafts
- Camshaft adjuster for exhaust camshafts
2
Steps 1 - 4
Steps 5.1-12
AR05.20-P-7201QC Remove/Install Camshafts

AR05.20-P-7201QC Remove/install camshafts
- Camshaft adjuster for intake camshafts
3
Steps 1 - 3
4
Steps 4 - 19
Step 20
1
Variable Valve Timing Solenoid: Description and Operation
GF05.20-P-2100V Component Description For A Camshaft Solenoid
Location
The solenoids are located in front of the respective camshaft.
Task
The solenoids actuate the control plunger on the vane-cell adjuster according to the performance map related duty cycle. Depending on their
position, more or less pressure oil flows from the hollow camshaft into the oil galleries of the vane-type adjuster.
Design
The solenoids for camshaft adjustment are designed as proportional magnets, i.e. the direction of the armature and thus the position of the control
plunger in the vane-type adjuster are dependent on the intensity of the current in the coil.
Function
2
The solenoids before the camshafts are actuated by the ME control unit at the ground end by means of a PWM signal (150 Hz). The voltage supply
for the solenoid takes place from circuit 87. The vane-cell adjuster are actuated according to the performance map related duty cycle.
The maximum current (duty cycle 100 %) is emitted for a short time (about 0.5 seconds) for rapid adjusting of the anchor. A hold-in winding
voltage with a small duty cycle is then set afterwards. The coil resistance at room temperature is approx. 7.5 ohms.
Depending on their position, the oil volume in the vane-type adjusters is controlled. This takes place through differently arranged holes in the
control plunger as well as through oil ducts in the vane-cell adjusters. The adjusting range of the camshaft is limited by the forming of the vane-cell
adjuster mechanically. If the solenoids are no longer actuated then resetting takes place against the direction of rotation.
The following positions are possible:

- Filling the oil gallery
Pressure oil flows out of the hollow camshafts into the vane- cell adjuster. The camshafts adjust themselves to the respective direction of
rotation. The inlet camshafts adjust to "advanced". The exhaust camshafts adjust themselves due to their reversed direction of rotation to
"retarded".
- Oil gallery closed
Each camshaft position is detected by a camshaft Hall sensor. Once the requested adjustment has been achieved then the respective solenoid
will be actuated in such a way that oil galleries in the vane-cell adjusters are closed.
- Emptying the oil gallery
The camshafts adjust themselves against their direction of rotation.
1
Variable Valve Timing Solenoid: Service and Repair
AR05.20-P-7295QC Remove/Install Solenoid Camshaft
AR05.20-P-7295QC Remove/install solenoid camshaft
- Camshaft solenoids in right cylinder head
Steps 1 - 8
Step 9
2
Position Sensor
1
Compression Check: Testing and Inspection
AR01.00-P-1200QB Testing Compression Pressure
AR01.00-P-1200QB Testing compression pressure
Steps 1 - 9
2
Steps 10 - 12
Compression pressure
Special Tools
1
AR01.00-P-1300-01VA Connect Cylinder Leakage Testing Unit
AR01.00-P-1300-01VA Connect cylinder leakage testing unit
Special Tools
1 Calibrate cylinder leakage tester (04). tester (pressure loss).

2 Screw threaded adapter (06) to high-pressure testing hose (05).
3 Turn threaded adapter (06) with high-pressure testing hose (05) in tapped bore for spark plug.
4 Mount high-pressure testing hose (05) on cylinder leakage tester (04).
1
AR01.10-P-0010-01PR Connect Compression Tester
AR01.10-P-0010-01PR Connect compression tester
Special Tools
1 Open cover (1) of front backup fuse box (F32).

2 Connect clamp (3) on compression recorder on terminal (2) of front backup fuse box (F32).
Shown on model 203
3 Remove cover on fuse box.
Installation: Check the rubber seal in the cover. Replace it if necessary. The cover must be seated in the groove at the rear.
4 Remove starter relay (N10/1kS) from relay position S.
2
5 Insert adapter line (6) into relay position S.
6 Link adapter cable (6) to the cable of the compression recorder (7).
1
Camshaft Gear/Sprocket: Service and Repair
AR05.20-P-7201-05VA Lock the gear backlash compensation
The tooth flanks (1, 2) are held against each other by spring pressure and should not be skewed, otherwise the camshaft adjuster will be
irreparably damaged
1 Insert the drift (3, diameter 3mm) into the bore (4) of the cover plate and lock the tooth flanks (1, 2) with each other.
Push the drift (3) through to the end of tooth flank (2).
To allow the drift (3) to be inserted more easily, align the tooth flanks with each other (in the direction of the arrows).
Shown on camshaft adjuster, engine 273.965
Shown on camshaft adjuster, engine 272.968
1
Camshaft: Testing and Inspection
AR05.20-P-6010QB Check Basic Position of Camshafts
AR05.20-P-6010QB Check basic position of camshafts
- Basic position of camshaft for an installed front cover on cylinder head at a 55° crank angle BTDC
Steps 1 - 7
Step 8
2
Special tools
1
Camshaft: Testing and Inspection
AR05.20-P-6010-01VB Inspect Basic Position of Camshaft
AR05.20-P-6010-01VB Inspect basic position of camshaft
Shown without pulse wheels on the camshaft adjusters

1 Crank the engine at the crankshaft in Turn the direction of engine rotation (arrow) to 40 degrees crank angle after ignition TDC.
The 40 degrees marking (1) on the belt pulley must be aligned with the positioning edge (2) on the timing case cover.
The markings (3) on the camshaft adjusters face upward, and the markings (4) align with the contact surfaces on the cylinder head covers.
1
Camshaft: Procedures
AR05.20-P-6020QB Set basic position of camshafts
2
Steps 6 - 19
Camshaft, Camshaft Adjustment
3
Special Tools
Repair materials
1
Camshaft: Removal and Replacement
AR05.20-P-6992QB Remove/install camshafts
Steps 1- 3
2
Steps 4 - 17
3
Steps 18 - 20
Camshaft, Camshaft Adjustment
Special tools
Repair materials
1
Lifter / Lash Adjuster: Testing and Inspection
AR05.00-P-2010QB Inspect hydraulic valve clearance compensating elements
Steps 1 - 8
1
Lifter / Lash Adjuster: Service and Repair
AR05.00-P-2011QB Removing/installing hydraulic valve clearance compensation elements
Steps 1 - 9
1
Cylinder Block Assembly: Procedures
AR01.40-P-9202QB Measuring Cylinder Bores

AR01.40-P-9202QB Measuring Cylinder Bores
Work Instructions
Check Values For Cylinder Bore
Check Values For Cylinder Bore
2
Special Tools
AR03.10-P-7021-01SX Removing/Installing Oil Deflector Plate

AR03.10-P-7021-01SX Removing/installing oil deflector plate
Oil pump
Oil pump
Shown on engine 273
3
1 Unscrew bolts (1).

2 Remove oil baffle (2) from crankcase.
3 Install in the reverse sequence.
AR01.40-P-9202QB Measure Cylinder Bores
AR01.40-P-9202QB Measure cylinder bores
Cylinder bore measurement
Work instructions
Check values for cylinder bore
4
Special Tools
1
Cylinder Block Assembly: Removal and Replacement
AR03.10-P-7021-01SX Removing/installing oil deflector plate
Oil pump
Shown on engine 273
1 Unscrew bolts (1).

2 Remove oil baffle (2) from crankcase.
3 Install in the reverse sequence.
1
Balance Shaft: Service and Repair
AR03.20-P-1000QB Remove/install balance shaft
2
Steps 1-19
3
Torque converter
Balance shaft
Special Tools
1
Connecting Rod Bearing: Service and Repair
AR03.10-P-6111-06VA Install and gauge connecting rod bearings
Test specifications for crankshaft bearing clearance
Assignment of conrod bearings to conrod bearing journals on engine 272
1 Clean the bearing points of connecting rod, connecting rod bearing caps and connecting rod bearing journals with a chamois leather.
Blow through oil ducts in direction of flow oil with compressed air. Never use hard objects for cleaning.
2 The assignment of connecting rods to connecting rod bearing journals is indicated on the back of connecting rod bearing shells by a colored
dot.
Only the assigned color combinations of the conrod bearing shells (per the table) may be installed together. The sequence of the individual
color combinations on the connecting rod bearing journals can be selected at random.
3 Insert connecting rod bearing shells (1) into connecting rod and connecting rod bearing cap (2).
The anti-twist locks (3) of the conrod bearing shells (1) must be located in the slots (4) of the conrods (2) and the conrod bearing caps.
1
Connecting Rod: Testing and Inspection
AR03.10-P-6111-01VA Check connecting rod bolts
Test specifications for connecting rod bolts
Connecting rod bolt shank length inspection
1 Measure length (L).
If the length (L) exceeds maximum permissible size, the connecting rod bolts must be replaced!
1
Crankshaft Main Bearing: Service and Repair
AR03.20-P-4291-03VA Determine Crankshaft Bearing Axial Play
AR03.20-P-4291-03VA Determine crankshaft bearing axial play
Modification Notes
Modification notes
Special Tools
Only the one washer disc thickness is used.

1 Install dial indicator (2) with dial indicator holder (1)
2 Using a suitable tool, press the crankshaft axially on one side up to the attachment and hold it.
3 Set scale of dial gage (2) to zero.
4 Using a suitable tool, press the crankshaft axially on the other side up to the attachment and hold it.
5 Read off measurement value at dial indicator (2).
The measured value corresponds to the axial play of the crankshaft.
1
AR03.20-P-4351-02VA Tightening Procedure For Crankshaft Bearing Caps
AR03.20-P-4351-02VA Tightening procedure for crankshaft bearing caps
Crankshaft bearing cap
Tightening sequence for the crankshaft bearing cap and the crankshaft fitted bearing cap
Tighten the crankshaft bearing cap (2, 3, 4) and the crankshaft fitted bearing cap (1) individually in the numerical sequence. The arrow identifies
direction of travel.
Tightening sequence for bolts for the crankshaft bearing cap and the crankshaft fitted bearing cap
1 Lubricate bolts for bearing cap at thread and bolt head contact surfaces.
2 Tighten bolts for bearing cap in the specified sequence.
If no torquing angle wrench is available for the final tightening, the bearing cap bolts can be torqued further by the specified angle in a single
operation using a wrench and locking handle. Do not use a flexi-rod torque wrench for tightening in order to avoid any angle errors.
2
3 Tighten the screws:

^ Tighten bolt 1 (M10) to stage 1.
^ Tighten side bolt 5 (final tightening).
^ Tighten bolt 3 (M8) with the stage 2 tightening angle (final tightening).
1
AR03.20-P-4360-01VA Assign Crankshaft Bearing Shells
AR03.20-P-4360-01VA Assign crankshaft bearing shells
Inspection data for crankshaft bearing clearance
Assignment of crankshaft bearing shell upper half (crankcase)
Assignment of crankshaft bearing shell lower half (bearing cap)
1 Clean crankshaft bearing points in crankcase, crankshaft bearing caps and crankshaft journal for crankshaft using a chamois leather.
After bearing damage has occurred, it may be necessary to remove swarf from the conrod bores and from the crankshaft and crankcase oil
galleries as well as from the crankcase!
- Do not use a hard object for cleaning.
- Blow through oil galleries in direction of flow oil with compressed air.
The top main bearing halves are assigned to the crankshaft journal by means of a colored coding (on the rear of the main bearing shells) and
numbers or chisel punches, which are stamped on the crankcase (per the arrows).
Only assigned color and numerical combinations (per the table) may be fitted together.
2
^ The bottom crankshaft bearing shells are assigned to the crankshaft journal of the crankshaft by means of letters (initial letter of the particular
color).
^ The colored coding of the lower crankshaft journal is located at its rear.
^ The initial letters of the particular colors are engraved on the crankshaft journal.
When installing the crankshaft bearing shells it is important to keep to the order of the colors which is engraved on the crankshaft journal!
Arrow identifies direction of travel.

- First letter r: A crankshaft bearing shell must be inserted in the crankshaft bearing cap (1) with the colored coding red
- Second letter b: A crankshaft bearing shell must be inserted in the crankshaft bearing cap (2) with the colored coding blue.
- Third letter v: A crankshaft bearing shell must be inserted in the crankshaft bearing cap (3) with the colored coding violet
- Fourth letter w: A crankshaft bearing shell must be inserted in the crankshaft bearing cap (4) with the colored coding white.
2 Insert top crankshaft bearing shell halves (1) with the oil drill holes (2) and the oil grooves (3) into the crankcase.
When doing this, ensure that the anti-twist locks (4) of the crankshaft bearing shell halves (1) are located in the recesses of the crankcase.
3 Insert bottom bearing shell halves (7) into the bearing caps (6).
When doing this, ensure that the anti-twist locks (5) of the bottom crankshaft bearing shell halves (7) are located in the recesses of the
crankshaft bearing caps (6).
3
4 Insert crankshaft (7) in the crankcase.

5 Install top thrust washers (8).
There is only one fitted bearing width and therefore only one washer disc width is used.
The oil grooves of the thrust washers (8) must point toward the crankshaft webs (10).
6 Install crankshaft bearing caps (2) according to their identification.

Installation: The anti-twist locks (11) of the lower thrust washers (8) must be located in the slots (12) of the fit bearing cap (3). The oil
grooves (9) of the lower thrust washers (8) must point toward the crankshaft webs (10).
When installing the crankshaft fit bearing cap (3), hold both repair thrust washers (8) tight.
1
Crankshaft: Description and Operation
AH03.20-P-4351-02VA Interference fit of crankshaft bearing cap
^ The crankshaft bearing cap (main bearing cap (1), fitted bearing cap (2)) are to be machined together with the cylinder crankcase and must
not get exchanged with each other.
^ The crankshaft bearing caps are fitted on the side in the crankcase and must only be mounted in one position. If the installation position is
correct, the semicircle will point (3) in the direction of travel (arrow).
^ The crankshaft bearing caps are numbered consecutively on the semicircles (3) beginning with the first crankshaft bearing cap at the front.
1
Crankshaft: Service and Repair
AR03.20-P-4351QB Remove/install crankshaft
2
Modification notes
Steps 1-19
3
Steps 20-34
4
5
Connecting rod
6
Oil pump
Special Tools
1
Cylinder Liner: Service and Repair
AR01.40-P-9202QB Measure cylinder bores
Cylinder bore measurement
Work instructions
2
Special Tools
1
Harmonic Balancer - Crankshaft Pulley: Service and Repair
AR03.30-P-1600QB Removing/installing the belt pulley/vibration damper
Steps 1 - 12
2
Flywheel, Driven Plate, Vibration Damper, Starter Ring Gear
1
Piston: Procedures
AR03.10-P-7021-02VA Assigning a standard size piston to a cylinder bore
Test values for cylinder bore
Test values for pistons
2
Cylinder bore diameter identification
1 Assign piston to the cylinder bore
Piston diameters are specified in two tolerances. The piston diameters are differentiated from each other by the identification x or (x). This is
located on the top of the piston crown. Pistons marked with x must only be installed in cylinder bores marked with x.
Pistons marked with x must only be installed in cylinder bores marked with x.
3
Piston diameter identification
Cylinder bore diameters are specified in two tolerances. The cylinder bore diameters are differentiated from each other by the identification x or
(x). This is located at the bottom right on the crankcase at the mount for engine support.
Shown on engine 272
1
Piston: Removal and Replacement
AR03.10-P-7021QB Remove/install piston
Steps 1-2
2
Steps 3-26
3
Steps 27-33
Connecting rod
4
Oil pump
Special Tools
1
Piston Ring: Procedures
AR03.10-P-7311-01VA Measure Vertical Clearance of Piston Rings

AR03.10-P-7311-01VA Measure vertical clearance of piston rings
Check values for piston rings
Compression ring side clearance measurement
1 Measure vertical clearance between compression ring and mounting groove in piston with a feeler gauge for the compression ring concerned;
replace compression ring or piston if necessary.
The vertical clearance of the oil scraper ring cannot be measured because of its three part structure. The oil scraper ring must be replaced
along with the compression rings.
AR03.10-P-7311-02VA Measure Piston Ring End Gap
AR03.10-P-7311-02VA Measure piston ring end gap
2
Piston ring end gap measurement
1 Clean the cylinder barrel.

2 Insert both compression rings one after the other above running surface in the cylinder bore, and measure end gap with a feeler gauge;
replace piston rings if necessary.
The end gap of the oil scraper ring cannot be measured because of its three-part structure. The oil scraper ring must be replaced along with
the compression rings.
1
Piston Ring: Removal and Replacement
AR03.10-P-7311VA Removing/Installing Piston Rings

AR03.10-P-7311VA Removing/installing piston rings
- Piston removed
Steps 1-9
Inspection Data For Piston Rings
2
Inspection Data For Piston Rings
Special Tools
AR03.10-P-7311VA Remove, Install Piston Rings

AR03.10-P-7311VA Remove, install piston rings
- Piston removed
3
Steps 1-7
Test values for piston rings
4
Test values for piston rings
Special Tools
1
Cylinder Head Assembly: Procedures
AH01.30-P-1000-02V Notes on Sealant Path For Front Cover to Cylinder Head

AH01.30-P-1000-02V Notes on sealant path for front cover to cylinder head
Application of sealant to the right front cover

The line (A) identifies the sealant run.
The sealing compound must only be applied along the line (A) in the form of a bead with a height and width of 1.0 mm (+0.5 mm).
The sealing compound must be applied within 10 min.
The sealant bead must not be spread. Only the approved seal be used.
Application of sealant to the left front cover

AH01.30-P-1000-04RX Information on Applying Sealant to Cylinder Head Gasket
AH01.30-P-1000-04RX Information on applying sealant to cylinder head gasket
2
Information on applying sealant to cylinder head gasket
Before mounting the cylinder heads, apply sealant around the timing case cover on the cylinder crankcase.
Repair information
The sealing surface must be cleaned. Sealant should be applied only to the specified surface, in the form of a bead 2.0 mm (±0.5 mm) in height
and width (per the picture).
The sealant remains workable for 10 min.
The bead should not be spread.

AH01.30-P-1000-05A Information on Cylinder Head Contact Surface
AH01.30-P-1000-05A Information on cylinder head contact surface
The cylinder head contact surface should only be machined if there is mechanical damage.
It should not be machined (by face grinding) if the contact surface of the cylinder head is uneven (warped) in the longitudinal and transverse
directions.
When the cylinder head is mounted again, surface warping will be evened out when the cylinder head bolts are tightened.
Stock removal from the cylinder head and cylinder crankcase of an engine should together be no more than 0.3 mm
If the cylinder head contact surface is machined, the valve seats must be reset.
AR01.30-P-5800-03VA Checking Cylinder Head Bolts
AR01.30-P-5800-03VA Checking cylinder head bolts
Cylinder head/cylinder head bolts
3
Cylinder head bolt length inspection
If the length (L) is greater than the maximum permissible dimension, use new cylinder head bolts.
AR01.30-P-5800-04V Pull Out Guide Rail Pins at Cylinder Head
AR01.30-P-5800-04V Pull out guide rail pins at cylinder head
Special Tools
4
Shown on tensioning rail bolts
Only extract the tensioning rail bolts (1) using the impact extractor (03) in order to avoid damaging the contact surface on the front cover.
1 Screw threaded insert (02) into the tensioning rail bolts (1) and extract the tensioning rail bolts (1) using an impact extractor (03).
The guide rail pins (2) are like tensioning rail bolts (1).
AR01.30-P-5800-07VA Tightening Specifications For Cylinder Head Bolts
AR01.30-P-5800-07VA Tightening specifications for cylinder head bolts
Modification Notes
Modification notes
Cylinder head
Tightening of the cylinder head bolts must take place according to the numerical sequence given in the figure. Loosening of bolts takes place in
reverse order.
1 Tighten cylinder head bolts (1-8) to stage 1.
3 Tighten cylinder head bolts (1-8) to stage 2 (follow-up tightening).
6 Tighten bolts (9).
5
M272
1
Cylinder Head Assembly: Removal and Replacement
AR01.30-P-5700QB Remove/Install Front Cover on Cylinder Head

AR01.30-P-5700QB Remove/install front cover on cylinder head
- Front cover on right cylinder head
2
Steps 1-16
Cylinder head
3
Position sensor
Special Tools
Repair materials
AR01.30-P-5700QC Remove/Install Front Cover on Cylinder Head

AR01.30-P-5700QC Remove/install front cover on cylinder head
- Front cover on left cylinder head
4
Steps 1-5
5
Steps 6-22
Cylinder head
6
Position sensor
Special Tools
Repair materials
AR01.30-P-5800QB Remove/Install Cylinder Head

AR01.30-P-5800QB Remove/install cylinder head
- Left cylinder head
7
8
Modification notes
Steps 1-13
9
Steps 14-31
10
Steps 32-37
Exhaust system
Air shutoff valve
11
Cylinder head
Special Tools
Repair materials
AR01.30-P-5800QC Remove/Install Cylinder Head

AR01.30-P-5800QC Remove/install cylinder head
- Right cylinder head
12
Modification notes
13
Steps 1-13
14
15
Exhaust system
Oil pan
16
Cylinder head
Special Tools
Repair materials

17

The sealing compound must be applied within 10 min. The sealant bead must not be spread. Only the approved sealant may be used.
1
Fuel Pressure Release: Service and Repair
AR07.03-P-1460-01VA Danger! Reduce fuel pressure through service valve
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin
caused by contact with fuel
No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers.Wear protective clothing when
handling fuel.
Injection nozzles, injection valves, lines
Special Tools
Shown on engine 272 in model 171 without fuel tank with exterior filter, code 917
1 Unscrew protective cap (1) of the service valve (2) of the fuel distributor.
2 Insert end of the pressure hose (01) into the container (3).
3 Screw on union nut of the angled piece (01 a) to the service valve
(2).
At this point, the service valve (2) is opened and the fuel pressure in the fuel distributor is reduced. Fuel escapes from the end of the hose.
4 Unscrew the union nut of the angled piece (01a) from the service valve (2).
5 Screw protective cap (1) onto the service valve (2) of the fuel distributor.
For vehicles with fuel tank with exterior filter, code 917 the protective cap (1) must be tighten with torque.
Ensure that the sealing ring of the protective cap (1) is replaced.
1
Valve Cover: Procedures
AH01.30-P-1000-08V Notes on Application of Sealant to Cylinder Head Cover

AH01.30-P-1000-08V Notes on application of sealant to cylinder head cover
Sealant beads on the right cylinder head cover

The lines (A) identify the sealant beads.
The sealant must be applied along the specified lines (A) in the form of a sealant bead of
1.0 mm ±0.2 mm.
The sealant must be applied within 10 min.
The sealant bead must not be spread. Only the approved sealant may be used.
Sealant beads on the left cylinder head cover
sealant beads on the left cylinder head cover

The sealant must be applied along the specified lines (A) in the form of a sealant bead of
1.0 mm ± 0.2 mm.
AR01.20-P-5014-03VA Bolt Tightening Diagram For Cylinder Head Cover
2
AR01.20-P-5014-03VA Bolt tightening diagram for cylinder head cover
Cylinder head
Cylinder Head Cover Bolts
Right cylinder head cover
Right cylinder head cover

Tighten cylinder head cover bolts in the numerical sequence.
1 Tighten bolts (1-18) in the 1st stage.
2 Tighten bolts (1-18) in the 2nd stage.
Left cylinder head cover
Left cylinder head cover

Tighten cylinder head cover bolts in the numerical sequence.
1 Tighten bolts (1-18) in the 1st stage.
2 Tighten bolts (1-18) in the 2nd stage.
1
Valve Cover: Removal and Replacement
AH01.30-P-1000-08V Notes on Application of Sealing Compound

AH01.30-P-1000-08V Notes on the course of the application of sealing compound on a cylinder head cover
AR01.20-P-5014-03VA Bolt Tightening Diagram For Cylinder Head cover

AR01.20-P-5014-03VA Bolt tightening diagram for cylinder head
cover
Bolt of cylinder head cover

- 1st stage .......................................................................................................................................................................................................... 12 Nm
- 2nd stage .............................................................................................................................................................................................................. 90°
2
AH01.30-P-1000-08V Notes on Application of Sealant to Cylinder Head Cover

AH01.30-P-1000-08V Notes on application of sealant to cylinder head cover

3
The sealant must be applied along the specified lines (A) in the form of a sealant bead of 1.0 mm ± 0.2 mm.
Sealant beads on the left cylinder head cover
sealant beads on the left cylinder head cover

The sealant must be applied along the specified lines (A) in the form of a sealant bead of 1.0 mm ± 0.2 mm.
AR01.20-P-5014QB Remove/Install Cylinder Head Cover
AR01.20-P-5014QB Remove/install cylinder head cover
- Left cylinder head cover
4
Steps 1-2
5
6
Steps 27-28
Injectors, injection valves, lines
Cylinder head
Engine wiring harness
Special Tools
7
Repair materials
AR01.20-P-5014QC Remove/Install Cylinder Head Cover

AR01.20-P-5014QC Remove/install cylinder head cover
- Right cylinder head cover
8
Steps 1-6
Steps 7-18
Cylinder head
9
Control unit
Engine wiring harness
Special Tools
Repair materials
1
Valve Spring: Service and Repair
AR05.30-P-3500QB Remove/install valve springs and / or valve stem seals
Modification Notes
2
Steps 1 - 7
Steps 8 - 19
3
Special Tools
1
Valve: Testing and Inspection
AR05.30-P-4201-01VA Inspect valves
Test values for valves
Valve dimensions
1 Check dimensions (A, B, C, D,) on valve.
1
Valve: Service and Repair
AR05.30-P-3511VA Remove/Install Valves
AR05.30-P-3511VA Removing/installing valves
Steps 1-2
2
Steps 3-12
Special Tools
3
1
Drive Belt: Testing and Inspection
AP13.22-P-1352PIT Check poly-V-belt in visible area for wear
Steps 1 - 4
2
Steps 5 - 6
1
Drive Belt: Service and Repair
AR13.22-P-1202QB Remove/Install Poly V-Belt
AR13.22-P-1202QB Remove/install poly V-belt
Steps 1 - 7
2
Steps 8 - 9
1
Drive Belt: Service and Repair
AR13.22-P-3902-02VA Routing Diagram of Poly V-Belt
AR13.22-P-3902-02VA Routing Diagram Of Poly V-belt
1
Drive Belt Tensioner: Service and Repair
AR13.25-P-3200QB Remove/install poly-V-belt tensioning device
Steps 1 - 8
Belt Tensioning Device
1
Engine Mount: Service and Repair
AR22.10-P-1100QB Remove/Install Engine Mount
AR22.10-P-1100QB Remove/install engine mount
Modification Notes
Steps 1 - 11
2
Engine Suspension, Engine Mounts, Engine Supports
Engine Mount, Engine Support (engine Side)
1
Engine Mount: Service and Repair
AR22.10-P-1200QB Remove/Install Engine Support
AR22.10-P-1200QB Remove/install engine support
Steps 1-12
2
Engine support (engine side)
1
Idler Pulley: Service and Repair
AR13.21-P-3350QB Remove/install poly-V-belt guide pulley
Steps 1 - 7
Coolant Pump, Coolant Thermostat
1
Engine Lubrication: Procedures
AH18.00-P-0102-01A Notes concerning extension of the oil change interval
When using engine oil conforming to Specifications for Operating Fluids, sheet 229.5, the oil change interval can be extended.
Vehicles without ASSYST or without ASSYST PLUS

^ On vehicles without ASSYST or without ASSYST PLUS the oil change interval increases from 15.000 km to 20.000 km.
Observes entries in the maintenance booklet.
Vehicles with ASSYST

^ In vehicles with ASSYST, the interval can be extended by a factor of 1.3 using the STAR DIAGNOSIS diagnosis system.
^ As of model refinement, extension of the interval is also possible with the instrument cluster.
Vehicles with ASSYST PLUS

^ For vehicles with ASSYST PLUS the intervals can be extended by a factor of 1.3 through the instrument cluster.
^ Alternatively, the intervals can also be extended using the STAR DIAGNOSIS system.
If this is not done, the shorter oil change interval will be stored automatically.
1
Engine Lubrication: Removal and Replacement
AP18.00-P-0101PIT Engine oil and filter change
Steps 1 - 12.1
2
Steps 12.2 - 14
Oil Filter
Oil Pan
Engine Lubrication
Special Tools
3
1
Engine Oil Pressure: Testing and Inspection
AR18.00-P-1250SX Check oil pressure
Steps 1-10
2
Oil pressure test specifications
Special Tools
1
Engine Oil Dip Stick - Dip Stick Tube: Service and Repair
AR18.40-P-3510QB Remove/Install Oil Dipstick Guide Tube
AR18.40-P-3510QB Remove/install oil dipstick guide tube
Steps 1 - 13
2
Oil Pan
1
Engine Oil: Procedures
AP18.00-P-0101-02Z Suction off engine oil
1 Suction off engine oil via the oil dipstick guide tube
Suction off engine oil only when the engine is at normal operating temperature.
Shown on engine 104
1
Engine Oil: Removal and Replacement
Modification notes
Steps 1-7
2
Steps 8-12
Oil filter
Oil pan
3
Engine lubrication
Special Tools
1
Oil Cooler: Service and Repair
AR18.30-P-3481QB Remove/Install Oil/Water Heat Exchanger at Oil Filter
AR18.30-P-3481QB Remove, install oil/water heat exchanger at oil filter
Steps 1 - 4
2
Steps 5 - 14
Oil Cooling System
1
Oil Filter: Service and Repair
AP18.00-P-0101-06PIT Replace Oil Filter Element, Drain Oil Filter
AP18.00-P-0101-06PIT Replace oil filter element, drain oil filter
Oil filter
Special Tools
1 Remove front engine cover.

2 Unscrew screw cap (1) using socket and remove.
To catch the dripping oil, use an oil receptacle.
3 Remove oil filter element (2) from screw cap (1).

4 Replace seals (3).
Shown on engine 272.963
5 Insert new oil filter element (2) in screw cap (1).

6 Screw in screw cap (1) with new oil filter element (2) and new sealing rings (3) and tighten.
1
Oil Filter: Service and Repair
AP18.00-P-0101PIT Engine Oil and Filter Change
Modification notes
Steps 1-7
2
Steps 8-12
Oil filter
Oil pan
3
Engine lubrication
Special Tools
1
Oil Filter Housing: Service and Repair
AR18.20-P-3471QB Remove/install oil filter housing
2
Steps 1-19
3
Coolant pump, coolant thermostat
1
Oil Level Sensor: Description and Operation
Component Description For The Oil Level Check Switch
Location
The oil level check switch is in the oil pan; the outer connector is located on the oil pan.
Task
To recognize reaching a minimum oil level in the oil pan.
Design
In the oil pan there is a dry-reed contact mounted in the float chamber and a float with ring magnet. A short line leads to the connector on the side
on the oil pan.
Function
When the oil level is adequate the contact to engine ground is closed. If the switch opens due to oil starvation then this is recognized by the ME-SFI
[ME] control unit and a message sent over the CAN to the instrument cluster.
1
Oil Level Sensor: Service and Repair
AR18.40-P-5113SX Remove/install oil level check switch
Steps 1-6
Oil sensor
1
Oil Level Sensor For ECM: Description and Operation
GF18.40-P-4114V Component Description For The Oil Level Check Switch
Location
The oil level check switch is in the oil pan; the outer connector is located on the oil pan.
Task
To recognize reaching a minimum oil level in the oil pan.
Design
In the oil pan there is a dry-reed contact mounted in the float chamber and a float with ring magnet. A short line leads to the connector on the side
on the oil pan.
Function
When the oil level is adequate the contact to engine ground is closed. If the switch opens due to oil starvation then this is recognized by the ME-SFI
[ME] control unit and a message sent over the CAN to the instrument cluster.
1
Oil Pan: Procedures
AH01.45-P-0001-01VA Notes on Sealant Path For Oil Pan

AH01.45-P-0001-01VA Notes on sealant path for oil pan
Application of sealant to oil pan bottom section for engine with rear sump
Application of sealant to oil pan bottom section for engine with rear sump
The line (1) identifies the sealant run.
The sealing surface must be cleaned. The sealant must only be applied to the specified surface in the form of a bead and a height and width of 2.0
mm (±0.5 mm).
The sealing compound must be applied within 10 min.
The sealant bead must not be spread. Use only the sealant listed in the Repair Products.
Application of sealant to oil pan bottom section for engine with middle sump
Application of sealant to oil pan bottom section for engine with middle sump
2
Application of sealant to oil pan bottom section for engine with front sump
Application of sealant to oil pan bottom section for engine with front sump
AH01.45-P-0001-01VB Notes on Application of Sealant to Oil Pan
AH01.45-P-0001-01VB Notes on application of sealant to oil pan
Modification Notes
Modification notes
Oil pan with rear sump

3
mm (±0.5 mm).
The sealant bead must not be spread. Only the sealant listed in the Repair Products may be used.
Oil pan with front sump
Oil pan with middle sump

AR01.45-P-7500-06VA Bolt Plan For Oil Pan
AR01.45-P-7500-06VA Bolt plan for oil pan
4
5
1
Oil Pan: Removal and Replacement
AH01.45-P-0001-01VA Notes on Application of Sealant to Oil Pan

AH01.45-P-0001-01VA Notes on application of sealant to oil pan
AR01.45-P-7555QB Remove/Install Oil Pan Bottom Section

AR01.45-P-7555QB Remove/install oil pan bottom section
2
Steps 1 - 5
3
Steps 6 - 9
Oil Pan
Special Tools
Repair materials
AH01.45-P-0001-01VB Notes on Application of Sealant to Oil Pan

AH01.45-P-0001-01VB Notes on application of sealant to oil pan
4
Modification notes

mm (± 0.5 mm).
The sealant bead must not be spread. Only the approved sealing compound may be used.
5

AR01.45-P-7500QB Remove/Install Oil Pan
AR01.45-P-7500QB Remove/install oil pan
6
Modification notes
7
Steps 1-11
8
Steps 12-24
Oil pan
9
Exhaust system
Transmission oil cooling system
Engine suspension, engine mounts, engine supports
Engine mount, engine support (engine side)
Housing
10
Complete manual transmission
Special Tools
Repair materials
AR01.45-P-7555QB Remove/Install Bottom Part of Oil Pan

AR01.45-P-7555QB Remove/install bottom part of oil pan
11
Steps 1-9
Oil pan
12
Special Tools
Repair materials
1
Oil Pump: Procedures
AR18.10-P-2140-01TX Separate Oil-Pump Chain

AR18.10-P-2140-01TX Separate oil-pump chain
Special Tools
1 Screw the pressure screw (02) with the pressure pin (02a) into the chain separating tool (03).
2 Fit chain separating tool (03) onto oil pump chain.
3 Turn in pressure screw (02).
Turn in until the pressure pin (02a) contacts the bolt on the oil pump chain (arrow).
4 Turn in pressure pin (02a) and press out bolt of oil pump chain.
5 Unscrew pressure screw (02) and remove chain separating tool (03).
6 Remove bolt (1) of oil pump chain from chain separating tool (03).
AR18.10-P-2140-02TX Rivet Oil Pump Chain
2
AR18.10-P-2140-02TX Rivet oil pump chain
Special Tools
1 Connect new oil pump chain (2) and old oil pump chain (1) together using an assembly link (3).
2 Slowly rotate crankshaft in the direction of engine rotation (arrowed) until it is possible to connect both ends of the new oil pump chain (2).
3 Remove assembly link (3) and old oil pump chain (1).
4 Connect ends of new oil pump chain (2) using a riveted link (4).
Insert riveted link (4) from front.
3
5 Place assembly insert with digit F10 into rivet press tool (arrow) and fix in place by a bolt (28).
6 Place moveable assembly insert with digit D10 into rivet press tool (arrow).
7 Insert outer plate (5) of the rivet link (4) into the assembly insert with the digit D10 (arrow).
8 Place rivet press tool on the new oil pump chain (2).
Fit in such a way that the rollers of the riveted link (4) rest on the spacer web (arrow).
4
9 Tighten pressure screw (6) until a firm resistance is felt.
While turning the pressure screw (6), ensure that pin in rivet link (4) is inserted in holes in the external mounting link (5).
10 Remove rivet press tool.
11 Move assembly insert with digit D10 onto rivet profile (arrow).
12 Place rivet press tool on new oil pump chain (2) riveted link (4).
Fit the in such a way that pins for the riveted link (4) are located exactly in the center of prism support (arrow).
13 Tighten pressure screw (6).
The torque applied to pressure screw (6) is about 30 to 35 Nm (reference value).
14 Rivet bolts for riveted link (4) individually.
15 Test riveted joints (arrow) and rivet the pins again if necessary.
1
Oil Pump: Removal and Replacement
AR18.10-P-2000SX Remove/Install Tensioning Device For Oil Pump Chain

AR18.10-P-2000SX Remove/install the tensioning device for the oil pump chain
Steps 1 - 3
Oil Pump
AR18.10-P-2140SX Replace Oil Pump Chain

AR18.10-P-2140SX Replace the oil pump chain
2
Steps 1 - 4
AR18.10-P-6020QB Remove/Install Oil Pump

AR18.10-P-6020QB Remove/install oil pump
3
Steps 1 - 7
Oil Pump
Special Tools
AR18.10-P-2140SX Replace the Oil Pump Chain

AR18.10-P-2140SX Replace the oil pump chain
4
Steps 1-4
1
Oil Spray Jet: Service and Repair
AR18.00-P-4000QB Remove/install oil spray nozzles (pistons)
Steps 1-6
Oil pump
2
Engine lubrication, engine oil cooling, general
1
Intake Manifold: Description and Operation
GF09.20-P-6010V Intake Manifold Component Description
Location
The intake manifold is located between the cylinder banks.
Task
Optimizes engine torque curve by means of two different intake manifold lengths Improves flow via swing-out tumble flaps in the intake port.
Design
The intake manifold is assembled out of several magnesium pressure castings. During assembly, the individual intake manifolds for each cylinder
and the air manifold collecting sections are in the center. The intake manifold cannot be disassembled. A total of four shafts are stored in the intake
manifold.
The vacuum pressure for the aneroid capsules is supplied by a vacuum reservoir in the intake manifold when the switchover valves are actuated.
The reservoir volume is designed for several operations without renewed evacuation.
2
Intake manifold switchover, function
The individual intake manifolds each approx. 800 mm long, are arranged in a spiral shape around the air collecting volume. Each single intake
manifold has a further opening to the air collecting volume somewhere in the middle. These can be opened or closed by rotating longitudinal switch
flap shafts. The switch flaps of a cylinder bank are interconnected by a shaft and each of the flap is actuated by an aneroid capsule in case of engine
272 BOTH aneroid capsules for the intake manifold switchover are connected to the variable intake manifold switchover valve via hose pipes.
Engine 273 has only one aneroid capsule. The flap shafts are connected in the intake manifold. The switch flaps open by spring force without
actuation and enable the short suction way
At higher speeds (from approx. 3500/min) the intake manifold switchover aneroid capsules are ventilated and the switch flaps opened by the spring
force. The intake air takes the short intake route.
3
At lower speed (up to approx. 3500/min) the intake manifold aneroid capsules are pressurized with vacuum pressure and the longitudinal switch
flaps closed. The intake air takes the long intake route. The result is improved cylinder charge and thus an increase in torque.
Tumble flap switchover function
At partial load, tumble flaps can be fully swung out in each cylinder intake port in the intake manifold. This closes the intake manifold by around
50 %.
The flow speed of the intake air is increased and allows for improved distribution of the fuel/air mixture in the combustion chamber. The tumble
flaps are actuated via an aneroid capsule and linkage.
1
Intake Manifold: Service and Repair
AR09.20-P-1961QB Remove/Install Resonance Intake Manifold
2
3
Steps 1 - 24
4
Steps 25 - 33
Control Unit
Engine Wiring Harness
Cylinder Head
Injection Nozzles, Injection Valves, Lines
5
Intake Manifold
ME Gasoline Injection And Ignition System
Special Tools
1
Rear Crankshaft Main Bearing Seal: Service and Repair
AR03.20-P-3063QB Replace Rear Crankshaft Radial Seal
AR03.20-P-3063QB Replace rear crankshaft radial seal
Steps 1 - 8
2
Steps 9 - 15
Crankcase, Timing Case Cover, End Cover
Special Tools
3
Repair Materials
1
AR03.20-P-3063-01VA Installing Rear Crankshaft Radial Sealing Ring
AR03.20-P-3063-01VA Installing rear crankshaft radial sealing ring
Modification notes
Special Tools
Repair materials
2
The crankshaft radial sealing ring (1) is vulcanized into the end cover (2) and can only, therefore, be replaced together with the end cover (2). Do
not reuse the end cover (2) with the rear crankshaft radial sealing ring (1) after removal.
The crankshaft radial sealing ring (1) has a protective lip (1s) in addition to the sealing lip (1d). The sealing lip (1d), protective lip (1s) and
contact surface (3a) at the crankshaft flange (3) must not be lubricated for assembly!
1 Clean and degrease crankcase (4) and oil pan in the area of the applied sealant as well as contact surface (3a) on the crankshaft flange (3).
2 Clean and degrease sealing surface of new end cover (2).

3 Apply sealant in the form of a bead (A) with a height and width of 2.0 mm (± 0.5) mm to crankcase (4) and oil pan.
Use exclusively approved sealants. Do not spread bead (A). Mount end cover (2) within 5 minutes after applying sealant.
3
4 Mount end cover (2) with crankshaft radial sealing ring (1) on insertion tool (6).
Make sure that protective lip (1s) faces towards the side applying the force and sealing lip (1d) faces in the direction of the crankcase (4).
Leakage could occur otherwise at rear crankshaft radial sealing ring (1).
The crankshaft radial sealing ring (1) can only be mounted on the insertion tool (6), if insertion tool (6) is fitted together with insertion tool
(7).
5 Separate insertion tool (7) from insertion tool (6).

6 Mount end cover (2) with crankshaft radial shaft sealing ring (1) and insertion tool (6) onto contact surface (3a) on crankshaft flange (3).
The contact surface (3a) must not be removed with emery board as this can destroy the surface of the crankshaft and render the crankshaft
unusable.
4
7 Tighten bolts (2a) gradually in crosswise pattern, then tighten the bolts (2b). Observe tightening torque.
8 Detach insertion tool (6) from crankshaft flange (3).
9 Carefully lift protective lip (1s) and check the correct installation position of sealing lip (1d).
A wrong installation position leads to leakage.
The sealing lip (1d) must point towards crankcase (4) all around its circumference.
10 Check for correct installation position of the protective lip (1s).
An incorrect installation position leads to premature wear of crankshaft radial sealing ring (1).
The protective lip (1s) must point towards transmission housing around its entire circumference.
1
AR03.20-P-3063QB Replace Rear Crankshaft Radial Sealing Ring
AR03.20-P-3063QB Replace rear crankshaft radial sealing ring
Modification notes
Steps 1-4
2
Steps 5-16
3
Special Tools
Repair materials
1
Cylinder Head Gasket: Service and Repair
AH01.30-P-1000-04RX Information on applying sealant to cylinder head gasket
Applying sealant to cylinder head gasket
Before mounting the cylinder heads, apply sealant around the timing case cover on the cylinder crankcase.
Repair information
The sealing surface must be cleaned. Sealant should be applied only to the specified surface, in the form of a bead 2.0 mm (± 0.5 mm) in height
and width (see picture).
The sealant remains workable for 10 min.
The bead should not be spread.
1
Front Crankshaft Seal: Service and Repair
AR03.20-P-3000QB Replace Front Crankshaft Radial Sealing Ring
AR03.20-P-3000QB Replace Front Crankshaft Radial Sealing Ring
Steps 1 - 12
2
Special Tools
1
Front Crankshaft Seal: Service and Repair
AR03.20-P-3000-01B Install Front Crankshaft Radial Seal
AR03.20-P-3000-01B Install front crankshaft radial seal
Special Tools
1 Deburr edge of mounting bore for crankshaft radial sealing ring at timing case cover.
2 Push the crankshaft radial sealing ring onto the side (a) of the sleeve (2).
Circumference and sealing lip of crankshaft radial seal as well as the mating contact surface on the vibration damper must be free of oil and
grease.
3 Align groove of sleeve (2) to the Woodruff key of the crankshaft.
Turn to ensure that the slot in the sleeve (2) is aligned with the Woodruff key in the crankshaft.
4 Push sleeve (2) onto crankshaft and press in crankshaft radial sealing about 2 mm.
If necessary, knock in sleeve (2) with light blows from a hammer until it is possible to insert the central bolt (3).
5 Draw in sleeve (2) with central bolt (3) as far as the stop.
6 Detach sleeve (2).
The crankshaft radial sealing ring must be positioned at right angles to the crank journal otherwise proper sealing is not assured.
2
Shown on engine 112
Repair size 1 is identified by a 3 mm wide shoulder on the contact surface.
7 Turn sleeve (2) and push onto the crankshaft with side of repair size 1 (b).
Turn to ensure that the slot in the sleeve (2) is aligned with the Woodruff key in the crankshaft.
8 Draw in sleeve (2) with central bolt (3) as far as the stop.
9 Detach sleeve (2).
Shown on engine 112
10 Check installation location of the crankshaft radial sealing ring (1) to the crank pin (4).
The crankshaft radial sealing ring (1) must be positioned at right angles to the crank journal (4) otherwise proper sealing is not assured.
The installation depth (B) of the crankshaft radial sealing ring (1) is preset through the sleeve (2) and must not be altered subsequently.
Shown on engine 112
1
Valve Guide Seal: Service and Repair
AR05.30-P-3500QB Remove/Install Valve Springs and / or Valve Stem Seals
AR05.30-P-3500QB Remove/install valve springs and / or valve stem seals
Modification Notes
2
Steps 1 - 7
Steps 8 - 19
3
Special Tools
1
Valve Guide Seal: Service and Repair
AR05.30-P-3500-02VA Replace Valve Stem Seals
AR05.30-P-3500-02VA Replace valve stem seals
Special Tools
1 Use pliers (01) to pull off valve stem seals (1).

2 Check surface of valve stems for roughness and ridging.
Replace valves with a rough stem surface or formation of burrs.
Shown on engine 273
3 Fit protective sleeve (02) onto valve stem.
2
4 Oil valve stem seals (1).
5 Press on the valve stem seals (1) with drift (03).
6 Pull protective sleeve (02) off the valve stem.
Shown on engine 273
1
Timing Chain: Procedures
AR05.10-P-7601-01VA Separate Timing Chain

AR05.10-P-7601-01VA Separate timing chain
Special Tools
1 Cover over timing case recess with a clean cloth.
The timing case recess must be secured against parts falling down. Parts that have fallen into the timing case recess must be removed.
2 Assemble the chain separating tool (01) and the pressure screw (02) together.
3 Fit the chain separating tool (01) at the timing chain (1).
Ensure that the pressure pin (03) lies at the pin (arrow) of a timing chain link.
4 Screw in the pressure screw (02) and separate the timing chain (1).
Do not let the pins that have been pushed out fall into the timing case recess.
5 Remove the pressure screw (02) and take off the chain separating tool (01).
AR05.10-P-7601-02VA Riveting the Timing Chain
AR05.10-P-7601-02VA Riveting the timing chain
2
Timing chain, chain tensioner
Special Tools
When carrying out work on the timing case recess, safeguard this with a clean cloth to prevent items dropping down. Parts which have fallen into
the timing case recess, must be removed.
Press the riveted link into the press-fit center plate

1 Place the assembly insert (F11) in the rivet press tool (01) and fix in place with the mounting screw.
2 Place the assembly insert (D12) in the rivet press tool (01).
3
3 Insert the riveted link (1), the centering fork (03) and the press-fit center plate (2) into the ends of the timing chain (4), and press the pins of
the centering fork (03) into the holes of the press-fit center plate (2) and center the press-fit center plate (2).
Insert riveted link (1) from the rear.
4 Screw in the pressure screw (02) at the rivet press tool (01), and press the riveted link (1) into the press-fit center plate (2) all the way to the
backstop.
Ensure that the riveted link (1) and the rivet press tool (01) are aligned. While screwing in the pressure screw (02) ensure that the pins of the
riveted link (1) are pressed into the holes of the press-fit center plate (2), and that the centering fork (03) that has been squeezed out does not
fall into the timing case recess.
5 Remove the pressure screw (02) and takeoff the rivet press tool (01).
Press the outer plate on the riveted link

6 Place the assembly insert (F401) in the rivet press tool (01) and fix in place with the mounting screw.
7 Place the assembly insert (01M) in the rivet press tool (01).
4
8 Insert the outer plate (3) into the assembly insert (D3).
The outer plate (3) is held magnetically.
9 Place the rivet press tool (01) in such a way that the spacer webs of the assembly insert (F4) lies on the rolls of the timing chain (4).
Ensure that the riveted link (1) and the outer plate (3) are aligned.
10 Screw in the pressure screw (02) at the rivet press tool (01) until there is solid resistance.
While turning the pressure screw (02), ensure that the pins of the riveted link (1) are pressed into the outer plate (3).
11 Remove rivet press tool (01).
Rivet timing chain

12 Shift the assembly insert (D3) on the riveted section (arrow).
5
13 Place the rivet press tool (01) in the center of a riveted link (1) pin.
Rivet the pins of the riveted link (1) individually.
14 Tighten the pressure screw (02) at the rivet press tool (01).
Tightening torque of the 01 pressure screw (02): reference value 32 Nm.
15 Remove rivet press tool (01).
16 Inspect riveting (arrows), re-rivet if necessary.

AR05.10-P-7601-04VA Drawing In Timing Chain
AR05.10-P-7601-04VA Drawing in timing chain
Special Tools
6
2 Connect the new timing chain (2) and the old timing chain (1) with the assembly link (01).
Fit the lock of the assembly link (01) in the direction opposite to that in which the timing chain is drawn; otherwise it could get jammed on
the slide rails and come off when the timing chain is drawn.
3 Remove the rags from the timing case recess.
Otherwise, they could get pulled into the timing case recess when the engine is cranked.
4 Turn the crankshaft slowly in the engine's direction of rotation (arrow) and draw in the new timing chain (2) until the ends of the new timing
chain (2) can be connected.
As the new timing chain (2) is being drawn in (arrows), pull out the end of the old timing chain (1) evenly as it becomes free.
6 Detach the assembly link (01), and separate the old timing chain (1) from the new timing chain (2).
The assembly link (01) must be removed. The assembly link is only an aid for assembly and is not suitable for engine operation.
1
Timing Chain: Removal and Replacement

Special Tools
Steps 1 - 5
AR05.10-P-7601-02VA Riveting Timing Chain

AR05.10-P-7601-02VA Riveting the timing chain
Timing Chain, Chain Tensioner
2
Special Tools
Steps 1 - 2
Step 3
Steps 4 - 5
3
Steps 6 - 7
Step 8
Steps 9 - 11
Step 12
4
Sep 13 - 15
AR05.10-P-7601-04VA Drawing In Timing Chain

AR05.10-P-7601-04VA Drawing in timing chain
Steps 1 - 2
Steps 3 - 6
5
Special Tools
AR05.10-P-7601QB Replace Timing Chain

AR05.10-P-7601QB Replace timing chain
6
Steps 1 - 2
Steps 3 - 12
1
Timing Chain Guide: Service and Repair
AR05.10-P-8484QB Remove/Install Slide Rail In Timing Case Cover
AR05.10-P-8484QB Removing/installing slide rail in timing case cover
Steps 1 - 10
1
Timing Chain Guide: Service and Repair
AR05.10-P-8127QB Remove/Install Tensioning Rail
AR05.10-P-8127QB Remove/install tensioning rail
2
Steps 1-3
3
Steps 4-15
4
Special Tools
Repair materials
1
Timing Chain Tensioner: Service and Repair
AR05.10-P-7800QB Remove/Install Chain Tensioner
AR05.10-P-7800QB Remove/Install Chain Tensioner
- Chain tensioner with thread M24x1.5
Steps 1 - 7
Timing Chain, Chain Tensioner
1
AR05.10-P-7800-02VA Installing Chain Tensioner
AR05.10-P-7800-02VA Installing chain tensioner
- M24 1, 5
Modification notes
1 Press out the bolt (8) and detent spring (9) from chain tensioner housing (5) (arrowed).
2
2 Insert the bolt (8) and detent spring (9) in chain tensioner housing (5) (arrowed).
Insert the bolt (8) and detent spring (9) so that the detent springs (9) sit in the first notch (10).
The bolt (8) must remain in this position.
3 Screw in the chain tensioner housing (5) with bolt (8), detent spring (9) and new sealing ring (7) into the timing case cover, and tighten.
4 Insert the push spring (3) and filler pin (4) in chain tensioner housing (5).
5 Screw in the end piece (1) with new sealing ring (2) into chain tensioner housing (5), and tighten.
3
When the push spring (3), filler pin (4) and end piece (1) are installed, bolt (8) is moved into the correct position in chain tensioner housing
(5).
1
AR05.10-P-8127QB Remove/Install Tensioning Rail
AR05.10-P-8127QB Remove/install tensioning rail
2
Steps 1-3
3
Steps 4-15
4
Special Tools
Repair materials
1
Timing Cover: Procedures
AH01.40-P-1000-01VA Notes on Sealant Path For Timing Case Cover

AH01.40-P-1000-01VA Notes on sealant path for timing case cover
The lines (1) identify the application of the sealant.
The sealing surface must be cleaned. Sealant should be applied only to the specified surface, in the form of a bead of height and width 1.5 mm ±
0.5 mm. The sealing compound must be applied within 10 min. The sealing compound bead must not be spread. Use only the sealant indicated in
Repair Materials.
AR01.40-P-8000-01VA Bolt Diagram For Timing Case Cover
AR01.40-P-8000-01VA Bolt diagram for timing case cover
Bolt diagram for timing case cover
1
Timing Cover: Removal and Replacement
AR01.30-P-5700QB Remove/Install Front Cover on Cylinder Head

AR01.30-P-5700QB Remove/install front cover on cylinder head
- Front cover on right cylinder head
2
Steps 1-16
Cylinder head
3
Position sensor
Special Tools
Repair materials
AR01.30-P-5700QC Remove/Install Front Cover on Cylinder Head

AR01.30-P-5700QC Remove/install front cover on cylinder head
- Front cover on left cylinder head
4
Steps 1-5
5
Steps 6-22
Cylinder head
6
Position sensor
Special Tools
Repair materials
AR01.40-P-8000QB Remove/Install Timing Case Cover

AR01.40-P-8000QB Remove/install timing case cover
7
Modification notes
Steps 1-8
8
Steps 9-34
9
Air shutoff valve
Cylinder head
10
Special Tools
Repair materials

11

The sealing compound must be applied within 10 min. The sealant bead must not be spread. Only the approved sealant may be used.

AH01.40-P-1000-01VA Notes on Sealant Path For Timing Case Cover
AH01.40-P-1000-01VA Notes on sealant path for timing case cover
12
Sealant path for timing case cover
The lines (1) identify the application of the sealant.
The sealing surface must be cleaned. Sealant should be applied only to the specified surface, in the form of a bead of height and width 1.5 mm ±
0.5 mm. The sealing compound must be applied within 10 min. The sealing compound bead must not be spread. Use only the approved sealant.
1
Water Pump: Service and Repair
AR20.10-P-1271QB Remove/Install Coolant Pump
AR20.10-P-1271QB Remove, install coolant pump
Steps 1 - 14
2
1
Cooling System: Testing and Inspection
AR20.00-P-1010QB Inspect cooling system for leaks
Steps 1 - 15
2
Cap For Radiator Expansion Reservoir
Special Tools
1
Cooling System: Procedures
AP20.00-P-2010PIT Engine Cooling System - Check Fluid Level, Adjust to Correct Level.
AP20.00-P-2010PIT Engine Cooling System - Check Fluid Level, Adjust to Correct Level. Inspect Anticorrosion/Antifreeze Protection,
adjust to correct concentration
Steps 1 - 6
AR20.00-P-1142QB Drain/Fill Coolant

AR20.00-P-1142QB Drain/fill in coolant
Modification Notes
2
Steps 1 - 7
Steps 8 - 16
Engine Cooling, General
3
Cooling System
Cooling System
Special Tools
AP20.00-P-2010PIT Engine Cooling System - Check Fluid Level, Adjust to Correct Level
AP20.00-P-2010PIT Engine cooling system - check fluid level, adjust to correct level. Inspect anticorrosion/antifreeze protection, adjust to
correct concentration
4
Mixture ratio for coolant
Mixture ratio for coolant
1
Cooling System: Removal and Replacement
AP20.00-P-2080PIT Replace coolant
Steps 1 - 8
1
Auxiliary Water Pump: Description and Operation
GF83.20-P-2109P Heating Water Circulation Pump, Location/task/function
- with CODE (581) Automatic air conditioning [models 203.0/2/7 up to 31.5.01]
- with CODE (581) Comfort automatic air conditioning [models 203.0/2/7 as of 1.6.01. 209.3/4]
- with CODE (450) Taxi version [models 302.0/2/7 up to 08, 209.3/4]
- with CODE (670) Residual engine heat utilization system (REST [MRA]) [models 302.0/2/7 up to 08, 209.3/4]
- except CODE (581) Comfort automatic air conditioning [model 209.3/4]
1
Auxiliary Water Pump: Service and Repair
AR83.25-P-1170P Remove/Install/Replace Heating Water Circulation Pump
AR83.25-P-1170P Remove/Install/Replace Heating Water Circulation Pump
- with CODE (670a) Residual engine heat utilization (REST)
- with CODE (228) Stationary heater
- with CODE (874) Coolant circulation pump
- with CODE (580a) Automatic air conditioning
- with CODE (581b) Convenience automatic air conditioning
Shown on Model 203.0
DANGER:
- Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.
- Do not open cooling system unless coolant temperature is below 90 degrees C. Open cap slowly and release the pressure. Do not pour
coolant into beverage bottles
- Wear protective gloves, protective clothing and eye protection.
1 Open engine hood

2 Reduce pressure in cooling system
3.1 Detach lower engine compartment lining
- Engines 111, 112
NOTE: Front paneling
3.2 Remove bottom section of sound-proofing capsule

- Engine 611, 612
NOTE: Front bottom section
4 Drain coolant at radiator

5 Disconnect connector (1) from coolant circulation pump (M13)
6 Remove hose clamps (2) from fitting
- Hose clamp pliers (length 210 mm; adjustment range 80 mm)
See "Commercially Available Tools" given below.
7 Remove coolant circulation pump (M13) from coolant

pansion reservoir (4)
8 Remove heating hoses (3)
9 Install in the reverse order
10 Adjust coolant to correct level
11 Perform leak check.
2
1
Auxiliary Water Pump: Service and Repair
AR83.25-P-1170PP Remove/Install/Replace Coolant Circulation Pump
AR83.25-P-1170PP Remove/Install/Replace Coolant Circulation Pump
- with CODE (670a) Residual engine heat utilization (REST)
- except CODE (228) Stationary heater
- with CODE (874) Coolant circulation pump
- with CODE (580a) Automatic air conditioning
- with CODE (581b) Convenience automatic air conditioning
DANGER:
coolant into beverage bottles.
1 Open engine hood

3 Pinch off coolant hoses (4)
- See "Special Tools" given below.
4 Disconnect connector (1) from coolant circulation pump (M13)

5 Remove hose clamps (2) from fitting
- Hose clamp pliers (length 210 mm; tensioning range 80 mm)
See "Commercially Available Tools" given below.
6 Remove coolant circulation pump (M13) from coolant expansion reservoir (4)
7 Remove heating hoses (3)
9 Adjust coolant to correct level
10 Perform leak check.
Special Tools
2
Clamp, P/N# 000 589 40 37 00
1
Coolant: Description and Operation
AH20.00-P-1141-01V Notes on Coolant Level
AH20.00-P-1141-01V Notes on coolant level
Model 171 with engine 271, 272

When the engine is cold, the engine coolant level must reach up to the marking "Min" on the coolant expansion reservoir (arrow).
When coolant is warm: approx. 1 cm above this scribe mark.
Model 220 with engine 112
Model 215, 220 with engine 113, 137
Model 215, 220 with engine 275, main circuit
Model 461, 463 with engine 612
Model 463 with engine 112, 113, 273, 628, 642

When engine is cold, the engine coolant level must reach up to the marking (arrow) on the coolant expansion reservoir.
2

When the engine is cold, the coolant level must reach up to the marking (arrow) on the coolant expansion reservoir.
When the coolant is warm, about 1 cm above the marking (arrow).



3
Model 230 with engine 275, main circuit

Model 211 with engine 112, 113, 156, 271, 272, 273 model 219 with engine 113, 156, 272, 273
When the engine is cold, the engine coolant level must reach up to the marking (arrow) in the coolant expansion reservoir.

4
Model 240 with engine 285, Main circuit

Model 215, 216, 220, 221, 230 with engine 275, low temperature circuit
Model 240 with engine 285, low temperature circuit

The engine coolant level must be placed, when coolant is warm or cold, in the crosshatched illustrated area of filler neck.
1
AH20.00-P-1142-01PI Notes on Coolant Level
AH20.00-P-1142-01PI Notes on coolant level
Coolant expansion tank cold level mark
The coolant level must reach on a cold engine up to the marking (arrow) on the coolant expansion reservoir.
For warm coolant the coolant level is about 1 cm above the marking (arrow).
1
AH20.00-P-1142-01V Notes on Coolant Level
AH20.00-P-1142-01V Notes on coolant level

When the engine is cold, the engine coolant level must reach up to the marking "Min" on the coolant expansion reservoir (arrow).
Model 461, 463 with engine 612

2
When the engine is cold, the coolant level must reach up to the marking (arrow) on the coolant expansion reservoir.
When the coolant is warm, about 1 cm above the marking (arrow).



3
Model 230 with engine 275, main circuit

Model 211 with engine 112, 113, 156, 2719 272, 273 model 219 with engine 113, 156, 272, 273
Model 221 with engine 156, 272, 273 629 642

4
Coolant cold level mark
Model 240 with engine 285, Main circuit

Model 215, 216 220 221 230 with engine 275, low temperature circuit
Model 240 with engine 285, low temperature circuit

The engine coolant level must be placed, when coolant is warm or cold, in the crosshatched illustrated area of filler neck.
1
Coolant: Procedures
AR20.00-P-1142QB Drain/Fill Coolant

AR20.00-P-1142QB Drain/fill in coolant
Modification Notes
Steps 1 - 7
2
Steps 8 - 16
Engine Cooling, General
Cooling System
3
Cooling System
Special Tools
AH20.00-N-2080-01A Notes on Coolant

AH20.00-N-2080-01A Notes on coolant
Coolant composition
Passenger car and commercial vehicle engines (normally):
50% water by volume and

50% anticorrosion/antifreeze agent by volume.
Observe different coolant composition for CV engines.
Tasks of anticorrosion/antifreeze agent

^ Corrosion and cavitation protection for all components in cooling system
^ Antifreeze protection (frost protection)
^ Increase the boiling point so that coolant does not evaporate so rapidly. Avoiding ejection of coolant at high coolant temperatures.
Antifreeze protection
50% anticorrosion/antifreeze agent by volume provides antifreeze protection down to approx. -37 degrees C. A higher concentration is only
necessary if the ambient temperatures are even lower. 55% anticorrosion/antifreeze agent by volume provides antifreeze protection down to
approx. -45 degrees C.
A concentration of more than 55% anticorrosion/antifreeze agent by volume should not be used as the maximum antifreeze protection is already
reached at this concentration. An even higher concentration once reduces antifreeze protection and impairs heat dissipation. Reduced heat
dissipation can result in damage to components of the cooling system and to the engine.
Water
Use water which is clean and not too hard. Drinking water often satisfies requirements, but not always. The amount of dissolved substances in
the water may be of significance for the occurrence of corrosion. If in doubt, analyze the water.
Period of use
The maximum permissible period of use of the coolant is given in the maintenance booklet or the applicable "Service/Maintenance Sheet."
Before pouring in fresh coolant, flush the used coolant out of the cooling system. In the case of severe fouling by dirt or oil, clean the cooling
system otherwise components of the cooling system can be damaged.
Disposing of coolants
Observe the legal provisions and local waste water regulations. The following brochures are available about disposing of waste products in auto
repair trade for the location Federal Republic of Germany:
"Environmental protection manual for motor vehicle repair operations"

Publisher: Verband der Automobilindustrie e.V. (VDA) 60325 Frankfurt am Main, Westendstrasse 61
to be ordered under:
Tel no.:069/97507-0 or at www.vda.de
or
"The new waste laws"

Publisher: Zentralverband Deutsches Kraftfahrzeuggewerbe e. V. (ZDK)
53129 Bonn, Franz-Lohe-Strasse 21
to be ordered under:
Tel no.:0261/8059-584, Fax no. 0261/8059-585 or at www.kfzmeistershop.de
1
Coolant: Removal and Replacement
AP20.00-P-2080PIT Replace coolant
Steps 1 - 8
1
Coolant Level Sensor: Service and Repair
AR20.30-P-4392PI Remove/install coolant level switch
Steps 1 - 6
Repair Materials
1
Coolant Reservoir: Service and Repair
AR20.30-P-4950PI Remove/install expansion reservoir
Steps 1 - 13
2
Step 14
Special Tools
Repair Materials
1
Radiator Cooling Fan: Description and Operation
GF83.40-P-2151P Electric Fan Motor/Air Conditioning System, Location/Task/Function
MODEL 203.0 /2 /7
- with CODE (580) Air conditioning (or Tempmatic for USA)
- with CODE (580) Automatic air conditioning
- with CODE (581) Comfort automatic air conditioning
- up to Model Year 8
M4/7 Engine and AC electric suction fan with integrated control
1
Radiator Cooling Fan: Service and Repair
AR20.40-P-5000QB Remove/install electric fan
- Model 209.377
- except CODE (P98) Black Series
2
Modification notes
Steps 1-22
3
Test values for gap dimensions on hoods, doors and lids
4
Test values for gap dimensions on hoods, doors and lids
Test and adjustment values for gap dimensions
Special Tools
1
Coolant Temperature Sensor / Switch HVAC: Description and Operation
GF83.40-P-2155P Air Conditioning Coolant Temperature Sensor Location/Task/Function
MODEL 203.0 /2 /7
- with CODE (580) Air conditioning (or Tempmatic for USA)
- up to Model Year 8
B11/4 Coolant temperature sensor
1
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
GF07.04-P-6040V Coolant Temperature Sensor Component Description
Location
The coolant temperature sensor is located at the rear in the left cylinder head.
Task
Detects the coolant temperature and supplies a voltage signal to the ME control unit.
Function
The NTC resistor integrated in the coolant temperature sensor, alters its electrical resistance in line with the coolant temperature. NTC is the
abbreviation for " Negative Temperature Coefficient", which means electrical resistance falls as the temperature increases (hot conductor).
Body
Metal casing with an integrated, highly responsive NTC resistor and a 2-pole, slanted plug connection. It is inserted into a bore hole and sealed with
an O-ring. Fixing via a bracket.
The rapidly responsive NTC temperature sensor is supplied with 5 V by the ME control unit via a series resistor (1470 ohms ± 1 %). Following a
short-circuit to battery voltage or 5 V (without a series resistor), the temperature sensor coolant is defective.
The signal is plausible between 0.1 V to 4.93 V, otherwise a fault is identified and a substitute value taken by the ME control unit from a stored
temperature model.
1
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
AR15.60-P-3000QB Remove/Install Temperature Sensor
- Coolant temperature sensor
2
Steps 1 - 13
Temperature Sensor
1
Heater Control Valve: Description and Operation
GF20.00-P-2200V Component Description For The Heating System Shutoff Valve
Location
The heating system shutoff valve is located behind the left cylinder bank at the coolant outlet of the engine.
Task
To rapidly warm up the engine following a cold start, locks the coolant circuit to the heat exchangers. When the vehicle heater is switched on, the
valve is always open.
Function
The heating system shutoff valve is actuated by the ME control unit via a ground signal. The valve is opened without a current. The coil resistance
at room temperature is approx. 12 Ohms.
1
Heater Core: Description and Operation
GF83.20-P-2108P Heating System Heat Exchanger, Location/Task/Function
GF83.20-P-2108P Heating System Heat Exchanger, Location/task/function
1
Heater Core: Service and Repair
AR83.25-P-1100P Remove/Install Heat Exchanger
CAUTION: Installation: Replace self-locking nuts and bolts.
DANGER:
coolant into beverage bottles.
2
1 Completely move adjustable steering column out and downward

2 Open engine hood
4.1 Detach lower engine compartment lining
NOTE: Front paneling.
4.2 Remove bottom section of sound-proofing capsule
NOTE: Front lower section.
5 Drain coolant at radiator
DANGER:
- Risk of explosion from gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury with caustic
burns to eyes and skin from battery electrolyte or from handling damaged lead-acid batteries.
- Wear acid-resistant gloves, clothing and eye protection. Pour battery electrolyte only into suitable and appropriately marked
containers.
6 Disconnect ground cable of battery
DANGER:
- Risk of injury when carrying out test or repair work on airbag or emergency tensioning retractor units.
- Store airbag unit with expulsion area on top, do not subject to temperatures above 100 degrees C. Interrupt power supply when
working on such units.
7 Remove steering wheel (7).

8 Remove cover below instrument panel (8)
NOTE: Driver's side
9 Remove instrument panel bottom section (6)
NOTE: Driver's side
10 Remove instrument cluster (A1)

11 Remove accelerator pedal
12 Fold back floor covering at front left
NOTE: Air duct to left rear compartment (9) must be accessible
13 Remove air duct to left rear compartment (9)

14 Remove jacket tube from instrument panel carrier and fold down into footwell
NOTE: Do not remove bottom steering shaft from steering coupling.
15 Remove tensioning springs (9a)
NOTE: Three tensioning springs.
16 Remove fittings (9)

17 Pull out insert forks (10)
CAUTION: Installation: Replace insert forks.
18 Pull heating water pipes (11) out of heat exchanger (12)
CAUTION:
- Coolant. Avoid contaminating passenger compartment. Plug heating water pipes (11) and openings on heat exchanger (12).
- Installation: Replace sealing rings.
- See "Special Tools - Set of Plugs" given below.
19 Unscrew bolts (13)

- See "Special Tools - Torx bit set" given below.
20 Remove bracket (14)

21 Pull out heat exchanger
3
CAUTION: Clean AC/heater housing from inside, if necessary remove coolant running out.

23 Operational check.
Special Tools
Special Tools
1
Radiator: Service and Repair
AR20.20-P-3865QB Remove/install radiator
2
Steps 1-14
1
Thermostat: Description and Operation
GF20.10-P-3160V Component Description For The Three-disk Thermostat Valve
Location
The three-disk thermostat valve is located at the front of the engine.
Task
To control the coolant temperature in the range of approx. 80 °C to 100 °C. From approx. 110 °C, to fully open independently of the control.
Function
Voltage supply to terminal 87, actuation of the heating element on the ground side of the ME control unit. The opening cross-section is set via the
operating time.
1
Thermostat: Testing and Inspection
AR20.10-P-2455QB Test coolant thermostat
Steps 1 - 6
Test Values For Coolant Thermostat
Special Tools
2
1
Thermostat: Service and Repair
AR20.10-P-2460QB Remove/install coolant thermostat
2
Steps 1-15
1
Exhaust System: Procedures
AZ49.10-P-0001J Retrofit AMG muffler system
- Model 203.054/061/261/064/264
- except CODE (949) Sport package
- except CODE (950) AMG Sport package
- Only for vehicles with center muffler fitted as standard
- Model 203.040/240
- except CODE (949) Sport package
- except CODE (950) AMG Sport package
- in combination with CODE (805) Model year 2005
- Only for vehicles with center muffler fitted as standard
2
Steps 1-10
3
Parts ordering notes
1
Exhaust System: Removal and Replacement
AR49.10-P-5531QB Remove/Install Catalytic Converter and Front Exhaust System

AR49.10-P-5531QB Remove/install catalytic converter and front exhaust system
2
Steps 1-16
3
Exhaust system
AR49.10-P-7000QB Remove/Install Exhaust System Complete

AR49.10-P-7000QB Remove/install exhaust system complete
4
5
Steps 1-16
Frame floor assembly
6
Exhaust system
1
Catalytic Converter: Description and Operation
GF49.10-P-2010V Three-Way Catalytic Converter, Component Description
GF49.10-P-2010V Three-way Catalytic Converter, Component Description
Location
Near the engine in the front section of the exhaust system.
Task
Reduction of the following pollutants in the exhaust:

- Carbon monoxide (CO)
- Hydrocarbon (HC)
- Nitrogen oxide (NOx).
In each catalytic converter, there are two ceramic monoliths with each approx. 600 cells. The exhaust gas flows through these passages. The
ceramic consists of high temperature-resistant magnesium aluminum silicate.
The monoliths are extremely sensitive to warping and are embedded in an elastic wire mesh of high-carbon steel wire and mounted inside a
double-wall housing of stainless steel.
Ceramic monoliths require a support layer of alumina (Al2O3) (the "washcoat"), which increases the effective surface of the catalytic converter by
a factor of 7000.
The active catalytic layer coated on the substrate is available in three-way catalysts primarily out of platinum and rhodium. Platinum promotes the
oxidation of hydrocarbons (HC) and carbon monoxide (CO) and rhodium the reduction of nitrogen oxides (NOx).
2
Owing to its property of simultaneously reducing three pollutant components, it is called a "three-way catalyst".
Function
The exhaust gases flow through the three way catalytic converter and hence come into contact with the rare metals, platinum and rhodium.
- The carbon monoxide (CO) is converted to carbon dioxide (CO2) and hydrocarbons (HC) converted to water (H2O) + carbon dioxide (CO2)
by oxidation.
- Due to reduction, nitrogen oxides (NOx) are converted into nitrogen (N2) + carbon dioxide (CO2).
The critical factors for the conversion of the pollutants is the residual oxygen content in the exhaust. It is determined through lambda control and
maintained at Lambda=1 in normal operation.
Operating conditions
As is the case for the O2 sensor, the operating temperature also plays a very important role in the case of the catalytic converter.
Appreciable conversion of the pollutants does not commence until an operating temperature of approx. 250 °C. This temperature is reached quickly
after the engine is started, due to the near-engine location, the air-gap insulation on the exhaust manifold and mixture enrichment.
Ideal operating conditions for high conversion rates and a long life prevail at temperatures between around 400 to 800 °C.
The temperature of the three way catalytic converter can increase beyond 1400 °C due to a malfunctioning of the engine such as misfiring etc.
These high temperatures can lead to destruction of the catalytic converter, by melting the ceramic monoliths.
Another requirement for reliable long-term operation is that only unleaded fuel be used. Lead compounds form a deposit on the active surface and
as a result prevent the exhaust gases from coming into contact with the catalytic layer.
If the vehicle is driven during direct injection in stratified charge operation with excess air, the catalytic converter cannot convert the nitrogen oxide
sufficiently. Additional NOX storage catalytic converters are necessary.
1
GF49.10-P-3033V Monitoring Catalytic Converter Efficiency, Function
GF49.10-P-3033V Monitoring Catalytic Converter Efficiency, Function
Each catalytic converter is evaluated on the basis of its ability to store oxygen. The oxygen stored during the lean phase is then reduced totally or
partially during the rich phases. Aging reduces the ability of catalytic converters to store oxygen. It also reduces the ability to convert HCs.
By law, HC emissions must not go above certain limits. The task of the catalytic converter monitoring is to evaluate aging through the ability to
store oxygen and therefore to convert hydrocarbons.
Active diagnosis depends on direct measurement of the oxygen stored during the transition from rich to lean mixture, when the catalytic converter
is at operating temperature and the lambda control is enabled. Several measurements are taken in the lower partial load range.
The wideband-lambda sensor is located upstream of the catalytic converter, and is used to obtain precise measurements of the mixture. Downstream
of the catalytic converter is a lambda discrete sensor, which identifies its current condition.
During the first stage, the oxygen stored when the mixture is rich (lambda about 0.95) is reduced until the sensor voltage downstream of the
converter is over about 650 mV.
The next stage switches to the lean mixture (lambda about 1.05) and monitors how long it takes until the sensor voltage downstream of the
converter is below about 200 mV.
If the length of time measured in this way is below the value set as the borderline characteristic for catalytic converters, then oxygen storage
capacity is insufficient and the converter must be replaced.
If a fault is detected, the engine diagnosis indicator lamp or the "CHECK ENGINE" indicator lamp (USA) is lit on the instrument cluster. The
stored faults can be read out and erased with the STAR DIAGNOSIS.
1
GF07.61-P-3032V ME-SFI TWC Heating-Up, Function
GF07.61-P-3032V ME-SFI TWC Heating-Up, Function
The TWC heating-up function heats up the catalytic converters more rapidly to their operating temperature (300 to 450 °C) and thus considerably
reduces the exhaust emissions in the cold start and heating-up phase.
The ME control unit is able to detect that the operating temperature has been reached and that the catalytic converters are operating at normal
efficiency from the signals supplied by the O2 sensors.
The following conditions determine whether TWC heating is enabled:

- Engine starting temperature
- Altitude level
- Residual heat in the catalytic convertor (from theoretical calculation)
- Difference between intake air and engine starting temperatures
- Air mass
The following systems are involved in the TWC heating-up:

- Ignition system
At idle speed and coolant temperature dependent, the ignition angle is retarded for e.g. 20 seconds and thus the exhaust temperature is
increased.
- Idle speed control
Dependent on coolant temperature, the idle speed is increased to approx. 1100 to 1300 rpm for a maximum of 20 seconds.
- Camshaft adjustment
For TWC heating, special positions are specified separately for the intake and exhaust camshafts
- Coolant-temperature dependent transmission shift delay is retarded for automatic transmissions.
- Secondary air injection
After starting and during warm-up, the enriched mixture results in more unburned hydrocarbons in the exhaust. The injected air (high oxygen
concentration) causes post-oxidation in the catalytic converters. Heat is released as a result, which more rapidly warms up the catalytic
converters to operating temperature.
2
1
Catalytic Converter: Service and Repair
AR49.10-P-5531QB Remove/install catalytic converter and front exhaust system
2
Steps 1-16
3
Exhaust system
1
Exhaust Manifold: Procedures
AR49.10-P-5531-01DA Replace the rivet nuts in the exhaust manifold.
Special Tools
1 Hammer rivet nuts with a suitable bolt (arrow) out of exhaust manifold bores.
Only screw bolt into rivet nut by hand.
2 Insert new rivet bushes into exhaust manifold bore.

3 Screw cocking bolt into rivet nut and tighten.
4 Unscrew cocking bolt.
1
Exhaust Manifold: Removal and Replacement
AR14.10-P-3930QB Remove/Install Left Exhaust Manifold

AR14.10-P-3930QB Remove/Install Left Exhaust Manifold
2
Steps 1 - 10
Exhaust Manifold
AR14.10-P-4005QB Remove/Install Exhaust Manifold on Right

AR14.10-P-4005QB Remove/Install Exhaust Manifold on Right
3
4
Steps 1 - 11
Exhaust Manifold
1
Muffler: Service and Repair
AR49.10-P-7141QB Remove/install center and rear muffler
Steps 1-9
2
Frame floor assembly
Exhaust system
1
Ignition System: Description and Operation
GF15.12-P-0001V ME-SFI Ignition System, Function
Cylinder arrangement and ignition firing order
The ME-SFI control unit essentially analyzes the following signals for determining the ignition angle:
- Air mass
- Position and rpm of crankshaft
- Positions of intake camshafts
- Positions of exhaust camshafts
- Coolant temperature
- Intake air temperature
- Knock sensor signals
- Intake manifold air pressure
- Engine torque requests
The ME-SFI [ME] control unit interrupts the respective ignition coil at the moment of the ignition timing of the primary circuit to "terminal 1".
Ignition angle adaptation
2
For the following partial functions an ignition angle adjustment in the direction "retarded" or "advanced" can take place:
- Catalytic converter heating-up
- Overheating / knock protection
- Deceleration fuel shutoff
- Transmission overload protection (with automatic transmission 722.9)
- Anti-knock control [AKC]
- Engine torque requests
The ignition angle can only be checked using the DAS.
1
Firing Order: Specifications
AR01.00-P-1300-03HA Firing order
Firing order
Firing order
Firing order
Firing order
2
Firing order - Engine 137, 275, 285
1
Camshaft Position Sensor: Description and Operation
GF07.04-P-6020V Component Description For A Camshaft Hall Sensor
Location
The camshaft Hall sensors are located before the respective camshaft.
Task
Detects the camshaft position for the following functions contactlessly via the pulse wheel at the front at every camshaft:
- Synchronization of the ignition and injection sequence (recognition of ignition TDC).
Design
Hall sensor in plastic housing with 3-pole plug connection, distance from pulse wheel of 0.2 to 1.8 mm.
Function
The camshaft positions are detected by the camshaft Hall sensor, which detects the position of the pulse wheels at the front on the camshafts. The
camshaft position can already be detected when the engine is stationary by the electronics for the Hall sensor. This results in an improvement in the
exhaust levels because the optimal injected quantity of fuel can be assigned to each cylinder immediately when the engine is started (quick-start
function).
Four signals are generated per rotation of the camshaft whereby the signal switches between about 5 V ("HIGH") and 0 volt ("LOW"). If an
opening in the pulse wheel is opposite the sensor, the signal is approx. 5 V.
The signals are used to control and diagnose the camshaft adjustment, to synchronize the crankshaft and camshaft position (detection of ignition
TDC cylinder 1) and for emergency starting of the engine when the crankshaft Hall sensor is faulty.
2
The stated angle at the pulse wheels must be doubled to maintain the crank angle.
3
1
Camshaft Position Sensor: Service and Repair
AR15.10-P-2000QB Remove/Install Camshaft Hall Sensor
Steps 1 - 8
Position Sensor
2
Special Tools
1
Crankshaft Position Sensor: Description and Operation
GF07.04-P-6220V Component Description For the Crankshaft Hall Sensor
GF07.04-P-6220V Component Description For The Crankshaft Hall Sensor
Location
The crankshaft Hall sensor is located behind the left cylinder bank.
Task
It detects the engine speed and the crankshaft position by scanning a perforated plate welded to the starter ring gear (incremental wheel).
Design
Hall sensor in plastic housing with 3-pole plug connection, distance from the increment wheel 0.3 to 1.3 mm.
Function
The crankshaft Hall sensor scans the increment wheel at the starter ring gear. The increment wheel has 58 links and a gap, at which two links are
missing (60-2).
Each 4 mm wide link generates a signal change at the crankshaft Hall sensor. The signal changes in the link center from around 5 V to around 0 V
(negative signal edge).
No signal change takes place at the gap with the 2 missing links. The ME-SFI [ME] control unit detects the TDC position of cylinder 1 with the 2nd
negative flank after the gap.
In the ignition TDC of cylinder 1, the signals from the camshaft Hall sensor are also "LOW".
Only the negative signal edge of the crankshaft Hall sensor signal is ever evaluated. For example, for a frequency measurement, the gap between
two negative edges must be measured.
2
The rising negative edge of the signals occurs when a window is located opposite the crankshaft Hall sensor (no material). At the wide gap in
particular, the signal fluctuates greatly and is therefore not used.
1
GF07.04-P-6230V Component Description For the Position Sensor Tumble Flap
GF07.04-P-6230V Component Description For The Position Sensor Tumble Flap
Location
The position sensors are located at the rear on the intake manifold over the tumble flap shafts.
Task
To diagnose the tumble flap switchover, the position sensors detect the mechanical limit positions of the shafts. The swivel range of the tumble
flaps between completely swiveled in or out is approx. 56°.
Design
The position sensors function according to the Hall principle.
Function
Two cylindrical magnets with different polarities are attached to each tumble flap shaft.
After swinging out the tumble flaps a cylindrical magnet is located at the Hall sensor and the position sensor interconnects. The signal at the
ME-SFI [ME] control unit is about 0 V (tumble flaps actuated).
If the tumble flaps swing back then the other poled cylindrical magnet is on the Hall sensor is in the rest position. The position sensor opens and
interrupts the connection to ground. The signal at the ME-SFI [ME] control unit is now about 5 V (tumble flaps not actuated).
The position sensors must switch no later than approx. 5° before the respective limit position. For reasons of tolerance, they may also switch up to
approx. 16° before the limit position.
1
Crankshaft Position Sensor: Service and Repair
AR15.12-P-2133QB Remove/Install Crankshaft Position Sensor
Steps 1 - 8
Position Sensor
1
Ignition Coil: Description and Operation
GF15.10-P-2100V Component Description For An Ignition Coil
Location
For each cylinder, a dedicated ignition coil is plugged directly onto the spark plugs.
Task
Supplying adequate ignition energy in all operating conditions for the particular ignition circuit.
2
The ignition output stages are integrated in the ignition coils.
Function
An output stage is located in each ignition coil for the primary circuit. The ME control unit actuated the ignition coil primary circuit between
terminals 2 and 4. The current flow in the primary coil (L1) causes a magnetic field to form. The dwell angle control determines the operating time
of the ignition coil primary circuit and thus the magnetic saturation of the ferrous core of the ignition coil. The primary current flow is interrupted at
the moment of ignition timing point. The sudden collapse of the magnetic field generates the ignition voltage in the secondary coil (L2) which is
fed directly to the spark plugs.
The voltage supply of the ignition coils is protected at circuit 87 M1
A diode is integrated in each ignition coil for suppressing additional ignition sparks when the output stage is switched off.
Because of the diodes, it is not possible to measure the resistance in the secondary windings. For diagnosis of the ignition coils, the primary current
is measured. The capacitive tap is used to connect measuring equipment.
1
Ignition Coil: Service and Repair
Remove/Install Ignition Coils
2
Steps 1 - 8
Ignition Coil
1
Knock Sensor: Description and Operation
GF07.04-P-6030V Knock Sensor Component Description
Location
The knock sensors are located at the top of the crankcase under the intake manifold.
Task
The knock sensors detect combustion knocks at excessively high vibrations at the crankcase. Anti-knock control thereby corrects the ignition
timing for each individual cylinder when the engine is warm.
Body
The knock sensors function according to the piezoceramic principle. The screened cables are connected directly to the knock sensors.
Function
Any vibrations which occur are converted with the aid of the piezoceramic into electrical signals.
2
Piezo-electric effect: If a mechanical force acts on a crystal, electrical voltages are produced.
The noise signal is modulated to a DC voltage from 0.13 to 4.7 V for transmission to the ME control unit.
Knock sensor signals may also indicate engine damage, e.g. increased engine noise resulting from a widened piston groove.
1
GF15.12-P-4024V the Anti-Knock Control Function
GF15.12-P-4024V The Anti-Knock Control Function
The task of the anti-knock control AKC is to ensure knock-free operation of the engine with different fuels and in all operating conditions from
idling speed up to maximum engine speed. For this purpose, if uncontrolled combustion (knocking) occurs, the ignition angle at the knocking
cylinders is retarded. The anti-knock control (AKR) is integrated in the ME-SFI [ME] control unit.
Input signals:
- Motor speed (crankshaft Hall sensor)
- Camshaft position (camshaft Hall sensor)
- Recognition of knocking over 2 knocking sensors
- Engine temperature (coolant temperature sensor)
- Engine load (hot film mass air flow sensor)
- Accelerator pedal position (accelerator pedal sensor)
- Precontrol by means of automatic RON switch (internal)
- RON correction with STAR DIAGNOSIS.
Output signals:
- Ignition angle correction for specific cylinder to the map value calculated by the ME control unit
- Ignition angle emergency mode if fault identified.
The anti-knock control is active from a coolant temperature of 40 °C. If cylinder knocking is recognized above an engine load of about 40%, its
ignition angle is adjusted to retarded by about a 3.0° crank angle after the next ignition. If knocking continues to be detected, the ignition angle is
continuously retarded in steps of a 3° crank angle until the maximum retardation is reached (approx. a 10 -15° crank angle, depending on the engine
speed). The automatic RON switch also influences the maximum retarding of the ignition timing - the higher the selected RON stage, the less is the
maximum retarding of the ignition timing.
If knocking-free combustion exists, the retardation is reduced in steps of approx. 0.75° crank angle after a few ignitions (depending on the engine
speed) until the map value is achieved, or knocking occurs again.
Adaptation of anti-knock control
The adaptation of the anti-knock control is active from a coolant temperature of approx. 75 °C. Any corrections required to the ignition
angle because of knocking combustion are constantly detected for the specific cylinder and stored together with the relevant operating state of the
2
engine (engine load/speed range).
The stored adaptation value is taken into account in the output of the individual cylinder angles so that each cylinder is immediately operated with
the optimal ignition angle.
During abrupt acceleration, no values are stored for about 2 seconds in order to avoid any incorrect adaptation values.
Faults if knocking is detected
If no signals are received from the knock sensors, the ignition angle of all cylinders is retarded by as much as a 11° crank angle for safety reasons,
depending on engine speed and temperature. The antiknock control and the adaptation are deactivated and a fault is stored.
Automatic RON switch
In addition to the RON correction using STAR DIAGNOSIS, the antitemperature knock control features an automatic RON switch. This detects a
persistent high knocking tendency of the engine and assists the antithe knock control by means of an appropriate pre-control.
This is done by analyzing the stored adaptation values, the ignition angles of all the cylinders and the number of control interventions in certain
engine load and speed ranges. Depending on the threshold which has been exceeded, the RON value is adjusted by one or several stages. The value
is retained until the engine is switched off. After engine start, only the RON correction which is carried out by means of STAR DIAGNOSIS is at
first active.
1
Knock Sensor: Service and Repair
AR15.12-P-2184QB Remove/Install Knock Sensors
Steps 1 - 8
Knock Sensors
1
Ignition Switch: Service and Repair
AR80.57-P-1000P Remove/Install Electronic Ignition/Starter Switch Control Module
1
Spark Plug: Description and Operation
GF15.10-P-2000V Component Description For Spark Plugs
Location
In the cylinder head, each cylinder has a spark plug located in the center between the engine valves.
Task
The compressed fuel-air mixture is combusted by sparks between the electrodes according to the actuation from the ME control unit.
Design
In the manufacturer's specific type symbols, all the spark plug features are assigned (e. g. heat rating, shape of seating, thread, width across flats,
electrode material, spark position).
Function
The ignition voltage flows from the ignition lines of the directly plugged in ignition coils to the spark plugs and causes arcing in the air gap
between the central electrode and ground electrode.
Spark plug table, see IS, Group 15.
1
Spark Plug: Service and Repair
Replace Spark Plugs
Steps 1 - 7
2
Spark Plugs
Special Tools
1
Spark Plug: Service and Repair
Replace Spark Plugs
Steps 1 - 7
2
Spark Plugs
Special Tools
1
Fuel Delivery and Air Induction: Description and Operation
GF07.61-P-3004V ME Fuel Supply, Function

GF07.61-P-3004V ME Fuel Supply, Function
The fuel supply system must make available to the injection valves an adequate quantity of filtered fuel from the fuel tank, and at an adequate
pressure (injection pressure), in all operating conditions.
The fuel pump suctions the fuel in the fuel tank and delivers it through the fuel filter with fuel pressure controller to the injection valves at the fuel
distribution tube (single-line system). The pressure regulator regulates the fuel pressure in the process to approx. 3.8 bar.
Both fuel pressure reservoirs and the high-volume fuel distributor rail ensure that in the event of abrupt acceleration, sufficient fuel is available at
all injection valves.
The return line from the fuel pressure regulator supplies a suction jet pump which supports filling of the swirl pot in the fuel tank. The voltage
supply for the fuel pump is performed via the fuel pump relay.
The injection valves actuated by the ME-SFI [ME] control unit spray finely atomized fuel into the inlet ports.
Diagnosis
If the fuel pressure is too low, combustion misfires can occur which are stored in the fault memory. A cause for this can, for example, be a soiled
fuel filter.
Therefore check the delivery rate of the fuel pump at the feed point to the fuel manifold during combustion misfires. If combustion misfiring occurs
at one cylinder bank only, the respective fuel pressure memory may be the cause.
GF07.61-P-3015V ME-SFI Acceleration Enrichment, Function
GF07.61-P-3015V ME-SFI Acceleration Enrichment, Function
2
Dynamic enrichment prevents jerking when accelerating.
If the throttle valve is opened quickly, a short-term mixed adaptation takes place. An additional quantity of fuel is added to the engine by the ME
control unit in line with the performance map. The ignition angle is adjusted to "Early".
Fuel pressure fluctuations at the injection valves are prevented by the fuel distribution pipe by both the fuel pressure reservoir and the particular
volume.
Acceleration enrichment is dependent on:

- Load change rate (accelerator rate)
- Engine speed
- Engine load
- Intake manifold length and tumble flap position
- Camshaft position
- Correction programming with STAR DIAGNOSIS
GF07.61-P-3016V ME-SFI Part Load/Full Load Operation, Function

GF07.61-P-3016V ME-SFI Part Load/Full Load Operation, Function
3
Part load operation: When the engine is at operating temperature optimal emission levels and good fuel consumption are assured in combination
with the lambda control.
Full load operation: Maximum engine torque is produced at a pedal value of > 90 %. The injection time is extended accordingly for this purpose.
The particular quantity of fuel is metered to the engine in line with the performance map. The fuel quantity depends on:
- Intake air temperature (only in warming-up phase)
- Engine speed
- Engine load
- Closed-loop mixture control
- Intake manifold length
- Tumble flap position
- Camshaft position
- Ignition angle.
4
GF07.61-P-3018V the ME-SFI Safety Fuel Shutoff Function

GF07.61-P-3018V the ME-SFI Safety Fuel Shutoff Function
The safety fuel shutoff has the following tasks:

- In the event of mechanical faults at the throttle valve actuator, the engine speed is limited to approx. 1400 to 1800 rpm by cutting in and out
the fuel injection valves (strong surging engine running).
- If the TNA engine speed signal is missing, interrupts fuel pump actuation.
- When the airbags are activated (head-on collision), shuts off the fuel pump. To do this, the ME control unit receive a crash signal from the
airbag control unit. The fuel valves are actuated briefly to reduce the pressure in the fuel system.
GF07.61-P-3019V the ME-SFI Limiting Maximum Vehicle Speed Function
5
GF07.61-P-3019V The ME-SFI Limiting Maximum Vehicle Speed Function
In order to limit maximum vehicle speed on vehicles with a corresponding engine power output, the throttle valve is closed and the quantity of fuel
injected is reduced accordingly once a speed of 250 km/h is reached. In addition, the ignition angle is adjusted to "Late".
These measures ensure simple maximum speed limitation by reduction of the torque.
GF07.61-P-3022V ME-SFI Warming-Up Control, Function

GF07.61-P-3022V ME-SFI Warming-Up Control, Function
6
After start and post-start enrichment the fuel-air mixture is further enriched by the warming-up control as part of the fuel-air mixture precipitates on
the parts of the engine which are still cold. An additional quantity of fuel is added to the engine by the ME-SFI [ME] control unit in line with the
performance map. As soon as it is enabled, the Lambda control monitors the enrichment rate.
At close to idle operation, the enrichment rate is mainly dependent on the coolant temperature at start. At partial load, the air mass is decisive.
The camshaft position determines the exhaust gas recirculation rate via the duration of the valve overlap. As the hot exhaust gases warm up the
combustion chamber, the fuel vaporization changes and the enrichment rate must be tuned to match it.
The coolant is controlled by the three-disk thermostat in such a way that it is warmed as quickly as possible.
During warm-up, the ignition angles are determined from a particular performance characteristic.
The warming-up enrichment is dependent on:

- Engine speed
- Engine load
- Idle speed/part load operation
- Camshaft position
7
GF07.61-P-4009V ME-SFI Synchronization of Fuel Injection and Firing Order, Function

GF07.61-P-4009V ME-SFI Synchronization Of Fuel Injection And Firing Order, Function
When the engine is started, the injection sequence is defined on the basis of the firing order signals supplied by the crankshaft Hall sensor and the
camshaft Hall sensors To do this, ignition TDC must be detected by cylinder 1.
The synchronization of the injection and firing order is further processed by the ME control unit for actuating the ignition coils and the fuel
injection valves. In addition, it is required for the anti-knock control and for the fuel cutoff at individual cylinders.
If the camshaft Hall sensors are defective, a switchover to the next sensor will take place in a particular sequence. If there is no signal available then
ignition occurs after a 360° crank angle and injection occurs in order to allow an emergency start.
When the engine is shut down, coasting detection takes place, which also evaluates turning back of the engine shortly before the engine is
stationary. When the computer powers down, the position found is saved as ° crankshaft angle and used the next time the engine is started. If
coasting detection does not provide a result, or the shutdown engine has been moved, synchronization takes place.
8
GF07.61-P-4019V ME-SFI Deceleration Fuel Shutoff, Function

GF07.61-P-4019V ME-SFI Deceleration Fuel Shutoff, Function
9
Deceleration fuel shutoff has the following tasks:

- Increasing the braking power of the engine in the deceleration mode
- Reducing fuel consumption
- Improving exhaust emissions in the deceleration mode.
In the overrun mode, the ME control unit switches off the fuel injection valves depending on the coolant temperature and the gear engaged, if the
accelerator pedal is not operated (detected via the actual value signal from the accelerator pedal sensor). The fuel injection valves are switched on
again when the accelerator pedal is operated.
The deceleration fuel shutoff is suppressed at too high exhaust gas temperatures, because the high oxygen content in the exhaust during
deceleration fuel shutoff can lead to an increased oxidation of carbon monoxide and hydrocarbon (afterburning). This can result in additional heat
(thermal reaction) that can overheat the catalytic converters.
After the deceleration mode, the mixture is briefly enriched in order to eliminate the enriched oxygen in the three way catalytic converters resulting
from the deceleration mode. The valve overlap is also set to its minimum value by the camshaft adjustment. This ensures that an optimal conversion
rate is more rapidly achieved.
In order to prevent a sudden torque rise when combustion is reestablished after deceleration fuel shutoff, the ignition timing is briefly adjusted
towards "retarded".
The engine speed when combustion cuts in is dependent on the coolant temperature, the engine and transmission versions and with automatic
transmission, dependent on the drive position selected (via the CAN from the transmission control unit).
Deceleration fuel shutoff is blocked under the following conditions:

- with automatic transmission in selector lever position P or N
- with manual transmission with clutch pedal depressed.
GF07.61-P-4024V ME Fuel Reserve Signal, Function
GF07.61-P-4024V ME Fuel Reserve Signal, Function
10
This signal serves as supplemental information for the ME control unit for detection of combustion misfires through fuel starvation.
The information about the fuel level is transferred to the instrument cluster via CAN. From there, the information reaches the ME-SFI [ME] control
unit via CAN.
(USA)
If the fuel reserve warning light is flashing, the purge system has a gross leak (tank lid missing).
If the fuel tank is filled to less than approx. 1/4 or to more than 3/4, the leak test of the fuel system is suppressed. A test for major leakage is still
performed.
1
Fuel Delivery and Air Induction: Adjustments
GF07.10-P-1029V Self-Adjustment Of Mixture Formation, Function
On vehicles fitted with a closed-loop controlled catalytic converter, the lambda control determines the injection time so exactly that a certain
fuel-air ratio (Lambda) is maintained in all operating states.
If faults occur, the ME-SFI [ME] control unit automatically makes a correction in the mixture formation. Here the lambda performance map is
shifted within certain limits in such a way that the lambda control is not at the upper or lower regulation limit (d).
The following faults require a mixture adjustment:

- Wear or carbon deposits on fuel injection valves
- Fault on mass air flow sensor
- Incorrect injection pressure (e.g. through blocked fuel filter)
- Defective purge control valve
- Engine wear (e.g. leaky valves)
If the mixture composition constantly drifts out of the middle control range (e.g. 0 ± 10%) the ME-SFI [ME] control unit under certain operating
conditions shifts the lambda map sufficiently far until a lambda control factor of approx. 0% (g) is again achieved.
Self-adjustment ensures that the mixture composition in the control mode (e.g. warming-up phase) is neither too rich nor too lean. This also
prevents the lambda control from moving up to the control limit at high altitudes.
Example:
As the result of a lean fuel/air mixture the readout of the lambda control factor changes to 18% (e). Under certain operating conditions the lambda
performance map is shifted (arrow) by the ME-SFI [ME] control unit.
This shifting of the lambda performance map is the self-adjustment of the mixture formation process to the existing air/fuel mixture. After this
self-adjustment the lambda control factor is again in the central control range (g).
This self-adjustment of the mixture formation can be carried out in the following operating states:
- Idle speed
- Lower part load
- Upper partial load.
The following actual values can be read out using STAR DIAGNOSIS
- Lambda map shift active
- Direction of the shift (tendency towards rich or lean)
- Extent of the shift
Representation of self-adjustment values with STAR DIAGNOSIS in idle
The representation in milliseconds means that the value displayed is added to, or subtracted from, the air mass inducted by the engine in order to
2
determine the injection time.
The maximum correction value is ± 1 ms.
Example:
Calculated injection time (performance map): 3.0 ms
Displayed correction value: +0,3 ms
For determining the injection time (fuel injection quantity) the ME-SFI [ME] control unit uses a calculated value of 3.3 ms
(3.0 ms+0.3 ms).
Representation of self-adjustment values with STAR DIAGNOSIS for partial load
The representation of the factor means that the indicated value for determining the injection time is multiplied by the air mass inducted by the
engine.
The correction factor lies between 0.68 and 1.32.
Example:
Calculated air mass: 150 kg/hour
Displayed correction value: 1,10
A calculated air mass value of the of 165 kg/h is used by the engine control unit to determine the injection time (fuel injection quantity).
1
AR07.03-P-1460-01VA Reduce Fuel Pressure Via Service Valve
AR07.03-P-1460-01VA Reduce Fuel Pressure Via Service Valve
2
1
AR07.03-P-1460-01VA Danger! Reduce Fuel Pressure Through Service Valve
AR07.03-P-1460-01VA Danger! Reduce fuel pressure through service valve
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin
caused by contact with fuel
No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers.Wear protective clothing when
handling fuel.
Injection nozzles, injection valves, lines
Special Tools
Shown on engine 272 in model 171 without fuel tank with exterior filter, code 917
1 Unscrew protective cap (1) of the service valve (2) of the fuel distributor.
2 Insert end of the pressure hose (01) into the container (3).
3 Screw on union nut of the angled piece (01 a) to the service valve
(2).
At this point, the service valve (2) is opened and the fuel pressure in the fuel distributor is reduced. Fuel escapes from the end of the hose.
4 Unscrew the union nut of the angled piece (01a) from the service valve (2).
5 Screw protective cap (1) onto the service valve (2) of the fuel distributor.
For vehicles with fuel tank with exterior filter, code 917 the protective cap (1) must be tighten with torque.
Ensure that the sealing ring of the protective cap (1) is replaced.
1
Idle Speed: Description and Operation
GF30.22-P-0003V ME-SFI Idle Speed Control, Function
The throttle valve actuator controls the idle speed by altering the position of the throttle valve. It is actuated by the ME-SFI control unit. To assist
the idle speed control, the ignition angle can be retarded by as much as 36° crank angle and advanced by as much as a 20° crank angle.
The ME control unit actuates the throttle valve motor in line with the input signals received at the ME control unit.
The throttle valve actuator controls the idle speed:

- At different engine loads, e.g. steering turned to full lock (power steering pump), drive position engaged, clutch pedal actuated, refrigerant
compressor engaged
- In the warming-up phase
- At undervoltage
- At different mixture composition e.g. through lambda control or fuel evaporation control system.
Heating-up speed
In order to warm up the catalytic converters more rapidly to operating temperature, the engine speed is increased in the idle speed range to 1100 up
to 1300 rpm for about 20 seconds after each starting procedure at coolant temperatures of < 40 °C. Following this period, the idle speed is increased
at a coolant temperature < 70 °C for around 50 seconds by approx. 50 to 100/rpm. When a drive position is selected, this is immediately reduced.
Automatic transmission (AT)
When a drive position is engaged, a lower engine speed is controlled in order to reduce the creeping tendency of the vehicle.
The information "Drive position engaged/not engaged" is transmitted by the transmission control unit via the CAN data bus to the ME control unit.
AC compressor
To avoid engine speed dropping in the idle speed range when the AC compressor is engaged, the automatic air conditioning control system issues a
signal to the ME control unit via the CAN data bus which is adapted appropriately to the idle speed (increased).
When the air conditioning unit is switched on and the external temperature exceeds 35 °C, the idling speed is increased for the driving mode
selected by about 100 rpm when the switch-on threshold of about 900 rpm is exceeded. This increase is canceled again when the external
temperature drops below 32 °C.
Undervoltage
2
If the engine control unit detects an undervoltage the idling speed is increased until the ignition is switched off for the driving mode selected by
about 100 rpm.
1
Accelerator Pedal: Service and Repair
AR30.12-P-1321P Remove/Install Accelerator Pedal
Remove/Install
1 Remove plug (1)

2 Unscrew nut (2)
NOTE: Installation: Replace nut (2).
3 Pull out accelerator pedal (3)
NOTE:
- The accelerator pedal (3) must not be disassembled.
- Installation: Ensure, that the recess of the accelerator pedal is seated in the bracket (4) of the firewall.
4 Separate electrical connector of accelerator pedal sensor (B37)
NOTE: Installation: ensure that lines are routed properly.
5 Separate electrical connector from kickdown switch (S16/6)
NOTE: Installation: ensure that lines are routed properly.
6 Remove accelerator pedal (3)

8 Read out DTC memory
1
Accelerator Pedal Position Sensor: Description and Operation
GF30.20-P-2010V Accelerator Pedal Sensor Component Description
Location
The accelerator pedal sensor is located at the top of the accelerator pedal module.
Task
Detects the accelerator pedal position and relays the corresponding voltage signals to the motor electronics control unit.
Replace accelerator pedal module always complete.
2
Function
The accelerator pedal sensor converts the mechanical operation input by the accelerator pedal into an electrical voltage corresponding to the
accelerator pedal position.
The accelerator pedal sensor operating on the Hall principle is integrated in the pedal lever shaft and consists of a shaft with a ring magnet. This
rotates in a printed circuit board with stator in the fixed Hall elements. This produces a change in the voltage.
The accelerator pedal sensor is supplied via pin 1 from the ME control unit with 5 V. Pin 3 and 6 are ground connections.
The information of the accelerator pedal position is transmitted to the motor electronics control unit in the form of two signals (pin 5 with signal 1
has maximum approximately 4.8 V and pin 4 with signal 2 maximum approximately 2.4 V).
The supply voltage in the accelerator pedal sensor is halved for sensor 2.
Signal 1 ranges are defined as percentages of the supply voltage (approx. 5 V) as follows:
- up to 4 % the signal is too small via short-circuit to ground or via line interruption
- 4 to 9.4 % idle range
- 9.4 to 81 % partial-load range
- 81 to 96 % full load range
- above 96 % the signal is too high via short-circuit to positive.
Kick-down detection takes place via the accelerator pedal sensor, is signals 1 and 2 fall within full load range for a certain period.
If the brake pedal is operated, only the idle speed values from the accelerator pedal sensor are accepted. If necessary, the engine control unit will
generate substitute values. The signals from the accelerator pedal sensor are rejected over this time
In the event of an error at signal 1, a switchover to signal 2 takes place and emergency mode is activated.
1
Air Cleaner Housing: Service and Repair
AR09.10-P-1150QB Removing/installing air filter housing
Steps 1 - 7
Auxiliary repair materials
1
Air Flow Meter/Sensor: Description and Operation
GF07.07-P-6000V Hot Film MAF Sensor, Component Description
Location
The hot film mass air flow sensor is located behind the intake manifold between the air filter housing and the throttle valve actuator.
Task
The hot film MAF sensor detects the air mass supplied to the engine and the intake air temperature.
Design
A temperature-controlled resistor detects the air mass and an integral NTC resistor detects the intake air temperature.
The flow to the hot film sensors is even through the grid. The hot film MAF sensor has an oval housing and 4-pin (production start) or 5-pin plug
connector.
The electronics and the housing have undergone a number of modifications (please note part number).
Function
The electronic control in hot film mass air flow sensor controls the temperature of the heating resistor [R(H)] by means of a variable voltage, so that
its temperature is 160 °C above the intake air temperature detected by the temperature resistor [R(L)].
The temperature of the heating resistor [R(H)] is detected by the sensor resistor [R(S)]. If a temperature change occurs as a result of an increased or
reduced air flow, the electronics adapts the voltage at the heating resistor [R(H)] until the temperature difference is again achieved.
2
This control voltage is used by the engine control unit as a measure for the metered air mass. The air mass is transmitted via a frequency signal (low
frequency for low air mass) to the ME control unit. Using STAR DIAGNOSIS, the cycle duration of the frequency signal can be read out in micro
seconds.
The intake air temperature is detected by an additional NTC resistor.
Hot film MAF sensors with the number A 273 094 08 48 and higher provide the engine control unit with an additional signal at a frequency ranging
between 17 and 21 Hz (44 to 54 ms). With this so called ratio-metric frequency signal, the engine control unit compensates for the temperature and
voltage influences at the air mass signal.
The engine control unit also detects the version of the hot film MAF sensor via the duty cycle.
1
Air Flow Meter/Sensor: Service and Repair
AR07.07-P-1453QB Remove/Install Hot Film Mass Air Flow Sensor
Steps 1 - 11
2
1
Fuel Filter: Service and Repair
Replace Fuel Filter
Steps 1 - 10
1
Fuel Injector: Description and Operation
GF07.03-P-6010V Component Description For Fuel Injection Valves
Location
The fuel injection valves are mounted between fuel distribution tube and cylinder heads.
Task
Spraying the fuel onto the injectors in the form a finely atomized spray
2
The diameter and number of the outlet holes (a) are adjusted to the fuel requirements of the engine.
Function
If solenoid winding is energized, the nozzle needle is raised by the solenoid armature about 0.1 mm against the force of the coil spring.
The fuel flows through an outlet opening and is sprayed onto the injectors in a finely atomized spray.
The supply voltage to the fuel injection valves is provided via fused terminal 87. Corresponding long electrical ground pulses from the ME control
unit facilitate actuation.
The fuel injection valves are actuated by the ME-SFI control unit, in other words one injection valve is assigned to each cylinder which meters the
quantity of fuel calculated for the cylinder.
In case of detected misfires, the actuation of the corresponding cylinder is interrupted.
1
Fuel Injector: Service and Repair
AR07.03-P-1451QB Remove/Install Fuel Distributor With Injection Valves (ME-SFI)
AR07.03-P-1451QB Remove/Install Fuel Distributor With Injection Valves (ME-SFI)
2
Steps 1 - 7
Steps 8 - 19
Control Unit
3
Engine Wiring Harness
Cylinder Head
Special Tools
Repair Materials
1
Fuel Injector: Service and Repair
AR07.03-P-6520QB Remove/Install Injection Valves (ME-SFI)
AR07.03-P-6520QB Remove/Install Injection Valves (ME-SFI)
2
Steps 1 - 14
Repair Materials
1
Fuel Pressure Regulator: Description and Operation
Component Description For The Fuel Filter With Fuel Pressure Regulator
Location
The fuel filter with fuel pressure regulator is located in the left fuel tank chamber.
Task
Filtering impurities out of the fuel. Maintaining constant fuel pressure in wide limits irrespective of the fuel pump delivery.
2
Function
The fuel filter element is integrated in a plastic housing. The fuel flows through it from the outside to the inside. As a result any impurities are
trapped.
The fuel pressure regulator controls the fuel pressure of around 3.8 bar (system pressure) via the fuel return volume
If the set fuel pressure is exceeded, the diaphragm is pushed against the push spring and the valve attached to the diaphragm continues to open the
passage for the fuel return.
If the set fuel pressure is below the limit, the valve is closed further again by means of the push spring.
A greatly varying fuel pump delivery (e.g. 20 or 140 liters per hour) does not have any great effect on the fuel pressure.
1
Fuel Pump: Description and Operation
GF07.61-P-3012V ME-SFI Fuel Pump Actuation, Function
GF07.61-P-3012V ME-SFI Fuel Pump Actuation, Function
The fuel pump is actuated over the fuel pump relay by a ground signal from the ME-SFI [ME] control unit.
If the power contact of the relay is closed, the in-tank fuel pump control unit is connected via "terminal 87" with "terminal 30" (B+). Terminal 30 is
protected by a 20 A fuse.
If the fuel pump does not run, first check the voltage supply to the ME-SFI [ME] control unit, then the fuel pump fuse and the fuel pump line
terminals.
Fuel pump actuation has the following tasks:

- The fuel pump is actuated for complete filling for "ignition ON" for about 5 seconds. The engine must be started before the fuel pump is
actuated again. In order to achieve short starting times, ensuring full fuel flow is required, in particular following long shutoff times.
- In order to start the engine the fuel pump is actuated for a recognized starter recognition (terminal 50 Signal).
- For a running engine the fuel pump is actuated by the recognized engine speed signal.
- In the case of a detected front crash actuation of the fuel pump is interrupted.
1
Fuel Pump: Description and Operation
GF47.20-P-2000V Fuel Pump, Component Description
GF47.20-P-2000V Fuel Pump, Component Description
Location
The fuel pump is located in the fuel delivery module in the fuel tank.
Location
The fuel pump is located under the fuel tank at the vehicle underfloor.
2
Task
The fuel pump supplies an adequate quantity of fuel to the fuel system at the required pressure in all driving states.
Function
The fuel pump draws the fuel from the swirl pot and drives it to the fuel filter with the integral fuel pressure regulator. While cornering when the
fuel level is low, the swirl pot prevents the fuel pump from drawing air.
The fuel pump is actuated via the fuel pump relay or the fuel pump control unit (engine 272.985). The voltage supply is fuse protected.
1
Fuel Pump: Service and Repair
AR47.20-P-5710PR Remove/Install Fuel Pump
Shown On Model 203.035 With Engine 111.951
Remove/Install
DANGER:
- Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through
burns to skin and eyes from battery acid or when handling damaged lead-acid batteries
- Wear acid-resistant gloves, clothing and goggles. Pour battery electrolyte only into suitable and appropriately marked containers.
CAUTION: Model 209: Do not connect quiescent current retention unit, otherwise damage may occur in the control module.
DANGER:
- Risk of explosion from fuel igniting, risk of poisoning from inhaling and swallowing fuel as well as risk of injury to eyes and skin
from contact with fuel.
- Pour fuels only into suitable and appropriately marked containers.
- Wear protective clothing when handling fuel.
2 Pump fuel out of the right-hand chamber of
NOTE:
- Suction off approx. 20 liters if fuel tank is the fuel tank full:
- Draining and filling fuel tank.
- Pay attention to fuel quantity.
- Fuel tank capacity, Total capacity = 62 Liters

Reserve capacity = 8 Liters
3 Fold rear seat cushion (1) forward

4 Unscrew retaining straps (2) of the rear seat cushions (1)
5 Fold back floor covering (3)
6 Remove right end cover (4)
2
7 Use pronged wrench to unscrew ring nut (5)
- Claw-type wrench: See Special Tools below.
- Ring nut to fuel tank = 85 Nm
8 Remove locating cover (6) with shaped seal (7)
NOTE: Installation: replace sectional sealing ring (7).
9 Detach plug connection (8) on fuel level sensor, right half of tank (B4/2)
10 Disconnect feed line (9) at fuel pump (M3)
NOTE: The fuel level sensor, right half of tank, (B4/2) and the fuel pump (M3) form a single unit.
CAUTION: Installation: Replace O-ring of feed line (9), in order to avoid fuel escaping.
11 Pull fuel level sensor, right half of tank (B4/2) out a little
12 Disconnect return line (10) at fuel level sensor, right half of tank (B4/2)
13 Remove fuel level sensor, right half of tank, (B4/2) together with fuel pump (M3)
- Installation: Check the three supports at the floor of the fuel level sensor, right half of tank (B4/2) for damage, if necessary exchange
fuel level sensor, right half of tank (B4/2) with fuel pump (M3).
NOTE:
- Marking on the locating cover (6) must be aligned with the marking on the tank.
- Do not exchange fuel pump (M3) individually, only in connection with fuel level sensor, right half of tank (B4/2).
- If any of the three supports is damaged, proper attachment of the fuel level sensor, right half of tank, is no longer assured. B4/2
Special Tools
Prong Wrench, P/N # 203 589 01 07 00
1
Fuel Pump Relay: Description and Operation
GF47.20-P-2010V Fuel Pump Relay, Component Description
Location
- Model 171: at the front of the luggage compartment
- Model 203, 209, 211, 219: at the left in the luggage compartment
- Model 164: at the right in the load compartment.
- Model 251: at the right in the spare wheel well
- Model 221: under the through-loading feature/ski bag
- Model 230: at the passenger-side fuse and relay module.
Task
The fuel pump relay actuates the fuel pump with voltage via a fuse.
Function
When actuated by the motor electronics control unit, with a ground signal at circuit 86, the relay closes its power contact. When the power contact
is closed the fuel pump is connected to circuit 30 (B+) via circuit 87.
To actuate the fuel pump relay and bridge terminal 30 and 87.
1
Fuel Tank: Procedures
AR47.10-P-4001P Draining and Filling Fuel Tank
Shown On Engine 112 In Model 203
Remove
1.1 Take off top engine trim panels

1.2 Remove engine trim panel with integrated air cleaner.
NOTE: Detach engine cover or air cleaner by lifting vertically up and off the cylinder head covers.
2 Remove rear seat cushion

- With code (287a) through-loading feature
NOTE: Fold rear seat cushion only forward.
Draining
DANGER:
3 Connect extraction hose (1) to extraction pump (2) on the suction side
CAUTION: Ground extraction pump (2), in order to prevent arcing.
- See Commercially Available Tools below.
DANGER:
4 Pump out fuel into a safety tank (3)
2
- If fuel pump is intact.
CAUTION: Except engine 271.942, because the high pressure pump could be damaged on this engine. Proceed as if fuel pump
would be defective.
- If fuel pump is defective.
Install
5 Install rear seat cushion
- With code (287a) through-loading feature
NOTE: Fold rear seat cushion only back.
6.1 Install top engine trim panels

6.2 Install engine trim panel with integrated air cleaner
NOTE: Position engine cover first at hot film cleaner mass air flow sensor, and then press down on cylinder head covers.
Filling
7 Fill fuel tank through tank filler opening
8 Inspect fuel system for leaks
1
Fuel Tank: Removal and Replacement
AR47.10-P-4100PR Remove/Install Fuel Tank
Remove/Install
2
DANGER:
- Risk of death. Death may result if vehicle slips or topples from the lifting platform.
- Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points
specified by the vehicle manufacturer.
- Wear acid-resistant gloves, clothing and glasses. Pour battery electrolyte only into suitable and appropriately marked containers.
CAUTION: Model 209: Do not connect quiescent current retention unit, otherwise damage may occur in the control module.
DANGER:
2 Drain fuel tank.

- Pay attention to fuel quantity.
3 Remove floor coverings (12)

4 Remove rear axle.
5 Remove end cover (1) of body
6 Disconnect connector (2) of fuel level sensor, left half of tank (B4/1)
7 Detach hand brake cable (4) at relay lever (5)
8 Pull outer cable (6) out of fixture
NOTE: Press together the two catches (arrows) for this step.
9 Remove right rear wheelhousing liner (7)

- See Remove inner fender from rear fender
10 Take off hose clamps (8)
NOTE: Installation: check hose clamps (8), replace if necessary.
11 Detach fuel lines (9)
CAUTION: In the event of fixed fuel lines (9) cut these with a knife and then detach. There is a risk of fixed fuel lines (9) shearing
off the connections at the tank.
12 Undo bolt (10) of filler pipe (11)

13 Detach fuel line (13) at fuel filter (14)
- Clamp: See Special Tools below.
CAUTION: Installation: check hose clamp (15) and fuel line (13), replace if necessary, to rule out any leakages.
14 Remove shroud (16)

15 Support fuel tank (17)
16 Unscrew retaining straps (18) at the body
Retaining straps of tank to underfloor = 20 Nm

M18 = 60 NM
17 Remove fuel tank (17)
NOTE: After removing the fuel tank, tie up propeller shaft (19) using a cable strap.

19 Dispose of fuel tank
- Only if necessary.
Special Tools
3
Clamp, P/N # 000 589 40 37 00
1
Fuel Filler Neck: Service and Repair
AR47.10-P-7541PR Remove/Install Filler Neck of Fuel Tank
AR47.10-P-7541PR Remove/Install Filler Neck of Fuel Tank
Shown On Model 203.035 With Engine 111
Remove/Install
DANGER:
- Risk of death. Death may result if vehicle slips or topples from the lifting platform.
- Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points
specified by the vehicle manufacturer.
1 Raise vehicle.
2 Take off right rear wheel
- Wheel bolt = 110 Nm
3 Remove fender liner (1) in right rear fender
DANGER:
4 Slacken hose clamps (2)

5 Detach connection lines (3)
6 Remove screws (4).
7 Unscrew fuel filler cap
8 Press out rubber seal (5)
NOTE: Installation: Check rubber seal (5) for damage, replace if necessary. Ensure correct seating of rubber seal (5).
9 Pull filler neck (6) down a little

10 Loosen hose clamp (7)
11 Detach vent line (8)
2
12 Remove filler neck (6)
NOTE: Installation: Check ground line (9) for damage, if necessary replace filler neck (6).
1
Fuel Filler Neck: Service and Repair
AR63.50-P-1400-01P Remove/Install Cover For Filler Fitting
AR63.50-P-1400-01P Remove/Install Cover For Filler Fitting
Special Tools
1. Remove inner fender at rear inner wheelhouse.

2. Remove compensation reservoir with filler fitting for tank.
3. Seal open fuel lines with rubber covers (arrows).
4. Attach cover to rear inner wheelhouse.
1
Fuel Gauge Sender: Description and Operation
GF47.10-P-2010V Component Description For The Fuel Level Sensor
Location
The fuel level sensor is located in the fuel tank. If the fuel tank is divided into two chambers, each chamber has a fuel level sensor.
Task
Determines the fuel level for the following functions:

- Fuel level indicator
- Leakage check of regeneration system (USA)
- Misfire detection.
Design
Float-and-lever sensor with two wiper contacts (potentiometer) and a float.
Function
To change the resistance values depending on the fuel level. The signals are transmitted to the nearest SAM control unit (e.g. rear SAM control unit
with fuse and relay module for models 171, 211, 219, 221). The signal are digitalized there and transmitted to the CAN data bus.
1
Intake Air Duct: Service and Repair
AR09.20-P-0080QB Remove/install the air duct housing
Steps 1 - 11
1
Variable Induction Position Sensor: Description and Operation
Component Description For The Position Sensor Tumble Flap
Location
Task
flaps between completely swiveled in or out is approx. 56 degree.
Design
Function
The position sensors must switch no later than approx. 5 degree before the respective limit position. For reasons of tolerance, they may also switch
up to approx. 16 degree before the limit position.
1
Variable Induction Position Sensor: Service and Repair
Remove, Install Tumble Flap Position Sensor At Intake Manifold
Steps 1 - 8
2
Intake Manifold
1
Variable Induction System: Description and Operation
GF07.61-P-3028V Intake Manifold Switchover, Function
GF07.61-P-3028V Intake Manifold Switchover, Function
With the intake manifold switchover, switching between a long or a short intake route is possible. For this purpose, a longitudinal switch flap is
located in the intake manifold for each cylinder. The longitudinal switch flaps for each cylinder bank are actuated by an aneroid capsule and a flap
shaft. Both aneroid capsules are connected by a vacuum line.
The variable intake manifold switchover valve is connected in series in the vacuum line to the aneroid capsules.
Short intake route (without actuation)
The variable intake manifold switchover valve is de-energized and the aneroid capsules are ventilated. Without actuation, the length switch flaps by
spring force and free up the short intake route.
Long intake route
If the variable intake manifold switchover valve is actuated by a ground signal from the ME control unit, vacuum pressure from the vacuum
memory enters the aneroid capsules. The flap shafts are operated and the length switch flaps close.
Under the following conditions, the long intake route is selected:

- Engine load more than approx. 50%.
- Engine speed lower than 3500 rpm
Only an intake manifold switchover aneroid capsule is installed for engine 273. The two flap shafts are combined in the intake manifold.
1
Variable Induction System: Description and Operation
GF09.20-P-6001V Component Description For the Variable Intake Manifold Switchover Valve
GF09.20-P-6001V Component Description For The Variable Intake Manifold Switchover Valve
Location
The variable intake manifold switchover valve is mounted at the front of the variable intake manifold.
Task
Pressurize intake manifold switchover aneroid capsules with vacuum or admitting air.
Design
Electromagnetic switchover valve in the plastic housing, coil resistance approx. 30 ohms. Ventilation via cap.
Function
The variable intake manifold switchover valve is actuated on the earth side by the engine control unit through its own output stage. The voltage is
supplied through circuit 87.
A valve plate operated by a coil armature shifts between atmosphere and vacuum storage.
1
Variable Induction Control Valve: Description and Operation
GF09.20-P-6001V Component Description For the Variable Intake Manifold Switchover Valve
Component Description For The Variable Intake Manifold Switchover Valve
Location
Task
Pressurize intake manifold switchover aneroid capsules with vacuum or admitting air.
Design
Electromagnetic switchover valve in the plastic housing, coil resistance approx. 30 t. Ventilation via cap.
Function
The variable intake manifold switchover valve is actuated on the earth side by the engine control unit through its own output stage.
The voltage is supplied through circuit 87.
2
A valve plate operated by a coil armature shifts between atmosphere and vacuum storage.
1
Variable Induction Control Valve: Description and Operation
GF07.05-P-6030V Component Description For the Intake Manifold Tumble Flap Switchover Valve
GF07.05-P-6030V Component Description For The Intake Manifold Tumble Flap Switchover Valve
Location
Task
Pressurize tumble flap switchover aneroid capsule with vacuum or admitting air.
Function
Voltage is supplied from terminal 87. Coil resistance is approx. 30 ohms. The switchover valve is actuated at the ground side by the engine control
unit through its own output stage.
A valve plate actuated by the coil armature switches between the atmospheric memory (ventilation via cap/flap??) and the vacuum memory.
1
Variable Induction Control Valve: Service and Repair
AR09.20-P-1993QB Remove/Install Resonance Flap Switchover Valve on the Intake Manifold
Removing/Installing the Resonance Flap Switchover Valve on the Intake Manifold
Steps 1 - 10
1
Variable Induction Control Valve: Service and Repair
AR09.20-P-1994QB Remove/Install Tumble Flap Switchover Valve at the Intake Manifold
Removing/Installing the Tumble Flap Switchover Valve At the Intake Manifold
Steps 1 - 10
1
Computers and Control Systems: Description and Operation
GF07.61-P-2003V ME-SFI Starting, Function

GF07.61-P-2003V ME-SFI Starting, Function
Battery voltage
The fuel injection quantity is determined by the opening time of the fuel injection valves. This opening time is dependent on the battery voltage.
The ME-SFI [ME] control unit extends the injection time in order to compensate the quantity injected if, for example, the battery voltage is low. No
further engine start is possible below approx. 7 V.
Start quantity control
In order to facilitate starting of the engine when cold, additional fuel must be injected during engine start operation (depending on the coolant
temperature). The increased fuel injection quantity is achieved by extending the injection time.
Starter control
The solenoid switch of the starter (circuit 50) is actuated through the starter relay by the ME-SFI [ME] control unit.
With an automatic transmission, the engine can only be started in selector lever position "P/N" and when the service brake is operated. The P/N
selector lever position information is sent via the CAN from the transmission control unit. The information "service brake operated " comes via
CAN from ESP control unit.
(USA) with manual transmission 716.6
According to legal requirements, the start enable clutch pedal switch is located on the underside of the clutch pedal. This switch ensures that the
engine can only be started when the clutch pedal is fully depressed.
Ignition
When the engine is started up to approx. 500 rpm, the ignition timing point is controlled based on the signals supplied by the camshaft Hall sensor.
It is only when an engine speed of about 600 rpm is reached that the system switches over to a performance map dependent firing point.
2
Synchronizing of fuel injection and firing order
In order to achieve correct synchronization of the fuel injection and firing order for the respective cylinder, the order is synchronized during the
first revolutions of the engine. The ME-SFI control unit requires the signals from the camshaft Hall sensor and crankshaft Hall sensor for this
purpose.
Post-start enrichment
After the engine is started from cold, enrichment with additional fuel is necessary for a short time. The fuel which precipitates on the cylinder walls
is compensated for by this enrichment, and the engine runs smoothly.
Enrichment of fuel in engine oil
For a cold start, fuel condensing on the still cold cylinder liner can enrich the fuel in the engine oil. Once the engine oil becomes hot, the fuel
evaporates the fuel again and this is led again via the crankcase ventilation system to the engine for combustion. The mixture deviation (a rich
mixture) in neutral can be up to 30% and is corrected by the lambda control. Mixture adaptation saves this correction as a long-term effect. This
means that a subsequent start could fail if the start mixture is too lean, although no exhalation of fuel takes place. To prevent this, the ME-SFI [ME]
control unit constantly calculates the fuel quantity in the engine oil. To do this, the number of starts, the start temperature and the subsequent
operating duration are evaluated.
GF07.61-P-2004V Diagnosis Fault Memory, ME-SFI Function

GF07.61-P-2004V Diagnosis Fault Memory, ME-SFI Function
The ME-SFI [ME] control unit checks its input and output signals for plausibility and recognizes possible faults. The detection of faults and their
storage is differentiated in:
- Faults constantly present
- Loose contact fault (only on coolant temperature sensor (B11/4) and accelerator pedal sensor (B37))
The following components and systems are monitored:

- Oxygen sensors
- Catalytic converters
- CAT heater
- Smooth running control (combustion misfire)
- Fuel system
- Control units which are linked via the data bus
3
Fault recognition
The following faults and error states are detected:

- Signals above or below the limit value (open circuits, short circuits, faulty sensor)
- Frequency of fault
- Illogical combination of signals
- Function chains with faults
- Fault messages of all systems transmitted via CAN data bus (control units)
- Fault states from the alternator (G2) with interface controller
Fault display via engine diagnosis indicator lamp or CHECK ENGINE
If an exhaust gas relevant error occurs or if it was already stored in the last driving cycle, the indicator lamp lights up in the instrument cluster.
In the event of a fault which could damage the catalytic converter, the engine diagnosis indicator lamp flashes. The indicator lamp goes out after 3
correct, successive driving cycles.
Fault storage
Recognized faults are stored when they arise for the first time with their environmental data in the fault memory. If the fault is not confirmed during
the following driving cycle, it is deleted. Emission relevant faults are always entered, they have a high priority.
After 40 correct driving cycles an exhaust gas relevant fault and after 80 correct driving cycles a CAT damaging fault is erased from the fault
memory.
Read out the fault memory
The ME-SFI [ME] control unit is connected via a serial interface (Kline) to the data link connector. The stored faults can be read out and deleted
with STAR DIAGNOSIS or with a standard output device (generic scan tool) with "Ignition ON" or with the engine running via the data link
connector (SAE standard ISO 9141-2).
The fault memory is not erased if the vehicle battery is disconnected.
Emergency running
If a fault is detected, substitute values are formed for the emergency running and the engine diagnosis/CHECK ENGINE indicator lamp lights up.
ME-SFI [ME] control unit run-on
After faults are erased it is necessary to wait until the processor has completed its power-down sequence after the ignition is switched off. The
duration is dependent on the coolant temperature and is between 5 and 150 seconds.
GF07.61-P-3003V ME Alternator Interface Function
GF07.61-P-3003V ME Alternator Interface Function
Messages between the engine control unit and the alternator are exchanged via the alternator interface. The tasks are:
- Switch on and regulate alternator following the engine start according to the performance maps stored in the engine control unit. To do this,
the control voltage is preset by the engine control unit.
- Adapts the control voltage with a delay in the event of frequent load changes at the alternator to stabilize idling.
- Protects alternator against overheating.
- Generates circuit 61 (information "alternator is turning").
- Detects fault and actuates charge indicator/multifunction display.
The engine control unit actuates the control response of the alternator via the alternator interface, in order e.g. to decrease the charging voltage in
idle when battery is sufficiently charged. Less fuel is injected due to the reduced engine load. Fuel consumption is reduced and the exhaust
characteristic is further optimized.
For alternators with an alternator interface, the line with circuit 61 (information "alternator is turning") is no longer required. From the information
which the engine control unit receives via the alternator interface, the terminal 61 in the engine control unit is simulated and is indicated via a
downstream of ground shifting output stage e.g. for the instrument cluster.
The alternator constantly performs self-diagnosis and sends the results when requested to the engine control unit. The engine control unit compares
them with other signals (e.g. engine speed, battery voltage and time after engine start) and detects the following faults:
- Electrical and mechanical faults at alternator (regulator or diodes defective, stator interruption or short circuit, exciter interruption,regulation
voltage and charging current are not achieved, regulation voltage too high, cracked or loose poly-V-belt).
- Short circuit or open circuit at output terminal 61 of engine control unit.
- Line of alternator interface between engine control unit and alternator interrupted, or defective interface driver in engine control unit. In the
event of such an error, a control voltage from 13.45 V to 14.15 V is preset.
4
The upper limit value of the regulation voltage can be up to 15 V. If the battery is full or discharged, the regulation voltage be reduced do to the
battery voltage.
For alternator test and test prerequisites see STAR DIAGNOSIS (menu item "Actuations" or "List of tests performed").
GF07.61-P-3005V ME-SFI Ignition ON, Function
GF07.61-P-3005V ME-SFI Ignition ON, Function
Functions in the case of ignition ON:

- The gasoline, injection and ignition system (in the ME-SFI [ME] control unit) is supplied with a voltage.
- To protect against cylinder flooding, the fuel pump is actuated for approx. 5 seconds (only for first "Ignition ON")
- The engine diagnosis indicator lamp or CHECK ENGINE lights up in the instrument cluster (lamp check).
- Data exchange with the EIS [EZS] control unit (terminal 50 signal and drive authorization system) takes place via the CAN data bus.
- The fault memory can be read out and erased via the data link connector.
- Correction programming or diagnosis can be undertaken using STAR DIAGNOSIS via the data link connector.
- The throttle valve actuator checks its return spring (via the position of the throttle valve) may lead to a positioner adaptation.
- The tumble flap switchover is actuated and a check is performed to ensure that the end positions have been reached.
GF07.61-P-3007V The ME Limiting Maximum Vehicle Speed Function
GF07.61-P-3007V The ME Limiting Maximum Vehicle Speed Function
The ME control unit detects the engine speed via the crankshaft Hall sensor signal. As a protection for the engine and the drive train, engine speed
5
is limited by retarding the ignition timing and switching off the fuel injection valves if the following conditions exist:
1. Transmission overload protection

1.1. Torque converter protection of automatic transmission
In order to protect the torque converter in selector lever positions P and N (no power flow) from excessive static internal pressure,
engine speed is limited to approx. 4200 rpm.
1.2. Mechanical transmission (no gear engaged)
In order to avoid damage to the transmission engine speed is limited to approx. 4000 rpm.
2nd Limiting maximum engine speed when driving

In order to protect the engine from the consequences of impermissibly high revs, engine speed is limited to 6000 rpm. The driving mode is
detected from the vehicle speed signal.
3rd Throttle valve actuator defective

If the throttle valve actuator is faulty, the engine speed in neutral is restricted to approx. 1400 rpm and in driving mode to approx. 1800 rpm.
GF07.61-P-3010V The ME-SFI Start Quantity Control Function
GF07.61-P-3010V The ME-SFI Start Quantity Control Function
The start quantity control must guarantee the safe start of the engine. To do this, a decision is made as to whether this is a cold start, a warm start, a
repeat start or a start following operation of the stationary heater.
In order to facilitate starting a cold engine, in addition fuel must be injected during the starting procedure, depending on the coolant temperature.
The increased quantity of fuel injected is achieved by extending the injection time.
The start quantity control is dependent on:

- Start identification (CAN message "Terminal 50 ON")
- Engine speed
- Following operation of the stationary heater, in addition to the external air temperature when the engine was last shut-off (CAN message
from the instrument cluster), intake air temperature and shut-off time of the engine.
The start quantity control is enabled after start recognition. It remains activated until a temperature-related engine speed is exceeded.
The higher the coolant temperature, the lower is the start quantity enable by the ME-SFI control unit.
GF07.61-P-3011V The ME-SFI Post-Start Enrichment Function

GF07.61-P-3011V The ME-SFI Post-Start Enrichment Function
6
After a cold start the fuel-air mixture is enriched for a short time. The fuel which precipitates on the cylinder walls and the intake manifold is
compensated for by this enrichment and the engine runs smoothly. Torque converter protection of automatic transmission (e.g. 1400 rpm with no
gear engaged (automatic transmission) at +30 °C coolant temperature for about 30 s).
The post-start enrichment is dependent on:

- Coolant temperature at start
- Combustion cycles after start
GF07.61-P-3017V ME Engine Speed Signal, Function

GF07.61-P-3017V ME Engine Speed Signal, Function
7
The short-circuit proof engine speed signal "TNA" is generated from the signals from the crankshaft Hall sensor in the ME control unit. The output
stage output can accept a maximum load of 20 mA.
The signal is picked up at the data link connector. In addition, the control unit outputs a CAN message with the engine speed to further control units
and to the instrument cluster.
The engine speed signal "TNA" is a square wave signal with a constant duty cycle. 6 pulses are output per engine revolution. If the signal from the
crankshaft Hall sensor fails, then the signals of the camshaft Hall sensor are used as a replacement.
GF07.61-P-3020V ME-SFI Two-Sensor Control, Function

8
The ME engine control unit determines the lambda mean value from signals from the O2 sensors downstream of TWC. This value is compared with
a stored value for optimum exhaust emissions. If the deviation is too large after a number of measurements, a correction variable (delay time) is
determined for the lambda control. The correction variable (value for new O2 sensor upstream TWC approx. 0) makes it possible to compensate for
aging of the O2 sensor upstream of TWC within certain limits. If the correction variable exceeds the limit value, the O2 sensor upstream of TWC
must be replaced.
The correction values are map-controlled and are implemented by the ME control unit by adapting the fuel injection.
Two sensor control is only enabled when the catalytic convertors have reached their operating temperature and the O2 sensors downstream of TWC
are correct.
If the limit values are exceeded or the plausibility check of the O2 sensor signals is negative, a fault is stored in the fault memory. The stored faults
can be read out and erased with the STAR DIAGNOSIS.
The effect of the firewall catalytic converters is monitored based on the O2 sensor signals downstream of TWC.
GF07.61-P-3023V The Fan Control Function

GF07.61-P-3023V The Fan Control Function
9
The ME-SFI [ME] control unit indirectly actuates the electric suction fan engine and AC with integrated control infinitely.
The fan specified speed is transmitted by the ME control unit via a pulse width modulated signal (PWM signal).
The on/off ratio is 10 to 90%.
Meaning:
10% Electric suction fan OFF
20% Electric suction fan "ON", minimum speed
90% Electric suction fan "ON", maximum speed.
If the actuation is faulty, the electric suction fan rotates with maximum rotational speed (fan emergency mode).
The status of the automatic air conditioning is transmitted from the instrument cluster via the CAN data bus to the ME-SFI [ME] control unit. The
fan specified speed is dependent on this information and on the coolant temperature.
The suction fan continues running for up to 5 minutes after ignition

"OFF" if the coolant temperature, the engine oil temperature (from the temperature model) or the temperature of the ME control unit exceeds
specified maximum values.
If the battery voltage drops excessively during this operation, suction fan run-on is suppressed.
GF07.61-P-3031V The Correction Programming Function
GF07.61-P-3031V The Correction Programming Function
Different performance maps for the engine control can be activated with the correction programming function in the ME control unit.
The programming can be carried out with STAR Diagnosis when ignition is "ON", via the data link connector.
10
The following maps can be influenced:

- Ignition maps for adapting to different fuel quality (except (USA))
- Mixture maps for enriching the air/fuel mixture in different operating states (except (USA))
- Idle speed for automatic transmission and drive position engaged
- Temperature correction for switching electrical suction fan on and off.
GF07.61-P-4015V ME Engine Torque Requirements Function
GF07.61-P-4015V ME Engine Torque Requirements Function
The function (torque interface) coordinates and prioritizes the requirements of all vehicle systems requiring torque. At the same time, the dynamics
of the conversion for each requirement are established.
The engine torque is modified as follows:

- Increase or reduction of injected volume
- Early or late adjustment of the ignition angle (rapid)
- Combination of both options
If the injected volume is increased and the ignition angle simultaneously adjusted to "late", the engine torque first stays the same, but the
option is available to rapidly achieve a subsequent torque increase by early adjustment of the ignition angle (torque reserve).
The following functions can require an engine torque:

- Driver preset
- Transmission control/protection
- ESP
- Cruise control/Distronic
- Torque limitation, e.g. during start-up
- Limitation of engine speed and max. speed
- Ancillary assemblies (coolant compressor, generator, power steering pump)
- Functions such as idle speed control and deceleration fuel shutoff.
GF07.61-P-4016VB ME Engine Coolant Heat Management Function
GF07.61-P-4016VB ME Engine Coolant Heat Management Function
11
Heat management controls the coolant temperature of the engine. Advantages are
- The operating temperature is reached more rapidly
- Emissions reduced
- Fuel savings up to around 4%
- Improved heat comfort.
Heat management is dependent on the following input signals:

- Engine load
- Engine speed
- Outside air temperature
- Actuation of the suction fan
- Vehicle speed
- Driver type (quiet or sporty).
Depending on the operating conditions, the ME control unit actuates the heater element in the three-disk thermostat depending on performance
mapping via a ground signal. The voltage is supplied to the three disk thermostat via circuit 87. The coolant temperature is regulated between 80 °C
and 100 °C via the duty cycle.
If the coolant temperature is too high, the coolant temperature warning lamp in the instrument cluster is actuated. To do this, the ME control units
sends a CAN command to the instrument cluster.
Full throttle position (A)
For a cold start, the three disk thermostat is not actuated and additionally, when the vehicle heater is shut off, the heater circuit is closed via the
heater system shutoff valve. The standing coolant now warms up very quickly. Heat is sent from the engine oil via the heat exchanger at the front of
the engine.
At a coolant temperature from around 70 °C or from around 45 °C (with outside temperature above around 12 °C), switching from full throttle to
short-circuit operation takes place. In addition, the closing disk opens due to pressure via the running coolant pump over around 3500 rpm.
Short-circuit operation position (B)
Short-circuit operation with the engine and heat exchanger can be throttled so that the heater responds more rapidly.
Mixed fuel operation position (C)
Temperature regulation with the three-disk thermostat is not enabled until the coolant temperature following start reaches around 98 °C. At outside
12
temperatures above around 12 °C it is active immediately.
At partial load, the three-disk thermostat regulates at an increased coolant temperature of around 100 °C.
To prevent critical temperatures, the increased coolant temperature range is reduced under the following conditions to around 90 °C (with outside
temperature below 12 °C) or to around 80 °C (with outside temperature over 12 °C):
- Engine speed greater than 3000 rpm
- Engine load more than 30%
- Intake air temperature more than around 38 °C
- sporty driver detected.
Maximum radiator operation position (D)
The three-disk thermostat is actuated constantly during radiator operation. Above around 110 °C, the three-disk thermostat is always fully opened
independently of actuation (emergency operation function).
GF07.61-P-4017V ME Tumble Flap Switchover Function
GF07.61-P-4017V ME Tumble Flap Switchover Function
At partial load, tumble flaps can be fully swung out in each cylinder intake port in the intake manifold. This closes the intake manifold by around
50%. The flow speed of the intake air is increased and allows for improved distribution of the fuel/air mixture in the combustion chamber.
The tumble flaps are moved via an aneroid capsule and a rod to the flap shafts.
The intake manifold tumble flap switchover valve is integrated in the vacuum line to the aneroid capsule. If it is de-energized, the aneroid capsule is
ventilated and the tumble flaps are lowered in the intake duct (closed position).
If the intake manifold tumble flap switchover valve is actuated by a ground signal from the ME control unit, vacuum pressure from the intake
manifold enters the aneroid capsules. The tumble flaps turn in the intake duct.
Actuation is enabled under the following conditions:

- Engine speed less than about 3000 rpm (e.g. engine 272.963)
- in neutral for variants VC5 and VC6
(on neutral locked from variants VC7)
- Engine load less than approx. 30%.
- Coolant temperature greater than 60 °C
Read out the variants using STAR DIAGNOSIS under the menu item "Control unit version".
13
The mechanical end position of all tumble flap shafts are monitored by a position sensor. For diagnosis, following engine start, the tumble flap
switchover is actuated briefly to test the actuation and achievement of the end positions.
GF07.61-P-4021V Camshaft Adjustment, Function

GF07.61-P-4021V Camshaft Adjustment, Function
With camshaft adjustment, all the four camshafts can be adjusted progressively up to a crank angle of 40°. This means the valve overlap in the
event of a load change can be varied within wide limits. In the event of valve overlap, the intake valves open even before the exhaust valve has
fully closed.
Adjustment range of camshafts in ° crank angle:

Intake camshaft 4° BTDC up to 36° ATDC
Exhaust camshaft 20° BTDC up to 20° ATDC.
Interlocked start position in ° crank angle:

Intake camshaft 36° ATDC
Exhaust camshaft 20° BTDC.
At a lower engine speed and load, a large valve overlap is set to obtain an inner exhaust gas recirculation. In doing so, less fresh gases are drawn in,
as some exhaust gas low in oxygen still remains in the cylinder. The combustion temperature drops and the formation of NOx is reduced. The
inducted air mass is reduced by the quantity of exhaust gases which remain. In line with this, the ME control unit meters less fuel.
The smallest valve overlap in the event of a load change takes place when the exhaust camshafts are turned to the maximum "Early" and the intake
camshafts are turned to the maximum "Late". The increased fresh gas proportion leads to a greater torque and performance.
Enabling of the camshaft adjustment is dependent on the engine speed and engine oil temperature, to ensure sufficient oil pressure, even when the
engine oil is hot (oil pressure for adjustment at least around 1.5 bar). If oil pressure is inadequate, first of all, adjustment of the exhaust camshafts is
not guaranteed, as these must be adjusted when the engine speed is dropping and thus at a lower oil pressure to the direction of rotation of the
engine. A return spring is located in each exhaust-side vane-type adjuster for support.
The engine oil temperature is determined by the ME control unit using various operating data (e.g. load, coolant temperature, time) and a stored
temperature model determined.
Enabling of the load-dependent and speed-dependent camshaft adjustment takes place:

- from around 600 rpm at 80 °C engine oil temperature
14
- from around 800 rpm at 120 °C engine oil temperature (intake side)
- from around 1050 rpm at 120 °C engine oil temperature (exhaust side)
The solenoids upstream of the camshafts are actuated by the ME control unit on the ground side. The control plungers of the vane type actuators are
operated via the map-dependent duty cycle. Depending on their position, the oil volume in the vane-type adjusters is controlled.
Camshaft adjustment takes place gradually when all camshafts must be further adjusted simultaneously to prevent oil supply problems. In doing so,
the intake camshaft adjustment is projected.
Each camshaft position is detected via a camshaft Hall sensor. These are located upstream of the camshaft adjusters and detect the window
positions in the pulse wheels. During diagnosis, a check is performed to establish whether the camshafts are in the interlocked start position and
whether following a short waiting time, the required adjustment has also been performed. In addition, output stage errors for the solenoids and
defective camshaft Hall sensors are detected.
The upper half of the illustration shows: filling oil galleries A, oil galleries B open. The lower half the illustration shows: filling oil galleries B, oil
galleries A open.
15
GF07.61-P-4023V ME-SFI Transmission Shift Delay, Function

GF07.61-P-4023V ME-SFI Transmission Shift Delay, Function
The transmission shift delay warms up the catalytic converter more rapidly to its operating temperature after engine start.
The transmission shift delay is fully electronic. No additional components are required.
The engine control unit requests from the transmission control unit via the CAN data bus to alter the shift characteristic curves. The speed signal is
provided via the CAN data bus.
The partial load shifts from 1st and 2nd gear into 3rd gear take place at higher engine speeds. Starting takes place in 1st gear only when drive
program C is selected.
The transmission shift delay is active for max. 60 s under the following conditions:
- Coolant temperature at start less than 35 ° C
- Speed less than 40 km/h
GF07.61-P-4026V Transmission Overload Protection, Function
GF07.61-P-4026V Transmission Overload Protection, Function
16
This function protects the shift elements of the automatic transmission from thermal overload during load changes in the upper engine speed range.
Through brief retardation of the ignition and closing of the throttle valve during shift operations, the engine torque is reduced. The ME-SFI [ME]
control unit is supplied with a signal for this purpose by the transmission control unit via the CAN data bus.
GF07.61-P-4027V Overheating/Pinging Protection, Function

GF07.61-P-4027V Overheating/Pinging Protection, Function
The task of the overheating/pinging protection is to prevent engine damage as a result of excessive thermal overload and overheating damage of the
catalytic converters.
The heat output by the cooling system into the environment is mainly dependent on the fan speed, vehicle speed, outside temperature and coolant
temperature.
The heat and engine output generated from it in the cooling system by combustion must be restricted so that the maximum permissible coolant
temperature is not exceeded.
Here, the throttle valve is no longer fully opened. The air mass drops accordingly and less fuel is injected.
1
Body Control Module: Description and Operation
GF54.21-P-4105PP Upper Control Panel Control Unit, Location / Task / Design / Function
GF54.21-P-4105PP Upper Control Panel Control Unit, Location / Task / Design / Function
- MODEL 203.0 /2 /7 up to Model Year 8
Shown on model 203.0 as of 24.4.04 up to 31.8.04
N72/1 Upper control panel control unit
1
GF54.21-P-4108-01PP Front SAM Control Unit With Fuse and Relay Module, Task
GF54.21-P-4108-01PP Front SAM Control Unit With Fuse And Relay Module, Task
The tasks of the front SAM control unit with fuse and relay module (N10/1) are as follows:
- Controlling the wiper system
- Control of windshield washer system
- Actuation of headlamp cleaning system
- Controlling the exterior lights
- Control of fanfare horns (H2), right fanfare horn (H2/1)
- Control of control unit box blower motor (M2/2)
Reading in the following components:

- Refrigerant pressure and temperature sensor (B12/2)
- Outside temperature indicator temperature sensor (B14)
- Light switch module (S1)
- Stop light switch (S9/1)
- Brake fluid indicator switch (S11)
- Parking brake switch (S12)
- Coolant level indicator switch (S41)
- Windshield washer system fluid level indicator switch (S42)
- ATA [EDW] hood switch (S62)
(with code (551) Anti-theft alarm system (ATA [EDW]))
- Backup lamp switch (S16/2) (with transmission 716)
Scanning the following signals:

- Terminal 61 (the preexcitation current is produced by a series resistor)
- Circuit 15
- Term. 15R
- Term. 31b (Wiper motor cam controller)
Switching consumers via semiconductor switches:

- Lamps of exterior lighting system
- Lamps of the interior lighting system
- Windshield washer fluid pump (M5/1)
- Rear-end door washer fluid pump (M5/3) (on model 203.2)
- HCS [SRA] pump (M5/2) (for code (600) Headlamp cleaning system)
- Coolant circulation pump (M13) (with code (450) Taxi version or code (581) Automatic air conditioning or code (581) Comfort automatic air
conditioning or code (670) Residual engine heat utilization system)
- SEQ [ASG] hydraulic pump (M46) (with code (424) Sequentronic automated manual transmission (SEQ))
- Control unit box blower motor (M2/2)
- Washer nozzle heating (R2/1)
- Washer nozzle hose heater R2/11 (with code (875) heated windshield washer system)
- Air conditioning regulating valve
Switching the following relays:

- Terminal 87 relay, chassis (N10/1kK)
- Fanfare horn relay (N10/1kl)
- Wiper speed 1 and 2 relay (N10/1kL)
- Terminal 15R relay (N10/1kM)
- SEQ [ASG] pump control relay (N10/1kN) (with code (424) Sequentronic automated manual transmission (SEQ))
- Air pump relay (N10/1kO) (with engine 112, 113 and 272)
- Terminal 15 relay (N10/1kP)
- Wiper ON/OFF relay (N10/1kQ)
- Terminal 87 relay, engine (N10/kR)
- Starter relay (N10/1kS)
For the exchange of data the front SAM control unit with fuse and relay module (N10/1) is connected to the Control Area Network bus class B
(interior) (CAN-B).
1
GF54.21-P-4115PP Rear SAM Control Unit With Fuse And Relay Module, Location / Task / Design
/ Function
GF54.21-P-4115PP Rear SAM Control Unit With Fuse And Relay Module, Location / Task / Design / Function
- MODEL 203.0 /2 /7 up to Model Year 8
Illustrated on Model 203.0
N10/2 Rear SAM control unit with fuse and relay module
1
GF54.21-P-4116PP Lower Control Panel Control Module, Location / Task / Design
GF54.21-P-4116PP Lower Control Panel Control Module, Location / Task / Design
- MODEL 203
- with CODE (219) Distronic (DTR) up to Model Year 8 up to Model Year 8
- MODEL 203
- with CODE (228) Stationary heater up to Model Year 8
- MODEL 203
- with CODE (450) Taxi version up to Model Year 8
N72 Lower control field control module

N72r1 DTR distance potentiometer
N72s9 DTR switch
N72s11 Radio switch
N72s12 STH switch
1
Body Control Module: Service and Repair
AR54.21-P-1259P Remove/Install SAM With Fuse and Relay Box, Rear
AR54.21-P-1259P Remove/Install Sam With Fuse and Relay Box, Rear
Shown In Model 203.0
DANGER:
- Risk of explosion from hydrogen gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of Injury to eyes
and skin suffering caustic burns from battery electrolyte or from contact with damaged lead acid batteries.
- No fire, sparks, open flames or smoking.
- Wear acid-resistant gloves, clothing and glasses. Pour battery electrolyte only into suitable and appropriately marked containers
CAUTION: Do not connect quiescent current retention unit due to risk of short circuit.
2 Remove paneling in trunk
NOTE: Side paneling on driver's side only.
3 Unscrew bolt(1)
4 Unlock and remove rear SAM control module with fuse and relay module (N10/2)
NOTES:
- Do not damage the retaining lugs (arrows).
- Unlock by tilting through 90 degrees towards the spare wheel recess
5 Unlock connectors (2) and disconnect
NOTE:
- Removal: Disconnect lines at the control module and fuse and relay box.
- Installation: Connect cables to control module and fuse and relay box
6 Remove rear SAM control module with fuse and relay module (N10/2)
NOTE: Check fuse and relay assignment when replacing.

8 Read diagnostic trouble code memory and erase
9 Perform basic programming
1
Body Control Module: Service and Repair
AR54.21-P-1260P Remove/Install SAM With Fuse and Relay Box, Left Front
AR54.21-P-1260P Remove/Install SAM With Fuse and Relay Box, Left Front
Shown In Model 203.0
DANGER:
- Risk of injury in the form of trapping or crushing, or even severing of limbs, if caught in windshield wiper mechanism
- Always remove ignition key when working on windshield wiper mechanism.
1 Set wiper arms to vertical position
DANGER:
- Wear protective gloves, acid-resistant clothing and safety glasses. Pour battery electrolyte only into suitable and appropriately
marked containers
CAUTION: Do not connect quiescent current retention unit due to risk of short-circuit.
3 Unlock and remove cover (1) on module housing (4)
NOTE: Installation: Check gasket for damage
4.1 Remove injection system control module

4.2 Remove front SAM control module with fuse and relay module (N10/1) from guide.
5 Unscrew bolts (3)
6 Release and remove connectors
NOTE:
- At top on front SAM control module with fuse and relay module (N10/1)
- Removal: Disconnect cables from control module and fuse and relay box
- Installation: Connect cables on control module and fuse and relay box
7 Expose wiring harness.

8 Remove front SAM control module with fuse and relay module (N10/1) upwards.
NOTE: Pull out only until connectors are accessible from below.
2
9 Release and remove connectors
NOTE:
- At top on front SAM control module with fuse and relay module (N10/1)
- Removal: Disconnect cables from control module and fuse and relay box
- Installation: Connect cables on control module and fuse and relay box
10 Remove front SAM control module with fuse and relay module (N10/1).
NOTE: When replacing, the fuse and relay assignment must be inspected.

12 Perform basic programming
13 Read diagnostic trouble code memory and erase
14 Check for proper function
1
Engine Control Module: Description and Operation
AH07.61-P-0002-02V ME-SFI Vehicle Features

AH07.61-P-0002-02V ME-SFI Vehicle Features
Comparison of engines 272, 273 with engines 112, 113 (except AMG)
AH07.61-P-0002-02VU ME-SFI Vehicle Features

AH07.61-P-0002-02VU ME-SFI Vehicle Features
Functions/components for national version (USA):

- CHECK ENGINE indicator lamp (A1e26)
- Fuel system open warning (fuel tank cap indicator)
- Purge system with leak test.
Additional components:
- Fuel tank pressure sensor (B4/3)
- Activated charcoal canister shutoff valve (Y58/4)
- Vent line to activated charcoal canister without vent valve and with large diameter, model 171.
- During refueling the fuel vapors are collected at the filler neck and passed to the activated charcoal filter (ORVR = Onboard Refueling Vapor
Recovery).
- The activated charcoal canister is enlarged.
- The pulse switchover valve is designed for a larger flow volume (color coding).
- From MY 2005 a PremAir sensor (B11/15) can be installed on the radiator in model 211. It has the task of recognizing a coated PremAir
radiator. This catalytically converts ozone into oxygen and therefore needs controlling. The engine control unit recognizes the PremAir
sensor via a local interconnect network interface and checks the plausibility of the detected temperature pattern.
If a PremAir radiator is replaced by an uncoated radiator then an error is detected and the "CHECK ENGINE" indicator lamp actuated.
- Flexible Fuel Vehicle (FFV), engine 272.920/940 as standard from 1.6.06
Flexible-fuel vehicle vehicles can be filled up premium fuel or ethanol (proportion of ethanol: 85 %). This creates mixtures in the fuel tank
with an ethanol concentration of 0 to 85%. The proportion of ethanol is taught in at every filling of the tank and the mixture formation is
adjusted accordingly.
GF07.61-P-0001-02V Motor Electronics (ME-SFI) Fuel Injection and Ignition System Function
Diagram
2
GF07.61-P-0001-02V Motor Electronics (ME-SFI) Fuel Injection And Ignition System Function Diagram
GF07.61-P-0001-06V Motor Electronics (ME) Fuel Injection and Ignition System Control Unit,
Input Signals
GF07.61-P-0001-06V Motor Electronics (ME) Fuel Injection And Ignition System Control Unit, Input Signals
3
GF07.61-P-0001-07V Motor Electronics (ME) Fuel Injection and Ignition System Control Unit,
Output Signals
GF07.61-P-0001-07V Motor Electronics (ME) Fuel Injection and Ignition System Control Unit, Output Signals
4
GF07.61-P-0001V Motor Electronics (ME-SFI) Fuel Injection and Ignition System, Function
GF07.61-P-0001V Motor Electronics (ME-SFI) Fuel Injection And Ignition System, Function
The ME 9.7 fuel injection and ignition system is an advance development of the ME 2.8. The abbreviated designation ME-SFI 9.7 means:
M = Motronic (motor electronics)
E = Electronic accelerator pedal
9.7 = Version 9.7
In engine control unit, the ME-SFI [ME] control unit (N3/10), the following function are consolidated:
- Ignition system
- Injection system
- Electronic accelerator
- Torque interface
5
- Diagnosis and fault storage
- Gateway between the drive CAN and the chassis CAN
- Immobilizer and drive authorization
- Evaporative emission control system (for (USA) with leak test)
- Fuel supply
- Starter control
- Fan control
- Emission control
The ME-SFI [ME] control unit is flashable. The software required to program the control units is provided on the DAS Update DVD.
The ME-SFI [ME] control unit evaluates the following basic information:
- Air mass
- Engine speed/crankshaft position
- Smooth operation of the engine (misfire detection)
- Throttle valve position
- Accelerator pedal position
- O2 sensor signals
- Intake manifold pressure
- Outside air temperature
- Air pressure (altitude)
- Inlet and exhaust camshaft position
- Vehicle speed (via CAN)
- Steering angle (via CAN)
- Alternator interface
- Knocking of engine
- Brake recognition (via CAN)
- Oil level
- Position of the clutch pedal (for manual transmission 716.6)
GF07.61-P-6000V ME-SFI [ME] Control Unit, Component Description
GF07.61-P-6000V ME-SFI [ME] Control Unit, Component Description
Location
The ME 9.7 control unit is located on the intake manifold supporting the engine.
Task
Controls in line with the input signals the functions of:

- Ignition system/fuel injection system
- Electronic accelerator/cruise control/idle speed control
6
- Diagnosis/fault storage
- Drive authorization system/immobilizer
Design
Connection is achieved on the engine-side and on-board via two couplings interlocked via slide valves. Cooling fins on the upper side provide the
necessary rejection of heat. Vibrations are suppressed by rubber brackets.
Function
Control of fuel injection system
The ME control unit actuates the fuel injection valves separately corresponding to the firing order (sequentially) according to the input signals and
the performance maps stored in the ME control unit. The ME-SFI control unit calculates the opening times (injection times) of the fuel injection
valves.
Control of ignition system
The ME-SFI [ME] control unit actuates the ignition system according to the input signals and performance maps stored in the ME-SFI [ME] control
unit. The ME-SFI control unit calculates the ignition angle values and controls the anti-knock control (AKC).
Control of idle speed control
The throttle valve actuator is actuated on the basis of the input signals and the performance maps stored in the ME control unit.
Control of cruise control
The ME control unit operates the throttle valve actuator for the cruise control function on the basis of the input signals and the position of the cruise
control switch.
Additional cruise control functions include variable speed limiter and Distronic.
Diagnosis/DTC memory
The ME-SFI control unit checks its inputs and outputs for plausibility and recognizes possible faults. The following faults can be distinguished:
- Faults present all the time
- Loose contact faults that have occurred while driving
The faults are erased in the ME-SFI control unit after circuit 30 is interrupted.
Drive authorization system/immobilizer
The ME-SFI control unit is always equipped with an immobilizer. When the vehicle is locked, the drive authorization system control unit transmits
information over the CAN data bus to the ME-SFI control unit, which thereupon interlocks the engine management system (fuel injection system).
The engine can be started (start enable) only when the vehicle is unlocked with the authorized key again and the control unit of the drive
authorization system sends information to this effect to the ME-SFI [ME] control unit via the CAN data bus.
The ME control unit is functional only with a CAN data bus and the FBS 3 drive authorization system.
Engine speed signal
The ME control unit generates the short-circuit proof engine speed signal TNA from the signals supplied by the crankshaft position sensor, and
outputs them to other control units. 3 pulses are output per engine revolution.
Actuations with STAR DIAGNOSIS
Functions can be actuated specifically for diagnostic purposes. These are listed in a menu item.
Variant coding
For adapting the ME control unit to different vehicle versions and vehicle equipment by means of matching code numbers. Coding is performed
with STAR DIAGNOSIS. The variant coding can be used to code the following vehicle versions and equipment variants:
- Vehicle model
- National version
- Transmission version
- with or without TWC
Fuel consumption signal
The consumption signal is calculated from the injection times (e.g. 8 liters/hour) and is transmitted via CAN to the trip computer in the instrument
cluster.
7
Start recognition
The engine control unit is informed about the introduced starting procedure via the CAN message "circuit 50". This is necessary in order, for
example, to trigger the start quantity control, the starter control, the post-start enrichment and the ignition timing when starting.
Computer run-on
After the ignition is switched off, the ME-SFI control unit performs a delayed-off run during which certain data memories are updated (e.g. the
DTC memory). The run-on time with a warmed up engine is approx. 5 s, but may be extended to several minutes by various functions. After the
fault memory has been cleared, the run-on time must expire.
Various engine operating information is transmitted via the CAN databus from the ME control unit to the instrument cluster and to other control
units which are connected to the CAN databus.
SM07.08-P-0004B Check Engine Control Unit Software and Install If Necessary
SM07.08-P-0004B Check Engine Control Unit Software And Install If Necessary
- ENGINE 272.920 in MODEL 203.052
1 Fitted
1
Engine Control Module: Service and Repair
AR07.08-P-7008QB Remove/Install Injection System Control Unit
2
Steps 1 - 13
Control Unit
1
Accelerator Pedal Position Sensor: Description and Operation
GF30.20-P-2010V Accelerator Pedal Sensor Component Description
Location
The accelerator pedal sensor is located at the top of the accelerator pedal module.
Task
Detects the accelerator pedal position and relays the corresponding voltage signals to the motor electronics control unit.
Replace accelerator pedal module always complete.
2
Function
The accelerator pedal sensor converts the mechanical operation input by the accelerator pedal into an electrical voltage corresponding to the
accelerator pedal position.
The accelerator pedal sensor operating on the Hall principle is integrated in the pedal lever shaft and consists of a shaft with a ring magnet. This
rotates in a printed circuit board with stator in the fixed Hall elements. This produces a change in the voltage.
The accelerator pedal sensor is supplied via pin 1 from the ME control unit with 5 V. Pin 3 and 6 are ground connections.
The information of the accelerator pedal position is transmitted to the motor electronics control unit in the form of two signals (pin 5 with signal 1
has maximum approximately 4.8 V and pin 4 with signal 2 maximum approximately 2.4 V).
The supply voltage in the accelerator pedal sensor is halved for sensor 2.
Signal 1 ranges are defined as percentages of the supply voltage (approx. 5 V) as follows:
- up to 4 % the signal is too small via short-circuit to ground or via line interruption
- 4 to 9.4 % idle range
- 9.4 to 81 % partial-load range
- 81 to 96 % full load range
- above 96 % the signal is too high via short-circuit to positive.
Kick-down detection takes place via the accelerator pedal sensor, is signals 1 and 2 fall within full load range for a certain period.
If the brake pedal is operated, only the idle speed values from the accelerator pedal sensor are accepted. If necessary, the engine control unit will
generate substitute values. The signals from the accelerator pedal sensor are rejected over this time
In the event of an error at signal 1, a switchover to signal 2 takes place and emergency mode is activated.
1
Air Flow Meter/Sensor: Description and Operation
GF07.07-P-6000V Hot Film MAF Sensor, Component Description
Location
The hot film mass air flow sensor is located behind the intake manifold between the air filter housing and the throttle valve actuator.
Task
The hot film MAF sensor detects the air mass supplied to the engine and the intake air temperature.
Design
A temperature-controlled resistor detects the air mass and an integral NTC resistor detects the intake air temperature.
The flow to the hot film sensors is even through the grid. The hot film MAF sensor has an oval housing and 4-pin (production start) or 5-pin plug
connector.
The electronics and the housing have undergone a number of modifications (please note part number).
Function
The electronic control in hot film mass air flow sensor controls the temperature of the heating resistor [R(H)] by means of a variable voltage, so that
its temperature is 160 °C above the intake air temperature detected by the temperature resistor [R(L)].
The temperature of the heating resistor [R(H)] is detected by the sensor resistor [R(S)]. If a temperature change occurs as a result of an increased or
reduced air flow, the electronics adapts the voltage at the heating resistor [R(H)] until the temperature difference is again achieved.
2
This control voltage is used by the engine control unit as a measure for the metered air mass. The air mass is transmitted via a frequency signal (low
frequency for low air mass) to the ME control unit. Using STAR DIAGNOSIS, the cycle duration of the frequency signal can be read out in micro
seconds.
The intake air temperature is detected by an additional NTC resistor.
Hot film MAF sensors with the number A 273 094 08 48 and higher provide the engine control unit with an additional signal at a frequency ranging
between 17 and 21 Hz (44 to 54 ms). With this so called ratio-metric frequency signal, the engine control unit compensates for the temperature and
voltage influences at the air mass signal.
The engine control unit also detects the version of the hot film MAF sensor via the duty cycle.
1
Air Flow Meter/Sensor: Service and Repair
AR07.07-P-1453QB Remove/Install Hot Film Mass Air Flow Sensor
Steps 1 - 11
2
1
Camshaft Position Sensor: Description and Operation
GF07.04-P-6020V Component Description For A Camshaft Hall Sensor
Location
The camshaft Hall sensors are located before the respective camshaft.
Task
Detects the camshaft position for the following functions contactlessly via the pulse wheel at the front at every camshaft:
- Synchronization of the ignition and injection sequence (recognition of ignition TDC).
Design
Hall sensor in plastic housing with 3-pole plug connection, distance from pulse wheel of 0.2 to 1.8 mm.
Function
The camshaft positions are detected by the camshaft Hall sensor, which detects the position of the pulse wheels at the front on the camshafts. The
camshaft position can already be detected when the engine is stationary by the electronics for the Hall sensor. This results in an improvement in the
exhaust levels because the optimal injected quantity of fuel can be assigned to each cylinder immediately when the engine is started (quick-start
function).
Four signals are generated per rotation of the camshaft whereby the signal switches between about 5 V ("HIGH") and 0 volt ("LOW"). If an
opening in the pulse wheel is opposite the sensor, the signal is approx. 5 V.
The signals are used to control and diagnose the camshaft adjustment, to synchronize the crankshaft and camshaft position (detection of ignition
TDC cylinder 1) and for emergency starting of the engine when the crankshaft Hall sensor is faulty.
2
The stated angle at the pulse wheels must be doubled to maintain the crank angle.
3
1
Camshaft Position Sensor: Service and Repair
AR15.10-P-2000QB Remove/Install Camshaft Hall Sensor
Steps 1 - 8
Position Sensor
2
Special Tools
1
GF07.04-P-6220V Component Description For the Crankshaft Hall Sensor
GF07.04-P-6220V Component Description For The Crankshaft Hall Sensor
Location
The crankshaft Hall sensor is located behind the left cylinder bank.
Task
It detects the engine speed and the crankshaft position by scanning a perforated plate welded to the starter ring gear (incremental wheel).
Design
Hall sensor in plastic housing with 3-pole plug connection, distance from the increment wheel 0.3 to 1.3 mm.
Function
The crankshaft Hall sensor scans the increment wheel at the starter ring gear. The increment wheel has 58 links and a gap, at which two links are
missing (60-2).
Each 4 mm wide link generates a signal change at the crankshaft Hall sensor. The signal changes in the link center from around 5 V to around 0 V
(negative signal edge).
No signal change takes place at the gap with the 2 missing links. The ME-SFI [ME] control unit detects the TDC position of cylinder 1 with the 2nd
negative flank after the gap.
In the ignition TDC of cylinder 1, the signals from the camshaft Hall sensor are also "LOW".
Only the negative signal edge of the crankshaft Hall sensor signal is ever evaluated. For example, for a frequency measurement, the gap between
two negative edges must be measured.
2
The rising negative edge of the signals occurs when a window is located opposite the crankshaft Hall sensor (no material). At the wide gap in
particular, the signal fluctuates greatly and is therefore not used.
1
GF07.04-P-6230V Component Description For the Position Sensor Tumble Flap
GF07.04-P-6230V Component Description For The Position Sensor Tumble Flap
Location
Task
flaps between completely swiveled in or out is approx. 56°.
Design
Function
The position sensors must switch no later than approx. 5° before the respective limit position. For reasons of tolerance, they may also switch up to
approx. 16° before the limit position.
1
Crankshaft Position Sensor: Service and Repair
AR15.12-P-2133QB Remove/Install Crankshaft Position Sensor
Steps 1 - 8
Position Sensor
1
Fuel Level Sensor: Description and Operation
Component Description For The Fuel Level Sensor
Location
The fuel level sensor is located in the fuel tank. If the fuel tank is divided into two chambers, each chamber has a fuel level sensor.
Task
Determines the fuel level for the following functions:

Fuel level indicator
- Leakage check of regeneration system I
- Misfire detection.
Design
Float-and-lever sensor with two wiper contacts (potentiometer) and a float.
Function
To change the resistance values depending on the fuel level. The signals are transmitted to the nearest SAM control unit (e.g. rear SAM control unit
with fuse and relay module for models 171, 211, 219, 221). The signal are digitalized there and transmitted to the CAN data bus.
1
Fuel Level Sensor: Service and Repair
AR47.10-P-7000PR Remove/Install Fuel Level Sensor
Modification Notes
Part 1
2
Part 2
Fuel Tank
1
Fuel Tank Pressure Sensor: Description and Operation
GF47.30-P-2100VU Component Description For The Fuel Tank Pressure Sensor
- with CODE (494) USA version
Location
- Model 203, 209, 211, 219: in the closing plate of the left fuel tank chamber
- Model 171: in the closing plate of the fuel filter
- Model 164: at the top of the filler neck (Version 1 for standard series) or at the top in the fuel tank
- Model 221: above on the filler neck
- Model 251: at the top in the fuel tank
- Model 230: at the top in the fuel tank at the fuel level sensor.
Task
Detects the in-tank pressure for leakage testing of the purge system.
Function
The voltage supply of 5 V is performed by the ME control unit. The measuring range extends from approx. -50 mbar up to approx. +30 mbar.
The output signal is dependent on the in-tank pressure: -50 mbar approx. 0.5 V, 0 mbar approx. 3 V and +30 mbar approx. 4.5 V.
1
GF15.12-P-4024V the Anti-Knock Control Function
GF15.12-P-4024V The Anti-Knock Control Function
The task of the anti-knock control AKC is to ensure knock-free operation of the engine with different fuels and in all operating conditions from
idling speed up to maximum engine speed. For this purpose, if uncontrolled combustion (knocking) occurs, the ignition angle at the knocking
cylinders is retarded. The anti-knock control (AKR) is integrated in the ME-SFI [ME] control unit.
Input signals:
- Motor speed (crankshaft Hall sensor)
- Camshaft position (camshaft Hall sensor)
- Recognition of knocking over 2 knocking sensors
- Engine temperature (coolant temperature sensor)
- Engine load (hot film mass air flow sensor)
- Accelerator pedal position (accelerator pedal sensor)
- Precontrol by means of automatic RON switch (internal)
- RON correction with STAR DIAGNOSIS.
Output signals:
- Ignition angle correction for specific cylinder to the map value calculated by the ME control unit
- Ignition angle emergency mode if fault identified.
The anti-knock control is active from a coolant temperature of 40 °C. If cylinder knocking is recognized above an engine load of about 40%, its
ignition angle is adjusted to retarded by about a 3.0° crank angle after the next ignition. If knocking continues to be detected, the ignition angle is
continuously retarded in steps of a 3° crank angle until the maximum retardation is reached (approx. a 10 -15° crank angle, depending on the engine
speed). The automatic RON switch also influences the maximum retarding of the ignition timing - the higher the selected RON stage, the less is the
maximum retarding of the ignition timing.
If knocking-free combustion exists, the retardation is reduced in steps of approx. 0.75° crank angle after a few ignitions (depending on the engine
speed) until the map value is achieved, or knocking occurs again.
Adaptation of anti-knock control
The adaptation of the anti-knock control is active from a coolant temperature of approx. 75 °C. Any corrections required to the ignition
angle because of knocking combustion are constantly detected for the specific cylinder and stored together with the relevant operating state of the
2
engine (engine load/speed range).
The stored adaptation value is taken into account in the output of the individual cylinder angles so that each cylinder is immediately operated with
the optimal ignition angle.
During abrupt acceleration, no values are stored for about 2 seconds in order to avoid any incorrect adaptation values.
Faults if knocking is detected
If no signals are received from the knock sensors, the ignition angle of all cylinders is retarded by as much as a 11° crank angle for safety reasons,
depending on engine speed and temperature. The antiknock control and the adaptation are deactivated and a fault is stored.
Automatic RON switch
In addition to the RON correction using STAR DIAGNOSIS, the antitemperature knock control features an automatic RON switch. This detects a
persistent high knocking tendency of the engine and assists the antithe knock control by means of an appropriate pre-control.
This is done by analyzing the stored adaptation values, the ignition angles of all the cylinders and the number of control interventions in certain
engine load and speed ranges. Depending on the threshold which has been exceeded, the RON value is adjusted by one or several stages. The value
is retained until the engine is switched off. After engine start, only the RON correction which is carried out by means of STAR DIAGNOSIS is at
first active.
1
Location
The knock sensors are located at the top of the crankcase under the intake manifold.
Task
The knock sensors detect combustion knocks at excessively high vibrations at the crankcase. Anti-knock control thereby corrects the ignition
timing for each individual cylinder when the engine is warm.
Body
The knock sensors function according to the piezoceramic principle. The screened cables are connected directly to the knock sensors.
Function
Any vibrations which occur are converted with the aid of the piezoceramic into electrical signals.
2
Piezo-electric effect: If a mechanical force acts on a crystal, electrical voltages are produced.
The noise signal is modulated to a DC voltage from 0.13 to 4.7 V for transmission to the ME control unit.
Knock sensor signals may also indicate engine damage, e.g. increased engine noise resulting from a widened piston groove.
1
Knock Sensor: Service and Repair
AR15.12-P-2184QB Remove/Install Knock Sensors
Steps 1 - 8
Knock Sensors
1
Manifold Pressure/Vacuum Sensor: Description and Operation
GF07.04-P-6060V Pressure Sensor Component Description
Location
The pressure sensor is located at the top on the left cylinder head.
task
The pressure sensor detects the absolute pressure in the suction pipe.
The intake manifold pressure is used to detect the air mass when starting the engine. When the engine has started, the signal from the hot film MAF
sensor is monitored.
Function
The intake manifold pressure distorts a diaphragm which has an effect on the piezo resistor. This alters the resistance value of the piezo resistor and
influences the output voltage, which is used as information regarding the intake manifold for the ME control unit.
1
Oxygen Sensor: Description and Operation
GF07.04-P-6100V O2 Sensors, Component Description
GF07.04-P-6100V O2 Sensors, Component Description
O2 sensors upstream TWC, location
The O2 sensors upstream TWC are bolted into the exhaust pipe upstream of the catalytic convertors.
Task of the O2 sensors upstream TWC
The O2 sensors upstream TWC (control sensors) are designed as wideband oxygen sensors and detect the residual oxygen content in the exhaust
gas for the following tasks:
- Lambda control
- Self-adaptation of mixture formation
- Function chain tests.
2
The balance resistor (6) is dependent on the overall length (L) and on the type of sensor.
While changing the wideband oxygen sensor, the balance resistor is already fitted on the new sensor and must not be changed (resistance depends
on the sensor).
The broadband oxygen sensor is a planar two-cell limit current sensor which as a result of its modular design integrates several functions.
The sensor element consists of a combination of a Nernst concentration cell (sensor cell) and an oxygen pump cell which transports (pumps) the
oxygen ions. The pump action is a purely physical process.
The sensor is able to measure accurately not only at (Lambda) = 1, but also in the lean and in the rich range.
In combination with the control electronics integrated in the ME-SFI control unit, it supplies within a wide lambda range an unequivocal signal
within a wide lambda range (0.7 < (Lambda) < 4.0).
In the case of the oxygen pump cell oxygen ions are "pumped" from the cathode to the anode when an electric voltage is applied to the zirconium
dioxide ceramic.
The oxygen pump cell and the Nernst concentration cell are arranged in such a way as to produce a diffusion gap of about 10 - 50 (Micro)m
between them.
Two porous platinum electrodes, a pump electrode and a Nernst measuring electrode are located within this gap.
The diffusion gap is connected to the exhaust gas by means of a gas inlet hole. The porous diffusion barrier in this case limits the extent to which
the oxygen molecules are able to continue flowing.
As a result of this, provided the pump voltage is sufficient, a limit current is produced which is proportional to the oxygen concentration in the
exhaust gas. The reference electrode of the Nernst concentration cell is exposed to the ambient air by means of an opening in the reference air
passage. The components of the exhaust gas diffuse through the diffusion gap to the electrodes of the oxygen pump cell and of the Nernst
concentration cell where they are brought into a thermodynamic equilibrium.
3
The electronic circuit in the ME-SFI control unit controls the pump flow through the oxygen pump cell in such a way as to maintain a constant
composition of the gas in the diffusion gap (Lambda) = 1. This corresponds to a voltage at the Nernst concentration cell of U(N) = 450 mV. The
current required to do this (pump flow), is converted by the ME-SFI control unit into a lambda value.
If the exhaust gas is "lean", U(N) < 450 mV and the pump cell is actuated in such a way that oxygen is pumped out of the diffusion gap.
if the exhaust gas is rich, U(N) > 450 mV and the direction of flow is reversed in such a way that the pump cell pumps oxygen into the diffusion
gap.
Based on the law of diffusion the pump flow in this case is proportional to the oxygen concentration in the exhaust.
An integrated sensor heating system ensures that it remains at the required operating temperature of approx. 750 °C. To ensure the sensor function
during engine operation, the broadband sensor is heated constantly.
The temperature control and temperature measurement (by measuring the internal resistance) is performed by the ME-SFI control unit with an
internal control electronics.
As a result of its wide control range and its constant sensor characteristic, the wideband oxygen sensor can be used for lambda control of < 0.7 and
(Lambda) < 4. It therefore also influences leaner and richer air-fuel mixture compositions, for example during deceleration fuel shutoff or when the
engine is warming up.
With these characteristics, these sensors are also suitable for lambda control of gasoline engine lean-burn concepts, diesel engines and gas engines.
1
The ME engine control unit determines the lambda mean value from signals from the O2 sensors downstream of TWC. This value is compared with
a stored value for optimum exhaust emissions. If the deviation is too large after a number of measurements, a correction variable (delay time) is
determined for the lambda control. The correction variable (value for new O2 sensor upstream TWC approx. 0) makes it possible to compensate for
aging of the O2 sensor upstream of TWC within certain limits. If the correction variable exceeds the limit value, the O2 sensor upstream of TWC
must be replaced.
The correction values are map-controlled and are implemented by the ME control unit by adapting the fuel injection.
Two sensor control is only enabled when the catalytic convertors have reached their operating temperature and the O2 sensors downstream of TWC
are correct.
If the limit values are exceeded or the plausibility check of the O2 sensor signals is negative, a fault is stored in the fault memory. The stored faults
can be read out and erased with the STAR DIAGNOSIS.
The effect of the firewall catalytic converters is monitored based on the O2 sensor signals downstream of TWC.
1
GF07.61-P-3025V O2 Sensor Heater Function
GF07.61-P-3025V O2 Sensor Heater Function
The purpose of the O2 sensor heater is to rapidly heat up the O2 sensors to their operating temperature while preventing damage to the sensor
ceramic as a result of controlled heating.
O 2 sensor downstream TWC (Lambda discrete sensor)
The sensor heater of the O2 sensors downstream of TWC is actuated via GND and pulsed by the ME control unit. The mean pulsed heating current
is approx. 400 mA in idle speed range. The current in the cold state is increased approximately by the factor 4. The sensor heater is switched off at
coolant temperatures below approx. 20 °C and at high engine speeds as a protection for the sensor ceramic.
O2 sensor upstream of TWC (broadband oxygen sensor)
The O2 sensors upstream of TWC are heated continuously during engine operation, to guarantee their function.
Temperature control and temperature measurement (by means of an internal resistance measurement) are performed by the ME control unit by
means of a special internal control electronics.
Voltage supply to the sensor heater takes place fused over the relay for circuit 87. Every sensor heater has its own short circuit-proof output stage
with diagnosis switching to ground in the engine control unit.
1
GF07.61-P-4022V ME-SFI Lambda Control, Function
GF07.61-P-4022V ME-SFI Lambda Control, Function
The mixture composition is maintained within limits as close as possible to (Lambda)=1 in order to achieve a high conversion of the exhaust gases
in the catalytic converter.
The O2 sensors detect the oxygen share in the exhaust and transmit corresponding signals to the ME-SFI [ME] control unit. This changes the
mixture composition so that in all engine operating statuses, the desired oxygen (usually (Lambda)=1) is set.
This procedure is repeated (control loop), the control speed is dependent on engine load and speed.
The lambda closed-loop control is operational in the following operating conditions (closed-loop control):
- Coolant temperature > approx. -10 ° C,
- Blocking time after starting expired
- O2 sensors upstream CAT have reached operating temperature
2
Lambda control loop
Assuming a leaner air/fuel mixture is produced. The consequence of this is that the O2 sensor voltage drops and the ME-SFI [ME] control unit
compensates for this lean drift by enriching the mixture accordingly.
This makes it possible to achieve an air/fuel composition of approximately (Lambda) =1. The reading of the lambda control factor with the STAR
DIAGNOSIS moves towards +25% The more the lambda control factor moves towards +25%, the leaner is the air/fuel mixture and the greater is
the enrichment of the mixture on the part of the ME-SFI [ME] control unit.
3
1
Oxygen Sensor: Service and Repair
AR07.52-P-5303QB Remove/Install Heated O2 Sensor
2
Steps 1 - 11
O2 Sensor
Special Tools
3
Repair Materials
1
Malfunction Indicator Lamp: Description and Operation
GF54.30-P-5011V Check Engine Indicator Lamp, Component Description
Check Engine Indicator Lamp, Component Description
Location
The CHECK ENGINE indicator lamp is located in the instrument cluster.
Task
To indicate faults in the fuel injection system.
Function
The indicator lamp is actuated by the instrument cluster via a CAN message from the engine control unit. To check it is functioning properly, the
indicator lamp lights up for approx. 1 second at ignition "ON" and from an engine speed of approx. 500 rpm. The indicator lamp goes out if there
are no faults present.
1
Malfunction Indicator Lamp: Description and Operation
GF54.30-P-5011V Component Description For the "Check Engine" Indicator Lamp
GF54.30-P-5011V Component Description For The "CHECK ENGINE" Indicator Lamp
- with CODE (494) USA version
Location
The "CHECK ENGINE" indicator lamp is located in the instrument cluster.
Task
To indicate faults in the fuel injection system
Function
The indicator lamp is actuated by the instrument cluster via a CAN message from the engine control unit. To check the function it lights up with
ignition on ON and as of an engine speed of approx. 500 rpm for approx. 1 s. If there is no fault, the indicator lamp goes out
1
Information Bus: Description and Operation
GF54.00-P-0005VA CAN Data Bus, Function

GF54.00-P-0005VA CAN Data Bus, Function
CAN stands for "Controller Area Network". This is an electrical bus system for carrying data over two wires.
The tasks are:

- Data exchange between individual control units
- Readying sensor signals for several systems
- Reducing the number of electrical lines
- Improving the electromagnetic compatibility (EMC)
The CAN data bus consists of a special twisted two-core data line that connects all CAN subscribers (control units) in parallel.
The two lines of the data line must not be swapped (low level/high level). The motor electronics (N3/10) control unit is always a consumer with
regard to bus adaptation.
A 120 Ohms terminating resistor is therefore installed in the motor electronics control unit.
The data are transmitted digitally over the CAN databus at various intervals. The individual data blocks are defined in a data protocol and it is
specified which data are received or transmitted by a control unit. Each connected control unit is able to transmit or receive data (bidirectional bus).
The sum of the data blocks, the short break between the two transfer intervals and other properties of the CAN data bus are checked constantly.
Detected faults are stored and placed in the fault memory.
In the vehicle a distinction is made between the fast (500 kbit/s) engine compartment data bus and diagnostic CAN-data bus and the slower (83.3
kbit/s) interior CAN data buses.
The new control unit must be coded when a control unit is replaced. This control unit coding takes place via a STAR DIAGNOSIS menu.
The international standardized network management "OSEK" ( Open systems and their Interfaces for Electronics in motor vehicles) is used for all
control units of the CAN data bus.
GF54.00-P-0005-01A CAN Data Bus Data Telegram
GF54.00-P-0005-01A CAN Data Bus Data Telegram
During normal operation, messages consist of the following transfer frames:

^ Data frame
for transmitting CAN messages (such as coolant temperature, etc.).
^ Remote frame
for requesting CAN data from a different control unit.
^ Error frame
informs all connected control units that an error has occurred and that the most recent CAN message is invalid.
The CAN protocol supports two different data frame formats, with the only difference residing in the length of the identifier:
- the standard format
- the expanded format
Only the standard format is currently in use at DaimlerChrysler.
2
The data telegram for transmitting CAN messages through the CAN data bus consists of seven sequential blocks:
- Start of Frame: marks the start of a CAN message
(Start bit) and synchronizes all stations.
- Arbitration Field: This field consists of an identifier

(identifier and ) (address) with 11 bits and a control bit
Request) (Remote Transmission Request-Bit). This
control bit indicates if the message contains a data frame or a remote frame without bytes.
- Control Field: To distinguish between the standard and extended format the Control Field (6 Bit) contains the
(control bits) IDE- bit (Identifier Extension Bit), a reserved bit for future expansions and in the last 4 bits the number of data bytes
contained in the data field.
- Data Field: The data field can contain between 0 and 8 Bytes
(data) of data contained. A CAN message with a length of 0 can be employed to synchronize distributed processes.
- CRC Field: The CRC Field (Cyclic-Redundancy Check Field)

(check field) comprises 16 Bit and serves as security for detecting transmission errors.
- ACK Field: The ACK Field (Acknowledgment Field) contains a

(confirmation of confirmation signal from all recipients which
receipt) have received the CAN message free from faults.
3
- End of Frame: Identifies the end of the data telegram

(frame end)
- Intermission: Interval between two data telegrams The

(interval) interval must contain at least 3 bits. The next message can then be sent by any control unit.
- IDLE: If no control unit transmits, the CAN data bus in idle

(bus idle) condition until the next data telegram is sent.
GF54.00-P-0005-02A CAN Data Bus Specification
GF54.00-P-0005-02A CAN Data Bus Specification
In order to be able to process data in real time, it must be possible to transfer data quickly.
This presupposes not only a quick physical data path but also demands a quick CAN data bus division when multiple control units simultaneously
want to transfer.
To distinguish between the importance of different CAN messages that are being sent over the CAN data bus there exists priorities for the
individual messages.
The ignition angle, for example is assigned high priority, the slip value medium priority and the outside temperature has a lower priority.
The priority by which the CAN message is established is through the identifier of the (address) particular CAN message.
An identifier which corresponds to a low binary number has a high priority and vice versa.
The Controller Area Network event log is based on two logical conditions: The bits are either "recessive state" (logical 1) or "dominant state"
(logical 0). If a dominant bit is sent by at least one station, recessive bits sent by other stations are overwritten.
Example
If several control units transmit a message at the same time, the conflict of bus access is solved by means of bus arbitration using the appropriate
identifiers.
The transmitter checks every bit when the arbitration field is sent whether it is able to be sent or whether another control unit is sending a CAN
transmission of higher priority.
If a recessive bit transferred by the first sending unit is overwritten by a dominant bit from another sending unit, the first sending unit looses its
right to transmit (arbitration) and it becomes a receiver.
The first control unit (N I) looses arbitration with bit 3.
The third control unit (N III) looses arbitration with bit 7.
The second control unit (N II) retains bus access and can send its CAN message.
The other control units then try to send their CAN messages when the CAN data bus is free.The send authorization is then allocated again in
accordance with the priority of the CAN message.
GF54.00-P-0005-03A CAN Data Bus Fault Recognition
GF54.00-P-0005-03A CAN Data Bus Fault Recognition
Faults which occur during data transfer can result in errors. These transmission errors must therefore be detected and rectified. A distinction is made
between two levels of fault identification in the CAN protocol:
^ Mechanisms at the data frame level
^ Mechanisms at the bit level
Mechanisms at the data frame level
Cyclic redundancy check:
4
The transmitter establishes test bits from the CAN messages that are to be sent in the data telegram "CRC Field". The receiver calculates these test
bits from the received CAN message and compares them to the received test bits.
Frame check:
This mechanism checks the structure of the transferred frame by comparing the bit fields with the specified fixed format and frame length.
Errors detected using the frame check are referred to as format errors.
Mechanisms at the bit level
Monitoring:
During transmission every station observes the CAN data bus gauge and recognizes the difference between sent and received bits. Both global and
local bit errors which occur at the sending unit can therefore be detected.
Bit stuffing:
In each message, a maximum of 5 successive bits may have the same polarity between the "start of frame" and the end of the "CRC field". After 5
consecutive identical bits, the sending unit inserts a bit of the opposite polarity into the bit stream. The receiver removes these bits again after the
CAN message reception.
Error handling
If any station on the CAN data bus detects an error, it interrupts the current transmission by sending an error message. The error message consists
of 6 dominant bits. When an error message appears a local error is distributed to all the connected control units so that they ignore the transmitted
CAN message.
After a short interruption the other control units can transmit CAN messages again according to their priority.
The control unit whose CAN message caused the error also begins to send its CAN message again (Automatic Repeat Request).
GF54.00-P-0005-04A CAN Data Bus Applications
GF54.00-P-0005-04A CAN Data Bus Applications
Application areas for the CAN data bus
At this time different CAN data bus systems are used for the engine compartment and the passenger compartment. They differ from one another by
the rate of transmission.
The CAN engine compartment (CAN C) has a transfer rate of 500 kbit/ sec, the CAN interior (CAN B) has only a transfer rate of 83 kbit/sec on
account of less time-critical CAN messages.
Data is exchanged between the two data bus systems via so-called "Gateways", control units which are connected to both.
CAN C/CAN engine compartment
On the last control unit on each side there is a so-called data bus terminator, a resistor with 120 ohms, which is connected between the two lines.
The CAN engine compartment is only active when the ignition is turned on.
CAN B/CAN passenger compartment
Many of the control units that are found in the CAN passenger compartment are not dependent upon the activation of the ignition (for example,
central locking).
In this case the CAN passenger compartment has to be accessible with out ignition. This means that it can transmit data telegrams without the
ignition being activated.
To keep the resting energy consumption as low as possible the CAN data bus goes into a "sleeping mode" if no data telegrams are being transmitted
and is activated again when the data bus is accessed. If when the Controller Area Network interior is "sleeping" a control unit (e.g. on model 202:
overhead control panel control unit (N70)) transmits a CAN message, the CAN message is only received by the master (e.g. on model 202: EIS
[EZS] control unit (N73)). The respective master control unit stores the CAN message, and transmits a wake-up message) to all control units on the
CAN interior. For "wake-up" the control unit (N73) checks the presence of all participants on the CAN data bus and then sends the message stored
previously.
GF54.00-P-0005A CAN Data Bus, Function

GF54.00-P-0005A CAN Data Bus, Function
5
The CAN data bus (Controller Area Network) is a data bus system specially designed for use in the motor vehicle.
The CAN data bus is a bi-directional bus, that is, each connected control unit is able to send and receive information.
The CAN data bus consists of a special twisted two-core cable. The users (control units) are connected to this cable. Transmission of data takes
place redundantly via both cables, whereby the data bus levels are mirrored (that is, if the level on one cable is 0, the other cable transmits level 1
and vice versa). Two-line operation is used for two reasons: for fault detection and as a safety concept.
If a voltage peak occurs on just one line (e.g. due to EMC problems), the receivers can identify this as a fault and ignore the voltage peak.
If a short circuit or a discontinuity occurs on one of the two CAN lines, then due to a safety concept coupled to the software/hardware, the system
can change over to single-line operation. The defective data line is shut down.
A specific data protocol controls how and when the participants can send and receive.
The CAN data bus is significantly different to other data bus systems that are based on the participant addressing principle, in that it uses a
message-related addressing system, which identifies the CAN message content (e.g. coolant temperature). The CAN log permits up to 2048
different CAN messages, the addresses of 2033 to 2048 being permanently assigned. Data capacity per CAN message is 8 bytes.
A recipient only evaluates those CAN messages (data messages) which are stored in its list of CAN messages to be accepted (acceptance filtering).
Data messages can only be sent when the CAN data bus is free (i.e. once a 3 bit interval has elapsed after the last data message, and no control unit
starts to send). The data bus level is then in recessive state (logical 1).
If several control units simultaneously start to send, a procedure is applied whereby the CAN message with the highest priority takes precedence,
without loss of time or bits (attributing).
Each control unit which looses the attributing becomes a receiver automatically and repeats its transmission attempt as soon as the CAN data bus is
free again.
Besides data messages, there is also a request message used for calling a particular CAN message. The control unit that can provide the requested
data message then reacts to the request.
GF54.00-P-0004-03A Data Bus System, Block Diagram

GF54.00-P-0004-03A Data Bus System, Block Diagram
All control units are interlinked through the CAN data bus.
A control unit receives a measured value from a sensor, prepares a data telegram from this and places it on the CAN data bus.
All other control units can then read and process this data packet.
GF54.00-P-0004-04A Data Bus System, Advantages
GF54.00-P-0004-04A Data Bus System, Advantages
With the former wiring of the individual electrical and electronic components (standard wiring) each control unit is directly connected to all sensors
and actuators, from which it obtains measured values or which it actuates.
In some cases, this can result in long or redundant cable runs. The data bus system affords the following advantages relative to conventional wiring:
6
GF54.00-P-0004A Data Bus System Function

GF54.00-P-0004A Data Bus System Function
A data bus connects the individual control units and enables them to exchange data.
The signal from a sensor is passed on to the nearest control unit, processed by it and placed on the CAN data bus.
Each control unit that is connected to the CAN data bus can read this signal and use it to calculate an input to control an actuator.
GF82.00-P-2001A Wake-Up, Function

GF82.00-P-2001A Wake-up, Function
7
Normal wake-up
Because the transmission and reception diodes along with the digital data bus (D2B) system chip are automatically switched off when not required
(sleep mode), at the start of a new data transfer a wake-up pulse is required to activate the system. This is accomplished via the separate wake-up
line. To this end, the master unit actuates a wake- up signal (electrical signal), which reduces the voltage in the wake- up line to a defined value.
The digital data bus (D2B) system's chip in the components recognizes that the signal is a wake-up one based on the duration of the signal, and the
digital data bus (D2B) is activated. The digital data bus (D2B) is then in activated status. A "wake-up" can take place in a deactivated system (sleep
mode) even without a wake-up pulse from the master unit through activation of a component installed in the digital data bus (D2B).
Wake-up diagnosis
For the purpose of diagnosing the wake-up circuit in the components, the master unit can be induced using STAR DIAGNOSIS via the data link
connector (X11/4) to actuate a wake-up diagnosis signal. This signal differs from the wake-up signal due to its distinctly greater duration. For their
part, the components respond to this long wake-up pulse with a signal on the wake-up line (message to the master unit). This enables the master
unit to recognize which components have received the long wake-up pulse. The diagnosis wake-up signal can only be actuated, if the digital data
bus (D2B) is unable to be activated because of a fault. If all components answer the master unit, the voltage supply is correct.
GF00.19-P-0001-02PM Overall Network (GVN), Networking of Components
GF00.19-P-0001-02PM Overall Network (GVN), Networking Of Components
- MODEL 203.0 /2 /7 as of 24.4.04
- except CODE (494) USA version
- except CODE (498) Japan version up to Model Year 8
A1 Instrument cluster
A2 Radio (with code (523) MB Audio 20 radio)
A2/56 Radio and navigation unit (for code (525) MB Audio 50 APS radio)
A6n1 STH control unit (with code (228) Stationary heater)
A40/3 COMAND operating, display and controller unit (with code (527) COMAND APS with single DVD drive (with navigation system))
N2/7 Restraint systems control unit
N3/9 CDI control unit (with diesel engine)
N3/10 ME-SFI [ME] control unit (with gasoline engine)
N10/1 Front SAM control unit with fuse and relay module
N15/3 ETC control unit (with transmission 722.6)
N15/5 Electronic selector lever module control unit (with transmission 722)
N22 AAC control and operating unit (without code (581) Comfort automatic air conditioning)
N22/7 Comfort AC control and operating unit (with code (581) Comfort automatic air conditioning)
N26/9 Special vehicle multifunction control unit (SVMCU [MSS]) (for special-purpose vehicles)
N28/1 Trailer recognition control unit (with code (550) trailer hitch)
N32/1 Driver-side front seat adjustment control module with memory (with code (275) driver seat, steering column and electrically adjustable
outside mirror with memory)
N32/2 Passenger-side front seat adjustment control unit with memory (with code (242) Electrically adjustable front passenger seat with memory)
N47-5 ESP and BAS control unit
N62 PTS control unit (with code (220) Parktronic system (PTS))
N69/1 Door control unit front left
8
69/2 Door control unit front right
N69/3 Left rear door control unit (model 203.0/2)
N69/4 Right rear door control unit (model 203.0/2)
N70 Overhead control panel control unit
N72 Lower control panel control unit (with code (228) Stationary heater or for special-purpose vehicles)
N73 EIS [EZS] control unit
N80 Steering column module
N93 Central gateway control unit (up to 27.7.04)
Y3/8n4 Fully integrated transmission control (VGS) control unit (with transmission 722.9)
CAN-B Controller Area Network bus class B (interior compartment) (CAN-B)
CAN-C Controller Area Network bus, class C (engine compartment) (CAN-C)
MOST Media Oriented System Transport (MOST)
A2 Radio
A2/6 CD player with changer (in glove box) (for code (819) 6-disk CD changer)
A2/13 Sound amplifier (with code (810) Sound system)
A2/56 Radio and navigation unit
A35/11 Voice control system control unit (with code (813) Voice control system (VCS [SBS]))
A40/3 COMAND operating, display and controller unit
N123/1 UPCI (Universal Portable CTEL Interface) control unit (with code (386) Preinstallation for telephone "Handy", UPCI system)
CAN B Controller area network bus class B (interior compartment) (CAN B)
GF00.19-P-0001-02PMJ Overall Network (GVN), Networking of Components
GF00.19-P-0001-02PMJ Overall Network (GVN), Networking Of Components
- MODEL 203.0 /2 /7 as of 24.4.04 with CODE (498) Japan version up to Model Year 8
9
A2 Radio (without code (529) HIGH Class Japan)
N3/10 ME control unit N10/1 Front SAM control unit with fuse and relay module
N69/2 Door control unit front right
N80 Steering column module N93 Central gateway control unit (up to 27.7.04)
N93/1 Audio gateway control unit (with code (529) HIGH Class Japan)

10
A2 Radio
A35/1 Hands-free system control unit
A40/3 COMAND operating, display and controller unit (with code (529) HIGH Class Japan)
N93/1 Audio gateway control unit
CAN B Controller area network bus class B (interior compartment) (CAN B)
GF00.19-P-0001-02PMU Overall Network (GVN), Networking of Components
GF00.19-P-0001-02PMU Overall Network (GVN), Networking Of Components
- MODEL 203.0 /2 /7 as of 24.4.04 with CODE (494) USA version up to Model Year 8
A2 Radio (without code (530) COMAND APS USA (with navigation system))
A40/3 COMAND operating, display and controller unit (with code (530) COMAND APS USA (with navigation system))
N2/13 WSS (Weight Sensing System) control unit
N3/10 ME control unit
11
N123/4 Emergency call system control unit
CAN-D Controller Area Network bus class D (diagnosis) (CAN-D)
A2 Radio
A40/3 COMAND operating, display and controller unit
N87/5 SDAR control unit (with code (536) SIRIUS satellite radio)
CAN-B Controller area network bus class B (interior compartment) (CAN B)
GF00.19-P-0001PM Overall Network (GVN) Function
GF00.19-P-0001PM Overall Network (GVN) Function
- MODEL 203.0 /2 /7 as of 24.4.04 up to Model Year 8
Illustrated on model 203.0
12
A2 Radio (with code (523) MB Audio 20 radio, without code (529) HIGH Class Japan, without code (530) COMAND APS USA (with
navigation system))
A2/56 Radio and navigation unit (for code (525) MB Audio 50 APS radio)
A6n1 STH control unit (with code (228) Stationary heater)
A35/1 Hands-free system control unit (only (J))
A40/3 COMAND operating, display and controller unit (with code (527) COMAND APS with single DVD drive (with navigation system) or
with code (529) HIGH Class Japan or with code (530) COMAND APS USA (with navigation system))
N2/13 WSS (Weight Sensing System) control unit (only (USA))
N3/9 CDI control unit (with diesel engine)
N3/10 ME-SFI [ME] control unit (with gasoline engine)
N26/9 Special vehicle multifunction control unit (SVMCU [MSS]) (for special-purpose vehicles)
N72 Lower control panel control unit (with code (228) Stationary heater or for special-purpose vehicles)
N87/5 SDAR control unit (with code (536) SIRIUS satellite radio)
N93/1 Audio gateway control unit (with code (529) HIGH Class Japan)
N123/4 Emergency call system control unit (only (USA))
Gateways:
The following control units form interfaces for the data exchange between CAN-C and other bus systems:
13
- EIS [EZS] control unit or central gateway control unit
(interface to CAN-B and CAN-D)
CAN-D
An external tester (e.g. STAR DIAGNOSIS) can be connected via CAN-D. Furthermore, it is responsible for the data transfer of the emergency call
system control unit.
The CAN-D operates at a transfer rate of 500 kbits/s.
The following control units are connected to CAN-D:

- EIS [EZS] control unit or central gateway control unit
- Emergency call system control unit
- External tester (e.g. STAR DIAGNOSIS)
Gateways:
The following control units form interfaces for the data exchange between CAN-D and other bus systems:
- EIS [EZS] control unit or central gateway control unit (interface to CAN-B and CAN-C)
MOST
MOST is an optical networking system. Here, data is transferred via fiber optic cables to the connected information, navigation, and communication
components. The MOST operates with a transfer rate of 22 Mbits/s.
The following control units are connected to MOST:

- Radio or COMAND
- CD player with changer (in glove compartment)
- Sound amplifier
- Hands-free system control unit
- Voice control system control unit
- SDAR control unit
- Audio gateway control unit
- Universal Portable CTEL Interface (UPCI [UHI]) control unit
Gateways:
The following control units form interfaces for the data exchange between MOST and other bus systems:
- Radio, COMAND or audio gateway control unit (interface to CAN-B)
Steering column module and instrument cluster

Although the instrument cluster and the steering column module are linked to both CAN-B and CAN-C, they are not used as an interface (gateway).
14
15
16
1
Information Bus: Procedures
Notes On Fiber Optical Cable
Position of the identification
For vehicle models 170, 202, 203, 208, 210, 215, 220, 230, 463 an identification plate is located on the fiber optical cable wiring harness behind the
radio on which the fiber optical cable modules (1, 2, 3, 4) specially fitted to these vehicles are specified together with their exact length.
With models 129, 414 the identification plate is in the trunk next to the CD changer.
With model 168, the identification plate is in the passenger footwell in the area of the control unit box. If there is no length specification on the
identification plate, the respective fiber optical cable module must be removed and the necessary length measured.
NOTE:
- Vehicle model 163 doesn't have any identification plate.
- With repairs, the individual fiber optical cable modules with corresponding length specification can be ordered (see spare-parts
documentation Group 82).
Routing
2
The inserts (5) of the fiber optical cable modules may only be routed as in production. The fiber optical cable modules must always be provided
with a protective cap when routing. For every vehicle model, the sequence of components in the D2B ring is specifically predetermined. The
components are connected by fiber optical cable modules They are secured to a wiring harness with an orange-colored casing.
CAUTION: Danger of breaking. Do not kink fiber optical cable, route over sharp edges or bend in radii smaller than 25 mm. Tensile forces on
inserts must not exceed 65 N.
The fiber optical cable must not be exposed to temperatures greater than 85 degree C or lower than -40 degree C. Do not squeeze fiber optical
cable, in other words do not compress with clamps or tie straps.
Connection between the devices
The Digital Data Bus ring (D2B) connects the new radio generation and COMAND (monitor) to the CD changer (CDC) (USA preinstallation),
telephone and portable CTEL. The sound amplifier remains wired as before with models 129, 170, 202, 208 and 210. The radio and COMAND as
head unit (HU) performs the master function and also forms the interface to the Control Area Network bus Class B (interior) (CAN-B) (for vehicles
with multifunction steering wheel).
Ring sequence of vehicles/models/interface
Model 129 HU - telephone (or Tele Aid) - CDC - HU

Model 163 HU - sound - CDC - telephone (or Tele Aid) - HU
Model 168 HU - telephone - CDC - HU
Model 170 HU - telephone - HU (ECE); HU - CDC - HU (Japan)
Model 202/208 HU - CDC - telephone (or Tele Aid) - VCS - HU
Model 203/209 HU - sound - portable CTEL interface - VCS - CDC - HU
Model 210 HU - CDC - VCS - telephone (or Tele Aid) - HU
Model 215/220 HU - sound - CDC - telephone (or Tele Aid) - VCS - optional portable CTEL interface - HU
Model 230 HU - Sound - CDC - Telephone (or TELE AID) - VCS - HU
Model 414/463 HU - CDC - telephone - HU
NOTE: The sequence represents the current maximum equipment.If special equipment (SA) is omitted, the respective item is deleted, resulting in
a new ring sequence.
Read out actual configuration using STAR DIAGNOSIS
As of September 1999 it is possible to read out the current actual configuration of a functioning D2B ring by means of STAR DIAGNOSIS.
This is particularly important in the case of later expansion of the D2Bring and when retrofitting D2B components
e.g. telephone.
In the diagnosis system there is the menu item "Retrofitting D2B components". Under this menu item, the current actual configuration of a vehicle
can be read out and written back immediately as a new nominal configuration. The process is self-explanatory.
1
Information Bus: Removal and Replacement
Notes On Fiber Optical Cable
Position of the identification
For vehicle models 170, 202, 203, 208, 210, 215, 220, 230, 463 an identification plate is located on the fiber optical cable wiring harness behind the
radio on which the fiber optical cable modules (1, 2, 3, 4) specially fitted to these vehicles are specified together with their exact length.
With models 129, 414 the identification plate is in the trunk next to the CD changer.
With model 168, the identification plate is in the passenger footwell in the area of the control unit box. If there is no length specification on the
identification plate, the respective fiber optical cable module must be removed and the necessary length measured.
NOTE:
- Vehicle model 163 doesn't have any identification plate.
- With repairs, the individual fiber optical cable modules with corresponding length specification can be ordered (see spare-parts
documentation Group 82).
Routing
2
The inserts (5) of the fiber optical cable modules may only be routed as in production. The fiber optical cable modules must always be provided
with a protective cap when routing. For every vehicle model, the sequence of components in the D2B ring is specifically predetermined. The
components are connected by fiber optical cable modules They are secured to a wiring harness with an orange-colored casing.
CAUTION: Danger of breaking. Do not kink fiber optical cable, route over sharp edges or bend in radii smaller than 25 mm. Tensile forces on
inserts must not exceed 65 N.
The fiber optical cable must not be exposed to temperatures greater than 85 degree C or lower than -40 degree C. Do not squeeze fiber optical
cable, in other words do not compress with clamps or tie straps.
Connection between the devices
The Digital Data Bus ring (D2B) connects the new radio generation and COMAND (monitor) to the CD changer (CDC) (USA preinstallation),
telephone and portable CTEL. The sound amplifier remains wired as before with models 129, 170, 202, 208 and 210. The radio and COMAND as
head unit (HU) performs the master function and also forms the interface to the Control Area Network bus Class B (interior) (CAN-B) (for vehicles
with multifunction steering wheel).
Ring sequence of vehicles/models/interface
Model 129 HU - telephone (or Tele Aid) - CDC - HU

Model 163 HU - sound - CDC - telephone (or Tele Aid) - HU
Model 168 HU - telephone - CDC - HU
Model 170 HU - telephone - HU (ECE); HU - CDC - HU (Japan)
Model 202/208 HU - CDC - telephone (or Tele Aid) - VCS - HU
Model 203/209 HU - sound - portable CTEL interface - VCS - CDC - HU
Model 210 HU - CDC - VCS - telephone (or Tele Aid) - HU
Model 215/220 HU - sound - CDC - telephone (or Tele Aid) - VCS - optional portable CTEL interface - HU
Model 230 HU - Sound - CDC - Telephone (or TELE AID) - VCS - HU
Model 414/463 HU - CDC - telephone - HU
NOTE: The sequence represents the current maximum equipment.If special equipment (SA) is omitted, the respective item is deleted, resulting in
a new ring sequence.
Read out actual configuration using STAR DIAGNOSIS
As of September 1999 it is possible to read out the current actual configuration of a functioning D2B ring by means of STAR DIAGNOSIS.
This is particularly important in the case of later expansion of the D2Bring and when retrofitting D2B components
e.g. telephone.
In the diagnosis system there is the menu item "Retrofitting D2B components". Under this menu item, the current actual configuration of a vehicle
can be read out and written back immediately as a new nominal configuration. The process is self-explanatory.
1
Central Electronics Box: Procedures
SM54.18-P-0009P Seal Module Box Wiring Harnesses
Operation No. Of Operation Texts Or Standard Texts And Flat Rates
Steps 1 - 8
Parts Ordering Notes
1
Central Electronics Box: Removal and Replacement
AR54.20-P-2360P Remove, Install Module Box
2
Steps 25 - 36
1
Electronic Throttle Actuator: Description and Operation
GF30.20-P-2020V Component Description For the Throttle Valve Actuator
Component Description For The Throttle Valve Actuator
Location
The throttle valve actuator is flanged to the intake manifold at the rear.
Task
The throttle valve actuator regulates the functions:

- Idle speed
- Drive mode, according to accelerator pedal position, load and requests of momentary interface
- Engine 272.985: In stratified charge operation with excess air open the throttle valve as wide as possible depending on the performance map.
- Cruise control mode
- Emergency electronic accelerator pedal
2
Function
The actuator motor (M16/6m1) in the throttle valve actuator (M16/6) adjusts the opening angle of the throttle valve (1) continuously from approx. 0
to 90 degree according to presets from the ME control unit.
The typical power consumption of the pulse width modulation signal is approx. 1 A, however it is possible up to approx. 9 A. For output stage
protection the power is limited to 6 A after approx. 30 seconds.
The actual value potentiometers (M16/6r3, M16/6r4) report the current position of the throttle valve to the ME control unit. The signals of both
actual value potentiometer are opposed.
A. Ignition "Off"
In a deenergized state, throttle valve position is determined by the spring capsule (3) (8 up to 10 degree opening angle).
B. Ignition "On"
When the ignition is switched on, the actuator motor in the throttle valve actuator is operated by the ME control unit.
The throttle valve adopts a position which depends on the coolant temperature.
c. Idle speed
Depending on the coolant temperature and engine load, the actuator motor changes the rpm in the idle speed range by opening the throttle
valve further (increased mixture) or closing it further. (less mixture). Here the throttle valve can be closed further by the actuator motor
against force of the spring capsule.
D. Driving mode
In the driving mode (full / partial load), the actuator motor changes the throttle valve position depending on the different load states and / or
according to the input signals from the accelerator pedal sensor dependent on the performance maps.
E. Emergency running
If the actuator is deenergized, the throttle valve is set by the spring capsule to approx. 8 to 10 degree opening angle. In the idle speed range,
this results in an engine speed of approx. 1200 to 1400 rpm.
For first time connection of the throttle valve actuator to circuit 30 or 87, the ME control unit carries out the following actions automatically within
approx. 60 seconds:
- Determination of the emergency running position
- Determination of the lower mechanical stop
- Adaptation of the actual value amplifier (signal 1 and 2) in the ME control unit.
- Checking the return spring (always takes place when ignition ON) Prerequisite: gear P or N, vehicle stationary, engine OFF, ignition ON,
coolant temperature 5 degree C to 100 degree C and accelerator pedal not operated. The procedure must be activated with STAR
DIAGNOSIS, if the throttle valve actuator or the ME control unit was replaced, otherwise engine surges can occur.
1
GF30.20-P-3012V ME-SFI Electronic Accelerator, Function
GF30.20-P-3012V ME-SFI Electronic Accelerator, Function
The electronic accelerator function is integrated and controlled in the motor electronics control unit depending on the driver input and the operating
condition, the opening angle of the throttle valve.
Input signals for the electronic accelerator pedal:

- Accelerator pedal position
- Brake actuation (from ESP control unit)
- Cruise control operation (from ESP control unit)
- Engine torque requirements (via CAN)
- Gear ranges (over electronic selector lever module control unit (N15/5)) (for automatic transmission 722.9)
- Clutch operating system (for manual transmission 716.6)
- Reverse travel (for manual transmission 716.6)
The position of the accelerator pedal and speed at which the position of the accelerator pedal changes are transmitted to the sensor located on the
accelerator pedal mechanically. The Hall sensor in the accelerator pedal sensor sends an appropriate voltage signal to the ME-SFI [ME] control
unit. The ME-SFI [ME] control unit analyzes the voltage signal and, depending on the performance map, activates the throttle valve actuator. The
opening angle of the throttle valve is altered appropriately by the actuator motor (M16/6m1) in the throttle valve actuator.
The opening angle is only determined by the accelerator pedal request if no limiting functions are active (e.g. idle request or a torque reduction).
The throttle valve actual value potentiometer (M16/6r1) reports the current throttle valve position back to the ME-SFI [ME] control unit.
Throttle valve damping
The throttle valve damping function closes the throttle valve up to the idle speed range with a time delay if the accelerator pedal is suddenly
released. In this way, the engine torque goes down slowly and the vehicle does not slow down with jerks.
Following input signals are processed:

- Change in the speed of the accelerator pedal position.
- Engine speed
- Throttle valve position
- Vehicle speed
Reversing
If the ME-SFI [ME] control unit recognizes a reverse travel, the throttle valve will be opened more slowly and the maximum opening angle limited
to about 50%. This function has the task of optimizing ride comfort and safety when reversing.
Adaptive accelerator pedal
The ME-SFI [ME] control unit evaluates how the accelerator pedal is being actuated and switches between characteristic curves. After a 50% pedal
2
travel, about 80% of the engine load is released for a sporty driver and 40% of the engine load is released for a quiet driver.
There is no further difference felt above a pedal travel of about 90%.
If, for example, the characteristic curve for a quiet driver is active after a long drive on the freeway then the accelerator pedal must be pressed down
unusually hard to obtain a higher acceleration level.
Additional functions of the electronic accelerator pedal:

- Cruise control (CC [TPM])
- Torque interface
- Emergency running
If the brake pedal is operated, this always means idle speed input.
1
GF30.20-P-4026V Electronic Accelerator Pedal Emergency Running Mode, Function
GF30.20-P-4026V Electronic Accelerator Pedal Emergency Running Mode, Function
The task of the emergency running consists of enabling a safe continuation of journey if interference occurs at the electronic accelerator.
Accelerator pedal sensor, emergency mode
If a Hall sensor fails, the system switches over to the second Hall sensor. The throttle valve opening is limited to approx. 60%. In addition, the
throttle valve opening rate is dynamically limited, in other words the throttle valve opens with a time delay.
If the result of the plausibility check is negative, or if both potentiometers are faulty, only the idle speed is then controlled.
Throttle valve actuator, emergency mode (electrical)
If a potentiometer fails, the system switches over to the second potentiometer. The signal from the hot film MAF sensor is used as an additional
comparative size.
If the plausibility check is negative or if both potentiometers are faulty, the throttle valve adopts a mechanical emergency running position (approx.
8 10°) which is fixed by the spring capsule in the throttle valve actuator (EPC malfunction indicator lamp comes on).
Throttle valve actuator, emergency mode (mechanical)
If the actuator motor is defective or there are other faults present the power supply to the throttle valve actuator will be shut off.
The throttle valve is resting against the mechanical stop (spring capsule) as a result of which the throttle valve opening is maintained constantly at
approx. 8 to 10°.
In neutral at engine speeds of > 1400/min, the fuel injection valves are deactivated and at engine speeds of < 1200 rpm actuated again.
While driving, depending on the engine load, engine speed is controlled by switching the cylinders on and off on the fuel side. The maximum
engine speed is approx. 1800 rpm and is fixed by the mechanical stop.
Faults detected by the accelerator pedal sensor and the throttle valve actuator are stored in the diagnostic trouble code memory and can be read out
and deleted with the STAR DIAGNOSIS.
Emergency mode is recognizable on a clearly surging engine running.
1
Electronic Throttle Actuator: Service and Repair
AR07.51-P-1401QB Remove/Install Throttle Valve Actuator
AR07.51-P-1401QB Remove/Install Throttle Valve Actuator
Steps 1 - 12
2
ME Gasoline Injection And Ignition System
1
Electronic Throttle Actuator: Service and Repair
AR30.20-P-1262A Remove/Install Electronic Accelerator Actuator With Flap Connection
AR30.20-P-1262A Remove/Install Electronic Accelerator Actuator With Flap Connection
Shown On M112 Engine
Removing, installing
1 Remove cylinder head cover trim or air filter
NOTE: Removal: Remove air filter housing or cylinder head cover trim by lifting upwards from the cylinder head covers.
Installation: Moisten the retaining rubber on the cylinder head covers and the hot film mass air flow sensor seal in the air cleaner housing
lightly with lubricant.
2 Remove hot film mass air flow sensor together with air intake pipe
3 Remove crank case purge line (1/2)

4 Disconnect electrical connector (arrow)
2
NOTE: Pull catch backwards.
5 Remove electronic accelerator pedal actuator (M16/1)
NOTE: Undo screws (8/1).
CAUTION: Installation: Replace O-ring (8/2).
Refer to Electronic Accelerator Pedal Actuator below
Electronic Accelerator Pedal Actuator
1
Vehicle: Specifications
Alignment Specs
Vehicle Alignment
Vehicle Level
Front Axle
203.0/2
except 4MATIC
except AMG
except MB sports suspension (CODE 486)
except suspension with increased ground clearance (CODE 482)
+4.5° (±1.6)
Permissible difference in vehicle level between right and left side of vehicle
When checking ....................................................................................................................................................................................... 1°
When calibrating with Star Diagnosis ................................................................................................................................................. 0.5°
203.0
with AMG or MB sports suspension (CODE 486)
except 4MATIC
+6.9° (±1.6)
When checking ....................................................................................................................................................................................... 1°
203
with suspension with increased ground clearance (CODE 482)
except 4MATIC
except AMG
+11.2° (±1.6)
When checking ....................................................................................................................................................................................... 1°
203.2
with AMG or MB sports suspension (CODE 486)
except 4MATIC
+4.5° (±1.6)
When checking ....................................................................................................................................................................................... 1°
203.7
except 4MATIC
except AMG
+6.9° (±1.6)
When checking ....................................................................................................................................................................................... 1°
Rear Axle
203
with 4MATIC
+20mm (±10)
+2.6° (±1.6°)
When checking ....................................................................................................................................................................................... 1°
203
2
except 4MATIC
except MB sports suspension (code 486)
except AMG
except suspension with increased ground clearance (code 482)
+20mm (±10)
+3.3° (±1.6°)
When checking ....................................................................................................................................................................................... 1°
203.0
with MB sports suspension (code 486) or AMG
except 4MATIC
+1.5° (±1.6°)
When checking ....................................................................................................................................................................................... 1°
203.0/7
with suspension with increased ground clearance (CODE 482)
except 4MATIC
+4.9° (±1.6°)
When checking ....................................................................................................................................................................................... 1°
203.2
with suspension with increased ground clearance (code 482)
except 4MATIC
+4.7° (±1.6°)
When checking ....................................................................................................................................................................................... 1°
203.2
except 4MATIC
except AMG
+3.1° (±1.6°)
When checking ....................................................................................................................................................................................... 1°
203.2
with MB sports suspension (code 486) or AMG
except 4MATIC
+3.1° (±1.6°)
When checking ....................................................................................................................................................................................... 1°
203.7
except 4MATIC
except AMG
+2.2° (±1.6°)
When checking ....................................................................................................................................................................................... 1°
NOTE: To measure vehicle level use (86) Electronic inclination measuring instrument (CM 9606)
3
Rear
Front
Front Camber (at vehicle level)

Model 203 without 4MATIC.
+13.6° ........................................................................................................................................................................................ +0°22' (±20')
+12.6° ........................................................................................................................................................................................ +0°13' (±20')
+11.6° ........................................................................................................................................................................................ +0°05' (±20')
+10.6° ......................................................................................................................................................................................... -0°03' (±20')
+9.6° ......................................................................................................................................................................................... -0°10' (±20')
+8.6° ......................................................................................................................................................................................... -0°16' (±20')
+7.6° ......................................................................................................................................................................................... -0°21' (±20')
+6.6° ......................................................................................................................................................................................... -0°26' (±20')
+5.6° ......................................................................................................................................................................................... -0°30' (±20')
4
+4.6° ......................................................................................................................................................................................... -0°33' (±20')
+3.6° ......................................................................................................................................................................................... -0°37' (±20')
+2.6° ......................................................................................................................................................................................... -0°38' (±20')
+1.6° ......................................................................................................................................................................................... -0°40' (±20')
Note maximum permissible difference in front-axle camber between the right and left-hand sides of the vehicle: 24'
Front Camber (at vehicle level)

Model 203 4MATIC.
+5.1° ........................................................................................................................................................................................... -0°04' (±20')
+4.8° ........................................................................................................................................................................................... -0°04' (±20')
+4.5° ........................................................................................................................................................................................... -0°07' (±20')
+4.2° ........................................................................................................................................................................................... -0°08' (±20')
+3.9° ........................................................................................................................................................................................... -0°10' (±20')
+3.6° ........................................................................................................................................................................................... -0°12' (±20')
+3.3° ........................................................................................................................................................................................... -0°14' (±20')
+3.1° ........................................................................................................................................................................................... -0°15' (±20')
+2.8° ........................................................................................................................................................................................... -0°17' (±20')
+2.5° ........................................................................................................................................................................................... -0°18' (±20')
+2.2° ........................................................................................................................................................................................... -0°20' (±20')
+1.9° ........................................................................................................................................................................................... -0°22' (±20')
Note maximum permissible difference in front-axle camber between the right and left-hand sides of the vehicle: <=20'
Front Caster
Measure heights of front and rear axles, then consult table for the caster data
VA = Front axle
HA = Rear axle
Maximum deviation between left and right (degrees) ....................................................................................................................................... 30'
Tolerance ........................................................................................................................................................................................................ ±30'
Model 203 With 4MATIC
5
Model 203 As Of 04/2004, Without 4MATIC
Front Toe-in
203
except 4MATIC .............................................................................................................................................................................. 0°12' ±10'
with 4MATIC .................................................................................................................................................................................. 0°00' ±10'
Toe-out on turns with inner wheel steered through 20°
203
with 4MATIC .................................................................................................................................................................................. 1°12' ±30'
203.0/2
except 4MATIC
except AMG .................................................................................................................................................................................... 1°31' ±30'
203.0
with MB sports suspension (code 486) or AMG ............................................................................................................................. 1°40' ±30'
203.0/7
with suspension with increased ground clearance (code 482) or AMG........................................................................................... 1°30' ±30'
203.2
with ride-height control ................................................................................................................................................................... 1°37' ±30'
203.2
with suspension with increased ground clearance (code 482) ........................................................................................................ 1°30' ±30'
203.2
with MB sports suspension (code 486) or AMG ............................................................................................................................. 1°42' ±30'
203.7
except 4MATIC
except AMG .................................................................................................................................................................................... 1°37' ±30'
Rear Camber (at vehicle level)
Note: Rear camber is not adjustable
203 without 4MATIC

6.9° ............................................................................................................................................................................................. -0°24' (±30')
6
5.9° ............................................................................................................................................................................................. -0°32' (±30')
4.9° ............................................................................................................................................................................................. -0°40' (±30')
3.9° ............................................................................................................................................................................................. -0°48' (±30')
2.9° ............................................................................................................................................................................................. -1°00' (±30')
1.9° ............................................................................................................................................................................................. -1°11' (±30')
0.9° ............................................................................................................................................................................................. -1°24' (±30')
Note maximum permissible difference in front-axle camber between the right and left-hand sides of the vehicle: 30'
Overall toe-in at rear axle ............................................................................................................................................................................ 0°33' ±15'
Permitted difference between right and left side of vehicle for rear toe (degrees) ............................................................................................. <=30'
Test Values For Distance/Comparison Measurement on Front Axle

Test Values for Distance And Comparative Measurements on Front Axle
Dimension (Model 203, except 203.08/09/28/29)
V1............................................................................................................................................................................................................................. 4 mm
V2............................................................................................................................................................................................................................. 4 mm
V3............................................................................................................................................................................................................................. 3 mm
V5............................................................................................................................................................................................................... 1150 (±3) mm
V6............................................................................................................................................................................................................................. 3 mm
V8................................................................................................................................................................................................................. 714 (±2) mm
V10........................................................................................................................................................................................................................... 3 mm
Dimension (Model 203.08/09/28/29)
V1.......................................................................................................................................................................................................................... ±2 mm
V2.......................................................................................................................................................................................................................... ±2 mm
V3....................................................................................................................................................................................................................... ±1.5 mm
V8.............................................................................................................................................................................................................. 802.5 (±3) mm
V10........................................................................................................................................................................................................................ ±2 mm
Test Values For Distance/Comparison Measurement on Rear Axle
Test Values For Distance And Comparison Measurement On Rear Axle
Dimension
H1.......................................................................................................................................................................................................................... ±2 mm
H2....................................................................................................................................................................................................................... ±1.5 mm
H5.......................................................................................................................................................................................................................... ±3 mm
H6............................................................................................................................................................................................................... 1012 (±2) mm
H7................................................................................................................................................................................................................. 738 (±2) mm
H8....................................................................................................................................................................................................................... ±1.5 mm
H9....................................................................................................................................................................................................................... ±1.5 mm
Camber Adjustment Bolt

Camber Adjustment Bolt (Self-locking nut, lower wishbone to front axle carrier)
Tightening Torque:.............................................................................................................................................................................................. 110 Nm

Engine Mounts, Engine Supports
Engine Mounts, Engine Supports
Bolt, rear engine crossmember to body.................................................................................................................................................................. 33 NM

Track Rod - Front Axle
Track Rod
Counter nut for tie rod on inner tie rod................................................................................................................................................................... 60 NM

Track Rod - Rear Axle
Track Rod
Self-locking nut, track rod to rear axle carrier

1st stage.................................................................................................................................................................................................................. 70 NM
7
Front & Rear Brake Rotor/Disc Thickness
Front Brake Disk Thickness
Model 203.004/006/035/045/081/204/206/235/245/281/706/735/745 with code 494 or 498 or 625

New .......................................................................................................................................................................................... 25 mm (0.984 in.)
Wear Limit ............................................................................................................................................................................... 22 mm (0.866 in.)
Service Limit ........................................................................................................................................................................ 22.6 mm (0.889 in.)
Model 203.004/006/204/206 with code 949 or 950

Model 203.007/008 with code 949 or 950
Model 203.061/261 with code 494 or 625 and 949 or 950
New .......................................................................................................................................................................................... 28 mm (1.102 in.)
Wear Limit ............................................................................................................................................................................... 26 mm (1.023 in.)
Model 203.004/006/605/035/045/705/206/235/811/706/735 w/o code

Model 203.007/008 w/o code
Model 203.042/043/046/242/243/246/707/708/742/743/746
Model 203.207/208 w/o code
Model 203.040/240/740 with code 494 or 498 or 625
Model 203.040 with code 165 and 498 or 625
Model 203.061/261 with code 494 or 498 or 625
New .......................................................................................................................................................................................... 25 mm (0.984 in.)
Wear Limit ............................................................................................................................................................................ 22.4 mm (0.881 in.)
Service Limit ........................................................................................................................................................................... 23 mm (0.905 in.)
Model 203.016/064/216/264/747 w/o code

Model 203.061/081/261/281 w/o code
Model 203.084/284/764
Model 203.740 w/o code
New .......................................................................................................................................................................................... 28 mm (1.102 in.)
Wear Limit ............................................................................................................................................................................ 25.4 mm (1.000 in.)
Model 203.335/018/065/218/265/276
New .......................................................................................................................................................................................... 30 mm (1.181 in.)
Wear Limit ............................................................................................................................................................................ 27.5 mm (1.082 in.)
Model 203.718
New .......................................................................................................................................................................................... 30 mm (1.181 in.)
Wear Limit ............................................................................................................................................................................... 28 mm (1.102 in.)
Rear Brake Disc Thickness
Model 203.004/006/035/045/706/735/745
New ............................................................................................................................................................................................ 9 mm (0.354 in.)
Wear Limit .............................................................................................................................................................................. 7.3 mm (0.287 in.)
Service Limit .......................................................................................................................................................................... 7.6 mm (0.299 in.)
Model 203.007/008 except 203.007/008 with code 949 or 950

Model 203.042/043/046/707/708/742/743/746
New ............................................................................................................................................................................................ 9 mm (0.354 in.)
Wear Limit .............................................................................................................................................................................. 7.3 mm (0.287 in.)

Model 203.016/061/064/081/084
Model 203.204/206/216/235/245/261/264/281/284/747
Model 203.040/207/208/240/242/243/246/740/764 except 203.040/740 with code 498 or 625
Model 203.042/043/046 with code 949 or 950 and 701
New .......................................................................................................................................................................................... 10 mm (0.393 in.)
Wear Limit .............................................................................................................................................................................. 8.3 mm (0.326 in.)
Model 203.018/218/718
8
New .......................................................................................................................................................................................... 22 mm (0.866 in.)
Wear Limit ............................................................................................................................................................................ 19.4 mm (0.763 in.)
Model 203.065/076/265/276
New .......................................................................................................................................................................................... 22 mm (0.866 in.)
Wear Limit ............................................................................................................................................................................ 19.5 mm (0.767 in.)
BE42.10-P-1000-05C Test Values For Brake Pad In Front Sliding Caliper
Test Values For Brake Pad In Front Sliding Caliper
9
10
11
12
BE42.10-P-1000-06E Test Values For Brake Pad In Front Fixed Caliper

Modification Notes
Test Values For Brake Pad In Front Fixed Caliper
13
14
15
16
BE42.10-P-1000-07C Test Values For Brake Pad In Rear Fixed Caliper

Modification Notes
Test Values For Brake Pad In Rear Fixed Caliper
17
BE42.20-P-1000-01A Test Values For Parking Brake

BE42.20-P-1000-01A Test Values For Parking Brake
Test Values For Parking Brake
18
Test Values For Parking Brake
BE42.20-P-1000-01C Adjustment Values For Parking Brake

BE42.20-P-1000-01C Adjustment Values For Parking Brake
Adjustment Values For Parking Brake
19
20
Parking Brake Adjustment Values
21
Brake Lines, Brake Hoses

Brake pipe to brake hose......................................................................................................................................................................................... 14 NM

Brake hose to fixed or floating caliper.................................................................................................................................................................... 18 NM
Front Axle Fixed Caliper
Front Axle Fixed Caliper
Self-locking screw fixed caliper to steering knuckle............................................................................................................................................ 115 NM
22
Bleeder screw at fixed caliper of front axle.............................................................................................................................................................. 7 NM
Front Axle Floating Caliper
Front Axle Floating Caliper
Self-locking bolt, caliper support to steering knuckle.......................................................................................................................................... 115 NM

Self-locking bolt, brake pad wear contact sensor to floating caliper: M6................................................................................................................ 8 NM
Fixed Caliper at Rear
Fixed Caliper At Rear
Self-locking screw, fixed caliper to wheel carrier.................................................................................................................................................. 55 NM

Brake Fluid Pressure Sensor/Switch
Electronic Stability Program (ESP)
Brake pressure sensor to master brake cylinder...................................................................................................................................................... 20 NM

Brake Hose/Line
Brake pipe to brake hose......................................................................................................................................................................................... 14 NM

Brake hose to fixed or floating caliper.................................................................................................................................................................... 18 NM
Master Brake Cylinder
Master Brake Cylinder
Nut, brake master cylinder to brake booster........................................................................................................................................................... 20 NM

Brake pipe to master brake cylinder....................................................................................................................................................................... 16 NM

23
24
25
26

Modification Notes
27
28
29
30

Modification Notes
31
BE42.10-P-1000-08K Test Values For Front Brake Disks

Test Values For Front Brake Disks

32
33
BE42.10-P-1000-09B Test Values For Rear Brake Disks

34
Modification Notes

Test Values For Rear Brake Disks
35
36
37
Hydraulic Control Assembly - Antilock Brakes

Electronic Stability Program (ESP)
Nut, bracket to ESP hydraulic unit......................................................................................................................................................................... 10 NM

Brake pipe to ESP hydraulic unit............................................................................................................................................................................ 15 NM
Parking Brake Cable
Parking Brake
38
Self-locking bolt of brake control cable at rear wheel carrier................................................................................................................................. 20 Nm

Parking Brake Pedal
Parking Brake
Bolt of pedal assembly, foot-operated parking brake, on front wall pillar............................................................................................................. 12 NM

Brake Booster - Pneumatic
Pneumatic Brake Booster
Nut, brake booster carrier to front end.................................................................................................................................................................... 20 Nm

Test Values For Pneumatic Brake Booster
Wheel Speed Sensor

Front Axle Rpm Sensor
Self-locking screw of front axle rpm sensor to knuckle......................................................................................................................................... 25 NM

System Specifications
AR25.10-P-0050P Clutch
- with TRANSMISSION 716.6
Clutch
Pressure Plate
39
AR25.10-P-0050P Clutch
- with TRANSMISSION 716.6
Clutch
Drive/Propeller Shaft
BE41.10-P-1000-01A Propeller shaft
Modification Notes
Check Values For Propeller Shaft Inclination Angle
40
41
42
43
44
BA01.30-P-1000-01O Cylinder Head

Modification notes
45
Cylinder Head
BA01.40-P-1000-01G Crankcase, Timing Case Cover, End Cover

46
BA01.45-P-1000-01M Oil Pan

BA01.45-P-1000-01M Oil Pan
Oil Pan
Belt Pulley/Vibration Damper Center Bolt

Replace center bolt.
Flywheel, driven plate, vibration damper, starter ring gear
BE01.00-P-1000-01B Compression Pressure
47
Modification
Compression Pressure
BE01.00-P-1000-02Z Cylinder Leaktightness

48
Cylinder Leaktightness
BE01.30-P-1000-04B Cylinder Head/Cylinder Head Bolts

Cylinder Head/cylinder Head Bolts
49
50
51
52
53
BE01.40-P-1000-01I Test Values For Cylinder Bore

Test Values For Cylinder Bore
Camshaft Bearing Cap Bolts
Connecting Rod
54
Connecting rod
Coolant Pump Bolts
Crankshaft Main Bearing
Cylinder Head Bolts

Check cylinder head bolts and replace if required.
55
Cylinder head
Exhaust Manifold Nuts
Exhaust manifold
Flywheel/Drive Plate Bolts
Oil Pump
Oil pump
AH01.30-P-1000-05A Information on Cylinder Head Contact Surface

AH01.30-P-1000-05A Information on cylinder head contact surface
The cylinder head contact surface should only be machined if there is mechanical damage.
56
It should not be machined (by face grinding) if the contact surface of the cylinder head is uneven (warped) in the longitudinal and transverse
directions.
When the cylinder head is mounted again, surface warping will be evened out when the cylinder head bolts are tightened.
Stock removal from the cylinder head and cylinder crankcase of an engine should together be no more than 0.3 mm.
If the cylinder head contact surface is machined, the valve seats must be reset.

Modification Notes
Modification notes
57
Cylinder head
reverse order.
M272

58

59
Camshaft Bearing
Camshaft Gear/Sprocket


60
Crankshaft Main Bearings
Piston Specifications
61
Test specifications for pistons
Connecting Rod
Check values for connecting rod bolts
Connecting rod
Cylinder Bore Specifications
AR03.10-P-6111-01VA Check Connecting Rod Bolts

62
Connecting rod bolt length inspection

AR03.10-P-6111-02VA Tighten Connecting Rod Bolts
AR03.10-P-6111-02VA Tighten connecting rod bolts
Connecting rod
Shown on engine 272
1 Lubricate the bolt thread and head contact surface with engine oil.
2 Tighten connecting rod bolts to step 1.
63
If no angle tightener is available, continue turning the connecting rod bolts to the specified angle using a socket wrench and locking handle.
Do not use a flexi-rod torque wrench for tightening in order to avoid any angle errors.
AR03.10-P-6111-06VA Install and Gauge Connecting Rod Bearings
dot.
AR03.10-P-7021-02VA Assigning A Standard Size Piston to A Cylinder Bore
64
65

(x) Pistons marked with x must only be installed in cylinder bores marked with x(x).
Shown on engine 272
(x) This is located at the bottom right on the crankcase at the mount for engine support.
66
Modification Notes
Modification notes
Special Tools

67
68

69
color).
70



71
Connecting Rod
Connecting rod
AR03.10-P-6111-06VA Install and Gauge Connecting Rod Bearings

dot.
72
Connecting Rod
Connecting rod
AR03.10-P-6111-01VA Check Connecting Rod Bolts

73
Connecting rod bolt length inspection

AR03.10-P-6111-02VA Tighten Connecting Rod Bolts
AR03.10-P-6111-02VA Tighten connecting rod bolts
Connecting rod
Shown on engine 272
1 Lubricate the bolt thread and head contact surface with engine oil.
If no angle tightener is available, continue turning the connecting rod bolts to the specified angle using a socket wrench and locking handle.
Do not use a flexi-rod torque wrench for tightening in order to avoid any angle errors.
Crankshaft Gear/Sprocket
74

Modification Notes
Modification notes
75
Special Tools

76

77
78
color).

79


80

Modification Notes
Modification notes
Special Tools
81

82

83
color).
84


85

Harmonic Balancer - Crankshaft Pulley
Piston Specifications
Test specifications for pistons
AR03.10-P-7021-02VA Assigning A Standard Size Piston to A Cylinder Bore

86
87

(x) Pistons marked with x must only be installed in cylinder bores marked with x(x).
Shown on engine 272
(x) This is located at the bottom right on the crankcase at the mount for engine support.
88
Modification notes
Cylinder Head
Cylinder Head LH
Cylinder Head LH
89
Cylinder Head
Cylinder Head RH
Cylinder Head RH
Cylinder Head
Exhaust Manifold LH
Exhaust Manifold LH
Exhaust Manifold
Exhaust Manifold RH
Exhaust Manifold RH
Exhaust Manifold

90

91
92
93
94
95
Cylinder Head Bolts

Check cylinder head bolts and replace if required.
Cylinder head
Camshaft Bearing Cap Bolts
96
Camshaft Sprocket Bolts
Exhaust manifold

97

Modification Notes
Modification notes
Cylinder head
reverse order.
98
M272
Valve Clearance
These engines are equipped with hydraulic lash adjusters. No adjustment is required.
Oil Pan
Oil pan
Bottom Part of Oil Pan
Oil pan
AR01.45-P-7500-06VA Bolt Plan For Oil Pan

AR01.45-P-7500-06VA Bolt plan for oil pan
99
100
Oil Pump, Engine
Oil pump
Timing Chain Tensioner to Timing Case

101
Bolt, Front Cover to Cylinder Head
Cylinder head
Cylinder Head Bolt on Timing Case
Cylinder head
Bolt, Timing Case Cover to Cylinder Crankcase

102
Timing Chain Tensioner

103
Bolt, Front Cover to Cylinder Head
Cylinder head
Cylinder Head Bolt on Timing Case
Cylinder head
Bolt, Timing Case Cover to Cylinder Crankcase

104
Exhaust Manifold LH
Exhaust Manifold LH
Exhaust Manifold
Exhaust Manifold RH
Exhaust Manifold RH
Exhaust Manifold
Exhaust manifold
Firing Order
AR01.00-P-1300-03HA Firing order
Firing order
105
Firing order
Firing order
Firing order
Firing order - Engine 137, 275, 285
Flywheel/Drive Plate
106
Steering Gear
BE46.20-P-1000-01C Test values for steering gear
Test Values For Steering Gear
107
Water Pump
Tightening Specifications
Wheel Bolt Torque Specification ........................................................................................................................................................................ 110 Nm
Tightening Sequence
Tightening Sequence
108
Lug Nut Torque Patterns
IMPORTANT
Check all parts, including rims, lug studs, lug nuts, and mating surfaces of hubs and tire rims for rust, damage, or dirt. Clean mating surfaces with a
wire brush to remove any foreign material. Replace any damaged parts as needed. Careless installation of tire/rim assemblies in a vehicle is a major
cause of tire installation problems. Proper installation, including fastener torque, is essential to economical, safe and trouble free service. Use only
the proper sizes and types of fasteners for safe and proper service.
Tighten the fasteners a quarter turn at a time using the tightening sequence diagram as a guide. This is very important to prevent misalignment of
the wheel. Continue tightening the fasteners in sequence until the fasteners are tightened to the proper torque.
CAUTION: Improper torque or tightening sequence can cause distortion, fatigue cracks, or alignment problems. After driving the vehicle for a
short distance, recheck the wheel fastener torque. Parts will usually seat naturally, reducing the torque on the fasteners. Retorque all fasteners to the
proper torque.
Wheel Hub
BE33.20-P-1000-01A Test specifications for wheel location, wheel hub
Modification Notes
109
Test Specifications For Wheel Location, Wheel Hub
110
111

Modification
112

272 Engine
113
Compression pressure
Power Steering Pump

BE46.30-P-1000-01C Power steering pump test specifications
Power Steering Pump Test Specifications
Power Steering Pump Test Specifications
Thermostat, Engine Cooling
Check values for coolant thermostat
Brake Fluid Pressure Sensor/Switch

Brake Fluid
Brake fluid Filling quantities ...................................................................................................................................................... approx. 0.45...0.6 Liters

Brake Master Cylinder
Brake Fluid
Brake fluid Filling quantity ......................................................................................................................................................... approx. 0.45...0.6 Liters

Engine Oil
Engine Oil
Capacity
With Oil Filter ................................................................................................................................................................................... 8.5 qts (8.0 liters)
114
Fluid - A/T
Automatic Transmission Fluid
Capacities ............................................................................................................................................................................................ 9.0 qts (8.5 liters)
Fluid - Differential
Rear Axle
Capacity ............................................................................................................................................................................................... 1.0 qts (1.0 liters)
Fluid - M/T
Manual Transmission Fluid
Capacities ............................................................................................................................................................................................ 1.3 qts (1.2 liters)
Engine Oil
Engine oil
For Vehicles with Mercedes-Benz Maintenance System - U.S. Vehicles as of Model Year 2005
Mercedes-Benz recommends that you use on MB 229.5 or MB229.51 approved synthetic motor oil for all vehicles equipped with the
Mercedes-Benz Maintenance System. Conventional petroleum based oils must not be used for vehicles equipped with the Mercedes-Benz
Maintenance System.
If the engine oil does not meet the above mentioned standard, engine damage is possible, which is not covered by the Mercedes-Benz New Vehicle
Limited Warranty.
Use of any oil additives is not recommended by Mercedes-Benz USA and may result in damage to the engine which is not covered by the
Mercedes-Benz New Vehicle Limited Warranty.
U.S. Vehicles Model Year 2005 to the Present Engine Oils
MB-Approved Sythetic Engine Oil

Mobil 1 ................................................................................................................................................................................................................... 0w-40
Mobil 1 Formula M ................................................................................................................................................................................................ 5w-40
Castrol Syntec European Formula* ....................................................................................................................................................................... 0w-30
Pennzoil Platinum European Formula Ultra* ........................................................................................................................................................ 5w-30
ELF Excellium 229.5* ........................................................................................................................................................................................... 5w-30
Mobil 1 ESP Formula M*++ (Diesel only) ............................................................................................................................................................ 5w-40
Valvoline Synpower MST*++ (Diesel only) ......................................................................................................................................................... 5w-30
ELF Solaris LSX*++ (Diesel only) ....................................................................................................................................................................... 5w-30
++As of model year 2007 diesel engines must only use 229.51 approved engine oil
229.51 is only approved for diesel engines
*Not approved for use in AMG engines
229.5 or 229.51 engine oils must be used in conjunctions with fleece oil filter in vehicles with Mercedes-Benz Maintenance System (as of
MY2005). Using other oil filters may lead to engine damage which is not covered by the Mercedes-Benz Limited Warranty.
MB Sheet numbers are printed on the outside of oil containers

Fluid - A/T
Automatic Transmission Fluid
722.6 / 5-Speed ........................................................................................................................................................ MB Automatic Transmission Fluid

MB Part No. ........................................................................................................................................................................................ 001 989 21 03 10
Note: The 722.6 transmission is filled with a special transmission fluid and is considered to be "filled for life".
Warning: Do not use on 722.9 transmissions.
722.9 / 7-Speed ........................................................................................................................................................ MB Automatic Transmission Fluid

MB Part No. ........................................................................................................................................................................................ 001 989 45 03 10
115
Note: Can be used on 722.6 transmissions. Must be used on 722.9 transmissions.

Fluid - Differential
For front (where applicable) and rear axle differentials
except SL65 AMG
MB Hypoid Gear Oil ........................................................................................................................................................................................ (85W-90)
MB Part No. ......................................................................................................................................................................................... 001 989 17 03 10
For rear axle differentials

SL65 AMG
Castrol .............................................................................................................................................................................................. SAF-XJ (75W-140)
Fluid - M/T
Manual Transmission Fluid
Up to model year 2002

MB 5-Speed & 6-Speed Manual Transmission
Type .................................................................................................................................................................................. MB Manual Transmission Oil
MB Part No. .............................................................................................................................................................................................. 001 989 26 03
From model year 2003 to present

MB 5-Speed & 6-Speed Manual Transmission
Type .................................................................................................................................................................................. MB Manual Transmission Oil
MB Part No. ...................................................................................................................................................................................... A001 989 26 03 10
1
Vehicle: Locations
AAC Pushbutton Control Module (View 1)
AAC Pushbutton Control Module (View 2)
2
AC Compressor (View 1)
3
Accelerator Pedal Sensor (View 1)
4
Accelerator Pedal Sensor (View 2)
Activated Charcoal Filter Connector (View 1)
5
Activated Charcoal Filter Connector (View 2)
Activated Charcoal Filter Shutoff Valve (View 1)
6
7
Adjustable Camshaft Timing Solenoid
Air Humidity Sensor (View 1)
8
Air Humidity Sensor (View 2)
Air Injection Valve (View 1)
9
10
11
Airbag Connector (View 1)
Airbag Connector (View 2)
12
Altitude Sensor (View 1)
13
14
AM/FM Antenna Module Connector (View 1)
AM/FM Antenna Module Connector (View 2)
15
Ambient Temperature Display Temperature Sensor (View 1)
Ambient Temperature Display Temperature Sensor (View 2)
16
Amplifier Module 1, Screen Antenna (203.2) (View 1)
17
18
Antenna Module Supply Connector (View 1)
19
20
Antenna System Connector (View 1)
21
Armrest CTEL Connector (View 1)
22
Armrest CTEL Connector (View 2)
ATA [EDW] Hood Switch (View 1)
23
ATA [EDW] Hood Switch (View 2)
ATA [EDW] Inclination Sensor (View 1)
24
ATA [EDW] Inclination Sensor (View 2)
Audio Amplifier (d2b) (view 1)
25
Audio Ampliifer (d2b) (view 3)
26
Automatic Light Switch Daylight Sensor (View 1)
27
Automatic Light Switch Daylight Sensor (View 2)
Automatic Transmission Program Selector (View 1)
28
Automatic Transmission Program Selector (View 2)
Auxiliary Battery
29
Backup Lamp Switch (View 1)
Backup Lamp Switch (View 2)
30
BAS Brake Booster (View 1)
BAS Brake Boooster (View 2)
31
Bass Module Loudspeaker (View 1)
Bass Module Loudspeaker (View 2)
32
Battery (View 1)
Battery (View 2)
33
Belt Tension Sensor (View 1)
Belt Tension Sensor (View 2)
34
Bluetooth Antenna (View 1)
Bluetooth Antenna (View 2)
35
Brake Booster Vacuum Pump (View 1)
Brake Booster Vacuum Pump (View 2)
36
Brake Booster Vacuum Pump Control Module (View 1)
Brake Booster Vacuum Pump Control Module (View 2)
37
Brake Fluid Indicator Switch (View 1)
Brake Fluid Indicator Switch (View 2)
38
Breakdown Assistance/info Button Connector (View 1)
Breakdown Assistance/info Button Connector (View 2)
39
C-AAC Sun Sensor (4 In Total) (View 1)
C-AAC Sun Sensor (4 In Total) (View 2)
40
C-ACC [K-KLA] Multifunction Sensor (View 1)
C-ACC [K-KLA] Multifunction Sensor (View 2)
41
Camshaft Hall Sensor (View 1)
42
CAN Databus Adapter Connector (2-pin) (View 1)
43
CAN Databus Adapter Connector (2-pin) (View 2)
Cassette Player Connector (View 1)
44
Cassette Player Connector (View 2)
CC Switch
45
CD Changer (In Glove Compartment)
Center Air Outlet Illumination
46
Center Cockpit Speaker (Centerfill) (View 1)
Center Cockpit Speaker (Centerfill) (View 2)
47
Center High-mounted Stop Lamp (View 1)
48
49
Central Ground, SAM/Rear (View 1)
Central Ground, SAM/Rear (View 2)
50
Charge Air Cooler Circulation Pump (View 1)
51
Charge Air Temperature Sensor (View 1)
52
Charge Air Temperature Sensor (View 2)
Circuit 15R Connector Sleeve (View 1)
53
Circuit 15R Connector Sleeve (View 2)
Circuit 15R Connector Sleeve, (fused, Sidebag) (View 1)
54
Circuit 15R Connector Sleeve, (fused, Sidebag) (View 2)
Circuit 30 Connector Sleeve (View 1)
55
56
Circuit 58d Connector Sleeve (View 1)
57
Circuit 58d Connector Sleeve (View 2)
Circuit 58d In FSS [RBA] Connector Sleeve (View 1)
58
Circuit 58d In FSS [RBA] Connector Sleeve (View 2)
Circuit 87 M1e Connector Sleeve (View 1)
59
60
61
62
Clutch Pedal Switch (View 1)
63
Clutch Pedal Switch (View 2)
Cockpit And Roof Connector (View 1)
64
Cockpit And Roof Connector (View 2)
Cockpit Wiring Harness And FFS [RBA] Connector (View 1)
65
66
Cockpit/AC Sensors Connector (View 1)
67
Cockpit/AC Sensors Connector (View 2)
Cockpit/FSS [RBA] Traction Systems Connector (View 1)
68
Cockpit/FSS [RBA] Traction Systems Connector (View 2)
COMAND Actuation, Dislpay And Control Unit
69
Combination Switch
Comfort AAC Pushbutton Control Module
70
Connector Sleeve 2, Microphone Ground (View 1)
Connector Sleeve 2, Microphone Ground (View 2)
71
Connector Sleeve 2, Microphone Signal (View 1)
Connector Sleeve 2, Microphone Signal (View 2)
72
Coolant Circulation Pump
Coolant Level Indicator Switch (View 1)
73
74
Coolant Temperature Sensor (View 1)
75
76
Crankshaft Hall Sensor (View 1)
77
Crankshaft Hall Sensor (View 2)
Crankshaft Position Sensor (View 1)
78
79
CTEL Antenna (View 1)
80
81
CTEL Separation Point (View 1)
CTEL Separation Point (View 2)
82
Cylinder 1 Ignition Coil (View 1)
83
84
85
86
87
88
89
90
91
92
93
94
95
Cylinder 7 Ignition Coil
Cylinder 8 Ignition Coil
96
Data Link Connector (View 1)
Data Link Connector (View 2)
97
DI Control Module (View 1)
DI Control Module (View 2)
98
Driver Airbag Ignition Squib 1 (View 1)
99
100
Driver Door CL Motor (View 1)
Driver Door CL Motor (View 2)
101
Driver ETR [GUS] Ignition Squib (View 1)
Driver ETR [GUS] Ignition Squib (View 2)
102
Driver Front Seat Adjustment Control Module With Memory
Driver NECK-PRO Head Restraint Solenoid (View 1)
103
Driver NECK-PRO Head Restraint Solenoid (View 2)
Driver Partially-electric Seat Adjustment Switch
104
Driver Power Window Switch Group (View 1)
Driver Power Window Switch Group (View 2)
105
Driver Seat Adjustment Motor Group With Memory
Driver Seat Backrest Release Microswitch (View 1)
106
Driver Seat Backrest Release Microswitch (View 2)
Driver Seat Contacting Strip (View 1)
107
Driver Seat Contacting Strip (View 2)
Driver Seat Height Release Microswitch
108
Driver-Side Frontal Acceleration Sensor (View 1)
Driver-Side Frontal Acceleration Sensor (View 2)
109
Driver-side Seat Belt Buckle Restraint Systems Switch
D2B Fiber Optical Cable Connector (View 1)
110
D2B Fiber Optical Cable Connector (View 2)
D2B Telephone And Tele AID Transmitter/Receiver (View 1)
111
D2B Telephone And Tele AID Transmitter/Receiver (View 2)
E-net Compensator (View 1)
112
E-net Compensator (View 2)
Electric Air Pump (View 1)
113
114
Electric Control Unit (View 1)
115
Electric Control Unit (View 2)
Electric Control Unit (VGS) (View 1)
116
Electric Control Unit (VGS) (View 2)
Electric Steering Lock Control Module (View 1)
117
Electric Steering Lock Control Module (View 2)
Electric Suction Fan Engine And AC With Integrated (View 1)
118
Electric Suction Fan Engine And AC With Integrated (View 2)
Electronic Selector Lever Module Control Module (View 1)
119
Electronic Selector Lever Module Control Module (View 2)
Electronics Ground (Left Of Component Compartment) (View 1)
120
121
Emergency Call Pushbutton Connector (View 1)
Emergency Call Pushbutton Connector (View 2)
122
Emergency Call Spare Antenna
Emergency Call Speaker Separation Point (View 1)
123
Emergency Call System Antenna Splitter (View 1)
124
Emergency Call System Antenna Splitter (view 2)
Emergency Call System Control Unit
125
Emergency Call System Left Backup Antenna (View 1)
Emergency Call System Left Backup Antenna (View 2)
126
Emergency Call System Right Backup Antenna (View 1)
Emergency Call System Right Backup Antenna (View 2)
127
Engine Compartment Connector Sleeve, Fanfare Horns
Engine Fan Connector (100C ETC Switch) (View 1)
128
Engine Fan Connector (100C ETC Switch) (View 2)
Engine Separation Point Connector (View 1)
129
Engine Separation Point Connector (View 2)
ESC [ELV] Motor Group (View 1)
130
ESC [ELV] Motor Group (View 2)
ESP And BAS Control Module (View 1)
131
ESP And BAS Control Module (View 2)
ESP Brake Pressure Hall Sensor (M271) (View 1)
132
133
ESP Brake Pressure Sensor 1 (View 1)
134
135
136
ESP Lateral Acceleration Sensor (View 1)
137
ESP Lateral Acceleration Sensor (View 2)
ESP Yaw Rate Sensor (View 1)
138
ESP Yaw Rate Sensor (View 2)
ETC [EGS] Control Module (View 1)
139
ETC [EGS] Control Module (View 2)
Evaporator Temperature Sensor (View 1)
140
Evaporator Temperature Sensor (View 2)
Fanfare Horns (View 1)
141
Fanfare Horns (View 2)
Fanfare Horns And Airbag Clock Spring Contact (View 1)
142
Fanfare Horns And Airbag Clock Spring Contact (View 2)
Frequency Switchover Control Module (View 1)
143
144
Fresh Air Flaps Actuator (View 1)
145
Fresh Air Flaps Actuator (View 2)
Fresh Air/Recirculated Air Flaps Actuator Motor (View 1)
146
Fresh Air/Recirculated Air Flaps Actuator Motor (View 2)
Front Ashtray Illumination
147
Front Axle Sensor (Headlamp Range Adjustment) (View 1)
Front Axle Sensor (Headlamp Range Adjustment) (View 2)
148
Front Cigar Lighter (with Illumination)
Front Passenger Airbag Ignition Squib 1 (View 1)
149
150
Front Passenger ETR [GUS] Squib (View 1)
151
Front Passenger ETR [GUS] Squib (View 2)
Front Passenger Front Seat Adjustment Control Module With Memory
152
Front Passenger NECK-PRO Head Restraint Solenoid (View 1)
Front Passenger NECK-PRO Head Restraint Solenoid (View 2)
153
Front Passenger Partially-electric Seat Adjustment Switch
Front Passenger Power Window Switch
154
Front Passenger Seat Backrest Release Microswitch
Front Passenger Seat Contacting Strip (View 1)
155
Front Passenger Seat Contacting Strip (View 2)
Front Passenger Seat Height Release Microswitch
156
Front Prefuse (View 1)
Front Prefuse (View 2)
157
Front SAM Control Module With Fuse And Relay Module (View 1)
158
Fuel Filler Flap CL Motor
159
Fuel Injectors (View 1)
Fuel Injectors (View 2)
160
Fuel Pump (FP) (View 1)
Fuel Pump (FP) (View 2)
161
Fuel Pump Wiring Harness Connector (View 1)
162
Fuel Tank (pressure, Activated Charcoal Filter) Connector (View 1)
163
Fuel Tank (pressure, Activated Charcoal Filter) Connector (View 2)
Fuel Tank Pressure Sensor (View 1)
164
165
Gear Display Sensor (View 1)
Gear Display Sensor (View 2)
166
Generator (View 1)
Generator (View 2)
167
Generator (View 3)
Glove Box Switch (ATA [EDW])
168
Glove Compartment Illumination With Switch (View 1)
Glove Compartment Illumination With Switch (View 2)
169
GPS Antenna (View 1)
170
Ground (at Left Headlamp Unit) (View 1)
171
Ground (at Left Headlamp Unit) (View 2)
Ground (battery) (View 1)
172
Ground (battery) (View 2)
Ground (Engine - Connection Point For Ground Wires) (View 1)
173
Ground (Engine - Connection Point For Ground Wires) (View 2)
Ground (Engine - Left Side) (View 1)
174
175
Ground (Left C-pillar)
Ground (Left Front Seat Crossmember)
176
Ground (Left Inner Door Sill)
Ground (Left Tailgate) (View 1)
177
Ground (Left Tailgate) (View 2)
Ground (Left Wheelhousing In Trunk) (View 1)
178
Ground (Left Wheelhousing In Trunk) (View 2)
Ground (Output Ground - Component Compartment) (View 1)
179
180
Ground (restraint Systems Control Module) (View 1)
181
Ground (restraint Systems Control Module) (View 2)
Ground (Right Front Seat Crossmember) (View 1)
182
Ground (Right Front Seat Crossmember) (View 2)
Ground (Right Inner Door Sill) (View 1)
183
Ground (Right Inner Door Sill) (View 2)
Ground (Right Wheelhousing In Trunk) (View 1)
184
Ground (Right Wheelhousing In Trunk) (View 2)
Ground Connector Sleeve (View 1)
185
186
187
188
Hands-Free System Microphone (View 1)
Turn Rate And Lateral Acceleration Sensor (View 2)
189
HCS Pump (View 1)
HCS Pump (View 2)
190
Heated Rear Window
Heating Systems Recirculation Unit (View 1)
191
Heating Systems Recirculation Unit (View 2)
Heating System Shutoff Valve (View 1)
192
Heating System Shutoff Valve (View 2)
Hot Film MAF Sensor (View 1)
193
194
195
Injectors (LH-SFI, HFM-SFI, PEC [LH, HFM, PMS])
196
Injectors (LH-SFI, HFM-SFI, PEC [LH, HFM] (View 1)
Injectors (LH-SFI, HFM-SFI, PEC [LH, HFM] (View 2)
197
Instrument Cluster
Intake Air Temperature Sensor (View 1)
198
Intake Air Temperature Sensor (View 2)
Intake Camshaft Solenoid
199
Intake Manifold Tumble Flap Switchover Valve (View 1)
Intake Manifold Tumble Flap Switchover Valve (View 2)
200
Interior Fuse Box (View 1)
Interior Fuse Box (View 2)
201
Interior Rearview Mirror Unit (View 1)
Interior Rearview Mirror Unit (View 2)
202
Interior Socket
Intermediate Frequency Antenna Module Connector (View 1)
203
Intermediate Frequency Antenna Module Connector (View 2)
Kickdown Switch (View 1)
204
Kickdown Switch (View 2)
Knock Sensor (View 1)
205
Knock Sensor (View 2)
Lamp Switch Module (View 1)
206
Lamp Switch Module (View 2)
Left Air Outlet Illumination
207
Left And Right Defroster Flaps Actuator (View 1)
Left And Right Defroster Flaps Actuator (View 2)
208
Left And Right Footwell Flaps Actuator (View 1)
Left And Right Footwell Flaps Actuator (View 2)
209
Left Blending Air Flap Actuator
Left Camshaft Exhaust Solenoid (View 1)
210
Left Camshaft Exhaust Solenoid (View 2)
Left Camshaft Intake Solenoid (View 1)
211
Left Camshaft Intake Solenoid (View 2)
Left Defroster Vent Flap Actuator Motor (View 1)
212
Left Defroster Vent Flap Actuator Motor (View 2)
Left E-Call Backup Antenna Connector (View 1)
213
Left E-Call Backup Antenna Connector (View 2)
Left Electrically Adjustable And Heated Exterior Mirror
214
Left Exhaust Camshaft Hall Sensor (View 1)
Left Exhaust Camshaft Hall Sensor (View 2)
215
Left Exterior Mirror Turn Signal Lamp
Left Fog Lamp
216
Left Footwell Flap Actuator Motor (View 1)
Left Footwell Flap Actuator Motor (View 2)
217
Left Fresh Air Flap Actuator (View 1)
Left Fresh Air Flap Actuator (View 2)
218
Left Front Axle Multiple Circuit Junction Connector, In
Left Front Axle Multiple Circuit Junction Connector, In Component
219
Left Front Backrest Heated Cushion
Left Front Brake Pad Contact Sensor (View 1)
220
Left Front Brake Pad Contact Sensor (View 2)
Left Front Door Contact Switch (View 1)
221
Left Front Door Contact Switch (View 2)
Left Front Door Control Module (View 1)
222
Left Front Door Control Module (View 2)
Left Front Door Entrance And Exit Lamp
223
Left Front Door ESA [ESV] Switch Group (with Memory) (View 1)
Left Front Door ESA [ESV] Switch Group (with Memory) (View 2)
224
Left Front Door Mirror Triangle Speaker
Left Front Door Separation Point (View 1)
225
Left Front Door Separation Point (View 2)
Left Front Door Speaker
226
Left Front Emergency Call Speaker (View 1)
227
Left Front Headlamp Unit
Left Front IR Receiver
228
Left Front Power Window Motor
Left Front Seat Heated Cushion
229
Left Front Side Airbag Ignition Squib
Left Front Side Marker Lamp {{USA}}
230
Left Front Wheel Speed Sensor
Left Fuel Level Sensor (View 1)
231
Left Fuel Level Sensor (View 2)
Left Intake Camshaft Hall Sensor (View 1)
232
Left Intake Camshaft Hall Sensor (View 2)
Left Intake Manifold Tumble Flap Position Sensor (View 1)
233
Left Intake Manifold Tumble Flap Position Sensor (View 2)
Left Knock Sensor 2 (View 1)
234
235
Left License Plate Lamp (View 1)
236
Left License Plate Lamp (View 2)
Left Multifunction Steering Wheel Pushbutton Group
237
Left O2 Sensor Downstream TWC [KAT]
Left O2 Sensor Upstream TWC [KAT] (View 1)
238
Left O2 Sensor Upstream TWC [KAT] (View 2)
Left Rear Door CL Motor
239
Left Rear Door Contact Switch
Left Rear Door Entrance And Exit Lamp
240
Left Rear Door Separation Point (View 1)
Left Rear Door Separation Point (View 2)
241
Left Rear Door Speaker
Left Rear ETR Ignition Squib (View 1)
242
Left Rear ETR Ignition Squib (View 2)
Left Rear Power Window Motor
243
Left Rear Power Window Switch
Left Rear Side Airbag Ignition Squib
244
Left Rear Side Marker Lamp (View 1)
Left Rear Side Marker Lamp (View 2)
245
Left Rear Surround Loudspeaker (View 1)
246
Left Rear Wheel Speed Sensor
Left Rear Window Airbag Ignition Squib (View 1)
247
248
Left Side Airbag And Window Airbag Sensor (View 1)
249
Left Side Airbag And Window Airbag Sensor (View 2)
Left Taillamp
250
Left Trunk Lamp (View 1)
251
252
Left Vanity Mirror Illumination (View 1)
Left Vanity Mirror Illumination (View 2)
253
254
Lower Control Field Control Module
MB-Info And Breakdown Assistance Button Group (View 1)
255
MB-Info And Breakdown Assistance Button Group (View 2)
ME-SFI Control Module (View 1)
256
ME-SFI Control Module (View 2)
Microphone Separation Point (View 1)
257
Microphone Separation Point (View 2)
Multicontour Seat Pneumatic Pump (View 1)
258
259
NECK-PRO Head Restraint Triggering Device (View 1)
NECK-PRO Head Restraint Triggering Device (View 2)
260
Oil Level Switch (View 1)
261
262
Oil Sensor (Oil Level, Temperature And Quality) (View 1)
263
264
Overhead Control Panel Control Module (View 1)
265
Overhead Control Panel Control Module (View 2)
O2 Sensor Ground Connector Sleeve (View 1)
266
O2 Sensor Ground Connector Sleeve (View 2)
O2 Sensor 1 Upstream TWC [KAT] (View 1)
267
268
O2S 2 (after TWC) (View 1)
O2S 2 (after TWC) (View 2)
269
Parking Brake Indicator Switch (View 1)
Parking Brake Indicator Switch (View 2)
270
Passenger Seat Adjustment Motor Group With Memory
Passenger Seat Occupied And Child Seat Recognition Sensor
271
Passenger-Side Frontal Acceleration Sensor (View 1)
Passenger-Side Frontal Acceleration Sensor (View 2)
272
Passenger-side Seat Belt Buckle Restraint Systems Switch
Pawl Rotary Tumbler Switch
273
Phone/CTEL/STH Radio Remote Control Antenna Splitter (View 1)
Phone/CTEL/STH Radio Remote Control Antenna Splitter (view 2)
274
Portable CTEL (View 1)
Portable CTEL (View 2)
275
Portable CTEL Antenna Amplifier
Power Steering Pump Pressure Regulator Valve (View 1)
276
277
Pressure Sensor (View 1)
278
279
280
281
Purge Control Valve (View 1)
282
283
284
285
Radio
Radio "mute" Plug Distributor (View 1)
286
Radio "mute" Plug Distributor (View 2)
Radio Additional Fan (View 1)
287
Radio Additional Fan (View 2)
Radio Interference Suppression Capacitor (View 1)
288
Radio Interference Suppression Capacitor (View 2)
Radio Interference Suppression Capacitor 1 (View 1)
289
290
Rain Sensor (View 1)
291
Rain Sensor (View 2)
Rain/Light Sensor
292
Rear Axle Multiple Circuit Junction Connector (View 1)
Rear Axle Multiple Circuit Junction Connector (View 2)
293
Rear Axle Sensor (headlamp Range Adjustment) (View 1)
Rear Axle Sensor (Headlamp Range Adjustment) (View 2)
294
Rear Blower Electronic Selector Wheel
Rear Blower Motor
295
Rear Blower Motor Control Module
Rear Dome Lamp
296
Rear Left Door Control Module (View 1)
Rear Left Door Control Module (View 2)
297
Rear Panel CL [ZV] Motor (View 1)
Rear Panel CL [ZV] Motor (View 2)
298
Rear Right Door Control Module (View 1)
Rear Right Door Control Module (View 2)
299
Rear SAM Control Module With Fuse And Relay Module (View 1)
Rear SAM Control Module With Fuse And Relay Module (View 1)
300
Rear Screen Blind Relay (View 1)
Rear Screen Blind Relay (View 2)
301
Rear Window Blind Motor
Recirculated Air Flap Actuator (View 1)
302
Recirculated Air Flap Actuator (View 2)
Refrigerant Pressure And Temperature Sensor (View 1)
303
304
305
Restraint Systems Control Module (View 1)
Restraint Systems Control Module (View 2)
306
RHR [KAF] Release Valve (View 1)
RHR [KAF] Release Valve (View 2)
307
Right Air Outlet Illumination
Right Blending Air Flap Actuator (View 1)
308
Right Blending Air Flap Actuator (View 2)
Right Camshaft Exhaust Solenoid (View 1)
309
Right Camshaft Exhaust Solenoid (View 2)
Right Camshaft Intake Solenoid (View 1)
310
Right Camshaft Intake Solenoid (View 2)
Right Defroster Vent Flap Actuator Motor (View 1)
311
Right Defroster Vent Flap Actuator Motor (View 2)
Right Electrically Adjustable And Heated Exterior Mirror
312
Right Exhaust Camshaft Hall Sensor (View 1)
Right Exhaust Camshaft Hall Sensor (View 2)
313
Right Exterior Mirror Turn Signal Lamp
Right Fog Lamp
314
Right Footwell Flap Actuator Motor (View 1)
Right Footwell Flap Actuator Motor (View 2)
315
Right Fresh Air Flap Actuator (View 1)
Right Fresh Air Flap Actuator (View 2)
316
Right Front Axle Multiple Circuit Junction Connector, In (View 1)
Right Front Axle Multiple Circuit Junction Connector, In (View 2)
317
Right Front Brake Pad Contact Sensor (View 1)
Right Front Brake Pad Contact Sensor (View 2)
318
Right Front Door CL Motor (View 1)
Right Front Door CL Motor (View 2)
319
Right Front Door Contact Switch (View 1)
Right Front Door Contact Switch (View 2)
320
Right Front Door Control Module (View 1)
Right Front Door Control Module (View 2)
321
Right Front Door Entrance And Exit Lamp
Right Front Door ESA [ESV] Switch Group (with Memory) (View 1)
322
Right Front Door ESA [ESV] Switch Group (with Memory) (View 2)
Right Front Door Mirror Triangle Speaker
323
Right Front Door Separation Point (View 1)
Right Front Door Separation Point (View 2)
324
Right Front Door Speaker
Right Front Headlamp Unit
325
Right Front IR Receiver
Right Front Power Window Motor
326
Right Front Seat Heated Cushion (View 1)
Right Front Seat Heated Cushion (View 2)
327
Right Front Side Airbag Ignition Squib
Right Front Side Marker Lamp {{USA}}
328
Right Front Wheel Speed Sensor
Right Fuel Level Sensor (View 1)
329
Right Fuel Level Sensor (View 2)
Right Intake Manifold Tumble Flap Position Sensor (View 1)
330
Right Intake Manifold Tumble Flap Position Sensor (View 2)
Right Knock Sensor 1 (View 1)
331
332
333
Right License Plate Lamp (View 1)
Right License Plate Lamp (View 2)
334
Right Multifunction Steering Wheel Pushbutton Group
Right O2 Sensor Downstream TWC [KAT] (View 1)
335
Right O2 Sensor Downstream TWC [KAT] (View 2)
Right O2 Sensor Upstream TWC [KAT] (View 1)
336
Right O2 Sensor Upstream TWC [KAT] (View 2)
Right Rear Brake Pad Contact Sensor (View 1)
337
Right Rear Brake Pad Contact Sensor (View 2)
Right Rear Door CL Motor
338
Right Rear Door Contact Switch
Right Rear Door Entrance And Exit Lamp
339
Right Rear Door Separation Point (View 1)
Right Rear Door Separation Point (View 2)
340
Right Rear ETR Ignition Squib (View 1)
Right Rear ETR Ignition Squib (View 2)
341
Right Rear Power Window Motor
Right Rear Power Window Switch
342
Right Rear Side Airbag Ignition Squib
Right Rear Side Marker Lamp (View 1)
343
Right Rear Side Marker Lamp (View 2)
Right Rear Surround Loudspeaker (View 1)
344
Right Rear Surround Loudspeaker (View 2)
Right Rear Wheel Speed Sensor
345
Right Rear Window Airbag Ignition (View 1)
Right Rear Window Airbag Ignition (View 2)
346
Right Rear Window Airbag Ignition Squib (View 1)
Right Rear Window Airbag Ignition Squib (View 2)
347
Right Side Airbag And Window Airbag Sensor (view 1)
Right Side Airbag And Window Airbag Sensor (view 2)
348
Right Taillamp
Right Trunk Lamp (View 1)
349
Right Trunk Lamp (View 2)
Right Vanity Mirror Illumination (View 1)
350
Right Vanity Mirror Illumination (View 2)
Right Voltage Distributor (CAN) Connector (View 1)
351
Right Voltage Distributor (CAN) Connector (View 2)
Right Rear Door Speaker
352
Roller Sun Blind Drive Unit
Roof Drive System
353
SDAR Control Unit (View 1)
SDAR Control Unit (View 2)
354
SDAR Trunk Lid Antenna Preinstallation Connector 1
SDAR Trunk Lid Antenna Preinstallation Connector 2
355
Sensor Ground Connector Sleeve (View 1)
356
357
358
359
360
361
362
Sensor Supply Connector Sleeve 1 (View 1)
Sensor Supply Connector Sleeve 1 (View 2)
363
Shielding Connector Sleeve (View 1)
Shielding Connector Sleeve (View 2)
364
Shielding Placed Inside Insulated Tubing (View 1)
Shielding Placed Inside Insulated Tubing (View 2)
365
SOS Pushbutton Switch (View 1)
SOS Pushbutton Switch (View 2)
366
Sound Amplifier Microphone (View 1)
Sound Amplifier Microphone (View 2)
367
Spark Plugs (View 1)
Spark Plugs (View 2)
368
SPS [PML] Connector (View 1)
SPS [PML] Connector (View 2)
369
SPS [PML] Solenoid Valve (View 1)
370
Starter (View 1)
371
Starter (View 2)
Starter (View 3)
372
Steering Angle Sensor (View 1)
Steering Angle Sensor (View 2)
373
Steering Column Adjustment Lock Indicator Switch
Steering Column Adjustment Switch
374
Steering Column Module (View 1)
Steering Column Module (View 2)
375
Stop Lamp Switch (4-pin) (View 1)
Stop Lamp Switch (4-pin) (View 2)
376
Subwoofer Speaker (View 1)
377
378
Sun Sensor Connector (View 1)
Sun Sensor Connector (View 2)
379
Super Charger Magnetic Clutch (View 1)
Super Charger Magnetic Clutch (View 2)
380
Tailgate Washer Fluid Pump (View 1)
Tailgate Washer Fluid Pump (View 2)
381
Tailgate Wiper Motor
Telephone Interface (View 1)
382
Telephone Interface (View 2)
Three-disk Thermostat Valve (View 1)
383
Three-disk Thermostat Valve (View 2)
Throttle Valve Actuator (View 1)
384
385
386
Traction System Hydraulic Unit (View 1)
387
Traction System Hydraulic System (View 2)
Transmission Mode Switch (View 1)
388
Transmission Mode Switch (View 2)
Transmitter Key
389
Trunk Lamp
Trunk Lid Contact Switch (View 1)
390
Trunk Lid Contact Switch (View 2)
Trunk Lid Emergency Release Switch (View 1)
391
Trunk Lid Emergency Release Switch (View 2)
Trunk Lid Exterial Operation Switch (View 1)
392
Trunk Lid Exterial Operation Switch (View 2)
Trunk Lid/FFS Separation Point (View 1)
393
Trunk Lid/FFS Separation Point (View 2)
394
TWC [KAT] Temperature Sensor (View 1)
395
TWC [KAT] Temperature Sensor (View 2)
UHI Portable CTEL Holder (Universal Handy Interface) (View 1)
396
UHI Portable CTEL Holder (Universal Hnady Interface) (View 2)
Universal Portable CTEL Interface (UPCI [UHI]) Control Module (View 1)
397
Universal Portable CTEL Interface (UPCI [UHI]) Control Module (View 2)
Upper Control Panel Control Module (View 1)
398
Upper Control Panel Control Module (View 2)
Variable Intake Manifold Switchover Valve (View 1)
399
Variable Intake Manifold Switchover Valve (View 2)
VCS [SBS] Switch
400
Voice Control System Control Module (View 1)
Voice Control System Control Module (View 2)
401
Wake-up Signal Connector (View 1)
Wake-up Signal Connector (View 2)
402
Walkman Separation Point (View 1)
Walkman Separation Point (View 2)
403
Washer Nozzle Heater (View 1)
Washer Nozzle Heater (View 2)
404
Washer Nozzle Heater Connector (2-pin) (View 1)
Washer Nozzle Heater Connector (2-pin) (View 2)
405
Washer Nozzle Hose Heater (View 1)
Washer Nozzle Hose Heater (View 2)
406
Washer Nozzle Hose Heater Connector (View 1)
Washer Nozzle Hose Heater Connector (View 2)
407
Windshield Washer Fluid Level Indicator Switch (View 1)
Windshield Washer Fluid Level Indicator Switch (View 2)
408
Windshield Washer Fluid Pump (View 1)
Windshield Washer Fluid Pump (View 2)
409
Wiper Motor (View 1)
Wiper Motor (View 2)
410
WSS Control Unit (Weight Sensing System) (View 1)
WSS Control Unit (Weight Sensing System) (View 2)
411
B1.1 - Engine Compartment (Left)
412
413
A7/7x1 - X62/7
B1.2 - Engine Compartment (Right)
414
X28/26 - X88/11
B1.3 - Interior Compartment (Cockpit)
415
X30/6(4) - X30/6(6)
B1.4 - Interior Compartment (Left)
416
417
H4/5x1 - X11/4
418
X18/23 - X35/1(2)
419
X35/1(4) - X55/3(D)
B1.5 - Interior Compartment (Right)
420
421
B25/6x1 - X30/4(9)
422
X30/4(10) - X58/3(3)
B1.6 - Trunk (Right)
423
X62/8(1) - X62/8(4)
424
425
W11/3 - W16/5
426
W10 - W16/6
B2.3 - Cockpit
427
W26
B2.4 - Interior Compartment (Left)
W28/1 - W29/3
428
W28/2
B2.6 - Trunk (Left)
429
W6
B2.7 - Trunk (Right)
430
W7
Z3/29 - Z85
431
Z3/29 - Z85
432
Z6/8 - Z85
B3.3 - Cockpit
433
Z6/30 - Z81/4
434
Z6/1 - Z7
B3.5 - Trunk (Left)
435
Z10
1
Vehicle: Electrical Diagrams
Accessory Control Display

Cockpit Management and Data System (COMAND) Control Module PE82.85-U-2101FG
Wiring Diagram, Part 1
2
3
4
5
6
Component Description/Coordinates, A2/23 To U208
7
Component Description/Coordinates, U500 To X120
Component Locations: Component Location photographs can be found via their component names at the vehicle level. See:
Locations/Component Locations
Electrical Diagrams
PE42.45-U-2101FB Electronic Stability Program (ESP)
8
9
10
Wiring Diagram PE42.45-U-2101FB
11
Connector A7/7
Connector N10/1
12
13
Connector N47-5
Connector N49
Connector X26/22 (X28/26)
14
Connector X63/4
Function Diagrams
Function Diagram For Electronic Stability Program (ESP) PE42.45-U-2050FA
- with CODE (472) Electronic Stability Program (ESP)
Function Diagram, Part 1
15
16
Component Description/Coordinates, A1 To Y3/8
Wheel Speed Sensor
For information regarding diagrams for this component, please refer to Vehicle Speed Sensor diagrams.
Anti-Theft Alarm System (ATA) PE80.50-U-2000FA, Sheet 1
PE80.50-U-2000FA Anti-Theft Alarm System (ATA), Sheet 1
17
18
19
Component Description/Coordinates, A1 To X63/4
Anti-Theft Alarm System (ATA) PE80.50-U-2000FB, Sheet 2
Anti-Theft Alarm System (ATA) PE80.50-U-2000FB, Sheet 2
20
21
22
23
24
Component Description,Coordinates, A2/71 To Z21/27
Drive Authorization System (DAS) PE80.57-U-2000FA

Drive Authorization System (DAS) PE80.57-U-2000FA
25
26
27
28
29
30
Component Description/Coordinates, A1 To Z81
Function Schematic For Antitheft Alarm (ATA) PE80.50-U-2050FA

Function Schematic For Antitheft Alarm (ATA) PE80.50-U-2050FA
31
32
33
34
Component Description/Coordinates, A1 To S17/3
Component Description/Coordinates, S17/4 To U208
Function Schematic For Drive Authorization System (DAS) PE80.57-U-2050FA
Function Schematic For Drive Authorization System (DAS) PE80.57-U-2050FA
35
Function Diagram
36
Automatic Transmission/Transaxle
For information regarding diagrams for this system, please refer to Transmission Control Systems diagrams. See: Powertrain
Management/Transmission Control Systems/Diagrams
Lower Control Panel (LCP) PE54.21-U-2120FA
Lower Control Panel (LCP) PE54.21-U-2120FA
Lower Control Panel Control Module (N72)
37
Lower Control Panel Control Module (N72)
38
Overhead Control Panel (OCP) PE54.21-U-2107FB

Overhead Control Panel (OCP) Control Module PE54.21-U-2107FB
39
40
41
Component Description/coordinates, A67 To X30/6
Connectors 1 - 4 PE54.21-U-2106FA (Sheet 1)

SAM Control Module With Front Fuse and Relay Module (N10/1) - PE54.21-U-2106FA
42
43
Wiring Diagram PE54.21-U-2106FA
44
Pin Information, Part 1
45
Connectors 5, 6, 24 PE54.21-U-2106FB (Sheet 2)

SAM Control Module With Front Fuse and Relay Module (N10/1) - PE54.21-U-2106FB
46
47
48
49
Connectors 16, 19, 20 PE54.21-U-2106FC (Sheet 3)

SAM Control Module With Front Fuse and Relay Module (N10/1) - PE54.21-U-2106FC
50
51
52
53
54
Wiring Diagram PE54.21-U-2106FC
55
56
Connectors 9, 10, 17, 18, 22 PE54.21-U-2106FD (Sheet 4)

SAM Control Module With Front Fuse and Relay Module (N10/1) - PE54.21-U-2106FD
57
58
Wiring Diagram PE54.21-U-2106FD
59
Pin Information
Connectors 11 - 15, 21, 23 - 26 PE54.21-U-2106FE (Sheet 5)

SAM Control Module With Front Fuse and Relay Module (N10/1) - PE54.21-U-2106FE
60
61
62
Wiring Diagram PE54.21-U-2106FE
63
Connector Assignment
64
65
Connector A2
Connector A35/17
Connector N10/1
Connector N96
66
Connector X18/37
Connectors 3, 7, 8 PE54.21-U-2106FF (Sheet 6)

SAM Control Module With Front Fuse and Relay Module (N10/1) - PE54.21-U-2106FF
Wiring Diagram PE54.21-U-2106FF
67
Pin Information
68
Connector N10/1
69
70
Connector N47-5
Connector N49
Connector X26/22 (X28/26)
Connectors 1 - 4 PE54.21-U-2108FA (Sheet 1)

SAM Control Module With Rear Fuse and Relay Module (N10/2) - PE54.21-U-2108FA
71
72
73
74
75
Connectors 15 - 28 PE54.21-U-2108FB (Sheet 2)

SAM Control Module With Rear Fuse and Relay Module (N10/2) - PE54.21-U-2108FB
76
77
78
79
Connectors 5 - 14 PE54.21-U-2108FC (Sheet 3)

SAM Control Module With Rear Fuse and Relay Module (N10/2) - PE54.21-U-2108FC
80
81
Wiring Diagram PE54.21-U-2108FC
82
83
Upper Control Panel (UCP) PE54.21-U-2119FA

Upper Control Panel (UCP) PE54.21-U-2119FA
84
85
86
Pin Information
Cellular Telephone (CTEL) PE82.70-U-2101FD

PE82.70-U-2101FD Cellular Telephone (CTEL)
87
88
Wiring Diagram PE82.70-U-2101FD
89
Pin Information
Emergency Call System (ECS) PE82.95-U-2101FF

Emergency Call System Control Module PE82.95-U-2101FF
- with CODE (359) TELE AID emergency call system
90
91
92
93
Component Description/Coordinates, A2 To Z81/4
Function Diagrams
Function Diagram For TELE AID Emergency Call System PE82.95-U-2050FB
- with CODE (359) TELE AID emergency call system
94
95
Component Description/Coordinates, A1 To U631
96
Emergency Contact Button
For wiring diagrams for this system please refer to Cellular Phone diagrams. See: Accessories and Optional Equipment/Cellular Phone/Diagrams
Emergency Contact Module
For wiring diagrams for this system please refer to Cellular Phone diagrams. See: Accessories and Optional Equipment/Cellular Phone/Diagrams
Garage Door Opener Transmitter
Function Diagram Of Electrical System Of Garage Door Opener PE68.05-U-2050FA
Function Diagram
Component Description/Coordinates, A67 To N73
Electrical Diagrams
Rear Window Defroster PE67.29-U-2000FA
97
Rear Window Defroster
98
99
100
Function Diagrams
Function Diagram For Heated Rear Window PE67.29-U-2050FA
101
Function Diagram
Component Description/Coordinates, B14 To U673
Electrical Diagrams
Automatic Air Conditioning (AAC) PE83.40-U-2101FA
102
103
104
105
106
Function Diagram, Interior Climate Control PE83.40-U-2050FA

Function Diagram, Interior Climate Control PE83.40-U-2050FA
107
108
Function Diagram, Interior Climate Control PE83.40-U-2050FB
Function Diagram, Interior Climate Control PE83.40-U-2050FB
109
110
111
Component Description/Coordinates, A9 To N69/3
Component Description/Coordinates, N69/4 To U58
Electrical Diagrams
Instrument Cluster (CLUS) PE54.30-U-2101FA
112
113
114
Pin Information
Function Diagrams
Function Diagram Of Instrument Cluster (IC) PE54.30-U-2051FA
115
116
117
118
Component Description/Coordinates, N15/5 To Y3/8
Cigarette Lighter
Cigarette Lighter wiring is included in the Interior Lights diagrams. See: Lighting and Horns/Diagrams
Fuel Gauge
For information regarding diagrams for this component, please refer to Instrument Panel, Gauges and Warning Indicators diagrams. See: Instrument
Panel, Gauges and Warning Indicators/Diagrams
Fuel Gauge Sender
Instrument Cluster / Carrier
Outside Temperature Display
Speedometer Head
119
Tachometer
Temperature Sensor (Gauge)
Exterior Lights PE82.10-U-2000FA (Part 1)
Exterior Lights PE82.10-U-2000FA (Part 1)
120
121
122
123
124
125
126
127
Exterior Lights PE82.10-U-2000FB (Part 2)

Exterior Lights PE82.10-U-2000FB (Part 2)
128
129
130
131
132
Stop Lamp PE82.10-U-2300FA

Stop Lamp PE82.10-U-2300FA
133
Component Description/Coordinates, A2/95X1 To Z4/3
Function Diagram of Fanfare Horn System (FAN) PE54.35-U-2050FA
Function Diagram Of Fanfare Horn System (FAN) PE54.35-U-2050FA
134
Function Diagram
Component Description/Coordinates, H2 To S111s5
Function Diagram For Exterior Lights PE82.10-U-2051FA
Function Diagram For Exterior Lights PE82.10-U-2051FA
- High beam, low beam
135
136
Component Description/Coordinates, A1 To S4
Function Diagram For Exterior Lights PE82.10-U-2051FB
Function Diagram For Exterior Lights PE82.10-U-2051FB
- Automatic headlamp actuation
137
Component Description/Coordinates, B38 To S4
Function Diagram For Exterior Lights PE82.10-U-2051FC
138
Function Diagram For Exterior Lights PE82.10-U-2051FC

- Daytime running lamps (steady light)
Function Diagram
Function Diagram For Exterior Lights PE82.10-U-2051FD
Function Diagram For Exterior Lights PE82.10-U-2051FD
- Standing lamp, parking lamp
139
Function Diagram
Component Description/Coordinates, E1e3 To S1
Function Diagram For Exterior Lights PE82.10-U-2051FE
Function Diagram For Exterior Lights PE82.10-U-2051FE
- Backup lamp
140
Function Diagram
Component Description/Coordinates, E3e3 To U25
Function Diagram For Exterior Lights PE82.10-U-2051FF
Function Diagram For Exterior Lights PE82.10-U-2051FF
- Front fog lamp, rear fog lamp
141
Function Diagram
Component Description/Coordinates, E1e2 To S1e1
Function Diagram For Exterior Lights PE82.10-U-2051FG
Function Diagram For Exterior Lights PE82.10-U-2051FG
- Turn signals
142
143
Function Diagram For Exterior Lights PE82.10-U-2051FH
Function Diagram For Exterior Lights PE82.10-U-2051FH
- Hazard warning flasher
144
145
Component Description/Coordinates, A1 To N72/1s5
Function Diagram For Exterior Lights PE82.10-U-2051FI
Function Diagram For Exterior Lights PE82.10-U-2051FI
- Turning lamps
146
Function Diagram For Exterior Lights PE82.10-U-2051FJ
Function Diagram For Exterior Lights PE82.10-U-2051FJ
147
- Stop lamp
Function Diagram
Component Description/Coordinates, E3e4 To S9/1
Function Diagram For Exterior Lights PE82.10-U-2051FK
Function Diagram For Exterior Lights PE82.10-U-2051FK
- Low beam actuation, for xenon headlamp assembly
148
Function Diagram
149
Function Diagram For Interior Lights PE82.20-U-2050FA
Function Diagram For Interior Lights PE82.20-U-2050FA
- Interior light (overhead control panel and rear)
Function Diagram
Function Diagram For Interior Lights PE82.20-U-2050FB
Function Diagram For Interior Lights PE82.20-U-2050FB
- Entrance illumination
150
Function Diagram
Component Description/Coordinates, E17/3 To U58
Backup Lamp
For information regarding diagrams for this component, please refer to Lighting and Horns diagrams. See: Lighting and Horns/Diagrams
Brake Lamp
151
Center Mounted Brake Lamp
Courtesy Lamp
Daytime Running Lamp
Dome Lamp
Fog/Driving Lamp
Hazard Warning Lamps
System Diagram
Headlamp Control Module
Horn
License Plate Lamp
Marker Lamp
Parking Lamp
Tail Lamp
Turn Signals
Vanity Lamp
Electrical Diagrams
Electric Circuit Wiring Diagram Comfort Lock System PE80.45-U-2000FA
152
153
154
Component Description/coordinates, B38 To X18/23
Function Schematic For Central Locking (CL) PE80.20-U-2050FA

Function Schematic For Central Locking (CL) PE80.20-U-2050FA
155
156
157
158
Function Schematic For Convenience Closing System PE80.45-U-2050FA
Function Schematic For Convenience Closing System PE80.45-U-2050FA
159
Function Diagram
160
Door Control Module (DCM) Front Left PE72.29-U-2101FA
Door Control Module (DCM) Front Left PE72.29-U-2101FA
161
162
163
164
Component Description/coordinates, A26/1 To X35/1
Door Control Module (DCM) Front Right PE72.29-U-2102FA

Door Control Module (DCM) Front Right PE72.29-U-2102FA
165
Wiring Diagram,part 1
166
167
168
169
Component Description/coordinates, A26/2 To X35/2
Door Control Module (DCM) Rear Left PE72.29-U-2103FA

Door Control Module (DCM) Rear Left PE72.29-U-2103FA
170
171
Component Description/coordinates, E17/5 To X35/4
Door Control Module (DCM) Rear Right PE72.29-U-2104FA

Door Control Module (DCM) Rear Right PE72.29-U-2104FA
172
173
Component Description/coordinates, E17/3 To X35/4
174
Electrical Diagrams
Manual Transmission (MT) PE26.19-U-2000FA
- Transmission 716.6
175
176
177
178
Function Diagrams
Electrical Function Diagram For Manual Transmission PE26.19-U-2050FA
179
Function Diagram
Component Description/Coordinates, E3e3 To U521
Auto Dimming Inside Rear View Mirror PE68.49-U-2000FA
Auto Dimming Inside Rear View Mirror PE68.49-U-2000FA
180
Automatic Dimming Inside Rear View Mirror
181
182
183
184
185
Vanity Mirror PE68.69-U-2000FA

Vanity Mirror PE68.69-U-2000FA
186
Vanity Mirror
187
Vanity Mirror
188
Function Diagram For Vanity Mirror PE68.69-U-2050FA

Electrical Function Diagram For Vanity Mirror PE68.69-U-2050FA
Function Diagram
189
Component Description/Coordinates, E14/1 To N73
Function Diagram of Automatic Inside Rearview Mirror Dimming PE68.49-U-2050FA
Function Diagram Of Automatic Inside Rearview Mirror Dimming PE68.49-U-2050FA
- with CODE (249) Automatically dimming inside rearview mirror
Function Diagram
190
Component Description/Coordinates, A67 To S16/5
Function Schematic For Mirror Adjustment PE88.79-U-2050FA
Function Schematic For Mirror Adjustment PE88.79-U-2050FA
Function Diagram
191
Component Description/Coordinates, M21/1 To S1s6
ME-SFI Fuel Injection/Ignition System PE07.61-U-2101FL (Sheet 1)
ME-SFI Fuel Injection And Ignition System Control Module PE07.61-U-2101FL (Sheet 1)
- ME 9.7
192
193
194
Component Description/Coordinates, B4/3 To Z7/38z2
ME-SFI Fuel Injection/Ignition System PE07.61-U-2101FM (Sheet 2)

ME-SFI Fuel Injection And Ignition System Control Module PE07.61-U-2101FM (Sheet 2)
- ME 9.7
195
196
197
198
199
200
201
Component Description/Coordinates, A16/1 To N3/10
202
203
Component Description/Coordinates, Y49/5 To Z7/44
Function Diagrams
Function Diagram Of Electrical System For ME Engine Control PE07.61-U-2050FA
- ME 9.7
204
205
206
207
Component Description/Coordinates, N10/2kA To Y110
System Diagram
For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams
Data Link Connector
Datalink Connector/Diagnostic Socket PE54.22-U-2000FA
208
PE54.22-U-2000FA
209
Pin Information
Engine Control Module

CAN Bus - Engine Compartment PE00.19-U-2200FA
CAN Bus - Engine Compartment PE00.19-U-2200FA
- CAN Voltage distributor (X63/4)
210
211
212
Pin Information
CAN Bus - Interior Compartment PE00.19-U-2300FB (Sheet 2)

CAN Bus - Interior Compartment PE00.19-U-2300FB (Sheet 2)
- CAN Voltage distributor (X30/6)
213
214
215
Pin Information
CAN Bus - Interior Compartment PE00.19-U-2300FC (Sheet 1)

CAN Bus - Interior Compartment PE00.19-U-2300FC (Sheet 1)
- CAN Voltage distributor (X30/4, X30/7)
216
CAN Bus - Interior Compartment
217
218
219
220
221
222
Legend 1 of 2
223
Legend 2 of 2
MOST Bus PE82.00-U-2710FA

Most Bus PE82.00-U-2710FA
224
225
Emission Control Systems

System Diagram
Fuel Pump
Function Diagram For Fuel Pump PE47.20-U-2050FA
226
Function Diagram
Ignition System
Radio (RD) Control Module PE82.60-U-2101FC
Radio (RD) Control Module PE82.60-U-2101FC
227
- except CODE (810) Sound system
228
229
230
231
Component Description/coordinates, A2 To X39/45
Satellite Digital Audio Radio (SDAR) System PE82.60-U-2300FA

Satellite Digital Audio Radio System (SDAR) PE82.60-U-2300FA
232
Wiring Diagram
Component Description/coordinates, A2/95x1 To Z4/3
Amplifier, Sound System

Sound Amplifier Control Module PE82.62-U-2101FC
233
234
Component Description/coordinates, A2/13 To Z20/26
CD Changer
CD Changer (CDC) Control Module PE82.64-U-2101FB
- with CODE (819) CD Changer
235
Wiring Diagram
Component Description/coordinates, A2/6 To W18
Electrical Diagrams
Airbag Control Module PE91.60-U-2101FB
236
237
238
239
240
241
Component Description/Coordinates, X35/4 To Z53/9
Function Diagrams
Function Diagram For Airbag PE91.60-U-2051FA
- with CODE (442) Airbag in steering wheel
- with CODE (292) Left and right front sidebag
- with CODE (293) Left and right rear sidebag
- with CODE (290) Windowbag
242
243
244
Retractable Rear Head Restraints
For information regarding diagrams for the Retractable Rear Head Restraints, please refer to the Seats diagrams. See: Body and
Frame/Seats/Diagrams
Air Bag Control Module
For diagrams for this component please refer to Restraint Systems diagrams. See: Restraint Systems/Diagrams
Clockspring Assembly / Spiral Cable, Air Bag
Seat Belt Control Module
Seat Occupant Sensor
Driver's Seat Control Module PE91.29-U-2104FB
Driver-Side Seat Control Module PE91.29-U-2104FB
245
246
Component Description/Coordinates, F34 To X30/7
247
Electrical Seat Adjustment (ESA) PE91.29-U-2000FA
Electrical Seat Adjustment (ESA) PE91.29-U-2000FA
248
249
Pin Information
Heated Seats (HS) PE91.30-U-2000FA

Heated Seats (HS) PE91.30-U-2000FA
250
Heated Seats (HS)
251
Heated Seats (HS)
252
Heated Seats (HS)
253
Heated Seats (HS)
Passenger Seat Control Module PE91.29-U-2105FB

Front Passenger-Side Seat Control Module PE91.29-U-2105FB
254
255
NECK-PRO Head Restraints PE91.16-U-2100FA

NECK-PRO Head Restraints PE91.16-U-2100FA
256
- with CODE (438) NECK-PRO
Wiring Diagram
Function Diagram, Heated Seats (HS) PE91.30-U-2050FA
Function Diagram, Heated Seats (HS) PE91.30-U-2050FA
- with CODE (873) Heated left and right front seats
257
Function Diagram
Component Description/Coordinates, N72/1 To R13/4
Function Diagram, Seat Adjustment (ESV) PE91.29-U-2050FA
Function Diagram, Seat Adjustment (ESV) PE91.29-U-2050FA
- with memory
258
259
260
Power Seat Control Module
For information regarding diagrams for this system, Please refer to Seat diagrams. See: Body and Frame/Seats/Diagrams
Seat Heater
For diagrams for this system please refer to Seats. See: Body and Frame/Seats/Diagrams
Electrical Diagrams
Starter, Generator, Battery PE15.00-U-2101FC
261
262
Function Diagrams
Electrical Function Diagram For Starter, Alternator, Battery PE15.00-U-2050FA
263
Function Diagram
Circuit 15/15R Wiring PE00.19-U-2720FA
264
Circuit 15/15R Wiring PE00.19-U-2720FA
265
266
Component Description/Coordinates, A35/17 To Z3/31
Circuit 30 Wiring PE00.19-U-2710FA

Circuit 30 Wiring PE00.19-U-2710FA
267
268
Front Backup Fuse Box (F32) PE54.15-U-2502FA

Front Backup Fuse Box (F32) PE54.15-U-2502FA
269
270
Pin Information
Ground Wiring PE00.19-U-2800FA (Sheet 1)

271
272
273
274
275
Component Description/Coordinates, A2/13 To S93/6
276
Component Description/Coordinates, U16 To Z83/6
Ground Wiring PE00.19-U-2800FB (Sheet 2)
277
278
279
280
281
282
283
Component Description/coordinates, A1 To N80
284
Component Description/coordinates, R3 To U597
285
Component Description/coordinates, U673 To X120
Ground Wiring PE00.19-U-2800FC (Sheet 3)

Ground Wiring PE00.19-U-2800FC (sheet 3)
- W26, W28/1, W28/2
286
287
288
289
290
Component Description/Coordinates, R3 To Z53/9
Interior Fuse Box (F34) PE54.15-U-2501FA (Sheet 1)
Interior Fuse Box (F34) PE54.15-U-2501FA (Sheet 1)
291
292
293
294
295
Pin Information
Interior Fuse Box (F34) PE54.15-U-2501FB (Sheet 2)

Interior Fuse Box (F34) PE54.15-U-2501FB (Sheet 2)
296
Interior Fuse Box
297
Interior Fuse Box
298
Interior Fuse Box
299
Interior Fuse Box
300
Interior Fuse Box
301
Legend 1 Of 2
302
Legend 2 Of 2
Solder Joints/Z Connector Sleeves PE00.19-U-2600FA (Sheet 1)

Solder Joints/Z Connector Sleeves PE00.19-U-2600FA (Sheet 1)
- Z3/31, Z4/3, Z4/10, Z7/35z1, Z7/35z2
303
304
305
306
307
308
Component Description/Coordinates, A35/17 To R4
309
Component Description/Coordinates, T1/1 To X55/4
310
Component Description/Coordinates, Y62 To Z7/35z2
Solder Joints/Z Connector Sleeves PE00.19-U-2600FB (Sheet 2)
Solder Joints/Z Connector Sleeves PE00.19-U-2600FB (Sheet 2)
- Z7/36, Z7/36z2, Z7/38z1, Z7/38z2
311
312
313
314
315
316
Component Description/Coordinates, B2/5 To G3/6x1
317
Component Description/Coordinates, M4/7 To Y22/6
318
Component Description/Coordinates, Y22/9 To Z7/36
Component Description/Coordinates, Z7/36z1 To Z7/38z2
Connector Separation Points PE54.18-U-2300FA
Connector Separation Points PE54.18-U-2300FA
319
320
321
322
323
324
Component Description/Coordinates, U739 To Z81/4
Fuse
For information regarding diagrams for this component, please refer to Power and Ground Distribution diagrams. See: Power and Ground
Distribution/Diagrams
Fuse Block
Relay Box
Alternator
For information regarding diagrams for this component, please refer to Starting and Charging diagrams. See: Starting and Charging/Diagrams
Ignition Switch
Electronic Ignition Switch (EIS) PE54.21-U-2104FB
325
Electronic Ignition Switch (EIS) Control Module
326
Electronic Ignition Switch (EIS) Control Module
327
Legend
Electrical Diagrams
Electric Steering Column Adjustment PE46.15-U-2000FA
328
329
330
331
332
333
Component Description/coordinates, A1 To Z81
Function Diagrams
Function Diagram For Steering Column Adjustment PE46.15-U-2050FA
- with memory
334
Function Diagram
Component Description/Coordinates, A1 To S91/2s13
Steering Column Control Module
Electric Steering Column (ESC) Control Module PE46.10-U-2101FA
335
Steering Column Module Control Module
336
337
338
339
Legend
Electrical Diagrams
Tilting/Sliding Roof (SR) PE77.20-U-2000FA
340
Sliding/Tilting Roof (SR)
341
342
343
344
345
346
347
348
Function Diagrams
Function Diagram For Tilting/Sliding Roof (SHD) PE77.20-U-2050FA
- with CODE (414) Power glass tilting/sliding roof (model 203.0/2)
- with CODE (413) Panoramic glass roof with top sliding roof (model 203.7)
Function Diagram
349
Electronic Selector Module Control Module PE27.19-U-2102FA
PE27.19-U-2102FA Electronic Selector Module Control Module
- Transmission 722.6/9
350
Pin Information
Electronic Transmission Control (ETC) PE27.19-U-2101FA
PE27.19-U-2101FA Electronic Transmission Control (ETC) Control Module
351
352
353
Electronic Transmission Control (ETC) Control Module PE27.19-U-2101FB

Electronic Transmission Control (ETC) Control Module PE27.19-U-2101FB
Wiring Diagram
354
Component Description/Coordinates, N10/1 To Y3/8y8
Function Diagram For Electronic Transmission Control (ETC) PE27.19-U-2050FA
Function Diagram For Electronic Transmission Control (ETC) PE27.19-U-2050FA
355
356
357
Function Diagram For Electronic Transmission Control (ETC) PE27.19-U-2050FB
Function Diagram For Electronic Transmission Control (ETC) PE27.19-U-2050FB
358
Voice Activation System
PE82.70-U-2102FB Voice Control System (VCS)
- with CODE (813) Voice control system (VCS [SBS])
359
Wiring Diagram
360
361
System Diagram
Function Schematic For Power Window PE72.29-U-2050FA
362
363
Electrical Diagrams
Rear Sun Shade PE68.50-U-2000FA
364
Rear Sun Shade
365
Rear Sun Shade
366
Rear Sun Shade
367
Function Diagrams
Electrical Function Diagram For Rear Sun Shade PE68.50-U-2050FA
- with CODE (540) Electric rear window roller blind
368
Function Diagram
Component Description/Coordinates, K74 To N73
Headlamp Cleaning System (HCS) PE82.15-U-2000FA
Headlamp Cleaning System (HCS) PE82.15-U-2000FA
369
370
371
Windshield Wipers (Part 1) PE82.30-U-2000FA
Windshield Wipers (Part 1) PE82.30-U-2000FA
Windshield Wiper
372
Windshield Wiper
373
Windshield Wiper
374
375
Windshield Wiper
376
Windshield Wiper
377
Windshield Wiper
378
Windshield Wiper
379
Legend For Wiring Diagram Of Windshield Wiper - 203
Windshield Wipers (Part 2) PE82.30-U-2000FB
Windshield Wipers (Part 2) PE82.30-U-2000FB
380
Windshield Wiper
381
382
Windshield Wiper
383
Windshield Wiper
384
385
Windshield Wiper
386
Windshield Wiper
387
Legend For Wiring Diagram Of Windshield Wiper - 203
Function Diagram For Windshield Wiper PE82.30-U-2050FA
Function Diagram For Windshield Wiper PE82.30-U-2050FA
388
389
390
Function Diagram For Headlamp Cleaning System (HCS) PE82.15-U-2050FA
Function Diagram For Headlamp Cleaning System (HCS) PE82.15-U-2050FA
391
Function Diagram
Component Description/Coordinates, M5/2 To S1s7
1
Technical Service Bulletins
All Technical Service Bulletins:

Number Date Name
S-54_21-234A Oct 10 Electrical - Aftermarket Tampering Malfunctions
S-80_57-56 Sep 10 Audio System - Radio Interruption Information
S-00_45-94 Aug 10 Chemicals/Lubrication - Multi-Grade Metal Grease Info.
S-98_00-28 Aug 10 Paint - Clearcoat With Higher Scratch Resistance
S-27_19-118A Jun 10 AT - Electrohydraulic Control Unit Order Notes Update
S-91_60-193 Jun 10 Restraints - Air Bag Durability And Reliability
LI27-50_P-049281 Apr 10 A/T - Harsh Engagement From Park To Drive
LI27-00_P-049253 Apr 10 A/T - Hard Converter Lock-Up/Hard 1-2 Shift
S-01_20-32 Apr 10 Engine - Cylinder Head Cover Leak Information
S-01_30-28A Mar 10 Engine - Misfire Or Oil Consumption Service Guidelines
LI91-16_P-048507 Mar 10 Interior - Creaking Noise From Seat Head Restraints
LI91-10_P-048503 Mar 10 Interior - Grunting/Ripping Noise At Front Seat-Back
LI91-10_P-048498 Mar 10 Interior - Front Seat Noise
LI91-10_P-048497 Mar 10 Interior - Front Seat Backrest Noise
LI58-40_P-049268 Mar 10 Computer/Controls - XD/DAS Add-On 2009-11-27-1321
LI82-60_P-0479903 Mar 10 Audio Sys. - iPod(R)/iPhone(R) Will Not Charge
S-98_00-13R Mar 10 Paint/Body - MBUSA Approved Refinishing Products Update
LI13-20_P-049041 Mar 10 Engine - Squeaking Noises From The Belt Drive
LI58-40_P-049123 Mar 10 Computers/Controls - DAS/XD add-on 2010-02-03-1352
LI58-40_P-049122 Mar 10 Computers/Controls - DAS/XD add-on 2010-01-15-1348
LI01-30_P-048997 Mar 10 Engine - Oil Leaks At Back Of Engine
S-01_30-31B Feb 10 BULLETIN OBSOLETE - REFER TO BULLETIN S-01_30-23B
S-68_00-81 Jan 10 Interior - Floor Mat Safety Information
S-46_25-70 Jan 10 Steering - Approved Hydraulic Fluids
LI33-15_P-0474712 Jan 10 Suspension - Front Axle Area Noise When Maneuvering
LI58-40_P-048776 Jan 10 Computers/Controls - DAS/XD Add-On 2009-12-03-1314
LI58-40_P-048775 Jan 10 Computers/Controls - DAS/XD Add-On 2009-11-27-1321
LI58-40_P-048666 Dec 09 Computer/Controls - DAS/XD Add-On 2009-11-27-1321
LI58-40_P-048663 Dec 09 Computer/Controls - DAS/XD Add-On 2009-11-18-1311
LI58-40_P-048537 Nov 09 Computer/Controls - DAS/XD Add-On 2009-10-21-1289
LI58-40_P-048527 Nov 09 Computer/Controls - DAS/XD 2009-10-05-1274
LI58-40_P-048530 Nov 09 Computers/Control - DAS/XD Add-On 2009-10-09-1280
LI80-57_P-0469352 Oct 09 Antitheft System - DAS3 Diagnosis/Replacement Info.
2008070001A Oct 09 Recall - ECM Update For Various Issues
LI82-10_P-045451 Oct 09 Lighting - Exterior Light Bulb Replacement
S-01_10-29A Sep 09 Engine - Surface Cleaning Recommendations/Precautions
LI58-40_P-048049 Sep 09 Computer/Control System - DAS/XD Software Update
LI58-40_P-048053 Sep 09 Computers/Controls - DAS Software Update
LI82-10_P-047936 Sep 09 Lighting - Automatic Lights Switch OFF Too Late
LI82-70_P-047462 Aug 09 Cell Phone - iPhone(R) Music Won't Mute During Call
2009060005 Aug 09 Recall - ECM Update For EVAP Diagnostics
LI01-45_P-047548 Aug 09 Engine - Oil Level Message General Information
S-00_20-91 Jul 09 Vehicle - Maintenance Systems Overview
LI83-00_P-047480 Jul 09 A/C - No Or Insufficient Cooling Output
S-67_10-27 Jul 09 Body - Windshield/Window Glass Bonding System
LI91-25_P-047234 Jul 09 Interior - Seat Backrest Control Valve Switch Broken
LI27-00_P-047119 Jun 09 A/T - 722.9, Delayed Reverse Engagement
LI46-20_P-047170 Jun 09 Steering - Squealing/Squeaking Noise When Turning
S-03_30-08J Jun 09 Engine - Multiple DTC's Set/MIL ON
S-42_10-111 Jun 09 Brakes - Caliper Bolt Replacement Information
S-42_10-110 Jun 09 Brakes - Brake Pad Paste Usage
S-42_10-109 Jun 09 Brakes - Brake Component Corrosion Information
S-83_30-74P Jun 09 A/C - Musty/Moldy Odor Issues
S-82_35-621A Jun 09 Wipers/Washers - Wiping Quality Maintenance
S-18_00-37F Jun 09 Engine - Low Oil Level Symptoms/Diagnostics
S-01_00-27 May 09 Engine - Cylinder Wall Inspection
P-63_50-20 May 09 Body - Rear Fender Corrosion
S-82_10-680 May 09 Lighting - Xenon Headlamp Brightness Explanation
S-82_70-686A May 09 Cell Phone - Bluetooth(R)/Cell Phone Diagnostic Tool
S-46_30-21B May 09 Steering, A/C - Grinding/Gushing Noises
S-82_60-690 May 09 Audio System - Copy Protected CD Information
S-27_50-59G May 09 A/T - Limp Home Mode/DTCs 2200/2201/2767/2768
2

Number Date Name
P-64_00-02 May 09 Body/Frame - Tail Lamp Cutout Tool Information

S-82_85-615B Apr 09 COMAND(R) - Inoperative Or Opening/Closing Errors
P-83_00-70D Apr 09 A/C - A/C Lamp Flashing/A/C Inoperative
S-27_19-82D Mar 09 A/T - Electro-Hydraulic Control Module ID/Ordering
S-82_70-475A Mar 09 Cell Phone - Calls Dropped Or Cut Off
S-91_40-130A Mar 09 Restraints - Seat Belts Don't Retract Properly
S-14_30-15F Mar 09 Emissions - Multiple Codes Set/MIL ON
S-83_55-87F Mar 09 A/C - Various Compressor Noise With A/C ON
S-40_10-69 Mar 09 Wheels/Tires - Alloy Wheel Radial Crack Information
S-83_55-118 Mar 09 A/C - No Or Low A/C Cooling Performance
S-35_00-08 Mar 09 Drivetrain - Axle Mount Service Guidelines
P-46_20-16E Feb 09 Steering - Leaks At Steering Gear/Hose Junction
S-82_85-544A Feb 09 Audio System - Various iPod(R) Malfunctions
S-54_21-215 Feb 09 Engine Controls - Engine Won't Start When Hot
S-46_10-68 Feb 09 Interior - Leather/Wood Steering Wheel Imperfections
S-67_00-25 Feb 09 Body - New Window Glazing Adhesive Repair Kit
S-40_10-66 Feb 09 Wheels - Approved Alloy Wheel Cleaning Product
S-46_50-34A Feb 09 Steering - Speed Sensitive Steering Malfunctions/DTC's
S-40_15-65 Jan 09 Tire Monitor System - Steel Valve Stem Cap Precautions
S-03_30-11 Jan 09 A/T, M/T - Flywheel/Flexplate Replacement Information
S-54_10-213 Jan 09 Electrical - Battery Maintenance Information
P-67_00-24 Jan 09 Body - Windshield/Rear Window Body Seam Corrosion
S-82_60-629A Jan 09 Audio System - Various iPod(R) Concerns
P-82_60-227A Jan 09 Audio System - AM/FM Interference With Rear Defogger ON
S-80_00-53 Jan 09 Keyless Entry - Various Malfunctions
P-62_10-08C Dec 08 Interior - Noise From The Center Of The Dash
S-68_05-47A Dec 08 Accessories - Can't Program Garage Door Opener
2008120008 Dec 08 Campaign - Automatic Trans. Pilot Bushing Replacement
S-91_10-125C Dec 08 Memory Systems - Easy Entry/Exit Feature Is Inoperative
S-27_00-102B Dec 08 A/T - Limp Home Mode/Multiple Codes Stored
P-33_00-33A Dec 08 Steering/Suspen. - Stabilizer Threads Pulled From Axle
P-77_20-26A Dec 08 Body - Sunroof Excess Lift Control Function
P-32_20-69 Dec 08 Suspension - Rear Axle Knocking Noises
S-09_10-30 Dec 08 Engine - Air Filter Replacement Precautions
S-46_30-40B Nov 08 Power Steering - Fluid Filling/Bleeding Precautions
S-82_70-666 Nov 08 Cell Phone - iPhone(R) Address Book Not Loading
S-27_60-61J Nov 08 A/T - Harsh 1-2/3-2 And 2-1 Shifts
S-54_35-193A Nov 08 Electrical - Horn Replacement Information
S-07_61-72A Nov 08 Engine Controls - Misfire Diagnostic Information
P-54_21-173A Nov 08 Electrical - Auxiliary Power Outlet Inoperative
P-82_10-398B Nov 08 Lighting - License Plate Bulb(s) Burned Out
S-00_00-80F Oct 08 Engine - Test For Increased Oil Consumption
S-13_22-01E Oct 08 Engine - Grinding/Howling/Whining Noises
S-18-00-37D Oct 08 Engine - Low Oil Level Symptom Diagnostics
S-00_30-08H Oct 08 Engine - MIL ON/Multiple Camshaft Codes Set
S-49_00-12A Oct 08 Engine Controls - MIL ON/Multiple O2 Sensor DTC's Set
P-27_60-94A Sep 08 A/T - Shudder On Upshifts/Downshifts
P-91_16-94B Sep 08 Restraints - Head Restraint Height Adjuster Is Inop.
S-18_00-17G Sep 08 Vehicle - Approved Service Products On WIS
P-91_29-106A Sep 08 Interior - Power Seats Intermittent Operation/Inop.
P-54_65-86A Sep 08 Parking Assist System - Erroneous Activation
S-82_30-634 Sep 08 Lighting - Auto Lamps/Rain Sensor Malfunctions
2006110005C Aug 08 Campaign - Navigation System Disc Update
2008070002A Aug 08 Campaign - Engine V-Belt Guide Pulley Replacement
P-72_00-88 Jul 08 Body - Door Frame Corrosion
P-91_12-150A Jul 08 Interior - Rear Seat Back Rest Rattling Noises
P-26_50-02A Jun 08 M/T - Hard To Engage 1st or Reverse/Shifter Sticking
S-32_25-19E Jun 08 Suspension - Shock/Strut Replace Guidelines
P-88_70-48B May 08 Body/Lighting - Moisture in Mirror Turn Signals
S-49_10-11 May 08 Exhaust System - Exhaust Pipe Chrome Tip Care
S-40_10-60 May 08 Wheels/Tires - Nitrogen Usage Recommendations
S-68_30-75 Apr 08 Interior - Interior Damage From Scent Dispensers
S-68_05-74 Apr 08 Garage Door Opener - Range Too Short/Can't Program
3

Number Date Name
P-82_10-195F Apr 08 Lighting - Front Turn Signal(s) are Inoperative

S-83_00-161 Apr 08 A/C - Control Module/Control Functions/Diagnostics
P-91_16-153 Mar 08 Restraints - Passenger Head Restraint Moves Sporadically
S-83_00-115 Mar 08 A/C - Unpleasant Odor From Air Conditioning Vents
S-91_18-151 Mar 08 Interior - Seats are Dirty/Stained
S-46_25-37A Mar 08 Steering - Power Steering Diagnostic Tips
P-68_20-33C Feb 08 Interior - Front Center Arm Rest Loose/Falls OFF
S-98_30-22 Feb 08 Paint - Adhesive Residue Removal
S-40_10-18A Feb 08 Wheels - Recommendation Against Chroming Alloy Wheels
P-80_57-48A Jan 08 Anti-Theft System - A/T Inop After Key Programming
P-91_60-65C Jan 08 Restraints - SRS Lamp ON/Multiple Codes Set
P-80_57-24B Jan 08 Anti-Theft System - DAS3 Diagnostic Information
P-27_00-102A Jan 08 A/T - Multiple DTC's Set/Limp Home Mode
P-27_50-59B Jan 08 A/T - Limp Home Mode/Various Codes Set
P-42_45-88 Jan 08 ABS/TCS - Cruise Control Message Displayed/DTR Lamp ON
P-42_45-86 Jan 08 Tire Monitor - Tire Pressure Monitoring Inactive Message
P-54_30-73B Dec 07 Instruments - Displaying Vehicle Voltage Instructions
P-46_20-10C Dec 07 Steering - Leaks From Steering Rack
P-46_30-40A Nov 07 Steering - Flow Noises/Fluid Foaming After Repairs
P-46_20-57A Nov 07 Steering - Steering Gear Apparent Leakage Information
P-35_30-03 Nov 07 Drivetrain - Rear Axle Surface Corrosion
P-80_35-43 Nov 07 Keyless Entry - LED on Transmitter Key Not Functioning
P-42_45-83 Nov 07 ABS/TCS - ESP Visit Workshop Displayed On I/P
P-32_20-58 Nov 07 Suspension - Front Axle Creaking Noises
P-32_25-19D Oct 07 Suspension - Shock/Strut Replacement Guidelines
P-98_10-19 Oct 07 Body - Paint Damage on Trunk Lid
P-07_61-78 Sep 07 Engine Controls - Mil ON/DTC P0217 Stored in Memory
P-83_25-76C Sep 07 A/C - Blower Motor Inoperative/DTC 09460 Set
P-83_00-97A Sep 07 A/C - Fluorescent Dye Leak Testing
P-42_10-79 Sep 07 Brakes - Front/Rear Brakes Squeal
P-47_20-53 Sep 07 Fuel System - Fuel Pump/Filter Module Replacement
S-68_00-54A Aug 07 Body/Frame - Rivet Replacement to Prevent Water Leakage
P-27_60-80A Aug 07 Engine Controls - Code 061B After Reprogramming
S-27_00-101 Aug 07 A/T - Throttle/Brake Pedal Application Precaution
P-91_60-139 Aug 07 Restraints - SRS Lamp ON/Code 90A06 Stored
S-91_00-37 Jul 07 Interior - Seat Noise Complaints
P-91_60-76D Jul 07 Restraints - SRS Lamp ON/DTC's 9103 or 9123 Set
P-60_00-17 Jul 07 Body/Frame - MIG Welding Requirements
P-97_00-03 Jul 07 Body - Replacement Sheet Metal With Seam Sealer
P-33_20-030 Jul 07 Drivetrain - Front Axle Grinding Noise Diagnosis
P-94_20-05C Jun 07 Interior - Strong Oily or Vinegar Like Odors
P-01_10-17 Jun 07 Engine/Steering - ECO Harness Replacement Information
P-54_18-98A May 07 Electrical - Connector Repair Information
P-77_20-53 May 07 Body - Interior Drafts With Sunroof Open
P-83_30-95 May 07 A/C - Control Unit is Inoperative
P-80_57-30A May 07 Electronic Ignition Switch - Central Gateway Information
P-83_00-94 May 07 Interior - Heat From Wheelhouse In Passenger Compartment
P-68_10-52 May 07 Interior - Instrument Panel Rubbing/Buzzing Noises
P-82_30-572 Mar 07 Wipers/Washers - Wiper Arm Scraping/Striking Hood
P-27_00-95 Mar 07 A/T Controls - Limp Home Mode/Harsh Engagement
P-27_60-64A Mar 07 A/T - Selection Range Sensor Learning Not Possible
P-27_35-52A Mar 07 A/T - No Power Output From A/T
P-82_30-366C Mar 07 Wipers/Washers - Wipers Chattering/Noisy
P-47_10-40B Feb 07 Fuel System - Tapping Noises From Fuel Tank Area
P-82_30-316A Feb 07 Wipers/Washers - Intermittent Function Operation
P-82_00-260B Jan 07 Entertainment System - CD's or DVD's Won't Eject
P-27_60-88A Jan 07 A/T - Limp Home Mode/Codes 2502/2505/P0894/P2711
P-43_10-02A Jan 07 Brakes - Squeal/Whistle When Releasing Brake Pedal
200611005B Dec 06 Campaign - Install Software for Navigation System
P-82_85-532A Nov 06 Diagnostic Enhancement - MCSII EDAC
P-15_40-60 Nov 06 Charging System - Returning Alternators & Regulators
P-07_00-57D Nov 06 Engine Controls - MIL ON/DTC P1089 Stored in Memory
S-27_56-83 Oct 06 A/T - Filter Part Number/Replacement Information
4

Number Date Name
P-82_85-507A Oct 06 Satellite Radio - Limited Channel 184 or Lower

P-88_50-53 Sep 06 Body - Trunk Lid Lock Valet Key Retrofitting
P-46_20-46 Aug 06 Steering - Play/Movement Explanation
P-91_10-112 Aug 06 Interior - Noises From The Front Seats
S-67_00-20 Aug 06 Body - Laminated Glass Chip/Crack Repair Information
2006080003 Aug 06 Campaign - COMAND(R)/Navigation Software Update
S-54_10-162 Apr 06 Electrical - Voltage Drop Testing at The Fuses
1
Vehicle: Technical Service Bulletins
How to Find Technical Service Bulletins by Category/Symptom

Selecting TSB's "By Symptom"
If you have a vehicle which displays system-related symptoms, WKLV0DQXDO provides a way to quickly search for any relevant Technical
Service Bulletins (TSB's). When you select TSB's "By Symptom," all relevant TSB's display at the top of the TSB title list. Viewing TSB's
by Symptom is helpful when the vehicle displays a distinct, system related, malfunction. You may also wish to review the symptom list with
your customer to uncover additional information that was not indicated on the Driveability Worksheet.
You can view TSB's by Symptom at any System or Sub-System level of the TurboView hierarchy. For example, a Symptom list will appear
when selecting Powertrain Management or Computers and Control Systems. Symptoms will not appear when selecting a component (such as
Mass Air Flow Sensor).
To view TSB's by Symptom:
1. Select the desired System or Sub-System and click the TSB icon.
2. Select "By Symptom" from the TSB list.
3. Select the symptom you wish to display.
4. Click on the desired TSB to display the article
Example:
Your customer complains of a noise in his 1989 Toyota Corolla (1.6L DOHC). The noise seems to be coming from the automatic
transmission. To find TSB's related to transmission noise:
1. Select Transmission and Drivetrain, then Automatic Transmission.

2. Click the TSB icon and select "Noise" from the TSB symptom list.
3. Notice that TSB's related to transmission noise are now located at the top of the TSB title list while non-related TSB's for the transmission
are listed below.
Technical Service Bulletin # 2008070001A Date: 091016
Recall - ECM Update For Various Issues

FILE:
SERVICE: GROUP 00 OF SERVICE INFORMATION BINDER
PARTS: GROUP I OF INFORMATION PARTS & ACCESSORIES BINDER
Campaign No. 2008070001, October 2009
TO: ALL MERCEDES-BENZ CENTERS
SUBJECT:
Models 164, 164.8, 171, 203, 204, 209, 211, 215, 216, 219, 220, 221, 230, 251, 463
Model Years 2003 - 2009
Re-code the Software Calibration Number (SCN)
Revision Date Purpose

a 10/16/09 Revision to step 2, in work procedure
- 7/30/08 Initial issue
This Recall Campaign has been initiated because Daimler AG (DAG), the manufacturer of Mercedes-Benz vehicles; has determined that between
April 15, 2008 and April 17, 2008 and between June 5, 2008 and June 10, 2008, a temporary failure occurred in the Mercedes-Benz computerized
on-line Workshop Systems. Due to this failure some online-inquiries from the Mercedes-Benz Workshop-Systems may have been answered with
incorrect SCN-Coding data. Depending on the model year and model affected, the results of an incorrect SCN coding can affect a number of
vehicle safety and emission functions including the following types of functions:
The fuel gauge readings may be incorrect.
A stuck fuel-level sensor may not be displayed in the instrument cluster.
The OBD system may cause the Check Engine Light to illuminate incorrectly.
The speedometer may be out of tolerance.
2
In the event of a vehicle crash the electrical fuel pump may not receive a crash signal as designed that is required for the fuel pump to disconnect
and prevent further fuel delivery.
Shown in this bulletin is a sample copy of a letter which owners of the affected vehicles will receive.
Prior to performing this Recall 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 Recall 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 409 vehicles are involved.
Procedure
Note:
^ Use DAS 07/09 with all associated patches or higher.
^ Follow the steps exactly as described in DAS.
^ Connect battery charger (battery voltage >12.5V).
1. Connect Star Diagnosis to vehicle.
2. SCN code Engine control module:
^ Follow the DAS path: Main groups/Check for necessary coding measures.
^ Perform corresponding "Control unit adaptations", "SCN coding" (follow on-screen instructions).
Note:
^ The Menu "Main groups/Check for necessary coding measures" will only appear when SDS is connected to a vehicle affected by this campaign.
^ For model 204, do not access the vehicle via XENTRY, but rather via Start/All Programs/Star Diagnosis/ DAS. A password must be requested
from the SDS Help Desk via the following e-mail address: mbdiagnosis@mbusa.com to recode the SCN. Please specify the Vehicle
Identification Number (VIN) and the DAS release used.
3. Fill out Repair Label and affix on underside of hood next to existing emissions labels (as shown in Figure 1).
Note:
^ Ensure the surface is clean prior to affixing the label.
^ Use a ball point pen to fill in the label; do not use a marker or felt tip pen.
^ Campaign is now complete except for California dealers.
^ California dealers only, please proceed to next step.
3
4. California dealers only: Print Proof of Correction form also shown above and fill out as shown in Figure 2.
Note:
The Proof of Correction form can also be found on STAR TekInfo under the "Forms and Test Sheets > Other Forms" heading.
^ Scan form and keep a copy for dealer records.
4
^ Hand the form to customer or place in glove box.
Warranty Information
Technical Service Bulletin # 2009060005 Date: 090807
Recall - ECM Update For EVAP Diagnostics

FILE:
Campaign No. 2009060005, August 2009
SUBJECT:
Models 164, 171, 203, 209, 251
Software Calibration Number (SCN) Coding - Engine Control Module This Recall Campaign has been initiated because Daimler AG (DAG), the
manufacturer of Mercedes-Benz vehicles, has determined that between May, 2006 and June, 2007, due to a software error, the vehicles fuel tank
leak diagnosis system may have been inadvertently deactivated during a visit to the workshop. This may cause the affected vehicles to fail to meet
the statutory requirements for Inspection/Maintenance (emissions inspection). Dealers will re-code the Software Calibration Number (SCN) -
Engine Control Module to correct this situation.
Shown in this bulletin is sample copy of a letter which owners of the affected vehicles will receive.
Approximately 12,848 vehicles are involved.
NOTE REGARDING CUSTOMER REIMBURSEMENT
5
Reimbursement to customers for repairs performed prior to this recall: If the customer already paid to have this recall campaign condition repaired
and provides adequate documentation to support their claim of a non-warranty repair of this item, they may be eligible to receive reimbursement.
Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement is limited to the amount the repair of a non illuminating check
engine malfunction indicator lamp (MIL would have cost if completed by an authorized Mercedes-Benz dealer under this campaign.
Submit a warranty claim, utilizing Damage Code 54952468 as a sublet, utilizing the sublet code of "SUB." Sublet repairs require dealer text as
stated in the Warranty Policies and Procedures Manual. Repair date should be the date that the customer paid for the repair.
Note:
Please note the claim submitted for customer reimbursement will not close the campaign (if still open). If the customer is still in possession of the
vehicle with an open campaign, please arrange to close the campaign in the usual manner as described in this bulletin. this bulletin.
Procedure
Note:
^ Use DAS/XENTRY 06/09 with all associated patches or higher.
^ Follow the steps exactly as described in DAS/XENTRY.
2. Follow the DAS path below to SCN code Engine control module:
Control units/Drive/ME 9.7/Control unit adaptations/Variant coding/SCN coding
Note:
^ The label is being mailed to dealers prior to the launch of this Recall Campaign. Additional labels are available as literature through NetStar free
of charge (order# P-BQ-AEM-LBL)
6
4. California dealers only: Print Proof of Correction form as shown above and fill out as also above shown in Figure 2.
Note:
7
8
Campaign - COMAND(R)/Navigation Software Update

FILE:
PARTS: GROUP I OF INFORMATION _ PARTS & ACCESSORIES BINDER
SUBJECT:
MODEL 203, MODEL YEAR 2005-2006
MODEL 164, MODEL YEAR 2006
CHECK COMAND AND NAVIGATION SOFTWARE AND UPDATE IF NECESSARY
9
This Service Campaign has been initiated because DCAG has determined that on affected vehicles with code 528 or 530 (see VIN range shown
below), incorrect software may have been installed potentially leading to COMAND malfunctions. In order to proactively deal with any potential
customer complaints, dealer will check the software releases using a workshop service CD and update if necessary.
Please review the Effective Serial Number chart, 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 31,188 vehicles are affected.
Effective Serial 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 Recall and Service Campaigns do not expire and may also be performed on a vehicle with a vehicle status
indicator.
Procedure
Note:
Prior to starting procedure ensure to:
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^ Use DAS version 05/06 or later
^ Connect battery charger
^ Turn off ignition and all electrical consumers
^ Follow the order of steps exactly as outlined below
^ Leave Service CD and DVD in workshop
1. Connect Star Diagnosis.
2. Check versions of COMAND and Navigation software.
^ Navigate through following DAS menu: Control units/Information and communication/Audio, video, navigation and telematics.
^ Select "COMAND..." to check COMAND software version or "NAVI..." to check Navigation software version.
^ Select "Control unit version".
3. Perform the following:
^ If COMAND software version is below 51/05, proceed to step 4 to install new COMAND software.
^ If Navigation software version is below 31/04, proceed to step 5 to install new Navigation software.
^ If neither COMAND nor Navigation software require an update, proceed to step 6.
Note:
If both COMAND and Navigation software require updating, the COMAND software must be updated first; then, the Navigation
software can be updated.
4. Install new COMAND software.
^ Insert Service CD W 203 589 04 22 00 into audio CD drive (B, Figure 1).
Note:
The update process begins automatically.
CAUTION!
Do not touch the head unit or turn on any consumers in the vehicle during the update process.
^ Select "Serv" hard key/ "System" soft key/ "Reset" soft key and confirm reset of head unit with "Yes".
5. Install new Navigation software.
^ Insert Service DVD W 203 589 05 22 00 into Navigation DVD drive (A).
Note:
CAUTION!
11
Note:
Destination memory and last destinations are cleared.
6. Recalculate vehicle position using GPS.
7. Disconnect Star Diagnosis.
Special Tool Information
Campaign - Engine V-Belt Guide Pulley Replacement

FILE:
SUBJECT:
Models 164, 164.8, 171, 203, 209, 211, 216, 219, 221, 230, and 251
With Engine 272 or 273, Model Years 2006 - 2007
Replace V-Belt Upper Guide Pulley
12
A 08/15/08 Revision to warranty information
- 08/15/08 Initial release
This Service Campaign has been initiated because Daimler AG (DAG) has determined that a V-belt upper guide pulley optimized for noise
reduction is available. The dealer will replace the V-belt upper guide pulley at the next workshop visit.
^ 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.
Procedure
1. Remove engine cover.
2. Remove plastic cap (A, Figure 1) covering pulley bearing and discard.
3. Remove V-belt (A, Figure 2) from pulley (arrow); refer to WIS for models:
^ 164/164.8/251: AR13.20-P-0001GZA.
^ 171: AR13.22-P-1202VA.
^ 203/209: AR13.22-P-1202QB.
^ 211/219: AR13.20-P-0001TS.
13
^ 216/221: AR13.20-P-0001SX.
^ 230: AR13.22-P-1202RX.
Note (regarding above WIS instructions):

^ Do not remove V-belt from engine.
^ Do not replace belt tensioner.
4. Replace guide pulley (arrow, Figure 2), torque guide pulley bolt to: 35 Nm.
Note:
Do not reinstall cap (A, Figure 1).
5. Assemble in reverse order.
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 InformationTechnical Service Bulletin # 2006110005C Date: 080817
Campaign - Navigation System Disc Update

FILE:
Revision History
C 8/17/08 Navi DVD part numbers updated, note added and revised in parts information
B 12/01/06 Updates to work instructions
A 11/22/06 Update to Navigation DVD version checking procedure
SUBJECT:
MODELS 164, 171, 203, 209, 211, 215, 219, 220, 221, 230, 251, X164
MODEL YEAR 2005-2007
INSTALL SOFTWARE FOR NAVIGATION SYSTEM
14
15
This Service Campaign has been initiated because DCAG has determined that certain affected vehicles (see VIN range shown above) may have an
earlier version navigation disc installed than that specified. This could in some cases lead to navigation directions based upon non updated map
data. Dealers will update the navigation disc in the affected vehicles as required.
Please review the Effective Serial Number chart shown above, and if necessary, repair the subject vehicles during the vehicle's next service.
Parts Information
NOTE:
^ Due to the multiple Navigation DVD released annually, there may be a newer Navi DVD version than the one referenced in this Campaign
Bulletin. Please use the latest Navigation DVD available from Navteq. MUBSA will update this bulletin to reflect latest Navi DVD part
numbers as they become available.
^ Repairs performed using any other part(s) than the ones in this Bulletin 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.
16
Procedures A - C
A. MODELS 171, 211, 215, 219, 220, 230: CHECK VERSION OF NAVIGATION DVD AND UPDATE NAVIGATION SYSTEM IF
NECESSARY
Note:
It is not necessary to connect Star Diagnosis to perform this procedure.
1. Check part number of Navigation DVD in vehicle.
Note:
On these models the Navigation module is located in the trunk.
^ Press Eject button on Navigation module.
^ Visually check part number on DVD label.
2. Perform one of the following.
^ If part number is BQ 646 0232: Reinsert DVD into Navigation module; this campaign has been completed.
^ If part number is not the above number: Proceed to next step to update Navigation system.
NOTE:
You must obtain Navigation DVD BQ 646 0232 (or newer) by calling Navteq. Navteq does not require the VIN for these vehicles.
3. Start vehicle and keep it running for duration of update process.
17
4. Eject old Navigation DVD from module if present.
5. Use new Navigation DVD to update Navigation system.
^ Insert new Navigation DVD into Navigation module.
Note:
The DVD is automatically detected and the update process starts. Shut off vehicle upon completion of the update process.
Note:
The Navigation DVD must remain inside the module from this point forward in order for the Navigation system to operate
correctly.
6. Ensure navigation system is functioning correctly after update.
Note:
The replaced Navigation DVD for the above models must be returned to Navteq through the standard process.
B. MODELS 164, 203, 209, 251, X164: CHECK VERSION OF NAVIGATION DVD AND UPDATE NAVIGATION SYSTEM IF
NECESSARY
Note:
Note:
On these models the Navigation drive is located inside the head unit.
^ Press Eject button on head unit to eject DVD from "Navigation" slot.
^ If part number is BQ 646 0226: Reinsert DVD into Navigation drive; this campaign has been completed.
NOTE:
4. Eject old Navigation DVD from drive if present.
^ Insert new Navigation DVD into Navigation drive.
Note:
The DVD is automatically detected and the update process starts.
^ Shut off vehicle upon completion of the update process.
Note:
The Navigation DVD must remain inside the drive from this point forward in order for the Navigation system to operate correctly.
Note:
C. UPDATE NAVIGATION SYSTEM (MODEL 221 ONLY)
18
NOTE:
^ You must obtain the correct DVD per VIN by filling out the form shown above and fax to Navteq. For reliability, we encourage
you to fax in the form. The DVD will be sequentially numbered according to the VIN you provide in the form. If you have
more than one vehicle listed in the campaign in your dealership, please submit multiple VINs in a single form, Navteq will mail
you one DVD per VIN entered.
Note:
^ Connect battery charger and turn OFF ignition and all electrical consumers
^ Turn ignition key to second position
1. Power on head unit.
CAUTION!
Ensure that slot # 1 in the DVD changer is empty prior to inserting the Navigation DVD.
19
2. Press Button 1 of the DVD changer (A, Figure 1) and insert the Navigation DVD BQ 646 0233 into the changer (B).
3. Press COMAND controller to confirm the "Disc Drive Audio Format Unknown" message.
4. Press COMAND controller to confirm the "Proceed with Update" message.
Note:
The update process takes approximately 30 minutes to complete. The technician is not required to be present during the process and
may perform other tasks while the process is running. The update process run time is not included in the labor time paid under this
Service Campaign.
5. Press COMAND controller to acknowledge completion of update process.
6. Press Button 1 to eject Navigation DVD and place it in DVD case.
Note:
This Navigation DVD is property of MBUSA; it must remain with the vehicle/customer after the update process has been
completed. Reproduction is prohibited!
Campaign - Automatic Trans. Pilot Bushing Replacement

Campaign No. 2008120008
December 2008
FILE:
SERVICE:
GROUP 00 OF SERVICE INFORMATION BINDER
PARTS:
GROUP I OF INFORMATION _ PARTS & ACCESSORIES BINDER
SUBJECT:
Models 203/ 209/ 211/ 219/ 230/ 463
Replace Pilot Bushing at Electrohydraulic Unit
This service campaign has been initiated because Daimler AG has determined that on affected vehicles the transmission pilot bushing may leak.
Dealer will replace the transmission pilot bushing at the next workshop visit.
- 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.
20
Procedure
CAUTION:
Ensure the temperature of the transmission is not higher than 50 degrees C prior to starting repairs.
NOTE:
If the vehicle has not been operated in a while, run the engine to fill the torque converter with transmission fluid to reduce the amount of fluid
that will run out when the pilot bushing is removed.
1. Remove underbody paneling.
2. Disconnect electrical connector at transmission.
NOTE:
Remove heat shield (arrow, Figure 1) if equipped.
3. Remove pilot bushing mounting bolt (Figure 2); remove pilot bushing.
NOTE:
When removing the pilot bushing, catch any transmission fluid that might leak out.
4. Install new pilot bushing and reassemble in reverse order.
- Torque pilot bushing mounting bolt to 3 Nm.
- Torque heat shield bolt to 6 Nm.
5. Reassembly in reverse order.
NOTE:
21
Ensure the transmission is cold (approx. 25 degrees C) prior to performing step 6.
6. Remove breakaway locking tab from dipstick and check fluid level (with engine running and transmission in P); the fluid level must be
between the min and max marks (A, Figure 3).
- Refill transmission fluid to correct level.
- Install new lock pin on cap.
Special Tools
NOTE:
The above-listed Special Tools have been previously released to all dealers and should already be in your Special Tool inventory.
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
- The following allowable labor operation should be used when submitting a warranty claim for this repair:
22
NOTE:
- To claim a repair performed during an A or B Maintenance or other necessary warranty repair requiring removal of underbody paneling, use
Repair 1.
- To claim a repair performed independently of an A or B Maintenance or other necessary warranty repair requiring removal of underbody
paneling, use Repair 2.

FILE:
SUBJECT:
Models 164, 164.8, 171, 203, 204, 209, 211, 215, 216, 219, 220, 221, 230, 251, 463

23
Procedure
Note:
Note:
Note:
24
Note:
25
Technical Service Bulletin # P-83_00-94 Date: 070504
Interior - Heat From Wheelhouse In Passenger Compartment

Date: May 4, 2007
Order No.: P-B-83.00/94
Supercedes:
Group: 83
SUBJECT:
All Model 203 / 209 Vehicles
As of Production 8/31/02
Heat from Wheelhouse Compartment Enters the Passenger Cabin
If you receive customer reports in the above model vehicles of heat entry into the passenger cabin from the wheelhouse, perform the following
procedure to resolve.
1. Remove filter housing above battery and remove housing (Figure 1, A). It is necessary to remove battery.
26
2. Remove rubber seal from engine dividing wall (Figure 2, B).
3. Remove drip molding (Figure 1, C) and replace with new drip molding part number A203 620 12 73 with rubber strip. Reinstall housing
(Figure 1, A).
4. Open the right side wiring duct and remove the duct (Figure 2, D). Replace with new cable duct part number A203 820 10 69. Ensure the
wires are routed properly in the guide.
5. Remove cover (Figure 3, E) above module box.
6. Remove front SAM and ME control units. Refer to WIS document AR07.08-P-7008P.
7. Open left wiring duct (Figure 3, F), move wiring to the side and remove the duct. Install new wiring duct part number A203 820 09 69.
Ensure that the wires are routed properly in the guide.
8. Remove the fuse and relay box. Refer to WIS document AR54.21-P-1260P, remove drip molding (Figure 4, G) and replace with new drip
molding part number A203 620 09 73 with rubber strip. Reinstall fuse and relay box.
9. Loosen foam rubber elements from old wiring ducts on the right and left sides and glue them to new wiring ducts.
10. Install rubber seal onto engine dividing wall (Figure 2, B).
27
Parts Information
Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generated
on May 4, 2007. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty, use the table.

Interior - Noises From The Front Seats

Date: August 9, 2006
Order No.: P-B-91.10/112
Supersedes:
Group: 91
SUBJECT:
Model 203.040/052/054/056/061/064/065/076/081/084/087/092/261/264/281/284/740/747/764
Model 211.026/056/065/070/076/082/083/087/256/265/276/282/283/287
Model 219.375/376 Front Seat Noise Complaints
If you receive customer reports in the above model vehicles regarding noises from the front seats, check if the noise fits any of the six descriptions
listed below and if yes, proceed as described.
A. Noise when the load on the backrest frame changes (Model 203 only)
B. Noise between seat frame brackets and seat cushion frame
C. Noise from lower trim cover end (Model 211 and 219 only)
D. Noise from perimeter of sidebag (Model 211 and 219 only)
E. Rubbing noise between seat cushion and trim cover (Model 211 only)
F. Noise from lumbar support in backrest at subfreezing temperatures (Code 403, 404, 433 or 434 only)
Note:
Replacement of seat components for any of the noise complaints in issues A to E is not permitted. The claim in these cases will be debited.
A. Noise When Load on Backrest Frame Changes
1. Remove backrest cover. Refer to WIS document AR91.10-P-1910P.
28
2. Disconnect padding support grid from the 4 suspension points (Figure 1), 2 on the right side and 2 on the left side.
3. Cut 4 pieces of felt, approximate size is 10 mm by 20 mm. Apply a generous amount of special sliding compound to the felt and then adhere
the felt to the suspension points of the padding support grid (Figure 2).
4. Reconnect the padding support grid to the 4 suspension points (2 on the right and 2 on the left).
5. Reinstall backrest cover. Refer to WIS document AR91.10-P-1910P.
B. Noise Between Seat Frame Brackets and Seat Cushion Frame - Model 203 (up to VIN A903977 and F817832) Model 211 (up to VIN
A967489 and X207037) and Model 219 (up to VIN A075885)
1. The seat frame brackets rub on the seat cushion frame and if there are burrs on the brackets, this may make noise.
2. If burrs are visible (Figure 3, circles), proceed as follows.
3. For he 211 and 219, remove the seat, refer to WIS document AR91.10-P-1000T (211) or AR91.10-P-1000TX (219).
4. Remove the brackets and replace with new brackets.
Note:
Always install new micro-encapsulated bolts.
5. For the 211 and 219, reinstall the seat, refer to WIS document AR91.10-P-10001 (211) or AR91.10-P-1000TX (219).
29
C. Noise from Lower Trim Cover End Door or Tunnel Side - Models 211 and 219 only
1. The rib on the back side of the lower trim covers at the front of the seat cushion may cause a noise as it rubs on the seat cover.
2. For only the 211 remove the seat, refer to WIS document AR91.10-P-10001.
3. For only the 211 remove trim cover (Figure 4). Refer to WIS Document AR91.10-P-26001. For only the 219, remove the 120 screws located
in the corners of the storage compartment.
4. Line side of trim cover rib (Figure 5) with felt.
5. For only the 211 reinstall trim cover (Figure 4). Refer to WIS Document AR91.10-P-26001. For only the 219, reinstall the 120 screws
located in the corners of the storage compartment.
6. For only the 211 reinstall the seat, refer to WIS document AR91.10-P-10001.
D. Noise from Perimeter of Sidebag - Models 211 and 219 only
1. The hard edge of the sidebag cover may make a noise as it rubs against the seat.
30
2. With a wedge, open a gap between the sidebag cover and the seat (Figure 6, arrows) and with a second wedge, apply special sliding
compound to the edge of the sidebag cover on the entire circumference.
E. Rubbing Noise Between Seat Cushion and Trim Cover - Model 211 only
1. Rubbing noise where the seat cover contacts the trim cover (Figure 7, arrows), tilt the backrest rearward.
2. Apply special sliding compound to the seat cover in this area (Figure 7, arrows).
3. Confirm that the noise is no longer present.
F. Noise from Lumbar Support in Backrest at Subfreezing Temperatures (Codes 403.404.433 or 434 only)
1. Confirm noise by actuating pneumatic bladders at sub freezing temperatures.
2. Remove backrest cover. Refer to WIS document AR91.10-P-1910P (203), AR91.10-P-19101 (211 up to MYO5), AR91.10-P-19101B (211
as of MYO5) and AR91.10-P-19101X (219).
31
3. Check if the guide wires are damaged (Figure 8) at the interface with the lumbar support basket (Figure 9).
Note:
Figure 9 shows the seat backrest frame with the seat cover and seat pad removed for clarity, it is not necessary to remove these parts to
inspect and lubricate the guide wires.
4. In case of minor damage to the guide wires, apply special sliding compound to the guide wires.
5. In the case of major damage to the guide wires (Figure 10), the complete backrest frame must be replaced. Refer to WIS Document
AR91.10-P-1060P (203), AR91.10-P-3331T (211 up to MY05), AR91.10-P-3331TA (211 as of MY05) and AR91.10-P-3331TX (219).
6. Reinstall backrest cover. Refer to WIS document AR91.10-P-1910P (203), AR91.10-P-1910T (211 up to MY05), AR91.10-P-1910TB (211
as of MY05) and AR91.10-P-1910TX (219).
32
Parts Information
33
34
In Case of Warranty
Technical Service Bulletin # P-82_30-366C Date: 070301
Wipers/Washers - Wipers Chattering/Noisy

Date: March 1, 2007
Order No.: P-B-82.30/366c
Supersedes: P-B-82.30/366b dated Jan. 10, 2006
Group: 82
Revision History
SUBJECT:
All Passenger Models
Adjusting Wiper Arms
If you receive customer reports in the above model vehicles of wipers chattering / noisy, proceed as follows.
1. Inspect wiper blades / inserts for wear and replace as needed.

2. Thoroughly clean the windshield.
3. Verify use of correct washer fluid.
4. Check washer nozzle adjustment.
5. If noises persist, proceed with steps 6 and 7.
6. Check the wiper arm angle adjustment and record values per the applicable model WIS document.
7. If required, adjust wiper arm angle.
Note:
Due to the natural aging process and wear, wiper blades should be replaced twice a year preferably in Spring and Fall (refer to Operator's
Manual).
Note:
Warranty claims for wiper blades / wiper blade inserts that are worn or damaged due to environmentally influenced reasons, abuse or physical
damage will not be accepted.
Note:
Special Tool (W211 589 02 21 00) was automatically shipped to all MB dealers as of June 2004.
Note:
Refer to Netstar message "Windshield Wiper Blades / Wiper Blade
35
Inserts" dated January 20, 2006.
Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair
In Case of Warranty
Technical Service Bulletin # P-82_85-507A Date: 061016
Satellite Radio - Limited Channel 184 or Lower

Date: October 16, 2006
Order No.: P-B-82.85/507a
Supersedes: P-B-82.85/507 dated June 15, 2006
Group: 82
Revision History
a 10/16/06 Remedy Available

SUBJECT:
Model 171.454/456/473, As of Model Year 2005
Model203.040/052/054/056/061/064/076/081/084/087/092/261/264/281
/284/740/764, As of Model Year 2006
Model 209.356/365/375/376/456/465/475/476, As of Model Year 2005
Equipped with Satellite Radio Receiver
Audio 20 Head Unit Cannot Tune to Any Satellite Radio Channel Higher Than 184
If you receive customer reports in the above model vehicles of the Audio 20 (entry) model head unit not able to tune to any channel higher than 184
36
in vehicles equipped with Satellite Radio (SDAR), the head unit must be replaced according to the vehicle model listed below.
NOTE:
Any unnecessary replacement of an SDAR Control Module or a Head Unit will be debited accordingly.
Parts InformationTechnical Service Bulletin # P-43_10-02A Date: 070116
Brakes - Squeal/Whistle When Releasing Brake Pedal

Date: January 16, 2007
Supersedes: P-B-43.10/02 dated May 30, 2006
Group: 43
Revision History
a 1/16/07 Applicable Models, Series Production Dates and Part Numbers Updated
SUBJECT:
Model171.454/456/473, Up to Series Production 11/2006
Model203.040/052/054/056/061/064/065/076/081/084/087/09
Up to Series Production 11/2006
Model209.356/365/375/376/456/465/475/476, Up to Series Production 11/2006
Squealing / Whistling Noise When Releasing Brake Pedal
If you receive customer reports in the above model vehicles of a squealing or whistling noise emanating from the brake pedal area after releasing
the brake pedal, replace the brake booster with a revised part. Reference WIS document AR43.10-P-0350V (Model171) or AR43.10-P-0350P
(Model203 and 209).
The whistling noise within the brake booster is the result of air flowing between the operating chamber and vacuum chamber of the booster, caused
by increased tolerances. The increased tolerances cause air to flow over an internal edge within the booster creating vortices. These vortices can
produce a sound which may be perceived as a whistle.
NOTE:
When ordering parts please ensure to add an index 28 to the part number. For models 203 and 209 the revised part will have a Q-status of Q7 or
higher. For model 171 the revised part will have a Q-status of Q3 or higher.
Parts InformationTechnical Service Bulletin # P-07_00-57D Date: 061113
Engine Controls - MIL ON/DTC P1089 Stored in Memory

Date: November 13, 2006
Order No.: P-B-07.00/57d
Supersedes: P-B-07.00/57c dated June 21, 2006
Group: 07
Revision History
37
d 11/13/06 Applicable Models Updated

c 6/21/06 Applicable Models / Software Version Updated
b 3/8/06 Paragraph 2 Updated
a 1/30/06 Warranty Information Updated
SUBJECT:
Model 171.454/456
Model 203.052/054/056/076/087/092
Model 209.356/376/456/476
Model 211.056/087/256/287
Model 221.171
Model 230.471
Check Engine Light / Engine Control Module Software Update
If you receive customer reports in the above model vehicles with check engine light activated and Diagnostic Code P1089 (fuel minor leak).
Perform leak tests as per guidelines in SDS.
If no leak is found, update engine control module software with DAS version 05/06 (or later DAS Release).
NOTE:
After the software flash, perform SCN coding. Refer to Star TekInfo Document S-B-07.61/38i dated July 24, 2006 or S-B-58.00/144b dated
July 24, 2006 for procedure. Technical Service Bulletin # P-27_60-88A Date: 070116
A/T - Limp Home Mode/Codes 2502/2505/P0894/P2711

Supersedes: P-B-27.60/88 dated Nov. 27, 2006
Group: 27
Revision History
a 1/16/07 Technical Content Revised

SUBJECT:
All Passenger Models Equipped with 722.9 Transmission (7G-Tronic) Fault Codes 2502, 2505, P0894 or P2711
If you receive reports in the above model vehicles of the automatic transmission being in limp-home mode or having no power transfer from the
transmission together with fault codes 2502, 2505 or P0894, P2711, these codes must be processed according to the vehicle symptoms. First,
attempts must be made to reproduce the problem.
If the above fault codes are stored in connection with shift quality complaints, please proceed according to the Diagnostic Tree posted on Star
TekInfo -> EDAC -> Diagnostic Guide for 722.9 NAG 2 (7G-Tronic) Transmission.
If the fault codes are stored together with loss of power transfer, proceed with the below solutions per the respective possible cause.
Cause 1: K1 piston is damaged (adaptation data for the 2-3 shift may be at the positive limit).
Solution 1: If the complaint can only be reproduced for the 2-3 upshift or if third gear can not be reached, there is a defect of the K1 piston.
- Replace the complete multi-disc clutch K1 as per the parts list.
- Reset the adaptation data.
Cause 2: Tolerance in the electrohydraulic control unit (valve body) may not be optimal.
Solution 2: If the K1 multi-disc clutch is not responsible for the concern, replace the electrohydraulic control unit (valve body) and perform initial
startup.
NOTE:
When diagnostic events lead to a transmission or valve body replacement, please refer to DTB P-B-27.00/38d for the proper completion of the
WSG pre-authorization requirements.
38
Parts InformationTechnical Service Bulletin # P-82_00-260B Date: 070131
Entertainment System - CD's or DVD's Won't Eject

Order No.: P-B-82.00/260b
Supersedes: P-B-82.00/260a dated August 25, 2004
Group: 82
Revision History
b 1/31/07 Applicable Models Updated

a 8/25/04 Content Updated
SUBJECT:
All Passenger Model Vehicles
Model Year 2000 through Current Model Year
CDs and DVDs May Not Be Ejected
If you receive customer reports in the above model vehicles that are equipped with COMAND with CD/DVD drives, CD changer, as well as
navigation processors with a single slot having the below symptoms, please review the possible causes listed below.
Symptoms
1. CDs / DVDs are not always pulled into the player, a light push may need to be applied.
2. CDs / DVDs are not always ejected by the player.
3. If the CD / DVD is forced in, it may not be possible to eject the disk.
4. CD / DVD player does not play the disk even if inserted correctly.
Causes
1. The disk is too thick, does not satisfy the specification thickness tolerance range of 1.1 - 1.5 mm.
2. CDs / DVDs with self-adhesive labels that may become delaminated from the disk in whole or in part due to length expansion of the material
used which results in the disk being out of thickness tolerance.
3. CDs / DVDs with diameter of 8 cm with / without an adapter resulting the in the adapter blocking the pull / eject mechanism.
NOTE:
These causes constitute misuse of the CD / DVD player that are not covered under warranty. Technical Service Bulletin #
P-47_10-40B Date: 070226
Fuel System - Tapping Noises From Fuel Tank Area

Date: February 26, 2007
Supersedes: P-B-47.10/40a dated Nov. 13, 2006
Group: 47
Revision History
b 2/26/07 Warranty Information Added

a 11/13/06 Applicable Models Updated
SUBJECT:
Model 203.052/054/056/087/092
Model209.356/372/456/472
Tapping Noise in the Area of the Fuel Tank
39
If you receive customer reports in the above model vehicles of a tapping noise in the area of the fuel tank, perform the following work instruction to
resolve:
Warning:
Risk of explosion caused by 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. Please take appropriate cautions.
1. Remove right rear wheel and its housing to reach the area of purge line.
2. Open purge line (Figure 1).
3. Insert restrictor in the purge line up to the red marking (Figures 2 and 3).
4. Reconnect purge line with a new clamp (Figure 4)

5. Install in reverse order.
40
Parts Information
NOTE:
The allowable labor operations should be used when submitting a warranty claim for this repair
In Case of Warranty
Operation: Restrictor between purge line and activated charcoal canister, retrofit (02-5337) Technical Service Bulletin # P-27_00-95
Date: 070329
A/T Controls - Limp Home Mode/Harsh Engagement

Date: March 29, 2007
Order No.: P-B-27.00/95
Supersedes:
Group: 27
SUBJECT:
All Passenger Vehicles Equipped with Transmission 722.9
Trans. in Limp-Home Mode or Harsh Engagement After Programming/SCN Coding
If a vehicle equipped with a 722.9 transmission goes into limp-home mode after performing SCN coding and/or programming of the transmission
control module; or if after performing these actions the transmission engages harshly, there can be two causes for this issue. Scan the transmission
control module for the below fault / event codes.
Event Codes: 0602, 1644, 2010 and/or 2011
Note:
Do not perform a road test! This may cause transmission damage.
1. Cause 1: SCN coding was not accepted by the transmission control module. This condition can be confirmed by looking at the following
menu within the transmission control module: Transmission Control Module --> Control Unit adaptations --> SCN Coding --> Display of
coding data
If the coding reads "NO VALUE", the transmission control module must be recoded again until it is confirmed that the coding has been
accepted by the transmission control module. This is confirmed when a four digit code is displayed as a coding value.
2. Cause 2: The coding was accepted by the transmission control module, but the vehicle is in limp home mode due to the presence of the stored
fault and/or event codes. In this case, simply erase the stored codes.
Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair.

41
Wipers/Washers - Wiper Arm Scraping/Striking Hood

Order No.: P-B-82.30/572
Supersedes:
Group: 82
SUBJECT:
Model 203.040/052/054/056/061/064/065/076/081/084/092
Wiper Arm Scraping/Striking Engine Hood
If you receive customer reports in the above model vehicles of the wiper arm scraping or striking the bottom side of the engine hood during wiping
sequence, this may be due to the wiper system being adjusted incorrectly. To resolve, check and adjust wiper system as per WIS document
AR82.30-P-6400-01P.
Note:

A/T - No Power Output From A/T

Supersedes: P-B-27.35/52 dated February 2, 2005
Group: 27
Revision History
SUBJECT:
All Passenger Models Equipped with 7G-Tronic (722.9) Transmission
No Transfer of Power from Automatic Transmission 722.9
In the above model vehicles if after replacing the electro-hydraulic control unit on automatic transmission 722.9 (7G-Tronic) you experience the
below conditions, this may be caused by an improper installation of the supply pipe for the multi-disc brake B3.
^ No gear can be selected in transmission mode "S" and there is no power flow in the transmission
^ In transmission mode "C" the vehicle can start off as usual.
To resolve, remove the electro-hydraulic control unit as described in WIS document AR27.19-P-0200w.
42
Before reinstallation, install the supply pipe (Figure 1) per WIS document AR27.19-P-0200w, step 6. Replacement parts are only necessary if the
original pipe was damaged during the original installation of the valvebody.
Parts Information
A/T - Selection Range Sensor Learning Not Possible

Supersedes: P-B-27.60/64 dated Dec. 13, 2005
Group: 27
Revision History
SUBJECT:
Learning in Selection Range Sensor Not Possible After EHS Replacement
In the above model vehicles, after removing/installing the electrohydraulic control unit (EHS), learning in the selection range sensor is not possible
if the retaining bolt of the detent plate was not inserted into the plastic bracket of the selector range valve (Figure 1). During initial start-up with
Star Diagnosis, the message "The prerequisites are not fulfilled or the peripherals are not operational" is displayed, although the shift rod has been
correctly adjusted. To resolve, remove/reinstall EHS being sure to insert bolt into bracket on valve and proceed to teach the sensor using Star
Diagnosis.
43
Technical Service Bulletin # S-91_00-37 Date: 070731
Interior - Seat Noise Complaints

Date: July 31, 2007
Order No.: S-B-91.00/37
Supercedes:
Group: 91
SUBJECT:
Model Year-All
Models All
Repairs for Noise Complaints Regarding Seats
This bulletin addresses complaints regarding noisy seats. Follow the steps to ensure that the problem is fixed correctly.
A. Repair Instructions
1. To better analyze the seat noises, maintain the customer's original seat positions, including cushion angles and backrest positions. It is a good
idea to also store the customer's seat positions in vehicle memory.
Note:
Seat noises can depend on individual seat positions involving the backrest and cushions as well as the manner in which customers enter
and sit in the vehicle.
2. Analyze the noise problem with the customer present. Note their interpretations of various seat adjustments and resulting sounds from each
seat and back rest positions.
3. Before performing any adjustments, be sure to unbolt the seat from the vehicle while keeping the electrical seat harness connected.
4. With the seat unbolted, use the seat control switch to move the seats over the entire adjustment ranges; i.e., all the way forward, back, up,
down, etc.
5. Bolt the seat back into the vehicle. The majority of complaints will be remedied by simply loosening and refastening the seats.
6. If noise still exists, remedy with felt and lubrication as specified in the Noise Kit (see Parts Information). Use only the parts from this kit.
Engine Controls - Code 061B After Reprogramming

Supersedes: P-B-27.60/80 dated August 30, 2006
Group: 27
Revision History
Revision Date purpose
a 8/8/07 Addition of Note Pertaining to Fault Code
SUBJECT:
Model 171.454/456
Model 203.052/054/056
Model 209.356/372/456/472
Model 211.056/072/256
44
Model 219.372
Model 221.171
Model 230.471
After Programming Engine and/or Transmission Control Units, Fault Code 061B Stored in Transmission Control Unit
If you encounter the situation described in the above model vehicles, the cause may be a torque interface issue between the engine and
transmission control modules.
To resolve, check for and install newer software for the engine control module using SDS and perform SCN coding of the engine control
module as well. Perform quick test and erase fault code.
Note:
If the fault code 061B reappears, it can be ignored. This is not cause for any parts replacement.
Note:
If no newer software is available for the engine control module, simply perform the SCN coding of the engine control module.
Restraints - SRS Lamp ON/Code 90A06 Stored

Date: August 2007
Order No.: P-B-91.60/139
Group: 91
SUBJECT:
MODEL 203
SRS warning lamp comes on and fault code 90A6 stored in restraint systems control Module (N2/7)
Failed communication between restraint system control module (N2/7) and passenger seat occupied and child seat recognition sensor (B48)
may cause fault code 90A6 to occur during system self-test.
Note:
Seat occupied recognition mats with the following part number are affected:
^& A 203 870 37 10
^ A 203 870 38 10
^ A 203 870 39 10
Do not remove/install/replace any parts. If further fault codes are stored, first process these faults and then flash the restraint systems control
module (N2/7) with DAS releases as of 03/2007:
1. Connect SDS
2. Select Main Groups/Control units/Body/AB - Airbag/Control unit adaptations/Read code and change if necessary/Test of seat mat
components: follow instructions in DAS.
Note:
^ As of DAS 03/2007, the software has been revised and the restraint systems control module detects the installed seat occupied
recognition mat.
^ The part number of the seat occupied recognition mat cannot be read out via DAS.
45
In Case Of Warranty, use the table.
Body - Interior Drafts With Sunroof Open

Date: May 17, 2007
Order No.: P-B-77.20/53
Supercedes:
Group: 77
SUBJECT:
All Model 203 Vehicles as per VINs Included in Content
Drafts in the Interior with Sliding Roof Open
If you receive customer reports in the above model vehicles of drafts in the interior when driving with the sliding roof open, this is caused by a
vacuum affect due to the roof being open. The vacuum pulls air from any opening in the interior that is not completely sealed. Follow the
procedures below to seal these areas.
A. Draft in Footwell Area from Air Leaks in Sound Deadening Material, Up to VIN A731367 and F634898:
1. Remove kick panels. Refer to WIS document AR68.20-P-2050P (driver side) and AR68.20-P-2070P (passenger side).
2. Loosen pedal assembly of parking brake and fold to the side. Brake cables do not need to be removed. Refer to WIS document
AR42.20-P-0510P.
3. On passenger side footwell, inspect sound deadening material for correct installation and cracking (Figure 1, 1).
4. If cracked, replace sound deadening material making sure it covers openings completely.
5. Route electrical lines (Figure 1 - 2, 3) above sound deadening material.
46
6. Tape electrical lines (Figure 2 - 2, 3) to sound deadening material.
7. On driver side footwell, inspect sound deadening material for correct installation and cracking (Figure 3, 4).
9. Cover sound deadening material (Figure 4, 4) and holes (Figure 4, 5) with adhesive tape.
10. Assemble vehicle in reverse order
B. Air Leaks Between Climate System Housing and Vehicle Firewall, Up to VIN A788400 and F693171:
1. Remove battery.
2. Remove the air inlet. Refer to WIS document AR83.25-P-1401P.
47
3. Seal climate housing to firewall using adhesive tape (Figure 5, 4).
Note:
Insure the recirculation flap and humidity sensor (B 31/2) are not obstructed with adhesive tape.
4. Reassemble in reverse order
5. Perform basic programming. Refer to WIS document AR00.19-P-0200P.
C. Air Leaks from Area of C-Pillar, Up to VIN A803730 and F706981
1. Remove side bolster of rear seat backrest. Refer to WIS document AR91.12-P-1710P.
2. Apply adhesive tape to the openings in the left rear (Figure 6, arrows) and right rear (Figure 7, arrows).
D. Air Leaks from Rear Door Panel, All Vehicles
1. Remove rear door panel. Refer to WIS document AR72.12-P-1010P.
2. Disassemble power window switch strip, door lever and door handle. Refer to WIS document AF72.12-P-3100-01P.
48
3. Seal switch strip with tape (Figure 8, 1) and reinstall in door panel.
4. Apply self-adhesive insulation mat (A220 682 07 08) over large surface of door panel in are of switch strip (Figure 9).
5. Seal opening by door lever with self-adhesive insulation (A203 682 04 31) (Figure 10). Cut to make two pieces 30 mm in length.
6. Note: Insure that lever remains free to move (Figure 10, arrow).
49
7. Remove door handle and install foam rubber piece (Figure 11). Position carefully with notch (Figure 11, arrow). Refer to parts table for
applicable part number for left and right side. When foam is installed, it should cover the openings as shown in Figure 12.
8. Reassemble door panel in reverse order.
Note:
When the handle is installed the foam rubber is pressed against the openings. The foam rubber pieces must be positioned and bonded
carefully to ensure the sealing is complete.
Parts Information
Note:
50
In Case of Warranty, use the table.Technical Service Bulletin # P-94_20-05C Date: 070628
Interior - Strong Oily or Vinegar Like Odors

Date: June 28, 2007
Supersedes: P-B-94.20/05b dated August 15, 2006
Group: 94
Revision History
c 6/28/07 Applicable Models, Parts and Warranty Information Updated
b 8/15/06 VIN Range and Applicable Models Updated/Warranty Information Removed
a 5/9/06 Warranty Information Updated (Addition of Op Code 83-6523)
SUBJECT:
All Model 203 Vehicles, Up to VIN A847400, F751400 and R208360
All Model 209 Vehicles, Up to VIN F178200 and T061100
Model 211.026/056/065/070/076/082/083/087/256/265/276/282/283/287, from VIN A445800 to A967400 and X117500 to X207000
Model 219.375/376, from VIN A000001 to A075800
Odor in the Interior
If you receive customer reports in the above model vehicles regarding an odor in the interior is either a strong oily (putty) or acidic (vinegar)
or butyric acid (rancid butter) smell and other potential sources have been ruled out, the source of the odor may be the soundproofing mat on
the interior side of the transmission tunnel. This odor will be present even with the engine and HVAC turned off and becomes more intense
after the vehicle is parked for an extended period of time with the windows and sliding roof closed.
1. Pull back the carpeting on the side of the transmission tunnel.
2. Smell the exposed tunnel soundproofing mat, if there is an odor similar to the customer complaint, proceed to step 3.
3. Flex the exposed tunnel soundproofing mat, if the mat breaks when bent back and forth proceed to step 4.
4. If there is a strong odor and/or the mat breaks after a few bending movements, the tunnel soundproofing mat material must be replaced. It is
51
necessary to remove the AC housing. Refer to the following applicable WIS documents:
Model 203 AR83.30-P-5200P
Model 209 AR83.30-P-5200Q
Model 211 without Heater Booster: AR83.30-P-5200T
Model 211 with Heater Booster (Diesel Models Only) AR83.30-P-5200TA
Model 219 AR83.30-P-5200TX
Note:
Soundproofing mat part number A203 682 01 01 must not be installed. Refer to Parts Table for respective replacement part numbers.
5. After replacing the tunnel soundproofing mat, check adjacent areas to determine if the odor remains.
6. If the odor is detectable on adjacent areas, apply stain remover and plastic cleaner to the affected parts.
7. It the odor is still detectable on the carpet, the affected carpet panels will need to be replaced.
Parts Information
Note:
on June 28, 2007. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
52
In Case of Warranty, use the table.Technical Service Bulletin # P-68_10-52 Date: 070501
Interior - Instrument Panel Rubbing/Buzzing Noises

Date: May 2007
Order No.: P-B-68.10/52
Supercedes:
Group: 68
SUBJECT:
MODEL 203
Noises at the Instrument Panel
Overview of noise sources
53
A. Rubbing noises in the area of the instrument cluster frame (1, Figure 1)
B. Buzzing noises in the area of the centerfill cover (2, Figure 1)
Note:
See individual repair procedures for relevant models.
Procedures
A. Rubbing noises in the area of the instrument cluster frame
Models 203.040/061/064/065/081/084/261/264/281/284/740/747/764 up to VIN A692258 or VIN F599665
The instrument cluster frame may rub on the instrument cluster when driving. This complaint occurs under rough road surface conditions.
1. Remove instrument cluster. (See WIS-document AR54.30-P-6015P)
2. Stick felt strip (material thickness: 0.5 - 1 mm) at the bottom of the ribs of the instrument cluster frame (Figure 2).
Note:
See Parts ordering notes
3. Install instrument cluster. (See WIS-document AR54.30-P-6015P)
B. Buzzing noises in the area of the centerfill cover
Buzzing noises occur due to there being too much play in the centerfill cover.
1. Remove centerfill cover. (See WIS-document AR68.10-P-1150PA)
54
2. Apply felt (1, Figure 3) in order to brace the grill.
Note:
3. Install centerfill cover. (See WIS-document AR68.10-P-1150PA)
Special Tools
In Case of Warranty, use the table.Technical Service Bulletin # P-91_60-76D Date: 070725
Restraints - SRS Lamp ON/DTC's 9103 or 9123 Set

Date: July 25, 2007
55
Supersedes: P-B-91.60/76c dated Jan. 17, 2006
Group: 91
Revision History
d 7/25/07 Process and Part Numbers Updated
c 1/17/06 Process, Part No. description and Damage Code Update
b 12/19/05 Parts Quantity Updated
a 12/12/05 Applicable Models and Technical Content Updated
SUBJECT:
Model 203.040/052/054/056/061/064/065/076/081/084/087/092/261/
264/281/284/740/747/764
Model 209.356/365/375/376/456/465/475/476
SRS Light Illuminated
If you receive customer reports in the above model vehicles of the SRS light being illuminated accompanied by either of the diagnostic fault
codes listed below, perform the following procedure. Replacement of the contact spiral is not necessary. All contact spirals returned will be
subject to testing and may be debited if found to be operational.
Fault Codes:
^ DTC 9103 - the resistance value in the ignition circuit containing component R12/13 is too high
1. Remove the Steering Wheel Module (SCM):
^ 203 refer to WIS document AR54.25-P-2802PQ
Note:
The battery ground cable must be disconnected. If this step is omitted, other faults may be introduced into the vehicle when cutting the
SCM harness.
2. Remove instrument panel bottom section on driver side:
^ 203 refer to WIS document AR68.10-P-1500P
^ 209 refer to WIS document AR68.10-P-1505Q
56
3. Remove the SCM harness from the jacket tube by releasing lock tabs on both sides of the connector (Figure 1). If present, release harness
from retainer (Figure 2). Gently pull the harness out from under the instrument panel to gain access.
Procedures for 203/209, As of Model Year 2005:
4. The repair harness is color coded to match the car side of the harness. Pins 8 and 12 of the SCM connector are brown wires and cannot be
interchanged. Pins 5 and 11 are both green wires and cannot be interchanged. These wires should be cut and spliced one at a time to ensure
that they are connected correctly.
Cutting Procedure First Time Repair:
5. Using a Digital Multi Meter (DMM), locate the brown wire (0.75 BN) connected to terminal 8 of the SCM connector of the repair harness.
6. Locate the brown wire (0.75 BN) connected to terminal 8 of the SCM connector of the vehicle harness and cut it at the connector.
57
7. Slip the solder connector (A002 546 13 41) onto the cut wire. Strip approximately 15 mm of insulation from the repair harness wire and the
SCM harness wire. Braid the 15 mm stripped ends of the repair wire and SCM harness wire (Figure 3). Solder the wires in accordance with
the specified repair method in WIS document AR54.18-P-0100-06A (Figure 4 and 5).
8. Repeat steps 2 to 4 for the brown wire (0.5 BN) at pin 12.
9. Repeat steps 2 to 4 for the green wires (0.5 GN) at pin 5 and 11.
10. Cut remaining wires at the SCM connector and follow step (4) for remaining wires. The repaired harness will be significantly longer than the
original harness (Figure 6).
Note:
Use appropriate WEB ETM document to confirm pin locations and wire colors.
Cutting Procedure Previous Repair:
58
11. If the SCM connector has been previously repaired using individual repair wires, remove the insulating tape of the repaired harness. The
solder connectors should be located close to where the SCM harness comes out of the cockpit harness.
12. Using a DMM locate the brown wire (0.75 BN) connected to terminal 8 of the SCM connector of the repair harness.
13. Locate white pigtail that is spliced to the brown wire (0.75 BN) connected to terminal 8 of the SCM connector of the vehicle harness. Cut it
at the solder connector so that the white pigtail and solder connector are completely removed.
SCM harness wire. Braid the 15 mm stripped ends of the repair wire and SCM harness wire, see (Figure 3). Solder the wires in accordance
with the specified repair method in WIS document AR54.18-P-0100-06A (Figure 4 and 5).
16. Repeat steps 12 to 14 for each of the green wires (0.5 GN) at pin 5 and 11.
17. Cut remaining wires at the solder connector and follow Step 14 for remaining wires. The repaired harness will be slightly longer than the
original harness.
Note:
Use appropriate WEB ETM document to confirm pin locations and wire colors. The new repair harness needs to be spliced directly to the
vehicle harness using new solder connectors.
Assembly
18. Insulate harness and solder connectors with fabric tape.
19. Install the retainer, harness and N80 connector onto the jacket tube. Secure extra length of harness with cable tie.
20. Reassemble the vehicle in the reverse order.
Up to End of Model Year 2004:
21. Make note of pin locations and wire colors. Cut the SCM connector wires of the vehicle harness 50mm from the terminal ends.
Note:
Reference the appropriate WEB ETM document to confirm pin locations and wire colors.
22. Cut the repair wire 65 mm from each female terminal end.
23. Strip approximately 15 mm of insulation from the repair wires and the SCM harness wires. Twist the 15 mm stripped ends of the repair wires
and SCM harness wires.
24. All the repair wires are the same size (A001 540 94 05).
25. Using solder connector (A002 546 13 41), solder the repair wires (A001 540 94 05) onto the four airbag wires pins 3, 4, 5, 6, the four CAN
wires pins 10, 11, 12, 13 and the two wires for circuit 30 and 31, pins 8 and 9. Follow the specified repair method in WIS document
AR00.19-P-0100A.
26. Remove the lock on the SCM socket connector (Figure 7). Depress the lock tab on the terminal and remove one cut wire terminal at a time.
Install the appropriate repaired wire into the correct position in the socket connector.
Note:
Ensure during the reassembly of the SCM connector that all terminals are reinstalled in their correct positions. Continue the twist for
CAN wires connecting to pins 10, 11, 12, and 13. Reference the appropriate WEB ETM document to confirm pin locations and wire
colors.
59
27. Insulate the solder connectors and the repaired harness with fabric tape.
28. If present, remove the reinforcement in the retainer (Figure 8) to prevent the harness from being crushed.
29. Install the retainer, harness and N80 connector onto the jacket tube.
Parts Information
Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been
generated on July 25, 2007. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.

Brakes - Front/Rear Brakes Squeal

Date: September 20, 2007
Order No.: P-B-42.10/79
Supercedes:
Group: 42
SUBJECT:
Model 171.454/456
All Model 203 Vehicles
Model 209.356/365/372/375/376/456/465/472/475/476/477
Model 215.374/375/376/379
60
Model 220.067/170/174/175/176/178/179/183/184
Model 230.471/474/475/476/477/479
Front / Rear Brakes Squeal When Braking
If you receive customer reports in the above model vehicles where either the front and/or rear brakes squeal, perform the following to resolve.
Note:
^ Bed in the brake pads in the course of a normal road test if new brake pads are installed. Do not perform any special "bedding-in"
operations.
^ Brake squeal does not usually necessitate the replacement of the brake disks. The only time the brake disks can potentially be the
cause of the brake squeal is when it is seriously warped or heavily scored.
^ A damping plate is adhered to the backing plate of the brake pads. This adhered joint must fix the damping plate to the backing plate
over its entire surface area in order to guarantee effective noise damping. If the adhered joint has become partially or entirely
detached and the damping plate can be lifted off as a result, the brake pads must be replaced.
^ If the brake pads exhibit signs of excessive heat (white or red discoloration at the edges), this is due to excessively high thermal stress
on the brakes (perhaps as a result of a misuse). In this case, the brake pads must be replaced because satisfactory noise damping can
no longer be guaranteed.
Front Brakes
1. Reproduce squealing noises when braking and ensure that the squealing noise is coming from the front wheel brake.
Note:
For vehicles with 4-piston fixed caliper brake on the front axle, continue and perform steps 2 through 4. For all other brake variants,
resume with step 5.
2. Check the version of the brake pads by comparing the designation number engraved on the backing plate (Figure 1) with the parts
information table. Replace brake pads and install the latest version if necessary.
3. Check the version of the removable damping plate (silver colored) and replace if necessary. The current version of the damping plate has
semicircular cutouts.
4. Check the version of the pressure spring. The current version of the pressure spring has retaining tabs (Figure 2). Replace the pressure spring
if necessary (corresponding to damage code 42116 36).
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5. Check and see if the brake pads can be easily moved. Clean the brake pad guides if necessary.
6. Apply brake paste to the pads/caliper based on the information shown for the particular application.
7. If new pads were not installed and the problem still persists, replace the brake pads. Refer to EPC for the latest part number. Ensure to follow
the above instructions (step 6) for proper greasing location per application.
8. For Model 211/215/219/220/230 vehicles, install dampers in pistons of front brake calipers. Ensure that the rounded part of the piston
damper(s) is inserted first for 4-piston fixed caliper brakes (corresponding to damage code 42186 36).
Note:
Refer to the WIS documents shown above for instructions on replacing the brake pads.
Rear Brakes
1. Reproduce squealing noises when braking and ensure that the squealing noise is coming from the rear wheel brake.
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Figure 3 and 4
3. Apply brake paste to the pads/caliper based on the table shown above for the particular application.
4. If the problem persists replace the brake pads, refer to EPC for the latest part number. Ensure to follow the above instructions (step 3) for
proper greasing location per application.
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Note:
Refer to the WIS documents shown for instructions on replacing the brake pads.
Parts Information
Note:
on September 20, 2007. Please refer to Netstar ?? Star TekInfo ?? Star Time for the most current labor time allowance.
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70

A/C - Blower Motor Inoperative/DTC 09460 Set

Supersedes: P-B-83.25/76b dated March 9, 2007
Group: 83
Revision History
C 9/28/07 Work Instructions, Part Number

and Warranty Information Updated
b 3/9/07 Applicable Models and Content Updated
a 9/20/06 Addition of Note Pertaining to DTC Code 9460
SUBJECT: All 171, 203, 209, 211, 219 and 230 Models
Heater Blower Motor Stops Running
If you receive customer reports in the above model vehicles that the heater blower motor stops running, the blower motor regulator should be
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replaced. The related symptoms for this condition are as follows:
1. During high blower demand, such as defrost or maximum cooling, the blower starts up and shuts off for approximately 90 seconds. The
blower tries to restart and may shut off again. This cycle may repeat.
2. Manual adjustment of the blower speed and the blower shuts off for 60 seconds and then restarts.
3. Once the blower has shut off by itself, cycling the ignition off and back on may allow the blower to operate again.
4. Diagnostic fault code DTC 9460 may be present.
These conditions may be caused by a high blower output requested by the climate system and the blower regulator overload protection engaging
unnecessarily. Follow the procedures below for corrective actions.
1. Replace the blower regulator as per the WIS document shown.
2. Additional procedures for 211 and 219 are shown above.
3. Following replacement, verify correct operation of the heater blower.
Parts Information
Note:
on September 28, 2007. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
72

Suspension - Front Axle Creaking Noises

Order No.: P-B-32.20/58
Supersedes:
Group: 32
SUBJECT:
Creaking Noises from Area of Front Axle When Suspension Compresses/Expands
If you receive customer reports in the above model vehicles of a creaking noise from the front axle area when the suspension is compressed or
expanded, perform the following.
Note:
This noise may be caused by the wearing out of the rubber mounts located on the front axle torsion bar. The noise may occur more at
higher temperatures.
1. Remove the lower engine paneling. Refer to WIS document AR61.20-P-1105P.
2. Remove the torsion bar on the front axle. Refer to WIS document AR32.20-P-0300P. If the vehicle has xenon headlamps, detach the linkage
from the level sensor.
3. Thoroughly clean the torsion bar.
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4. Preinstall both rubber mounts with seal boots and slide them onto the torsion bar (Figure 1). Take note of the installation position.
5. Screw on both caps for the rubber mounts (Figures 2 and 3). Use a new bracket if the torsion bar diameters are 20 mm and 21 mm.
6. Reinstall the torsion bar and lower engine paneling in reverse order.
Parts Information
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Note:
on November 2, 2007. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
In case of warranty, use the table.Technical Service Bulletin # P-07_61-78 Date: 070928
Engine Controls - Mil ON/DTC P0217 Stored in Memory

Order No.: P-B-07.61/78
Supersedes:
Group: 07
SUBJECT:
Model 171.454/456
Model 203.052/054/056/087/092
Model 204.054/056
Model 209.356/372/456/472
Model 211.056/072/087/090/256/287
Model 216.371
Model 219.372
Model 221.171/186
Model 230.471
Check Engine Light Illuminated / Fault Code P0217 Stored in Engine Control Unit
If you receive customer reports in the above model vehicles that the check engine light is illuminated with fault code P0217 stored in the engine
control unit, the cause may be the software in the control unit. Other possible stored fault codes may be P0868, P0872, P0190, P0208, P1347 or
P2182. To resolve, perform the following.
Note:
Vehicles produced as of 11/2005 have the modified software version installed.
1. Check the throttle valve for mechanical faults and check intake tract for residues. If there is no mechanical fault, the throttle valve actuator is
not the cause and must not be replaced. Proceed to step 2.
2. Program the engine control unit with the latest available ME software in DAS.
Note:
generated on September 28, 2007. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
75

Keyless Entry - LED on Transmitter Key Not Functioning

Order No.: P-B-80.35/43
Supersedes:
Group: 80
SUBJECT:
All Model 171, 202, 203, 208, 209, 210, 211, 215, 220 and 230
Equipped with Drive Authorization System (DAS3) (FBS3)
Battery Indicator (red LED) on Transmitter Key Not Functioning
If you receive customer reports on the above model vehicles that when using a new transmitter key for the first time the battery indicator is
nonfunctional (lock/unlock is unaffected), reinsert the key into the ignition a second time. Proper operation of the key is restored automatically once
the key is taught into the vehicle.
Steering - Steering Gear Apparent Leakage Information

Group: 46
Revision History
a 11/27/07 Updated to Include Model 204
SUBJECT:
All 171, 203, 204, 209, 210, 211, 215, 216, 219, 220, 221 and 230 Models
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Equipped with Rack-and-Pinion Steering Steering Gear Leaking Under Dust Cap on Control Head
During inspection of returned power steering racks, we have encountered cases where steering racks have been replaced due to leaking" but which
prove to exhibit merely "sweating" or a film of grease under the dust cap on the top of the control head.
If during power steering complaint diagnosis, moisture on the surface of the steering gear under the dust cap is noticed in a localized section, this is
considered sweating due to grease liquefying and not leakage.
This moisture can be caused by:
^ Grease under the dust cap to keep dirt (dust) away from the steering system.
^ Heat from the engine causes some of the grease under the cap to liquefy which produces a slight but noticeable moisture/grease film on the
surface and does not indicate leakage, nor is it a cause for power steering complaints.
Figures 1, 2 and 3 contain examples of steering racks that are "sweating" in this area. It can be seen that, on the sweating steering gear, only the top
of the control head is wet on one side (i.e. not all round). No droplets form (no run marks etc.) that run down the steering gear/control head. For this
reason, do not expect any contamination with grease/oil in the surrounding area or on the ground. The grease (film) adheres to the steering gear
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housing.
In contrast, if the steering is genuinely leaking, the steering gear housing appears very wet, even when combined with dirt, and sometimes droplets
are formed.
Note:
Another form of leakage in the steering system is a drop in the oil level in the reservoir of the power steering pump. For this reason, the oil level
must always be checked with the dipstick when ascertaining findings.
Therefore, when assessing whether a steering gear is merely "sweating" due to liquefying grease in the area of the control head or whether it is
actually leaking, strictly adhere to the procedure described below:
1. Clean steering gear.
2. Spray or coat steering gear with a suitable leak detector spray.
3. Warm up the steering system by turning the steering wheel from lock to lock several times and, if necessary, perform a test drive and observe
the oil level in the power steering pump reservoir.
4. Assess steering for leaks
Note:
If leakage is found at the screw connections of the internal/external lines or at the power steering valve, repair parts are available.
Steering racks must not be replaced for this reason.
Steering - Leaks From Steering Rack

Date: December 19, 2007
Group: 46
Revision History
C 12/19/07 Applicable Models Updated
b 3/27/06 Technical Content / Parts and Warranty Information Updated
a 8/26/05 Applicable Models / Technical Content Updated
SUBJECT:
Model 171.454/456/473
Model 203.052/054/056/061/064/065/081/084/261/264/281/284/740/747/764
Model 209.356/365/375/376/456/465/472/475/476
Model 211.026/065/070/076/082/083/265/276/282/283
Model 219.372/375/376/377
Model 230.471/472/474/475/476/477/479
Leak at Steering Rack Connection
If you encounter leakage at the steering rack connection in the above models, the cause may be damage to the sealing ring of the hydraulic lines. In
such instances, replacement of the rack will not resolve the situation. To resolve, replace the sealing ring at the steering gear connection as per the
below procedure.
1. Loosen line connection on steering gear.
Note:
If necessary, loosen line supporting bracket.
2. Replace sealing rings and support ring.
Note:
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Ensure that sealing rings and supporting ring are properly seated. Supporting ring only present on high pressure line (not on model 230
and 203 up to 03/02).
Note:
There are two versions of power steering high-pressure lines. The preceding version has a slotted support ring which can be replaced
individually. The new version has a support ring which is not slotted and which cannot be replaced individually; in this case the complete
power steering high-pressure line must be replaced (see parts list).
3. Fasten line connection on steering gear with retaining plate.
Note:
Observe below torque values for screw connection.
4. Bolt, oil line clamping plate to rack-and-pinion steering
a. Models 203, 211.082/083/087/282/283/287 - 20 Nm
Models 171, 209, 211 except 211/082/083/087/282/283/287 - 18 Nm
b. Bolt on Clamp Plate, high-pressure line / return line to rack-and-pinion steering
Model 230 - 18 Nm
5. Bleed steering system and check for leaks. Refer to the WIS documents shown for bleeding the system / checking for leaks.
Parts Information
Note:
on December 19, 2007. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
79

A/T - Multiple DTC's Set/Limp Home Mode

Group: 27
Revision History
SUBJECT:
All Passenger Models Equipped with 722.9 (7G-Tronic) Transmission
Transmission in Limp Home Mode
If you receive customer reports in the above model vehicles of the transmission being in limp home mode (intermittently or permanently) with fault
code(s) 0741, 0893, 0894, 2502, 2504, 2505, 2511, 2711, 2783 are stored in the transmission control module as well as particulate in the
transmission oil pan which corresponds to the pattern shown in Figure 1; the cause may be related to the torque converter lock-up clutch or the rear
planetary gear set.
Note:
Follow the WSG Pre-Authorization Process as outlined in DTB P-B-27.00/38d dated November 7, 2006 and be sure to provide all of the
required documentation.
To resolve, replace the transmission and torque converter. Be sure to flush all particulate out of the cooler before installing the new
transmission/torque converter.
Warning!
Do not clean any of the particulate from the oil pan or the magnets prior to sending the transmission back to the QEC.
Parts Information
Note:
on January 9, 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
80
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Anti-Theft System - A/T Inop After Key Programming

Supersedes: P-B-80.57/48 dated January 9, 2008
Group: 80
82
Revision History
SUBJECT:
Model 203.052/054/056
Model 209.356/372/375/377/456/472/475/477
Equipped with 722.9 Transmission (SA code 427)
Transmission Inoperable After Learning a New Spare Key
If you encounter an issue in the above model vehicles of the automatic transmission becoming inoperable after initializing a new spare key in the
electronic ignition switch (EIS), this may be due to the transmission control unit still performing the initialization process for the new key. To
resolve, reinsert the new key back into the EIS, switch to key position two and have key remain in EIS for approximately one hour. Do not replace
any parts for this condition!
Warning!
Ensure a battery charger is also connected.
Note:
When a key is initialized in the EIS and circuit 15 is switched on, the key is also initialized in the engine and transmission control unit. These
control units take different lengths of time to compute the drive authorization data. In most instances, the engine control unit finishes its
calculations in approximately 15 minutes. When the engine control unit finishes its calculations, the "vehicle computing" display in the
instrument cluster disappears, even though the calculation in the transmission control unit may not be complete. The computation of the drive
authorization data in the transmission control unit can take up to 45 minutes.
Note:

Interior - Front Center Arm Rest Loose/Falls OFF

Supersedes: P-B-68.20/33b dated February 2, 2007
Group: 68
Revision History
c 2/14/08 Note Pertaining to 203/209 Added to the beginning of this bulletin and Parts Information Updated
b 2/2/07 Content Revised and Warranty Information Updated
a 11/15/04 Applicable Models for Conditions 1 and 2 Updated
SUBJECT:
Model 203.040/052/054/056/061/064/065/076/081/084/087/092/261/264/281 /284/740/764/747
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Model 209.356/365/375/376/456/465/475/476
Front Center Armrest Lid
If you receive customer reports in the above model vehicles of either of the conditions listed below, perform the respective remedy as stated.
Condition 1:
Lid for the front center armrest and storage compartment has fallen off or is not closing correctly.
Applicable Models:
203/209 MY 05 or 06, Equipped with "Flip top" armrest design
Remedy 1a:
Reinstall the lid. If the pivots or levers are not damaged do not replace the lid, reinstall lid as per WIS document AR68.20-P-2370Q (or view the
video demonstration on the MBUSA Training and Education website at http://tech_trainingdev.mbusa.com/console and latch) and then check the
lid for correct functioning. Starting October 11, 2004, lids replaced under warranty will be inspected for damage to the pivots and levers. If the
pivots and levers are found to be okay, the claim will be debited.
Note:
For 203 MY 05 or 06, if the customer is not satisfied with remedy 1a, a new armrest lid (see parts information) can be retrofitted as per WIS
document AR68.20-P-1101Q. This retrofit is customer pay.
Remedy 1b:
Inspect the bin or lid for damage. If the bin or the lid is damaged, replace the bin and lid per WIS document AR68.20-P-2150QA. If the damage
causing part is the lid, use damage code 68119. If the damage causing part is the bin, use damage code 68115 or 68118 (depending on model).
Condition 2 (209 only - as of MY 05):
Front center armrest latch will not open or catches when opening.
Applicable Models:
209 MY 05 or 06, Equipped with "Flip top" armrest design
Remedy 2:
This may be caused by tolerance problems in the kinematics of the latch or the latch may be broken. If this occurs, it is not necessary to replace the
entire lid.
1. Replace only the latch (Figure 1, 1).
2. Remove and install the old lock cylinder (Figure 1, 2) as per WIS document AR68.20-P-2380P.
Condition 3:
Rubbing noise from center armrest lid.
Applicable Models:
203 - up to A044555 or F026062 / 209 - up to F147223 or T044943
Remedy 3:
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This may be due to the center armrest lid rubbing against the catch area when driving (Figure 2 for 209 or Figure 3 for 203, arrows). To resolve,
lightly grease the catch area.
Parts Information
Note:
on February 2, 2007. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
85

Tire Monitor - Tire Pressure Monitoring Inactive Message

Order No.: P-B-42.45/86
Supersedes:
Group: 42
SUBJECT:
All Model 171, 203 and 209 Vehicles
Equipped with Sales Code 477 - Tire Loss Warning System (indirect ESP based) with Run Flat Tires
Model Year: 2005 to 2007
"Tire Pressure Monitoring Inactive" Displayed in Instrument Cluster
If you receive customer reports in the above model vehicles with the message "Tire Pressure Monitoring Inactive" displayed within the instrument
and the following fault code is stored within the ESP control unit, perform the following.
^ C1550 - Test voltage supply at control unit N47-5 (ESP and BAS control module)
Note:
This may result from an incorrect fault setting condition with the tire pressure loss warning software. If there is an under-voltage in the
ESP control unit when writing to the EEPROM (Electrically Erasable Programmable Read-Only Memory) or if an ignition change occurs
when the vehicle is moving, an invalid value can be supplied to the EEPROM check. This can produce fault code C1550 even if the ESP
control unit is OK.
1. Check power supply (> 12 V) at component N47-5 (ESP control unit) and correct any connection issues.
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2. Check ground connection of component A7/3 (Traction system hydraulic unit) and correct any connection issues.
3. Using STAR Diagnosis perform a short test and erase fault codes
4. Cycle ignition on-off-on
5. Using STAR Diagnosis recheck for the above fault codes within ESP.
6. If no fault code is present the ESP control is OK.
7. If the fault code listed above is present, replace the ESP control module. Refer to ESP for latest part number. ESP control unit replacement is
only justifiable if the fault is currently stored and there is no under-voltage present at the ESP control or hydraulic unit.
Note:
generated on January 3, 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.

ABS/TCS - Cruise Control Message Displayed/DTR Lamp ON

Order No.: P-B-42.45/88
Supersedes:
Group: 42
SUBJECT:
All Model 203 Vehicles, as of August 2001 Production
"Speedtronic/Cruise Control, Visit Workshop!" Displayed In Instrument Cluster and / or DTR Lamp Illuminated After Engine Start and ESP
Control Unit Replacement
If after replacing the ESP control unit; "Speedtronic/Cruise Control, Visit Workshop!" is displayed in the instrument cluster and/or the DTR
indicator lamp is illuminated after the engine has been started, perform the following.
Note:
The following fault code and/or event code may be present. This is due to the incorrect ESP control unit replacement, since ESP control
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units are not universally compatible or interchangeable.
^ ESP control unit: C1510 - Fault in CAN communication with control unit N63/1 (DTR control module)
^ Instrument cluster: 9104 - Control module DTR is not sending any data
1. If one of the following ESP control units was replaced on the affected vehicle, replace the ESP control unit with A034 545 72 32.
Note:
Please refer to WIS document AR42.45-P-0820P for instructions on replacing the ESP control unit. After replacing the ESP control unit
it may be necessary to deactivate the speed-sensitive power steering via coding and activate the tire pressure loss warning system using
the "Initial Start-up" menu in STAR Diagnosis.
Parts Information
Technical Service Bulletin # P-27_50-59B Date: 080104
A/T - Limp Home Mode/Various Codes Set

Supersedes: P-B-27.50/59a dated March 16, 2006
Group: 27
Revision History
b 1/4/08 Operation Code Updated
SUBJECT:
Model 171.454/456/473
Model 203.052/054/056
Model 209.356/375/456/475
Model 211.056/070/256
Model 215.375
Model 219.375
Model 220.170/175
Model 230.475
Equipped with 7G-Tronic Transmission (NAG2)
Transmission in Limp Home Mode with Fault Codes 2200, 2201, 2767 and 2768
If you receive customer reports in the above model vehicles of the transmission being in limp home mode with fault codes 2200, 2201, 2767 and
2768, the condition can be related to an unfavorable production tolerance of the speed sensor ring of the K1 shift member.
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In such cases, the flange (Figure 1, call-out 164) should be replaced to resolve. Follow the work procedures outlined in WIS Document
AR27.51-P-0800W (Dismantling and Assembling clutch K1) as well as the other associated documents.
Note:
This work procedure only applies to the above fault codes and to transmissions with a production range of 7229xx 00 327088 to 7229xx 00
338693. For transmissions outside of the given production range, replace the electro-hydraulic control unit only. Refer to EPC for the specific
application / part number.
Parts Information
Note:
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Restraints - SRS Lamp ON/Multiple Codes Set

Supersedes: P-B-91.60/65b July 22, 2004
Group: 91
Revision History
c 1/11/08 Warranty Information Updated (Model Indicators Added)
b 7/22/04 Procedure Update - Return of connectors no longer necessary
a 1/9/04 Procedure Update
SUBJECT:
Model 203
All Model Years
SRS Indicator Lamp On
If you receive customer reports in the above model vehicles that the SRS light is illuminated and diagnostic fault code(s) B1035, B1037, B103B
and/or B1039 are stored in the SRS ECU, the resistance in R12/11, R12/12, R12/20 or R12/21 ignition circuits for the sidebag squibs may be too
high. This high resistance is caused by either of the following:
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^ The left front door separation point connector X35/1,
^ The right front door separation point connector X35/2,
^ The left rear door separation point connector X35/3
^ The right rear door separation point connector X35/4.
To resolve, remove connectors from the wires for sidebags in the left and right front footwells and the left and right rear entry ways and connect
wires directly. Please follow the below procedure to repair.
Note:
Always perform procedure on all 4 connectors.
1. Remove ignition key.
2. Remove A-pillar paneling in front foot well and door sill molding. Remove left front floor covering per WIS document AR68.20-P-2050P
and right front floor covering per WIS document AR68.20-P-2070P.
3. Remove left and right rear door sill molding.
4. Expose wiring harness. Figure 1 shows connector for front doors X35/1 (left front door separation door separation point) and X35/2 (right
rear door separation point) are similar. Wiring diagram of airbag control module with integrated E-call system can be found in WEB ETM
document 91.60-U-2101FA.
5. Remove connectors and connect wires directly with solder connectors.
a. Cut line approx. 10 mm in front of and behind connector.
b. Remove about 20 mm of fabric tape on the control unit side.
c. Strip about 15 mm of insulation from the wire.
d. Slide solder connector onto wires.
e. Twist both wire ends together, observing the wire color assignment.
f. Position solder connector in the middle and shrink it on (solder) using a heat gun.
^ Utilize wiring harness repair set W220 589 02 99 00 and heat gun part no. 458-HL1802E via the MBUSA Standard Service
Equipment Program.
g. Inspect solder connection.
h. Tape up both ends of the wires.
6. Delete fault memory with STAR DIAGNOSIS.
7. Install in the reverse order.
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Parts Information
Note:

Technical Service Bulletin # P-82_10-195F Date: 080408
Lighting - Front Turn Signal(s) are Inoperative

Date: April 8, 2008
Order No.: P-B-82.10/195f
Supercedes: P-B-82.10/195e dated March 15, 2006
Group: 82
Revision History
f 4/8/08 VIN Range and Applicable Models Updated
e 3/15/06 Warranty Information Updated
d 2/16/06 Applicable VIN Range Added
c 7/1/03 Warranty Information Updated
b 8/2/02 Warranty Information Included
a 6/12/02 Part Number Included
- 5/16/02 Initial Issue
SUBJECT:
Model 203.052/054/056/061/064/065/076/081/084/087/092/261/264/281/284/
740/747/764
Up to VIN A339771, F261050 and R053444
Front Turn Signal Inoperative
If you receive customer reports in the above model vehicles of the front turn signal not working, this may be due to a contact problem
between the turn signal bulb socket and the headlamp housing. In this case, perform the following repair only on the affected side of the
vehicle.
1. Remove E1e2 (left turn signal) or E2e2 (right turn signal) from the headlamp housing. Refer to WIS document no. AR82.10-P-1201P, R&R
Bulbs Headlamp Unit.
2. Check outer contacts of the bulb socket for damage. If damage is visible, repair as follows.
3. Disconnect 5-pin connector at headlamp housing.
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^ Plug from headlamp assembly
1. Turn signal wire located in chamber 1 of existing headlamp housing connector (2)
2. Headlamp housing connector
3. Connector locking tab
4. Open pin lock (Figure 1, 3) on connector (Figure 1, 2) and "un-pin" turn signal wire (Figure 1, 1) from connector. Left side, pin 1 is
white/black. Right side, pin 1 is green/black. Refer to WIS document no. AR00.19-P-0120-02B, Removing Contacts from Sensor Connector.
5. Plug empty chamber with a rubber plug, refer to parts information section for part number.
^ Turn signal repair set
1. Turn signal wire from headlamp
4. Repair set connector
5. Turn signal bulb socket connector
6. Turn signal bulb socket ground wire
6. Remove contact housing (Figure 2, 4) from connector (Figure 2, 5) and insert "un-pinned" turn signal wire removed in step 4 (Figure 2, 1)
into chamber 2 of contact housing (Figure 2, 4) (from repair set). Prior to assembly, check individual gaskets for damage.
7. Reconnect contact housing (Figure 2, 4) with connector (Figure 2, 5). Housing must audibly click into place.
8. Connect cable eyelet (Figure 2, 6) of the repair set with the component compartment ground (Figure 3, W16/3) if repairing the left turn signal
or the component compartment ground (Figure 4, W16/4) if repairing the right turn signal.
9. Install E1e2 (left turn signal) or E2e2 (right turn signal) into the headlamp housing.
10. Re-connect connector (Figure 1, 2) with headlamp housing.
11. Attach repair harness set along the original harness with two cable ties in such a way that the harness will not be abraded and /or cause any
noise.
Parts Information
93
Note:
on April 8, 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
In Case of Warranty, use the table.Technical Service Bulletin # S-68_05-74 Date: 080408
Garage Door Opener - Range Too Short/Can't Program

Date: April 8, 2008
Order No.: S-B-68.05/74
Supercedes:
Group: 68
SUBJECT:
All Model 129, 140, 163, 164, 170, 171, 202, 203, 204, 208, 209, 210, 211, 215, 216, 220, 221, 230, 251 and 463 Vehicles
Garage Door Opener Cannot Be Programmed and/or Range is Too Short
If you receive customer reports in the above model vehicles that the handheld garage door transmitter cannot be programmed into the integrated
garage door opener transmitter (inside the rearview mirror) or that the range of the integrated garage door opener transmitter is too short, refer to
the remedies below depending on the symptom encountered.
Symptom 1:
Integrated garage door opener buttons are already preprogrammed.
Remedy 1:
Before a handheld transmitter can be programmed, a reset must be performed on the integrated garage door opener. To do so, press and hold down
buttons 1 and 3 on the integrated garage door opener simultaneously for approx. 20 seconds until the LED begins to flash rapidly (also refer to the
operating instructions for the vehicle).
Symptom 2:
Garage door transmitter frequency or coding technology is not compatible with vehicle system.
Remedy 2:
Order and install a universal receiver for the opener installed in your home via the HomeLink hotline.
Note:
If you have further questions relating to the garage door opener, compatibility, programming of the regional code, synchronization or ordering
of a universal receiver, visit Internet site: www.homelink.com or contact the HomeLink toll-free hotline 1-800-355-3515.
Symptom 3:
Handheld transmitter uses a rolling code system.
Remedy 3:
It may be necessary to learn the code now stored to the integrated garage door transmitter into the garage door opener's receiver because they are
now out of sync. (Refer to the garage door opener on how to learn a transmitter into the receiver.)
Symptom 4:
Distance when programming handheld transmitter to integrated garage door opener is too small/too large or programming time is terminated too
soon.
94
Remedy 4:
Pay attention to the distance when programming. The distance varies between 5 cm and 30 cm depending on the system. Several programming
attempts may be necessary; every attempted setting position should be maintained for at least 15 seconds.
Symptom 5:
Timeout time of hand transmitter exceeded (switches off after approx. 20 sec).
Remedy 5:
Attempt learning the handheld transmitter into the vehicle again.
Symptom 6:
Timeout time of integrated garage door opener exceeded (switches off after approx. 60 sec).
Remedy 6:
Change the position of the hand transmitter and then start programming again.
Symptom 7:
On vehicles with infrared coated glass, the openers which use 390MHz have no range; however 300MHz is OK in same vehicle. (Sears/Liftmaster
openers used 390MHz up until 2005.)
Remedy 7:
Construct a passive repeater antenna from a piece of RG174 coaxial cable (locally sourced) to resolve the issue.
a) Cut a piece of coaxial cable (locally sourced) approximately 152 cm long.
b) Strip 18.5 cm of the outer shield from each end, leaving center conductor insulator intact (Figure 1).
c) Remove mirror from vehicle and open the mirror.
d) Remove cover on left A-pillar.
e) One end of the cable is cable tied to the garage door opener antenna in the mirror (Figure 2).
f) Route the cable above the headliner and place the other end of the cable along the edge of the glass on left side of the windshield (Figure 3).
g) Reinstall the mirror and test the range of opener.
h) Replace panels
Interior - Seats are Dirty/Stained

Order No.: S-B-91.18/151
Supersedes:
Group: 91
SUBJECT:
95
All Passenger and Light Truck Models Dirty Seats
If seat covers are stained/dirty caused by food, perspiration, skin peeling, creams, dirt from clothing, dust, inadequate or non-existent care of the
seat covers, or color bleeding from clothing or sheepskin covers, based on the type of seat covering perform the recommended action below to
resolve.
Note:
Leather covers are natural products that are subject to a natural aging process, and therefore might behave differently under different
temperature conditions.
Genuine leather covers:
Wipe down with a damp cloth and allow to dry. Be careful not to soak the leather especially in perforated areas. After they have been cleaned, treat
the leather covers with leather care foam (A001 986 59 7110).
Imitation leather covers:
Clean using approximately 1% mild soap solution and water with a damp cloth and allow to dry.
Alcantara covers:
Clean using only a damp cloth. It is important to treat complete sections of the covers, e.g. an entire side bolster or the entire cushion surface,
otherwise visible edges (cleaned vs. non cleaned areas) will be noticeable. When needed Alcantara covers can also be cleaned using a very soft
brush.
Restraints - Passenger Head Restraint Moves Sporadically

Order No.: P-B-91.16/153
Supersedes:
Group: 91
SUBJECT:
Passenger Head Restraint Moves Sporadically
If you receive customer reports in the above model vehicles of the passenger seat head restraint sporadically moving by itself, this may be caused
by a software discrepancy between the seat control unit and the weight sensing seat. To resolve, disable the Not occupied position of passenger
head restraint coding via Star Diagnosis menu path: Control units --> Seats and doors --> ESA passenger-Electric seat adjustment front passenger
(with memory) --> "Diagnosis as per factory specifications".
Note:
The menu "Diagnosis as per factory specifications" is protected by a password. The password can be obtained via the TAC Hotline. A quick test
will be needed to obtain a password. Enter the password via Star Diagnosis menu path, as shown above.
Note:
on March 26, 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
96
In Case of Warranty, use the table.Technical Service Bulletin # P-26_50-02A Date: 080616
M/T - Hard To Engage 1st or Reverse/Shifter Sticking

Date: June 16, 2008
Group: 26
Revision History
a 6/16/08 Applicable Models Updated (204 Added)
SUBJECT:
Model 170.449/465
Model 171.454/456
Model 203.040/052/054/056/061/064/261/264/740/747/764
Model 204.054
Equipped with Manual Transmission 716 Only First or Reverse Gears Difficult to Engage from Neutral and/or During 1-2 Up-Shift Shifter May
Catch Between Gears
If you receive customer reports in the above model vehicles of first or reverse gears being difficult to engage from neutral and/or the shifter
catching between gears during 1-2 up-shift, this may be due to insufficient lubrication of the transmission input shaft not allowing the clutch disc to
move freely.
Note:
Prior to removing the transmission, first confirm that the shifter console is properly adjusted.
^ For vehicles produced up to June 2000, refer to WIS AR26.60-P-0635-02D
^ For vehicles produced after June 2000, refer to WIS AR26.60-P-0635-02E
Proceed as indicated below only after the adjustment of the shifter console has been ruled out as the cause of the concern.
1. Remove the transmission.
2. Lightly grease the transmission input shaft around the splines with heat resistant lubricant (anti-size).
Warning!
It is critical that no grease gets onto any of the clutch friction surfaces.
3. Reinstall the transmission.
Body - Door Frame Corrosion

Date: July 7, 2008
Order No.: P-B-72.00/88
Supersedes:
Group: 72
SUBJECT:
Corrosion Complaints Concerning Door Frames
If you receive customer reports in the above model vehicles of corrosion in the area of the door frame, outside door panel or lower inside of door,
follow the procedures below to resolve.
97
Determining the repair scope
1. In the event of a customer complaint, all the doors must be checked for signs of corrosion.
2. Open the doors to be checked. Detach rubber seal at top and bottom of door. Clean rubber seal.
3. Perform visual inspection for corrosion (Figure 1, A and B). Select remedy according to damage profile.
4. In area Figure 1, C, use mirror to check for corrosion. Select remedy according to damage profile. (Figure 1).
Repair Remedy Overview
1. Corrosion in non-visible area (Figure 1, B and C) under rubber seal, refer to WIS document AR97.00-P-1001F (repair stage 1).
2. Corrosion also in visible area (Figure 1, A) where paint can be touched up, refer to WIS document AR97.00-P-1002F (repair stage 2).
3. Corrosion also in visible area where paint cannot be touched up on outside door panel near door handle and central trim strip or spot
corrosion on lower inside of door, which can be touched up with a brush with no additional painting work, refer to WIS document
AR97.00-P-1003F.
98
4. Corrosion effects in area (Figure 2, E) after cutting off the fold or in visible area where paint cannot be touched up on outside door panel and
corrosion on lower inside of door which cannot be touched up with a brush. (Figures 3 & 4), doors must be replaced. Wax inside of door
frames and window frames then install rubber seals.
Refer to WIS documents as shown above.
Parts Information
Note:
In the case of warranty, please damage code to the failed component. In the event of a sublet repair, please refer to Section 6.25.16 of the
Warranty Policies and Procedures manual.
Lighting - Auto Lamps/Rain Sensor Malfunctions

Order No.: S-B-82.30/634
Supersedes:
Group: 82
SUBJECT:
All Model 164, 171, 203, 204, 209, 211, 215, 216, 219, 220, 221, 230 and 251 Vehicles Equipped with Rain/Light Sensor (SA Code 345)
99
Auto On/Off Driving Lights and/or Rain/Light Sensor not Functioning Properly
If you receive customer reports in the above model vehicles that the auto on/off and/or rain/light sensor is not functioning properly, the cause may
be one of the following:
^ The windshield is not a genuine Mercedes-Benz part
^ The rain/light sensor is not the correct part
^ No adaptation or coding was performed on the rain/light sensor
Perform the following procedure to remedy the issue:
1. Verify that the windshield is indeed a genuine Mercedes-Benz part (the genuine parts have the Mercedes-Benz three-pointed star on them).
2. Verify that the correct rain/light sensor is installed by performing a quick test.
3. Perform adaptation and parameterization of the Rain/light sensor via DAS. In most vehicles, the process in DAS is as follows: Control Units
--> Body --> OCP - Overhead control panel --> Control unit adaptations --> Rain/light sensor --> Parameterization and windshield
adaptation.
4. If applicable, follow guided tests in Star Diagnosis.
Note:
Please submit all damaged parts along with an initial and final quick test. Costs for components submitted without a documented fault
code WILL NOT BE REIMBURSED.
Note:
generated on September 16. 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance labor
time allowance.
Interior - Rear Seat Back Rest Rattling Noises

Date: July 2, 2008
Supersedes: P-B-91.12/150 dated March 31, 2008
Group: 91
Revision History
a 7/2/08 Part Number Corrected
SUBJECT:
Model 203.052/054/056/076/087/092
Noise from Rear Backrest While Driving on Rough Roads
100
If you receive customer reports in the above model vehicles about a rattling noise coming from the rear backrest lock when driving on rough roads,
this may be caused by a slight displacement of the backrest. To resolve, slightly lift the rear shelf and apply self-adhesive foam block (30 x 20 x 13
mm) onto the cross member in the body shell (Figure 1).
Note:
Do not remove backrest. Do not use felt strips.
Parts Information
Note:
Parking Assist System - Erroneous Activation

Supersedes: P-B-54.65/86 dated April 13, 2003
Group: 54
a 9/17/08 Applicable Models Updated / Note Added (cause and remedy)
SUBJECT:
All Models Equipped with Parktronic (SA Code 220)
Erroneous Parktronic Activation
Parktronic, the optional vehicle parking assist system, can be erroneously activated with or without warning tones by the following conditions as
noted below.
Note:
The causes mentioned can lead to complaints that may be unduplicatable at the workshop. The workshop technician should thoroughly
inspect the Parktronic sensors for interferance, cleanliness, and proper orientation.
1) Accessory license plate frames installed on the front bumper.
101
2) Incorrect front license plate orientation.
3) Other detachable accessories that are located within range of the Parktronic sensors.
4) Decreased vehicle ride height, resulting in an echo from the ground.
5) Snow, slush, hail, and sleet.
6) Heavy rain
7) A gush of water, running down the vehicle's hood over the Parktronic sensors when the vehicle is braking.
8) Sensors heavily soiled.
9) Extraneous ultrasonic sources such as air brakes, jackhammer, etc.
10) In ground electrical induction loops, located at traffic lights or in basement garages.
11) Waste heat, from excessively heated engines (exhaust), forms in front of the vehicle when stopped.
Note:
Replacing sensors or control modules will not resolve the false activation. The sensitivity of the Parktronic system is a result of its design,
and is required for accurate operation. Please inform the customers accordingly. Additionally, present to the customer the information
contained within the vehicle's operating instructions, concerning Parktronic operation.
Note:
In cases where the sensors have been replaced/repainted previously, incorrect painting (Figure 1, incorrect) of the sensor may lead to
erroneous readings. Painting the entire front of the sensor changes its vibration characteristics. These altered vibration characteristics may
lead to erroneous readings and random triggering of the system. To remedy, paint the sensors in the provided box (Figure 2). If the box is
not available, mask off the sensor accordingly.
Technical Service Bulletin # S-00_30-08H Date: 081024
Engine - MIL ON/Multiple Camshaft Codes Set
102
DTB

Order No.: S-B-03.30/08h
Supersedes: S-B-03.30/08g dated October 20, 2008
Group: 03
SUBJECT: Model 164.172/186/871/886

Model 171.454/456
Model 203.052/054/056/087/092
Model 204.054/056/081
Model 209.356/372/456/472
Model 211.056/072/087/090/256/287
Model 216.371
Model 219.372
Model 221.171/186
Model 230.471
Model 251.156/165
Equipped with M272 or M273 Engine
Check Engine Light On / Fault Codes 0059, 0060, 0063, 0064, 0271, 0272, 0275, 0276, 1200 and/or 1208 Stored in ME-SFI Control
Module / Camshaft Adjustment Solenoid Leaking Oil
If you receive customer reports of the check engine light being illuminated and the following fault code scenario is found in the above model
vehicles, follow the applicable procedure below to resolve.
Fault Code Scenario 1: DTC 1200 and/or 1208 are stored in ME-SFI control module. The fault codes are recorded as current and stored in the
fault memory. When the fault memory is erased and the engine is restarted, the fault codes reoccur immediately. This is due to the positioning of
the camshafts of the right cylinder bank relative to the crankshaft being impaired by a worn sprocket on the balance shaft on engine M272 or by a
worn guide (idler) gear for the timing chain on engine M273.
Applicable Models (Not Applicable to Model 204): Equipped with M272 Engine Up to Serial No. 2729..30 468993 or M273 Engine Up to Serial
No. 2739..30 088611
Procedure 1:
a. Perform a visual inspection for wear of teeth on sprocket of balance shaft (M272) or of guide (idler) gear for timing chain (M273) by
removing the timing case cover on the engine.
NOTE: When inspecting the component, refer to Figure 1 for an example of a damaged gear.
b. To repair engine, replace the balance shaft on engine M272 or to replace the guide (idler) gear of chain drive on engine M273 as per WIS
103
instructions...
NOTE: When replacing the balance shaft on engine M272 the counterweight must also be replaced. The balance shaft and counter weight
are specific to engine designation. Order parts accordingly.
c. Replace the engine oil pump.
d. Replace the chain tensioner.
e. Change engine oil and filter.
f. Drive with engine at high load and rpm for approx. 15 miles.
g. After completed step f, change engine oil and filter once more.
h. Replace all four of the camshaft adjustment solenoids with A272 051 01 77.
Fault Code Scenario 2: One or more of the fault codes 0059, 0060, 0063, 0064, 0271, 0272, 0275, and 0276 are stored in ME-SFI control module.
The fault codes are recorded as current and stored in the fault memory. These codes are caused by a malfunctioning camshaft adjustment solenoid.
Applicable Models: Equipped with M272 Engine Up to Serial No. 2729..30 759427 or M273 Engine Up to Serial No. 2739..30 193592
Procedure 2: Diagnose each DTC as per Star Diagnosis. If it is determined the solenoid is faulty, replace with solenoid A272 051 01 77 as per
appropriate WIS instructions.
NOTE (Applicable to Procedure 2): Only replace the solenoid that has a corresponding fault code. Copy of the SDS short test must accompany
returned parts. If the documentation is missing or does not support the diagnosis, the warranty claim may be debited.
Fault Scenario 3: Camshaft adjustment solenoid is leaking oil, no fault codes current or stored.
Procedure 3: Replace solenoid sealing ring with A019 997 37 45.
NOTE: It is not necessary to replace the solenoid assembly if it is leaking oil.
Parts Information
NOTE: The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been
generated on October 24, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty
Operation: Scenario 1:
Short test perform (54-1011)
Ground cable-elec. system battery, D&C (when separating elec. connectors) (54-7989)
Ground cables on both batteries remove/install (when disconnecting elect. connectors w/o accidental contact protection) (54-7991)
Ground cables on both batteries remove/install (when disconnecting elect. connectors w/o accidental contact protection) vehicles as of
modification year (54-7992)
Ground cable to battery negative terminal replace vehicle as of modification year (54-7996)
Timing chain cover-(engine removed), R&R (01-8005)
Timing chain cover-R&R (engine removed) (01-0000)
Timing chain cover, R&R / seal (01-8000)
Engine compartment panels-bottom (all), R&R (61-1069)
Engine compartment panel, bottom-front & rear part, R&R (61-1070)
104
Engine compartment trim at bottom, remove/install (61-1105)
Front engine compartment paneling, remove/install (vehicle with offroad package) (61- 1101)
Engine with manual trans., R&R (01-2400)
Engine with auto. trans., R&R (01-2800)
Manual transmission, D&C from engine (engine with transmission removed) (26-2200)
Autom. Transmission, R&R (engine with transmission removed) (27-2110)
Engine balancing shaft R&R/replace as required (03-0000)
Timing chain idler sprocket, replace (timing chain cover removed) (05-0000)
Engine oil pump - (main/lower oil pan removed), R&R/replace (18-6022)
Engine oil pump - R&R/replace as required (oil pan removed) (18-6023)
Engine oil pump - (engine removed), R&R/replace if required (18-6025)
Solenoid units-(all) var. valve time-cam control mech, replace (05-7290)
Wheel alignment, check (40-6500)
Front wheel toe angle adjust (with vehicle alignment check) (40-4064)
Engine oil and filter, change (00-2080)
Oil change, perform (00-6555)
Road test (00-9151)
Additional to road test (00-0000)
Scenario 2:
Test program-after short test, perform (54-1012)
Magnet-Camshaft Adjustment Camshaft A, Replace (05-7300)
Magnet-Camshaft Adjustment Camshaft B, Replace (05-7301)
Magnet-Camshaft Adjustment Camshaft C, Replace (05-7302)
Magnet-Camshaft Adjustment Camshaft D, Replace (05-7303)
Scenario 3:
105
106
107
Suspension - Rear Axle Knocking Noises

Order No.: P-B-32.20/69
Supersedes:
Group: 32
SUBJECT:
VIN Range A279000 up to A283305 and F213965 up to F214690
Knocking Noise from Rear Axle
108
If you receive customer reports in the above model vehicles of a knocking noise from the rear axle area during normal driving operation, inspect the
torsion bar link rod (Figure 1, 6k, circle) at the top of the attachment point to wheel carrier for axial play and replace the corresponding bolt if
necessary. Refer to WIS document AF32.20-P-1500AG.
NOTE:
Torque for bolt -- link rod to wheel carrier 40 Nm (WIS document BA32.20-P-1005-04C).
Parts Information
NOTE:
on December 4, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty
Operation: Replace torsion bar link bolt (32-0000)
Technical Service Bulletin # S-27_00-102B Date: 081216
A/T - Limp Home Mode/Multiple Codes Stored

Order No.: S-B-27.00/102b
Supersedes: P-B-27.00/102a and T-B-27.00/103a, dated January 9, 2008
Group: 27
Revision History
109
SUBJECT:
All Models Equipped with 722.9 (7G-Tronic) Transmission
planetary gear set.
NOTE:
WARNING:
Parts Information
NOTE:
110
111
In Case of Warranty
Operation: Short test, perform (54-1011)

Oil pan on auto. trans. remove/install/seal, repl. if necessary veh. with 722.9 trans. (27-7033)
Oil level auto. trans. (after leak test), check/correct veh. with 722.9 trans. (27-1256)
Automatic transmission (veh. with 722.9 trans), R&R (27-2029)
Auto. transmission - (transmission removed), replace (27-2150)
Control unit - software (after short test), install (54-0991)
Control unit - ... code (after short test), perform (54-0992)
Adaptation perform (27-1047)
Analysis form, fill out (02-3472)
Technical Service Bulletin # S-49_00-12A Date: 081016
Engine Controls - MIL ON/Multiple O2 Sensor DTC's Set

DTB

Order No.: S-B-49.00/12a
Supersedes: S-B-49.00/12 dated August 18, 2008
Group: 27.49
SUBJECT: Model 164.172/186/871/886

Model 171.454/456
Model 203.040/052/054/056/092/087/740
Model 204.054/056/081
112
Model 209.356/372/456/472
Model 211.056/072/087/090/256/287
Model 215.376/379
Model 216.371/376/379
Model 219.372
Model 220.176/179
Model 221.171/176/179/186
Model 230.471/476/477/479
Model 251.156/165
Engine Running Characteristics / Check Engine Light Activated
If you receive customer reports in the above model vehicles about engine running characteristics, and the check engine light is activated by stored
oxygen sensor faults, this may be due to the below causes. To resolve, perform a new diagnostic test for the oxygen sensor, available as of DAS
DVD 09/07.
Causes
- Mixture formation not ideal
- Line connection of oxygen sensor incorrect
- Oxygen sensor heater defective
NOTE: Copy of the SDS short test and all tests performed must accompany returned parts. If the documentation is missing or does not
support the diagnosis, the warranty claim may be debited.
113
114
In Case of Warranty

O2 sensor - left before catalyst, replace (after test) (07-5210)
O2 sensor - right before catalyst, replace (after test) (07-5212)
O2 sensor - left after catalyst, replace (after test) (07-5211)
O2 sensor - right after catalyst, replace (after test) (07-5213)
115
Technical Service Bulletin # S-13_22-01E Date: 081027
Engine - Grinding/Howling/Whining Noises

DTB

Order No.: S-B-13.22/01e
Supersedes: S-B-13.22/01d dated July 10, 2008
Group: 13
116
SUBJECT: All Passenger and Light Truck Models

Equipped with Engine M272 Up to Engine Number 272xxx 30 476520
Noise Coming From Front of Engine
If you receive customer reports in the above model vehicles of a RPM dependent grinding, howling, whining or high pitch whistle noise coming
from the front section of the engine, this noise maybe caused by a faulty upper idler pulley. The noise can no longer be heard when the poly-V belt
is removed. To resolve, replace the upper idler pulley with a new unit (Figure 1). The pulley is supplied with a mounting bolt, dust cover, flat
spacer washer and a black plastic retainer (plastic assembly protection) that holds the assembly together.
NOTE: Revised instruction: It is not necessary to remove the spacer before installation. The black plastic retainer will assist in centering the flat
spacer washer and pulley on the mounting lug (Figure 2).
Parts Information
In Case of Warranty
117
Operation: Guide pulley A - V-belt, replace (13-3350)
Interior - Power Seats Intermittent Operation/Inop.

DTB

Group: 91
SUBJECT: All Model 203, 209 and 211 Vehicles

Electrical Seat Position Adjustment (ESA) Not Working or Working Intermittently
If you receive customer reports in the above model vehicles that the electrical seat position adjustment (ESA) is not working or working
intermittently, first follow normal diagnostic procedures to determine if it is a problem with the fuse, seat switch or ESA control unit. Before
replacing the ESA control unit, follow the below diagnostic procedure as many ESA control units are unnecessarily replaced.
1. Check the part number of the ESA, the following only applies to part numbers A211 820 15 26, A211 820 16 26, A211 820 01 26, A211 820
02 26, A211 820 40 85 and A211 820 41 85.
2. Check that the fuse is okay. If not, replace fuse, verify seat functions normally and end test
3. Check with SDS that the seat is normalized in both directions,
i. Up to the middle of model year 2005, this can be checked with SDS by performing a quick test and then checking and clearing codes.
Then with SDS, select the seat with the fault and with activations, move the seat through the full range of motion.
ii. As of the middle of model year 2005, perform a Quick Test. If the seat is not normalized, there will be a displayed after the line ESA
driver - Electric seat adjustment driver (with memory) or ESA passenger - Electric seat adjustment front passenger (with memory). This
is an indication that an event code has been stored. To view the event code, press F8 and then normalize using activations as described for
vehicles up to the middle of model year 2005.
4. If a normalization error is stored without the corresponding Hall effect sensor error, the seat must be adjusted in both directions. This insures
the Hall effect sensor error is reset. If there are no Hall effect sensor errors stored, it is sufficient to normalize the seat. Normalize seat with
SDS by following the path: Control units -> Seats and doors -> ESA driver -> Electric seat adjustment driver (with memory) -> Control unit
adaptations and then repeat if necessary for the passenger seat by selecting ESA passenger -> Electric seat adjustment front passenger (with
memory) -> Control unit adaptations. If no Hall effect sensor error is stored, skip to step 9.
5. Using SDS, perform the following for each seat adjustment direction
i. Read status
ii. Delete error
iii. Activate motor in either direction for at least 2 seconds
iv. Read status
118
v. Activate motor in the opposite direction for at least 2 seconds
vi. Read status
6. If Hall effect sensor errors are still present, remove seat cushion according to WIS Document AR91.10- P-1070P (203/209) and for Model
211 refer to Group 91.10 for correct document based on Model Year and seat options of vehicle.
7. The electrical connectors for this function must be checked for loose contacts and the wires checked for short circuits. Disconnect the
affected motor and Hall effect sensor. Check for the following:
i. a short circuit between the Hall effect sensor signal and ground wires
ii. a short circuit between the Hall effect sensor signal and motor line 1
iii. a short circuit between the Hall effect sensor signal and motor line 2
iv. a short circuit between the Hall effect sensor ground and motor line 1
v. a short circuit between the Hall effect sensor ground and motor line 2.
8. All resistance measurements must be greater than 1 Mohm
9. Check the rest current with a Digital Multimeter, this can be done at the fuse (use fuse adapter Special Tool W140 589 12 21 00). The
following rest currents are measured with an electrical system voltage between 10 and 15 volts. With the CAN inactive, backrest locked and
seat not moving <300 micro A, with the CAN inactive, door switches held closed, backrest folded and seat not moving <20 mA and with the
CAN active and seat not moving <200 mA. If okay, go to step 12.
10. If the rest currents are greater than the above values, remove the following plugs one at a time to locate the cause of the high rest current.
i. Plug 11 - violet - Dynamic driving seat, if present
ii. Plug 8 - white - Head restraint and backrest switch, Coupes and Cabriolets only
iii. Plug 7 - pink - Backrest release switch, Coupes and Cabriolets only
iv. Plug 6 - orange - Backrest angle and head restrain height motors
v. Plug 5 - brown - Height adjustment motor at front of seat cushion
vi. Plug 4 - black - Fore/aft adjustment motor
vii. Plug 3 - green - Height adjustment motor at rear of seat cushion
viii.Plug 1 - black - CAN Bus and steering column adjustment motors
11. If the rest currents remain greater than the above values after all the above plugs have been removed, 2 the ESA control module must be
replaced. Normalize seat, verify seat functions normally and end test. Please specify parts by VIN using EPCnet (Group 91/200).
12. The ESA control unit is good, continue to diagnose the system.
NOTE: The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has
been generated on September 26, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty

Fuse - specify location, replace (54-1286)
Driver seat cushion, R&R (91-5008)
Front passenger seat cushion, R&R (91-5028)
Electric seat adjustment test, perform (91-0000)
Power seat memory control module - for driver seat, replace (after test) (91-6685)
Power seat memory control module - front pass. seat, replace (after test) (91-6690)
119
Technical Service Bulletin # S-18-00-37D Date: 081024
Engine - Low Oil Level Symptom Diagnostics

DTB

Order No.: S-B-18.00/37d
Supersedes: S-B-18.00/37c dated October 6, 2008
Group: 18
120

Equipped with M156, M272, M273 or M642
Engines Low Oil Level Symptoms
NOTE: This document supersedes the following previously published DTBs.

T-B-01.45/20 dated September 19, 2007
P-B-18.00/31c dated February 1, 2007
T-B-18.00/32a dated August 21, 2006
T-B-18.00/33b dated March 27, 2007
P-B-18.00/35a dated July 26, 2007
P-B-18.40/34 dated May 8, 2007
If you receive customer reports in the above model vehicles of the oil level warning message frequently appearing in the instrument cluster, "Oil
level too low" or "Check Engine Oil Level at Next Service Stop", but the oil level is correct on the dipstick, there could be several causes
depending on the vehicle. This document is a consolidation of those possible causes.
1. Model 203.087/092 and 211.087/287, Equipped with M272 - Erroneous IC Warning Display "Check Engine Oil Level at Next Service Stop":
Oil level warning message frequently appears in the instrument cluster, however the oil level correct on the dipstick, the cause may be the
incorrect oil data record stored in the ASSYST control unit (Model 211), or instrument cluster (Model 203). To resolve, perform the
following procedures.
Message:
"Pour in one liter of oil at next refueling stop" (Model 211 4MATIC with M272 up to 6/2005) "Check oil level at next refueling stop"
(Model 211 4MATIC as of 6/2005 and Model 203 4MATIC with M272 as of production startup)
1a. Adaptation of Modified Oil Data Record with SDS 10/06 or Later
Model 203 4MATIC with M272 Engine, up to VIN F886321: Control Units -> Information and communication -> ICM - Vehicle code
12 / NO -> CU adaptations -> select code 807 -> select national version select M272 all-wheel drive change status 3 "or higher" confirm
selection.
Model 211 4MATIC with M272 Engine, up to VIN X218820
- Check whether CGW programming is possible by using SDS: Control units -> Body -> CGW -> Control Unit adaptations -> Control
Unit programming. If yes, perform control unit programming and then perform parameterization in ASSYST. If no, perform
parameterization in ASSYST.
- Perform parameterization in ASSYST by using SDS: Start Control -> Units -> Information and communication -> ASSYST -> CU
adaptations -> select engine M272 -> Select national version -> Select engine for ASSYST M272 Model 211 all-wheel drive
"National version" status 5 or higher.
1b. Check Oil Dipstick Marking on Handle (Model 203 / 211 up to Engine No. 2729..30467144)
NOTE: As of February 2, 2007, Section 1b of this DTB must not be performed on the following vehicles which are covered under
Service Campaign No. 2007010010
Model 203.087 - Serial Nos. AF725595 to F864624

Model 203.092 - Serial Nos. F725472 to F885088
Model 211.087 - Serial Nos. X177825 to X219293
Combining step 1b with the above referenced Campaign will result in a charge back of step 1b.
a. Oil dipstick with marking 27214 is correct.
b. Oil dipstick with different marking should be replaced with part number A272 010 14 72.
c. Check whether quantity of engine oil in engine corresponds to specification in WIS.
2. Model 164.186 - Erroneous IC Warning Display "Check Engine Oil Level at Next Service Stop" Confirm engine type coding in ASSYST
using the current issue of SDS: Control unit -> Information and Communication - ASSYST Active Service System -> Control Unit
Adaptations -> Engine Type - Code to correct engine type.
121
3. Model 164.871 - Oil Level Too Low Displayed In Instrument Cluster: Initial oil level too low, perform the following applicable corrective
measure.
3a. Vehicles Up to VIN No. A213990 / Production Date 12/20/2006 - Check and correct oil level where necessary by adding 0.3 liter oil at
PDI or at the customers "1st Visit" for all newly sold GL450 vehicles. Refer to WIS document AP-18.00-P-0101GZ. Costs are to be
charged using the warranty code 00001 70.
3b. Check Oil Dipstick Marking on Handle - Oil dipstick with marking 27314 is correct. Oil dipstick with different marking should be
replaced with part number A273 010 14 72. New specification for quantity of engine oil in engine is 9.0 liters with filter change.
3c. Vehicles with VIN No. A213991 up to A235524 / Production Date 2/9/2007
NOTE: Do not automatically add 0.3 liters of oil; check dipstick first.
Oil dipstick with marking 27314 is correct. Oil dipstick with different marking should be replaced with part number A273 010 14 72.
New specification for quantity of engine oil in engine is 9.0 liters with filter change.
4. Model 221.186, Equipped with M273 Engine and 4-Matic, Erroneous IC Warning Display "Check Engine Oil Level at Next Service Stop" -
Update oil data record in ASSYST using SDS: Control unit Information and Communication ASSYST Control Unit Adaptations SCN coding
Perform SCN online coding Work through steps 1-3 in SDS to perform SCN coding.
5. Model 209/211/219, Equipped with M156 Engine, Oil Level Warning Message "Add 1 liter engine oil at next refueling stop" or "Check oil
at next refueling stop" in Instrument Cluster / Oil Level on Dipstick is OK - Perform the following steps.
a. Check the coding of the engine model designation and oil data set of the ASSYST control unit in SDS -> Control units -> Information
and communication -> ASSYST -> Control unit adaptations -> Engine type -> Engine type M156 E63 Version for rest of world Status: 3
has been recognized -> Information and communication -> ASSYST PLUS -> Control unit adaptations -> Control module reset
b. Check installed oil dipstick and replace if necessary. The correct oil dipstick is identifiable by the red handle and by the code 156 16
(previously 156 12 or 156 14)
c. Check oil level and correct if necessary.
6. Model 164.122/822 (up to VIN A261645) and 251.122 (up to VIN A059019), "Check oil at next refueling stop" Warning in Instrument
Cluster - If you receive customer reports that at speeds above 75 mph the instrument cluster displays - Check engine oil level at next
refueling stop, the cause may be the position of the oil level switch.
NOTE: Condition only relevant when the oil level is significantly above "min".
a. To resolve, install a lengthened bracket (7 mm) for the oil level switch (part number A642 018 27 40) and check software in the Central
Gateway. For Model 164 vehicles, the data records in software version 30A9 (and higher) are OK and for Model 251 vehicles, the data
records in software version 30AA (and higher) are OK. SDS path: Control units -> Information and communication -> ASSYST ->
Control unit log. The software description in the ECU control unit log from ASSYST (not ASSYST Plus). In the Line "Variant code", the
first 4 characters "00 01..." gives you the information on the above mentioned software (Figure 1). If the software is incorrect, look for
the latest software with DAS.
b. Replace the oil level switch as per step 7.
7. All Passenger and Light Truck Models, Equipped with Engine M156, M272, M273 or M642 (Up to engine no. 642 xxx 40 673486), Faulty
Oil Level Switch - If after performing the applicable remedy(s) 1 through 6 stated within this document, the issue has not been resolved, the
cause may be a malfunctioning oil level switch. Perform the following.
a. Check the oil level using the dipstick.
b. If the oil level is confirmed between the "MIN" and the "MAX" marks on the dipstick, replace oil level switch with part number A001
122
153 11 32 as per the applicable WIS document.
NOTE: For Engines M272, M273 and M642 - If there is any deformation of the stamped steel bottom section of the oil pan after
removal, it must be replaced. Refer to EPCnet for applicable part number.
c. It is possible to install the switch upside down. For correct installation refer to Figure 2.
Parts Information
In Case of Warranty

Oil dipstick, check and replace if necessary (01-0000)
Engine oil level, correct (00-6000)
Control unit - .... code (after short test), perform (54-0992) Panels all, below all, engine R&R (Operation Code: 94-5305, 61-1069,
61-1070, 61-1071, 61-1072, 61-1075, 61-1105, 61-1110 or 61-1128)
Engine oil level / oil quality sensor, R&R/replace (18-4110)
123
124
Steering/Suspen. - Stabilizer Threads Pulled From Axle

Group: 33
125
Revision History
SUBJECT:
Model 203.040/052/054/056/061/064/065/076/261/264/740/747/764
Model 209.356/365/372/375/376/377/456/465/475/476/472/477
Threads for Front Stabilizer Bar Mounting Bracket Pulled Out of Axle Carrier
If you identify pulled threads on the front axle stabilizer bar mounting bracket, while removing the stabilizer bar, the cause may be due to
manufacturing tolerances which were not optimized in the tap/drill process.
To resolve, install a M8x1.25 x 16 mm Heli-Coil insert (follow instructions included with the Heli-Coil 8 mm repair kit) into the front axle carrier
and replace the existing bolts so that the specified torque can be achieved when tightening the stabilizer bar mounting bracket. Refer to WIS
document number AR32.20-P-0300P for further information.
Parts Information
NOTE:
In Case of Warranty
Operation: Stabilizer bar mounts modification (32-0000)
Technical Service Bulletin # S-27_60-61J Date: 081120
A/T - Harsh 1-2/3-2 And 2-1 Shifts

Order No.: S-B-27.60/61j
Supersedes: P-B-27.60/61i dated August 21, 2007 and T-B-27.60/62i dated Dec. 4, 2007
Group: 27
Revision History
SUBJECT:
All Models with Automatic Transmission 722.9, 7G-Tronic (NAG2) Uncomfortable Shift Quality of 1-2, 3-2 and 2-1 Gear shifts
126
If you receive customer reports in the above model vehicles of rough 1-2, 3-2 and 2-1 gearshifts, this may be due to the specific gear not being fully
adapted or there could also be a mechanical cause as well. To resolve, perform the following diagnostic sequence.
1. Reproduce the complaint and identify the affected shifts using Star Diagnosis.
2. Print out adaptation data in the form of a transmission control unit log (do not reset the adaptation values).
3. Re-adapt the problem shift using the adaptation process in Star Diagnosis and print a post process transmission control unit log.
NOTE:
For downshifts, the vehicle must coast to a stop without braking in order for adaptation to occur.
For upshifts, the vehicle must be driven and shifted within the valid torque window (green zone in torque display in Star Diagnosis).
If the condition still exists after adaptation, compare adaptation values before and after adaptation test drive. If the values for the filling times of
these shift operations are close to the negative limit of -20 cycles (between -15 and -20), but move further into the negative with further adaptation,
this may have the following cause / remedy.
Cause A - An incorrectly installed retaining ring for return spring B1 or B3.
Remedy A:
1. Remove the transmission
2. Disassemble multi-disk brake B1& B3
3. Remove / install / replace retaining ring and disk spring. Refer to test/repair work procedure in WIS document AR27.50-P-0870W and
AR27.50-P-0890W.
127
NOTE:
There are two different versions of the B1 and B3 multi-disk brake. It is essential to ensure that the retaining ring is ordered correctly.
Refer to Figures 1 through 3 and the parts table, identification groove on the inside/outside of the plate supports.
4. When assembling, insure that the anti-twist locks are correctly positioned! (See Figure 4: Correct positioning of anti-twist lock for thrust
bearing).
5. Completely reset all adaptation data.
6. If shift quality complaints still occur after the work has been completed, the affected shifts must be adapted before further steps are taken.
Cause B- Warped disks of the B1. This can be determined by placing them on a flat surface - they do not lie flat and are uneven.
Remedy B
1. Replace disks of B1, disk spring and retaining ring.
Parts Information
NOTE:
on November 20, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
128
129
In Case of Warranty
Operation: Road test, perform (00-9151)
130
Short test, perform (54-1011)
Oil level - auto. trans. (after leak test), check/correct vehicle w/ 722.9 trans. (27-1256)
Adaptation, perform (27-1047)
Automatic transmission (vehicle with 722.9 trans.), R&R (27-2029)
Auto. trans. (722.6/722.9) - K1/K2/K3/B1/B2/B3/Freewheel, D&A/repl. parts as required transmission removed) (27-9999)
A/T - Shudder On Upshifts/Downshifts

DTB

Group: 27
SUBJECT: Model 203.052/054/056/087/092

Model 209.356/372/456/472
Equipped with Transmission 722.6 / 722.9
Shift Chatter/Shutter While Upshifting/Downshifting
If you receive customer reports in the above model vehicles of shift chatter / shutter while upshifting/downshifting, the cause may be water inside
the automatic transmission as the result of an incorrectly positioned water outlet. Please perform the following procedure to resolve.
1. Check the transmission oil for signs of water contamination (white/pink discoloration of the oil).
2. If there is visible contamination of the transmission oil, clean the transmission oil pan and flush out the transmission by following the
procedure described in WIS document AR27.55-P-0100A.
3. Correct the position of the water outlet (A) and secure using a tie strap (B) as shown in Figure 1.
NOTE:
- Series production vehicles have been resolved as of VINs:
203 - A934352 or F864291 or E025775
209 - F212532 or T078387
- The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been
generated on March 30, 2007. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty
Operation: Oil change - automatic transmission 722.6, replace (00-6556)

Oil change - automatic transmission 722.9, replace (00-6557)
Automatic transmission and torque converter, flush (27-4863)
Water outlet to correct position, perform (67-0000)
131
Lighting - License Plate Bulb(s) Burned Out

Supersedes: P-B-82.10/398a dated Jan. 26, 2005
Group: 82
Revision History
SUBJECT:
License Plate Bulb(s) Burned Out
If you receive customer reports in the above model vehicles that one or both license plate bulbs is burned out, a resistor wiring harness is available
to reduce the voltage at the license plate bulbs. Check the vehicle history file to confirm that a resistor wiring harness for the license plate bulbs has
not been previously installed. If it has not, install a resistor wiring harness for each license plate lamp and replace the burnt out bulb(s) per the
below procedure.
1. Remove license plate lamps.
2. Remove trunk lid lining.
3. Disconnect plug from each license plate illumination socket (Figure 1, 1).
132
4. Install resistor wiring harness (Figure 2) between the disconnected plug and license plate illumination socket on each side.
5. Cover plug socket with foam sleeve (Figure 2) included with each resistor wiring harness.
6. Fasten the rest of each adapter cable to the trunk lid with felt (Figure 1, 2).
7. Reinstall trunk lid lining
8. Replace burnt out license plate bulb(s)
9. Reinstall license plate lamps
If a license plate resistor wiring harness was previously installed, only replace the burned out bulb(s).
Parts Information
NOTE:
In Case of Warranty
Operation: Wire harness adapter - license plate lamps, install (02-4542)
Keyless Entry - Various Malfunctions

Order No.: S-B-80.00/53
Supersedes:
Group: 80
SUBJECT:
MY- All, Models All
Replace Battery in Transmitter Key
In the event of complaints about the function of the vehicle key, first check for and remove any soil or grease from the battery or battery contacts
using the lint-free cloth and alcohol.
133
NOTE:
To ensure faultless contact, do not touch the batteries on their contact sides. Technical Service Bulletin # P-62_10-08C Date: 081222
Interior - Noise From The Center Of The Dash

Group: 62
Revision History
SUBJECT:
Model 203.052/054/092/056/087
Model 209.356/365/372/375/376/377/456/465/472/475/476/477
Noise Front of Vehicle / Dash Area
If you receive customer reports in the above model vehicles of noise from the center of the dash area, this may be caused by a portion of the ME
wiring harness contacting the plastic guide on the partition wall or the harness not properly positioned in the harness retainer clip (Figure 1).
Perform the procedure below to resolve.
1. Remove the air filter housing. Refer to WIS document AR09.10-P-1150QB.
134
2. Remove cowl drain tube on drivers side (Figure 2, arrow), unclip plastic cover clips (Figure 2, circle) and partially remove the harness from
the plastic guide.
3. Wrap the ME wiring harness with felt tape (A001 983 23 10) where it fits into the plastic guide on the partition wall (Figure 3).
4. Wrap the end of the felt tape on the harness near the clip location with fabric tape (Figure 3).
5. Insert 10 mm x 10 mm square piece of felt tape between partition wall cover and all screw clips (Figure 1, circles - 2 shown).
6. Check the ME wiring harness at the clip location (Figure 3), reposition the harness to fit properly into the retainer clip.
7. Apply special sliding compound (A000 989 36 60) to felt tape in the area where the harness is in contact with the plastic guide.
8. Reassemble in reverse order.
Parts Information
NOTE:
In Case of Warranty
Operation: Noise in front of vehicle / dash area, eliminate (62-0000)
Accessories - Can't Program Garage Door Opener

Group: 68
135
Revision History
SUBJECT:
All Passenger and Light Truck Models
Garage Door Opener Cannot be Programmed
If you receive customer reports in the above model vehicles of the integrated garage door opener on the interior rearview mirror or overhead control
panel unable to accept coding from a hand-held garage door transmitter, this may be caused by the integrated garage door opener being
preprogrammed. You can determine if the system has been preprogrammed by pressing a signal transmitter button. The indicator lamp will
illuminate but will not flash. To resolve, please refer the customer to the instructions noted in the Operator's Manual on erasing the integrated
remote control memory. Attached is a copy of the instructions that can be provided to the customer.
NOTE:
The enclosed procedure cannot be claimed under Warranty.
Instructions on Resetting the Integrated Remote Control Memory

1. Switch on the ignition.
2. Simultaneously press and hold down the outer signal transmitter buttons (Figure 1 or 2, 2 and 4) for approximately 20 seconds until the
indicator lamp (Figure 1 or 2, 1) flashes rapidly. Do not hold for longer than 30 seconds.
3. The codes of all three channels are erased.
4. Program integrated garage door opener as per the instructions outlined in the Operator's Manual.
WARNING:
Before programming the integrated remote control to a garage door opener or gate operator, make sure people and objects are out of the
way of the device to prevent potential harm or damage. When programming a garage door opener, the door moves up or down. When
programming a gate operator, the gate opens or closes. Do not use the integrated remote control with any garage door opener that lacks
safety stop and reverse features as required by U.S. federal safety standards (this includes any garage door opener model manufactured
before April 1, 1982). A garage door that cannot detect an object - signaling the door to stop and reverse does not meet current U.S.
federal safety standards. When programming a garage door opener, park the vehicle outside the garage. Do not run the engine while
programming the integrated remote control. Inhalation of exhaust gas is hazardous to your health. All exhaust gas contains carbon
monoxide (CO), and inhaling it can cause unconsciousness and possible death.

136
Electrical - Auxiliary Power Outlet Inoperative

Group: 54
Revision History
SUBJECT:
Model 203.052, from VIN E019387 up to VIN E021112
Power Outlet Nonfunctional / Missing Relay
If you receive customer reports in the above model vehicles of a nonfunctional power outlet (cigarette lighter), the Rear Signal Acquisition and
Actuation Module (SAM) may be missing a relay and/or fuse.
1. Check for missing relay in slot "F" and/or missing fuse (15 A) in slot "12" on Rear SAM (N10/2) (Figure 1).
2. If required, install new relay in slot "F" and new fuse (15 A) in slot "12" on Rear SAM (N10/2)
Parts Information
generated on November 18, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty
Operation: Fuse - specify location, replace (54-1286)
Technical Service Bulletin # S-91_10-125C Date: 081216
137
Memory Systems - Easy Entry/Exit Feature Is Inoperative

Order No.: S-B-91.10/125c
Supersedes: S-B-91.10/125b dated Oct. 20, 2008
Group: 91
Revision History
SUBJECT:
All 164, 171, 203, 209 and 251 Vehicles, Equipped with Memory Seats (Code 275)
All 211, 219 and 230 Vehicles
Easy Entry/Exit Feature for Seat Position Not Functioning
If you receive customer reports in the above model vehicles regarding the easy entry/exit feature for the seat position not functioning, this may be
due to prior replacement of the instrument cluster (A1) on vehicles up to production date 06/01/2005. This can be corrected by installing one of the
following seat ECU (N32/1 or N32/2) part numbers and programming the ECU with SDS release 09/06 or newer.
Models 164, 171, 219 and 251: Control units with the following part numbers should only be programmed and coded with SDS release 09/2006 or
later.
A211 820 11 85 A211 820 85 85 A211 870 05 85 A211 870 49 85
Model 203 without Central Gateway (CGW or N93): Control units with the following part numbers are to be replaced with A211 870 46 26 and
then programmed and coded with SDS release 09/2006 or later. Control units with part number A211 870 46 26 should only be programmed and
coded with SDS release 09/2006 or later.
A203 820 15 26 A211 820 01 26 A211 820 40 85 A211 820 11 85

A211 820 85 85 A211 870 05 85 A211 870 49 85
Model 203 with Central Gateway (CGW or N93) and Model 211: Control units with the following part numbers are to be replaced with A211 870
46 26 and then programmed and coded with SDS release 09/2006 or later.
A203 820 15 26 A211 820 01 26 A211 820 40 85
Control units with the following part numbers should only be programmed and coded with SDS release 09/2006 or later.
A211 820 11 85 A211 820 85 85 A211 870 05 85 A211 870 49 85
Model 209: Control units with the following part numbers are to be replaced with A211 870 46 26 and then programmed and coded with SDS
release 09/2006 or later.
A203 820 15 26 A211 820 01 26 A211 820 40 85
A211 820 89 85 A211 870 17 26 A211 870 46 26
NOTE:
On model 209 vehicles produced prior to 03/2004, the control units cannot be programmed in the vehicle. Instead, the control units must first be
installed and programmed in a model 211 vehicle, or a model 203 vehicle as of 08/2003, then installed in the 209 vehicle.
Model 230: Control units with the following part numbers are to be replaced with either A230 820 60 26 A230 820 61 26 (or equivalent
superseding parts) and then programmed and coded with SDS release 09/2006 or later.
A230 820 05 26 A230 820 06 26 A230 820 32 26 A230 820 33 26

A230 820 43 26 A230 820 44 26
138
Parts Information
NOTE:
on October 20, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty

Power seat control module - for driver seat, replace (seat cushion removed) (91-6687)
Control unit - .... code (after short test), perform (54-0992)
139
Restraints - Head Restraint Height Adjuster Is Inop.
DTB

Supersedes: P-B-91.16/94a dated June 16, 2008
Group: 91

Electric Head Restraint Height Adjuster Not Functioning
If you receive customer reports in the above model vehicles that the electric head restraint height adjuster is not functioning, the printed circuit
board (PCB) at the motor may have broken due to tension applied to it by the wiring harness. Fault code 9203, hall sensor of component M27m4
(Head restraint raise/lower motor) is faulty, may also be present.
1. Remove the head restraint height adjuster per WIS document AR91.29-P-1432P (203 and 209) or AR91.29-P-1432T (211).
2. Use a cable tie to secure wiring harness to strut (Figure 1, arrow)
3. Guide wiring harness behind top transverse wire (Figure 2, arrow)
4. Reinstall the head restraint height adjuster per WIS document AR91.29-P-1432P (203 and 209) or AR91.29-P-1432T (211).
Parts Information
140
generated on September 26, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty

Power seat motor - driver headrest adjustment, replace (91-6042)
Power seat motor - front passenger headrest adjustment, replace (91-6092)
A/C - No Or Low A/C Cooling Performance

Order No.: S-B-83.55/118
Supersedes:
Group: 83.55
SUBJECT:
Defective Refrigeration Circuit / Refrigerant Compressor
If you receive customer reports in the above model vehicles related to "no or low AC cooling performance", it may be due to a locked refrigerant
compressor, a broken torque limiter on the refrigerant compressor, the refrigeration circuit blocked or an electrical defect in the refrigerant
compressor. To remedy any of these issues please proceed with the following.
Note:
This document is intended as a supplement to the SDS function test "Refrigerant circuit test". Only perform repair and replacement work on the
refrigerant circuit if the SDS refrigerant circuit test was unsuccessful and you have received appropriate instructions in the SDS function test.
Prerequisites:
1. Before parts can be replaced, the exact quantity of the refrigerant in the refrigeration circuit must be determined by evacuating the system. When
returning parts be sure to indicate the exact amount of refrigerant in the circuit and any other findings by the technician. If the filling capacity is not
141
indicated, warranty claims may be rejected.
2. If the fill level of the refrigerant circuit is too low, parts should only be replaced if the torque limiter is broken.
3. If the fill level of the refrigerant circuit is too low and the torque limiter is damaged, the leak test (Test 6 "Leak in refrigeration circuit") must be
performed using the "Technology Guide Vehicle Climate Control" located in SDS SDMedia first and then the system must be refilled and checked.
If the amount of refrigerant in the circuit is less than 80% of the normal level, it is too low. Inadequate fill levels may be the cause of the air
conditioning shutting down or malfunctioning.
Remedy A - Broken Torque Limiter:
1. Ensure the alternator freewheel (when applicable) is not damaged and that the belt pulley of the refrigerant compressor rotates in the belt drive.
2. If the alternator freewheel is blocked, replace the alternator freewheel. For refrigerant compressors with a replaceable belt pulley, replace the belt
pulley only, otherwise replace the refrigerant compressor. Refer to EPCNet for applicable part number.
3. If the alternator freewheel is not blocked and black refrigerant/oil is evacuated from the system, replace the AC compressor. Refer to EPCNet for
applicable part number.
Remedy B - Blockage in the Refrigeration Circuit
1. Identify through SDS function test "Refrigeration circuit test" that the refrigerant circuit has not been underfilled or overfilled.
2. Inspect along the AC lines to check for blockage at the points with marked temperature differences.
3. Identify and replace the blocked components in the refrigeration circuit. Refer to EPCNet for applicable part number.
Remedy C - Electrical Defect in Refrigerant Compressor
2. After ruling out a short circuit in the actuation and ground wiring, replace the refrigerant compressor only. Refer to EPCNet for applicable part
number.
Note:
^ Always empty the oil from the new refrigerant compressor before installing.
^ When completely refilling the system, ensure the quantity of oil and refrigerant is correct (refer to WIS document BF83.00-Z-9999AZ). Take
into consideration whether individual components or the entire refrigerant circuit are to be replaced.
^ Always perform a leak test on the system after changing the refrigerant circuit but before filling it with refrigerant.
Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generated on
March 10, 2009. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
142
143
144
145
In Case of Warranty, use the tables above.
Technical Service Bulletin # P-83_00-70D Date: 090416
A/C - A/C Lamp Flashing/A/C Inoperative

Date: April 16, 2009
Group: 83
Revision History
SUBJECT:
All Model 171, 203, 209, 211, 216, 219 and 221 Vehicles
AC or AC Off Indicator Lamp Flashes After Actuation / Air Conditioning Not Functioning
If you receive customer reports in the above model vehicles of the AC or AC Off indicator lamp flashing and the air conditioning is not operating,
the cause could be the coding of the climate system control module. Follow the instructions below to overcome the specification parameter in the
refrigerant level logic circuit.
1. Process any fault codes in the climate system and repair as necessary.
2. Confirm refrigerant level by performing a Refrigerant Circuit Test as per SDS and following instructions for corrective actions.
3. Only after steps 1 and 2 are completed, use Star Diagnosis to deactivate the fill level control as per the instructions listed below.
Model 203: Control unit groups --> Body --> EZS - Electronic ignition switch --> Control unit adaptations --> Read coding and change if necessary
--> Climate control --> Standard setting: Climate control --> Refrigerant level check --> Set to Inactive
Model 216/221: Main groups --> Control units --> Air conditioning --> AAC - Automatic air conditioning (Interior CAC bus) --> Read coding and
change if necessary --> Control unit adaptations --> Workshop coding --> Refrigerant level check --> Set to Deactivated
146
147
Model 171, 211 and 219: If the fluid level control is still active, there will be a menu item in 'Main groups' labeled 'Check for necessary coding
measures' (Figure 1). Process this menu item to deactivate the coding of the fluid level controls (Figure 2 and 3). If the fluid level control is already
inactive, this additional menu item will not appear when "Main groups" is selected (Figure 4).
Note:
If the fluid level control has already been deactivated and the vehicle has the symptoms described, there is a fault that has not been corrected and
further diagnosis is necessary. Refer to applicable diagnostic trees in the Vehicle Heating, Ventilation, Air Conditioning (HVAC) Manual found on
STAR TekInfo --> EDAC --> Non EDAC Guides.
Note:
April 16, 2009. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
148
In Case of Warranty, use the table above.
Engine Controls - Engine Won't Start When Hot

Order No.: S-B-54.21/215
Supersedes:
Group: 54
SUBJECT:
All Models Equipped with Engine M272 and M273
Engine Cannot Be Started When Engine is Hot but Will Start After Engine has Cooled
If you receive customer reports in the above model vehicles that the engine cannot be started when the engine is hot but will start after the engine
has cooled and there are no Diagnostic Trouble Codes stored in the ME control unit, check the signal to the fuel pump relay from the ME Control
unit (12VDC with Key in position "1" N3/10 pin 17 + and pin 4). If no signal is found, check the wiring from the ME control unit to the fuel pump
relay. If the wiring checks out, it may be due to an open circuit in the ME control unit. In this case, replace the ME control unit and retest the signal
to the fuel pump relay. Refer to EPCnet for applicable part number.
Note:
A copy of the short test and all tests performed must accompany returned parts. If the documentation is missing or does not support the diagnosis,
the warranty claim may be debited.
Note:
149
February 11, 2009. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
COMAND(R) - Inoperative Or Opening/Closing Errors

Group: 82
Revision History
150
SUBJECT
Central Display Opening/Closing Errors or Inoperative, Voice Control Does Not Respond To User's Commands (Hands-free Conversation) and/or
Other Party May Not Hear Driver's Conversation
If you receive customer reports in the above model vehicles having any of the conditions below, it may be due to an incorrect
installation/mating/contact of the iPod Interface Cable (Refer to Figures 1-4 above) with the COMAND head unit connector.
To remedy, replace the iPod Interface Cable. Refer to the appropriate section of WIS Documents shown above.
151
Conditions
^ Central display opens and closes by itself or inoperative
^ Voice control system may not respond to driver's commands due to head unit connector contacts not mating securely as a result, the connection
to the microphone is lost
^ iPod playback intermittently inoperative
^ Back up camera (B84/3) intermittently inoperative
^ Intermittently the instrument cluster and audio/COMAND display fan motor M4/13 inoperative
^ Left or right side speakers intermittently not producing sound
^ COMAND head unit external fan not operating
Note:
When connecting the iPod Interface Cable to the wiring harness of the Head Unit, please make sure that all individual connections are securely
fastened as it is possible individual pins may pass unnoticed. Please ensure that you hear the "click" when mating the connectors and visually
inspect both sides of the connector for proper contact. Where possible, please perform a continuity check on the iPod Interface Harness.
Parts Information
Note:
Technical Service Bulletin # P-46_20-16E Date: 090227
Steering - Leaks At Steering Gear/Hose Junction

Order No.: P-B-46.20/16e
Supersedes: P-B-46.20/16d dated Nov. 10, 2008;

P-B-46.20/10c dated Dec. 19, 2007
Group: 46
152
Revision History
SUBJECT:
Models 171, 203, 204, 209, 211, 215, 216, 219, 220, 221, 230
Leaks at the Steering Gear Control Head Connection to High or Low Pressure Lines or Leaks at Internal Steering Lines of the Control Head
Connection to Steering Gear Housing
If you receive customer reports in the above model vehicles of leakage at the steering gear control head connection of high and low pressure lines
or from the internal steering lines at the connection between the control head and the steering housing, this may be caused by damage to a
respective O-ring at the control head or steering housing. Follow the below to resolve.
Note:
It is not necessary to replace the entire rack-and-pinion steering system. The O-rings are now available as separate parts or as part of repair kits.
Repair A (Model 171, 203, 204, 209, 211, 215, 216, 219, 220, 221 and 230)
To replace the O-rings of the affected connections at the steering gear control head to the high or low pressure steering lines, it is necessary to seal
both lines at the same time, due to the common retaining plate for both lines. Proceed as follows.
1. Loosen line connection on steering gear. Refer to applicable WIS documents shown above.
Note:
If necessary, loosen line supporting brackets.
Note:
Ensure that sealing rings and supporting ring are properly seated. Supporting ring only present on high pressure line.
Note:
There are two versions of power steering high-pressure lines. The preceding version has a slotted support ring which can be replaced individually.
The new version has a support ring which is not slotted and which cannot be replaced individually; in this case the complete power steering high
pressure hose must be replaced (refer to EPC to specify correct high pressure hose).
3. Fasten line connection on steering gear with retaining plate. Fasten any loosened line supporting brackets and reinstall any removed panelings.
Note:
Observe torque values for screw connection. Refer to WIS documents for specifications.
4. Bleed steering system and check for leaks. Refer to the DTB S-B-46.30/40b (or latest version).
Repair B (Model 203, 204, 209, 211, 215, 219 and 220):
To remedy leaks at the connections of internal lines between the steering gear head and the steering housing individually, replace the short or long
153
internal oil lines and respective seals. Proceed as follows.
1. Remove the steering gear from the vehicle as described in the WIS documents as shown above.
2. Replace internal pipelines from control head to steering gear housing. Refer to applicable WIS document as shown above.
3. Reinstall the power steering gear as described in the WIS documents listed under step 1 based on the respective model.
4. Toe adjustment after removal/reinstallation of the steering gear is NOT necessary. (Refer to latest version of DTB P-B-46.20/28
Note:
Always refer to EPC for the latest information on parts.
154
Parts Information
Note:
155
156
Technical Service Bulletin # S-14_30-15F Date: 090313
Emissions - Multiple Codes Set/MIL ON

Order No.: S-B-14.30/15f
Supersedes: S-B-14.30/15e dated Nov. 11, 1008
Group: 14
157
Revision History
SUBJECT
Check Engine Light with DTC P2003, P2047, P0810 and P0814 Stored in Engine ECU
If you receive customer reports in the above model vehicles of the check engine light coming on and codes P2003 (M112, M113, M275), P2047
(M271), P0810 (M272, M273), P0814 (M272, M273) are stored in the engine control module memory, please perform the below procedure.
1. Air Pump Relay
Valid for Models shown above.
This condition may be caused by a malfunctioning air pump relay. When the secondary air pump relay malfunctions, the air pump may be actuated
beyond the maximum permissible operating time. This overload may lead to failure of the secondary air injection pump and results in a malfunction
in the secondary air injection system. Proceed as follows:
Note:
If diagnosis reveals a malfunctioning air injection pump, refer to step 1.2.
158
1.1 Test the secondary air injection function chain with SDS.
1.2 If the secondary air pump is determined to be defective remove/replace secondary air pump and air pump relay (refer to WIS document:
AR14.30-P-7251QB).
1.3 If it is determined that only the relay is defective, replace the relay only and retest the secondary air injection function chain with SDS.
1.4 Program engine control module.
2. Check Valve for Vacuum Actuation of Air Pump
This condition may be caused by a malfunctioning check valve in the vacuum line (Figure 1) to the air pump switch over valve. When the check
valve malfunctions, vacuum flow to the diverter valve is restricted preventing it from opening. Proceed as follows.
2.2 If the air pump can be activated with SDS but the function chain test fails, the vacuum flow between the air pump switchover valve and the
diverter valve may be restricted preventing the diverter valve from opening.
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2.3 Check vacuum supply (Figure 2) at the diverter valve. If vacuum is < 500mbar, change check valve.
Note:
Copy of the SDS short test and all tests performed must accompany returned parts. If the documentation is missing or does not support the
diagnosis, the warranty claim may be debited.
Note:
When ordering a replacement relay order the part number of the relay being removed. The parts system will deliver the current version of the
ordered part.
Parts Information
Note:
160
161
Audio System - AM/FM Interference With Rear Defogger ON

Supersedes: P-B-82.60/227 dated Feb. 26, 2003
Group: 82
Revision History
162
SUBJECT:
All Model 202, 203, 208, 209, 210, 211, 215, 219 and 220 Vehicles
Equipped with Radio/TV Window Antenna
AM/FM Reception Interference When Rear Window Heater is Switched On
If you receive customer reports in the above model vehicles of AM/FM or TV reception interference when the rear window heater is switched on,
this may be caused by one or more interruptions in the heat conductor in the rear window which may cause interference in the FM/AM bands. To
remedy, perform the following.
Note:
Use a battery trickle charger
At ambient temperature, the rear window heater needs to be turned on continuously for approx. 45 minutes at 13.8V. Since the heating period is
regulated depending on the outside temperature, it is necessary to switch off the rear window heater every 5 minutes manually and turn it back on
again immediately.
This procedure eliminates transition resistance at the contacts of the heated rear window. If interference is still present, detach the connecting lines
of the rear window heater from the rear window and connect them to a resistive load (50-60W light bulb = approx. 240 Ohms). If there is no longer
any radio interference present while the ohmic load is connected, the antenna in the rear window is malfunctioning and the rear window needs to be
replaced. Refer to EPCnet for applicable part number. Refer to WIS AF67.29-P-1130AG for further instructions.
Note:
Interior - Leather/Wood Steering Wheel Imperfections

Order No.: P-B-46.10/68
Supersedes:
Group: 46
SUBJECT:
Without Leather or Wood/Leather Steering Wheels (Codes 280 and 289)
Noticeable Steering Wheel Imperfections
163
If you receive customer reports in the above model vehicles of steering wheel imperfections such as crimps, bursts or scrunches felt on the outside
surface of the steering wheel, this may be caused by foam (used in the steering wheel manufacturing process) escaping the mold and creating bursts
(Figure 1 and 2, A) on the outside surface. These bursts or scrunches are not entirely removed during finishing work. To remedy, very carefully
remove any such imperfections on the steering wheel (Figure 1, A) using a sharp utility knife (Figure 3, B).
Note:
Extreme care must be exercised when removing steering wheel imperfections. Use only a new, sharp blade of the utility knife when cutting off any
imperfections refer to Figure 3. Do not cut steering wheel (Figure 4) or cut with a blade at an angle (Figure 4). If it is determined that it is
impossible to remove steering wheel imperfections, the steering wheel should be replaced.
Note:
164
Body - Windshield/Rear Window Body Seam Corrosion

Order No.: P-B-67.00/24
Supersedes:
Group: 67
SUBJECT:
MY-All, Model 129, 140, 170, 202, 203, 208, 209, 210, 211, 215, 220, 230
Corrosion of Weld Seam on Sealing Flange of Windshield and/or Rear Window
If after the removal of the front or rear glass in the above model vehicles, corrosion of the weld seam flange is noted in either the front or rear
(Figure 1), repair the corrosion. Clean the sealing flange as it must be free of dust and grease.
In addition, perform any new paintwork according to guidelines from Mercedes-Benz using repair materials and instructions of approved paint
vendors.
Restraints - Seat Belts Don't Retract Properly

165
Supersedes: P-B-91.40/130 and T-B-91.40/131 dated October 11, 2006
Group: 91
Revision History
a 3/19/09 Parts Information Updated
SUBJECT:
All Model 164, 171, 203, 209, 211, 219, 220, 221, 230 and 251
Seat Belt Does Not Roll Up Correctly
If you receive customer reports in the above model vehicles of the front or rear seat belts not rolling up fully, the cause could be dirt deposits on the
seat belt guide due to a soiled seat belt. Cleaning the belt guide and seat belt should restore proper function of the seat belt retraction.
To resolve, perform the following.
1. Clean the belt guide using MB Plastic Cleaner (Figures 1 and 2).
2. Clean the seat belts using MB Car Shampoo mixed with water, MB Textile Carpet/Fabric Care or clean, lukewarm water and soap. Do not treat
the belt with any other cleaning agents.
3. Extend belt and allow to air dry. Do not dry at temperatures above 175°F (80°C) or in direct sunlight. Do not bleach or dye.
Note:
If these instructions are not followed, proper retraction of the seat belt may be impaired.
166
Note:
This repair cannot be claimed under warranty.
Parts Information
A/C - Various Compressor Noise With A/C ON

Group: 83
Revision History
SUBJECT
Replacement of Refrigerant Compressor Belt Pulley Due to Noise Complaints If you receive customer reports in the above model vehicles of noises
at the refrigerant compressor with air conditioning activated and deactivated, the cause could be a defective belt pulley or belt pulley bearing. The
pulley and pulley bearing can be diagnosed and replaced with the compressor still installed in the vehicle by following the procedures below.
1. Locate the noise by duplicating the conditions under which the complaint occurred.
2. If there is also a cooling performance complaint, the noise could be caused by low refrigerant level, perform a Refrigerant Circuit Test as per
SDS and follow instructions for corrective actions.
3. Before the belt pulley on the refrigerant compressor is replaced, verify that the following components in the belt drive are not the source of the
noise and repair as required.
^ Alternator
^ Power steering pump
^ Guide pulleys / tensioner pulleys
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^ Water pump
4. If there is a whining noise that is RPM-dependant which is present with the air conditioning on AND off and is determined to be caused by the
tensioner pulleys, guide pulleys or refrigerant compressor, continue with step 5.
Note:
Make sure that the AC is SHUT OFF! On the push button unit, select "AC off" then "OFF" to turn the Climate System off, then select climate
system on. The compressor should now be off. To see more details on the various push button units, please refer to the climate book, section 2.1 for
each model.
Engines M112/113/272/273
5. Remove the poly-V-belt from the refrigerant compressor.
6. Install shorter belt to bypass the compressor. Route belt as shown in Figure 1.
Engines M112/113 - 20 x 2315 to 2325 mm (A011 997 86 92 or A 011 997 96 92)

Engines M272/273 - 20 x 2330 to 2340 mm (A011 997 04 92)
Note:
A short test belt for OM642 is currently not available.
Note:
The belts can be sourced locally or by MB part number. The belts must be purchased to diagnose AC compressor pulley noise and are not to be
submitted on a warranty claim.
7. Run the engine with the short belt installed. If the noise is still present, check whether the tensioner and/or guide pulleys are the source of the
noise. Replace as necessary the defective tensioner and/or guide pulleys.
8. If the noise is no longer present, allow the engine to cool and proceed to step 10.
9. Replace the compressor pulley as follows.
Note:
It is not necessary to remove the compressor or evacuate the refrigeration circuit. Refer to WIS document AR83.55-P-7685B
10. Remove the pulley-V-belt. Determine if the diameter of the pulley is 100 mm or 110 mm.
11. Raise the vehicle and remove the lower engine compartment paneling.
168
12. Refer to Figure 2 for component number references. Remove the belt pulley circlip (Figure 2, Part 6). With plastic belt pulleys, it is possible to
insert a screwdriver under the circlip (Figure 2, Part 6) and pry it out of the groove.
13. Remove hub (Figure 2, Part 1) using a socket and counter hold tool W112 589 07 40 00. Use a small magnet to remove flat washer from shaft.
Note:
There are two versions of the compressor shaft, a 7mm hex and one with two flats. The shaft with two flats requires the use of socket W112 589 02
09 00. To loosen 7mm hex head, ensure that proper METRIC tool is utilized. To loosen the pulley:
Warning!
It is not a left hand thread!
Method A (Preferred and shown in picture above): Hold the compressor shaft stationary and turn the drive hub counter clockwise to loosen (Figure
3a). Turn the hub clockwise to tighten.
Method B: Hold the drive hub stationary and turn the compressor shaft clockwise to loosen. Turn counter clockwise to tighten.
14. Remove snap ring (Figure 2, Part 4) for pulley bearing.
15. Remove belt pulley (Figure 2, Part 2) from the end of compressor housing.
Note:
Do not apply a pulling force in an axial direction to the refrigerant compressor shaft.
Components damaged due to improper repair procedures may be subject to debit.
169
Assemble the rubber dampers (Figure 2, Part 5) into new pulley the as shown in example A in Figure 4 and Figure 5. Make note of the direction of
the curvature of the rubber dampers and install them over the reinforcing webs in the pulley, not in the spaces between the webs.
16. Install new belt pulley (Figure 2, Part 2) onto the end of compressor housing. Make sure it is the same diameter as the original, 100 mm, 110
mm.
17. Install the snap ring (Figure 2, Part 4) for pulley bearing with its flat side facing the refrigerant compressor. Make sure the snap ring is seated
correctly in the groove.
Note:
Use snap ring pliers with 90° tips that have a minimum reach of 19 mm (0.75").
18. Install washer (Figure 2, Part 3). Make sure it is flat against the shoulder of the shaft.
19. Install hub (Figure 2, Part 1) so the drive fingers are inserted into the gaps between the ends of the rubber dampers. Screw the hub onto the
compressor shaft clockwise and torque to 35 nm. The hub continues to tighten when in the compressor is in operation.
20. Install circlip (Figure 2, Part 6) into the belt pulley. Make sure it is seated in the groove of the pulley.
21. Install a new standard length poly-V-belt. Start engine and verify correct belt operation.
22. Install lower engine paneling.
170
Special Tools
Parts Information
Note:
November 20, 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
171
172
Audio System - Various iPod(R) Concerns

Supersedes: S-B-82.60/629 dated June 26, 2008
Group: 82
Revision History
SUBJECT:
All Model 164 / 203 / 209 Vehicles, as of Model Year 2005
All Model 171 / 251 Vehicles, as of Model Year 2006
All Model 204 Vehicles, as of Model Year 2008
All Model X204 Vehicles, as of Model Year 2010
All Model 211 Vehicles, as of Model Year 2004, Equipped with COMAND (528 or 530)
All Model 216 / 219 / 221 / 463 Vehicles, as of Model Year 2007
Equipped with iPod Interface System or Media Interface System (Option Code 518)
173
Various iPod Issues: iPod Battery Discharge, No Data Display, Slow Reaction When Listening to Audio Books
If you receive customer reports in the above model vehicles of the conditions below, this may be due to old iPod Software which must be updated
via Apple's Website.
^ iPod Battery discharged after a continuous lengthy use of iPod in vehicles (3-5 continuous hours).
^ Display illumination of iPod does not go out after docking the iPod connector.
^ Track display on the head unit (only in vehicles equipped with Media Interface) or instrument cluster does not correctly show the track number
and title.
^ Cluster or head unit do not display iPod data completely.
^ Pod-casts are intermittently not displayed.
^ Slow iPod reaction when listening to audio books.
^ iPod does not charge while connected to the vehicle's iPod Interface Cable or Media Interface.
Note:
In certain cases, you may need to reset the iPod if it locks up during operation. When the iPod does not charge while connected to the interface,
this may be caused by insufficient battery voltage at the iPod Interface Module. For this, make sure the voltage across PIN 1 and PIN 11 of the
iPod Interface Module Cable-set is > 10V, otherwise perform a continuity check and make sure the kit is correctly installed using the
corresponding WIS Document.
Apple Website Support Notes:
The Customer needs to ensure the iPod Software is up to date. For current iPod Application Software and supported iPod models, navigate to this
official Apple Website:
http://support.apple.com/kb/HT1353?
To find the correct iPod Application Software version for the iPod, navigate to this official Apple Website:
http://docs.info.apple.com/article.html?artnum=60984-en
Audio System - Various iPod(R) Malfunctions

Supersedes: P-B-82.85/544 and T-B-82.85/545 dated March 1, 2007
Group: 82
Revision History
a 2/12/09 Step 1 and Damage Code Updated
174
SUBJECT
iPod Intermittently Cannot Be Operated or Controlled Using Steering Wheel Controls, Delayed Response on Instrument Cluster Display, iPod
Volume Too Low Compared to Other Audio Sources
If you receive customer reports in the above model vehicles equipped with iPod Interface Kit of the below iPod conditions, this may be due to
incorrectly loaded MP3 files from the user's music library onto the iPod, the Aux level of the iPod is too low or a CAN communication error
between the head unit and the instrument cluster. To resolve, follow the diagnostic steps below.
^ Cannot be controlled by the multifunction steering wheel controls.
^ A delayed response (sometimes up to 2 minutes) in display of the track information or the radio station on the instrument cluster.
^ The iPod volume is too low in comparison to other Audio sources such as the CD or CD changer.
Step 1 - Compare Audio Volume of Identical Tracks from the iPod and an Audio CD
Note:
To complete step 1, you need a computer, an internet connection, iTunes, CD-R Compact Disc, a CD burner with reliable CD burning software set
to a lower burning speed (8x) with data verification option checked.
^ Using a reliable internet connection, log onto the website: www.mercedes-benz.tv/mixedtape
^ When the page loads, select the menu "Mixed Tape Music Magazine".
^ Select "MP3 Download"
^ Select "MP3 Download" again (note that the Album is in a "zip" format
^ Save and unzip the file onto a local folder on your Computer
^ Insert a blank CD-R in you CD burner start the burning software and burn the selected track from your computer onto the CD-R.
^ When the burn process is complete, copy the track from your computer (NOT from the CD-R) onto your music library in iTunes.
^ From iTunes, pull this track onto the iPod (make sure you have the MP3 format checked in your iTunes burning preferences).
^ On the iPod, scroll to Settings --> Sound check --> OFF
^ Adjust the iPod to max, connect the iPod and adjust head unit's volume to any desired level.
^ Scroll to the acquired iPod track and inspect the volume.
^ Insert the burned CD-R and play the same track on the Head Unit CD player, compare the audio levels of both tracks from the iPod and CD
player.
If no significant volume difference is noted between both audio sources from the iPod and the Audio CD-R, then any reported concern for volume
difference may be caused by an incorrect burning process or using a poor quality audio source file.
If a significant volume difference is noted, proceed to step 2 prior to any replacement of the iPod Interface Module.
Step 2 - Adjust the Aux Output Volume Level
^ Use the MFS buttons to select the iPod menu (Aux) in the instrument cluster (IC)
^ Simultaneously, hold down the down-arrow + Tel hang-up MFS buttons for about 8 seconds, the IC displays the words "DIAG" on the top and
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"SW.." on the bottom --> wait 5 seconds, the IC displays "DIAG", "HW.." --> wait another 5 seconds --> "DIAG", "Vol..."
Within 5 seconds of the "DIAG", "Vol" display appearing, you can press the up or down arrow to adjust the Aux output volume. Make sure it is set
to the loudest --> wait 5 seconds without pressing any MFS buttons --> the display will return to iPod main screen automatically.
If necessary replace the iPod Interface Module with part number B6 782 42 52 (or later). Reference the applicable WIS documents listed below and
adjust the Aux output volume level after replacement per the below procedure.
Note:
If the vehicle is equipped with the latest iPod interface Module, you can use the procedure to adjust the Aux volume output.
Instructions to Remove the Head Unit and iPod Interface Module
Parts Information
Note:
176
Steering - Speed Sensitive Steering Malfunctions/DTC's

Group: 46
Revision History
a 2/4/09 Applicable Models Updated. Content Revised, Parts and Warranty Info. Updated
SUBJECT:
Models 164, 171, 203, 209, 211, 215, 216, 219, 220, 221, 230, 251 with code 213 (Speed Sensitive Power Steering - Parameter Steering)
Speed Sensitive Power Steering (Parameter Steering) Malfunction
If you receive customer reports in the above model vehicles of malfunctioning Speed Sensitive Power Steering (Parameter Steering), this may be
due to the following causes.
1. Speed sensitive power steering valve, electrical malfunction.
2. Electrical connection on speed sensitive power steering valve damaged or broken.
As a result, the fault codes above may be stored in the ESP control unit.
To resolve issues, replace the speed sensitive power steering valve with a new part as per the below procedure.
Note:
It is not necessary to replace the entire rack-and-pinion steering system.
1. Remove steering gear as per respective WIS document shown above.
2. Remove loose dirt from steering gear and clean area around speed sensitive power steering valve. Do not use any cleaning agents!
Important!
Ensure that the utmost cleanliness is maintained at the work area during the following steps!
177
3. Unscrew bolts (Figure 1, 2) attaching speed sensitive power steering valve (Figure 1, 1).
4. Replace the speed sensitive power steering valve (Figure 1, 1). Ensure that the new sealing ring is seated properly. Attach speed sensitive power
steering valve (Figure 1, 1) by screwing in bolts (Figure 1, 2), observe torque (5 Nm +/- 0.3 Nm).
5. Install steering gear, refer to the respective WIS document as stated in Step 1
Note:
There are two versions of power steering high pressure lines that must be detached when removing steering gear. The earlier version has a slotted
support ring, which can be replaced individually. The new version does not have a slotted support ring. In this case, the complete power steering
high pressure line must be replaced (see parts list).
6. Check steering for leaks.
7. Check speed sensitive - parameter function using the DAS, read out fault memory and erase if necessary.
A toe adjustment after removing/installing the steering gear is no longer necessary according to the latest findings (refer to the latest version of the
DTB P-B-46.20/28).
Note:
Parts Information
Note:
February 4, 2009. Please refer to Netstar --> Star Teklnfo --> Star Time for the most current labor time allowance.
178
Technical Service Bulletin # S-83_30-74P Date: 090604
A/C - Musty/Moldy Odor Issues

Date: June 4, 2009
Order No.: S-B-83.30/74p
Supersedes: S-B-83.30/74o dated April 29, 2009
Group: 83
179
Revision History
SUBJECT:
All Model 164, 171, 203, 204, 209, 211, 215, 216, 219, 220, 221, 230 and 251 Vehicles
Air Conditioning Musty/Moldy Odor Complaints
Under certain environmental conditions, typically in a hot and humid climate, the vehicle may emit a musty/moldy odor from the air conditioning
system. This may be more noticeable when starting the vehicle due to residual condensation on the evaporator and on the interior surface of the
heater box.
If you receive customer reports in the above model vehicles regarding a musty/moldy odor from the air conditioning system, the evaporator should
be cleaned using Mercedes-Benz Contra Sept and the interior using the "ultrasonic atomizer", refer to WIS document AR83.30-P-5556A. For the
best lasting results, follow the instructions provided below.
1. Remove all filters installed in the air conditioning system. The following filter may be fitted: Pollen filter, dust filer, combination filter or active
charcoal filter.
2. Clean evaporator with Mercedes-Benz Contra Sept as per WIS document AR83.30-P-5555T.
Contra Sept is applied using a spray gun attached to a long probe. It is imperative to have as much of the evaporator sprayed with the cleaner by
moving the probe in / out and up / down inside the case. It may be necessary to bend the probe in order to gain access. The cleaner is applied and
allowed to dry. Refer to Figure 1a for spraying angle recommendation.
Note:
After cleaning the evaporator, a second treatment has to be conducted. After completion of section A (ContraSept), refer to section B (Wynns).
180
Parts Information
Note:
June 4, 2009. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
181
182
A. ContraSept Cleaning Procedure

A. ContraSept Cleaning Procedure:
Caution!
Wear safety glasses and respiratory protection when spraying cleaner.
^ Spray the evaporator in a 90° angle.
^ Move up and down, left and right to reach all areas of the evaporator
^ Do not rotate the probe to reach other areas of the evaporator. This will change the spraying angle and the cleaning effect will diminish.
183
Warning!
Do not exceed the manufacturer's recommended maximum air pressure as stated on the label affixed to the pressure cup (Figure 1b). Excessive air
pressure could cause the canister to explode and potentially cause personal injury. The recommended pressure to clean the evaporator effectively is
120psi.
To reduce the possibility for this condition to reoccur, advise the owner to operate the blower at a higher speed, especially during humid conditions.
For vehicles with a REST function, it also helps to use this feature during humid conditions when parking the car.
Additional Procedures - Model 203 / 209
1. Equipped with ACC climate system Option Code 580 - It is necessary to drill a 15mm hole in the climate housing to access the evaporator with
the spray probe. The location for drilling the hole is described in WIS document AR83.30-P-5555-01A and Figure 1, A1 and B1.
2. A white foam block may be mounted to the housing between the blower motor and the main section of the case, see (Figure 2). On these
184
housings, there is an alternate location of the hole as shown in Figure 1, A2 and B2.
Figure 3 - bend probe as shown
3. Bend the shorter of the two probes (Figure 3). Move the probe up and down as well as side to side to ensure the entire evaporator is sprayed with
the cleaner. Plug hole after cleaning with seal plug A110 987 10 44 64.
4. Using the instructions below check the "REHEAT" setting. It should be set to "Anti-icing". Control Units --> Body --> EIS --> Control unit
adaptations --> Read coding and change if necessary --> Climate control Standard setting: Climate control --> REHEAT mode --> Change From:
"Standard" to: "Anti-icing protection"
5. In case of customer reports that the air conditioning system is emitting a musty/moldy odor from the vents within three months after using the
Mercedes-Benz Contra Sept product as described above, a Biocide coated evaporator entered production as of VIN A731368 and F634900 (203)
and F144091 and T042954 (209). In this case, this part can be installed in earlier vehicles. Be sure to thoroughly clean the inside of the heater box
and make sure the drain tubes are not clogged before reassembling the system.
Additional Procedures - Model 211
1. Using the instructions below check the "REHEAT" setting. It should be set to "Fixed value". Control Units --> Air Conditioning --> C-AAC,
AAC --> Control unit adaptations --> Read coding and change if necessary --> Workshop coding --> Evaporator-Control (REHEAT mode) -->
Change From "Humidity-dependent (SERIES)" To: "Fixed value"
Mercedes-Benz Contra Sept product as described above, a new slanted heater box bottom which allows the condensation to drain better and a
coated evaporator entered production as of VIN A675828 and X171590. In this case, these parts can be installed in earlier vehicles. Be sure to
thoroughly clean the inside of the heater box and make sure the drain tubes are not clogged before reassembling the system.
Note:
Replacement of the heater box bottom and evaporator on the 211 and replacement of the evaporator on the 203 and 209 can only be claimed if the
Mercedes-Benz Contra Sept treatment has already been performed. Dealers must claim which option was performed in the text of the claim.
Procedure for 164 and 251
Caution!
Wear safety glasses and respiratory protection when drilling hole and spraying cleaner.
1. Clean the evaporator with MercedesBenz Contra Sept as per WIS document AR83.30-P-5555T and the additional information in this document.
2. To clean the driver side of the evaporator, the spray probe is inserted into the hole for the evaporator temperature sensor as described in WIS
document AR83.30-P-5555T, Step 4.1.
3. To clean the passenger side of the evaporator, the spray probe is inserted into a 15 mm hole that needs to be drilled in the climate housing as
described in Steps 4 through 6.
4. Remove the cover below the instrument panel on the passenger side and fold carpet down. Refer to WIS document AR68.10-P-1520GZ (164) or
AR68.10-P-1520RT (251).
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5. Location of hole is shown in Figures 4 and 5. The hole should be centered in the triangular shaped section of the climate housing as shown in
Figure 5.
6. Drill a 15mm hole in small increments using a mechanical drill stop to limit how far the drill bit penetrates the climate housing. A collar type drill
stop, a piece of rubber hose or tape can be used as the drill stop.
Warning!
The drill bit cannot be allowed to penetrate the housing more than 13mm or damage to the evaporator could occur. When the drill bit breaks
through the housing it has a tendency to pull inward. This is why a drill stop is necessary.
7. Bending of the probe may be required to be able to spray all parts of the evaporator. Move the probe up and down as well as side to side to
ensure the entire evaporator is sprayed with the cleaner.
8. Follow the remainder of instructions in WIS document AR83.30-P-5555T. Reassemble vehicle in reverse order. Do not replace any filter back
into the system!
Warning!
Do not exceed the manufacturer's recommended maximum air pressure as stated on the label affixed to the pressure cup (Figure 3). Excessive air
pressure could cause the canister to explode and potentially cause personal injury.
B. Wynns Treatment
B. Wynns Treatment
1. Warm up vehicle with air conditioning switched off for a minimum of 30 minutes in order to dry out the climate housing and ducts. Set the
climate control to the following settings:
Blower speed 2-3
Heat to maximum
Recirculation activated
Air distribution to the footwell
All doors, windows and sliding roof closed
Note:
AC compressor does not turn off immediately when the AC Off is selected at the control module. In order to ensure the compressor is off, use the
following instructions:
Select AC Off
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Select Climate System Off
Select Climate System On. The AC compressor will now be off.
2. Remove all filters installed in the climate system. This could include dust, activated charcoal or combination filters.
3. Close the recirculation flap for cleaning using SDS.
For 171, 204, 211, 219, 216, 221, 164 and 251 models follow path: Control Units --> Air Conditioning --> C-AAC, AAC --> Actuations -->
Closing air recirculation flap for cleaning --> Select recirculation.
For 203 and 209 models, follow path: Functions performed by more than one control unit --> Body --> Climate control --> Climate control -->
C-AAC --> Actuations
The system will come out of recirculation when SDS is disconnected from the vehicle.
Note:
This menu item is not available in SDS for all vehicles. On these vehicles, recirculation must be manually selected on the control module.
4. Place the Wynn's(R) AIRCOMATIC(TM) Ultrasonic Cleaning System in the passenger footwell. Insert the hose in the luggage net and orient the
end of the hose to insure the output from the device is sucked into the footwell vents.
5. Start engine, AC off, press recirculation button, select lowest blower speed and set the temperature(s) to minimum.
Note:
The compressor must not be running.
6. Install one container of Wynn's(R) AIRCO-CLEAN(TW) in the Wynn's system.
7. Plug in the Wynn's system and check that it is running.
8. Close all doors and windows.
9. When the fog stops coming out of the Wynn's(R) system (after approximately 20 minutes), the dispersion process has been completed.
10. When the cleaning procedure is finished, switch engine off, turn off the Wynn's(R) system and leave windows and doors closed for
approximately 1 hour.
11. Open doors and trunk lid/tailgate.
12. Open the air recirculation flap again if the automatic recirculation function has been deactivated by coding, and set the recirculated air function
to "unimited" again.
13. Restart engine, switch on A/C, select the highest blower speed and set the temperature(s) to minimum.
14. Allow system to run for about 10 minutes. The cleaning process is now complete.
15. After cleaning, install new filters.
16. If cleaning the interior does not remedy the complaint, please refer to the following documents: SI83.00-P-0004A and SI83.30-P-0008A.
Engine - Low Oil Level Symptoms/Diagnostics

Date: June 2, 2009
Supersedes: S-B-18.00/37e dated March 20, 2009
Group: 18
Revision History
187
f 6/2/09 Model 211 Production Information Included to Steps 1a and 4
e 3/20/09 Step 6 Revised
d 10/24/08 Damage Type Revised - Step 7
c 10/6/08 Warranty Information Updated - Step 7 Op Code 18 4110
b 9/17/08 Warranty Information - Step 7 Updated
a 7/28/08 Updated Step 3a (removed reference to 229.5 and 229.51 oil) and Step 7
SUBJECT:
Equipped with M156, M272, M273 or M642 Engines
Low Oil Level Symptoms
1. Model 203.087/092 and 211.087/287, Equipped with M272 - Erroneous IC Warning Display "Check Engine Oil Level at Next Service Stop": Oil
level warning message frequently appears in the instrument cluster, however the oil level correct on the dipstick, the cause may be the incorrect oil
data record stored in the ASSYST control unit (Model 211), or instrument cluster (Model 203). To resolve, perform the following procedures.
Message:
"Pour in one liter of oil at next refueling stop" (Model 211 4MATIC with M272 up to 6/2005) "Check oil level at next refueling stop" (Model 211
4MATIC as of 6/2005 and Model 203 4MATIC with M272 as of production startup)
1a) Adaptation of Modified Oil Data Record with SDS 10/06 or Later
Model 203 4MATIC with M272 Engine, up to VIN F886321: Control Units --> Information and communication --> ICM --> Vehicle code 12 / NO
--> CU adaptations --> select code 807 --> select national version --> select M272 all-wheel drive change status 3 "or higher" --> confirm selection.
Model 211 4MATIC with M272 Engine, up to VIN X218820 (up to production September 2006). As of approximately October 2006, vehicles
were produced with modified oil data record.
^ Check whether CGW programming is possible by using SDS: Control units --> Body --> CGW --> Control Unit adaptations --> Control Unit
programming. If yes, perform control unit programming and then perform parameterization in ASSYST. If no, perform parameterization in
ASSYST.
^ Perform parameterization in ASSYST by using SDS: Start Control Units --> Information and communication --> ASSYST --> CU adaptations
--> select engine M272 --> Select national version --> Select engine for ASSYST M272 Model 211 all-wheel drive "National version" status 5 or
higher.
1b) Check Oil Dipstick Marking on Handle (Model 203 / 211 up to Engine No. 2729..30467144)
Note:
As of February 2, 2007, Section 1b of this DTB must not be performed on the following vehicles which are covered under Service Campaign No.
2007010010
a) Oil dipstick with marking 27214 is correct.
b) Oil dipstick with different marking should be replaced with part number A272 010 14 72.
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c) Check whether quantity of engine oil in engine corresponds to specification in WIS.
2. Model 164.186 - Erroneous IC Warning Display "Check Engine Oil Level at Next Service Stop"
Confirm engine type coding in ASSYST using the current issue of SDS:
Control unit --> Information and Communication --> ASSYST Active Service System --> Control Unit Adaptations --> Engine Type --> Code to
correct engine type.
measure.
3a) Vehicles Up to VIN No. A213990 / Production Date 12/20/2006 - Check and correct oil level where necessary by adding 0.3 liter oil at PDI
or at the customers "1st Visit" for all newly sold GL450 vehicles. Refer to WIS document AP-18.00-P-0101GZ. Costs are to be charged using
the warranty code 00001 70.
3b) Check Oil Dipstick Marking on Handle - Oil dipstick with marking 27314 is correct. Oil dipstick with different marking should be replaced
with part number A273 010 14 72. New specification for quantity of engine oil in engine is 9.0 liters with filter change.
3c) Vehicles with VIN No. A213991 up to A235524 / Production Date 2/9/2007
Note:
Do not automatically add 0.3 liters of oil; check dipstick first.
Oil dipstick with marking 27314 is correct. Oil dipstick with different marking should be replaced with part number A273 010 14 72. New
specification for quantity of engine oil in engine is 9.0 liters with filter change.
4. Model 221.186, Equipped with M273 Engine and 4-Matic, Erroneous IC Warning Display "Check Engine Oil Level at Next Service Stop"
Vehicles Up to Production Date end of 03/2007 (as of 04/2007 vehicles produced with modified oil data record) - Update oil data record in
ASSYST using SDS: Control unit --> Information and Communication --> ASSYST --> Control Unit Adaptations --> SCN coding --> Perform
SCN online coding --> Work through steps 1-3 in SDS to perform SCN coding.
5. Model 209/211/219, Equipped with M156 Engine, Oil Level Warning Message "Add 1 liter engine oil at next refueling stop" or "Check oil at
next refueling stop" in Instrument Cluster / Oil Level on Dipstick is OK - Perform the following steps.
a) Check the coding of the engine model designation and oil data set of the ASSYST control unit in SDS --> Control units --> Information and
communication --> ASSYST --> Control unit adaptations --> Engine type --> Engine type M156 E63 Version for rest of world Status: 3 has been
recognized --> Information and communication --> ASSYST PLUS --> Control unit adaptations --> Control module reset
b) Check installed oil dipstick and replace if necessary. The correct oil dipstick is identifiable by the red handle and by the code 156 16
c) Check oil level and correct if necessary.
6. Model 164.122/822 and 251.122, "Check oil at next refueling stop" Warning in Instrument Cluster
If you receive customer reports when driving at constant speeds ranging from 60 to 75 mph the instrument cluster displays "Check engine oil level
at next refueling stop", the cause may be:
a) the position of the oil level switch,
b) a malfunctioning oil level switch,
c) incorrect oil data record coded into the instrument cluster.
Note:
Condition only relevant when the oil level is significantly above "min".
To Resolve:
164.122/822 up to VIN A261645
251.122 up to VIN A059019
a) Install a lengthened bracket (7mm) for the oil level switch (part number A642 018 27 40).
b) Replace the oil level switch as per step 7.
189
c) Code current oil data record with SDS to Version for USA even if already coded. This will update the oil data record (Figures 1 through 4).
164.122/822 from VIN A261645 up to A425120 (prod. 06/2008)

251.122 from VIN A059019 up to A086462 (prod. 06/2008)
164.122/822 as of A425120 (prod. 06/2008)

251.122 as of VIN A086462 (prod. 06/2008)
7. All Passenger and Light Truck Models, Equipped with Engine M156, M272, M273 or M642 (Up to engine no. 642 xxx 40 673486), Faulty Oil
Level Switch - If after performing the applicable remedy(s) 1 through 6 stated within this document, the issue has not been resolved, the cause may
be a malfunctioning oil level switch. Perform the following.
a) Check the oil level using the dipstick.
b) If the oil level is confirmed between the "MIN" and the "MAX" marks on the dipstick, replace oil level switch with part number A001 153 11
32 as per the applicable WIS document.
Note:
For Engines M272, M273 and M642 If there is any deformation of the stamped steel bottom section of the oil pan after removal, it must be
replaced. Refer to EPCnet for applicable part number.
190
c) It is possible to install the switch upside down. For correct installation refer to Figure 5.
Parts Information
Note:
191
192
Engine - Multiple DTC's Set/MIL ON

Date: June 17, 2009
Supersedes: S-B-03.30/08i dated April 29, 2009
Group: 03
193
Revision History
SUBJECT:
Check Engine Light On / Fault Codes Current and/or Stored in ME-SFI Control Module / Oil Leaking at Camshaft Adjustment Solenoid
If you receive customer reports of the check engine light being illuminated and one of the following Fault Code Scenarios (no corresponding Fault
Codes in Scenario 3) is found in the above model vehicles, follow the applicable procedure below to resolve.
Note:
Corresponding protocols (i.e. ME Control Module log file related to DTC code) must always be included with any returned parts as indicated on the
Warranty Return Form Printout Matrix (RFPM). If the documentation is missing or does not support the diagnosis, the warranty claim may be
debited.
Note:
Flashing the ME Control Module will not resolve these issues and is unnecessary at this point.
Note:
Mobil Training Coach (MTC) "M272 Engine Timing" can be referred to when performing repairs. However, this DTB takes precedence in terms of
technical and warranty content as well as referred WIS documents. Any parts specified in the DTB or in referenced WIS documents should be
replaced accordingly (e.g. seals, gaskets or bolts and screws as required).
Note:
When preparing / cleaning any surfaces for resealing, extreme care must be taken not to damage surfaces with sharp tools. It is absolutely not
permissible to use any abrasive materials (i.e. sand paper, abrasive pads, etc.) for cleaning resalable surfaces. Proper application of sealant is a must
as excessive sealant can result in damage to the engine (refer to MTC listed in the note above). Failure to follow these precautions could result in
severe and permanent engine damage.
194
Special Tools
Note:
Always refer to EPC for the latest parts information and use the correct VIN number when specifying parts.
Parts Information
Note:
June 17, 2009 Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
195
196
197
198
199
Fault Code Scenario 1

Fault Code Scenario 1:
200
DTC 1200 and/or 1208 is/are present in ME-SFI control module. The fault codes are recorded as current and/or stored in the fault memory. When
the fault memory is erased and the engine is restarted, the fault codes reoccur immediately. This is due to the positioning of the timing chain driven
camshafts relative to the crankshaft and can be caused by a worn sprocket on the balance shaft on engine M272 or by a worn guide (idler) gear for
the timing chain on engine M273. Figure 1, 2 and 3 show extremely worn sprocket gears. Figure 4, for comparison, shows a new sprocket gear.
Note:
201
In rare cases, a stretched timing chain might be the reason for the DTC fault codes when the sprocket does not exhibit any signs of wear.
Applicable Models (Not Applicable to Model 164.156, 204 or 216.386): Equipped with M272 Engine Up to Serial No. 2729..30 468993 or M273
Engine Up to Serial No. 2739..30 088611.
The material for the balance shaft sprocket and the timing chain guide wheel (idler) was modified on engines past the serial numbers listed above.
Procedure 1 (Follow all steps and the order as described):
a) Perform a visual inspection for any wear of the teeth (damage profile) on the sprocket of the balance shaft (M272) or of the guide (idler) gear
for timing chain (M273) by removing the timing case cover on the engine. Refer to WIS instructions AR01.40-P-8000* (* - applies to a specific
model designation e.g. AR01.40-P-8000SX models 221, 216). Ensure the use of the Special Tool W001 589 81 09 00 when removing /
installing timing case cover.
Note:
Refer to Figure 1 through 3 for examples of damaged / worn sprocket profile. Refer to Figure 4 for example of a new gear (for comparison).
b) Only if worn (sprocket teeth profile damaged), replace the balance shaft on engine M272 or replace the guide (idler) gear of the chain drive on
engine M273 as per WIS instructions AR03.20-P-1000* (* - applies to a specific model designation e.g. AR03.20-P-1000VA model 171).
Note:
Cylinder heads are not needed to be removed.
Note:
When performing repair, pay attention to cleanliness. Remove any debris, shavings and contaminants.
Note:
When replacing the balance shaft on engine M272, the counterweight must also be replaced. The balance shaft and counter weight are specific to
engine designation. Order individual parts and kits specifically to a VIN number.
c) Replace the engine oil pump. Refer to WIS instructions AR18.10-P-6020* (* - applies to a specific model designation).
d) Replace the chain tensioner.
Caution!
New timing chain tensioner must be installed and only after the engine head covers (valve covers) are installed / bolted on. Failure to observe that,
will result in the over tightening the timing chain which will ultimately lead to engine head damage. Noted the timing chain tensioner is a single use
part. Once the tensioner is installed, it cannot be taken out or readjusted, doing so will result in over tightening of the timing chain as well.
e) Change engine oil and filter.
Note:
Use inexpensive, appropriate engine oil from MB sheet 229.1 and 229.3 for this step.
f) Drive with engine at high load and rpm for approx. 15 miles.
g) After 15 miles, drive, change engine oil and filter once more. Use appropriate engine oil from MB sheet 229.5 in this step.
h) Replace all four of the camshaft adjustment solenoids with A272 051 01 77 this step applies only to Scenario 1.

One or more of the fault codes 0059, 0060, 0063, 0064, 0271, 0272, 0275, and 0276 is/are present in ME-SFI control module. The fault codes are
recorded as current and/or stored in the fault memory. If current and/or stored, these codes are caused by a malfunctioning camshaft adjustment
solenoid.
Applicable Models: Equipped with M272 Engine Up to Serial No. 2729..30 759427 or M273 Engine Up to Serial No. 2739..30 193592. Engines
produced after serial nos. listed above are already equipped with improved camshaft adjustment solenoids (A272 051 01 77).
Procedure 2:
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Diagnose each DTC as per Star Diagnosis. If it is determined the solenoid is faulty, replace with solenoid A272 051 01 77 as per appropriate WIS
instructions. Refer to WIS instructions AR05.20-P-7295* (* - applies to a specific model designation e.g. AR05.20-P-7295RTB model 251).
Note:
For this scenario only, replace the solenoid that has a corresponding fault code. Copy of the SDS short test and ME Control Module log file related
to DTC code must accompany returned parts. If the documentation is missing or does not support the diagnosis, the warranty claim may be debited
(i.e. only two Fault Codes but all four solenoids are changed or low voltage situation might result in a code to be stored but not current).

Fault Scenario 3:
Camshaft adjustment solenoid is leaking oil, and no Fault Codes are current or stored in the ME Control Module. Determine the cause of the leak.
The solenoid can be leaking from under the sealing ring or through the harness connector.
Procedure 3:
a) If the leak appears to be between the solenoid and the cylinder head replace solenoid sealing ring (Figure 5, 145).
b) If the leak is from the electrical connector, replace the solenoid (Figure 5, 140).
Note:
Provide description of where the leaking occurred and mark the replaced solenoid.
Steering, A/C - Grinding/Gushing Noises

Date: May 12, 2009
Supersedes: S-B-46.30/21a dated Feb. 12, 2008
Group: 46
Revision History
b 5/12/09 Parts Information Updated / Sound Files Included
a 2/12/08 Applicable Models, Content, Parts and Warranty Information Updated
SUBJECT:
Model 163.154/157/172/174/175
Model 164.172/175/186/871/886
Model 171.454/456/473
203
Model 203.052/054/056/061/064/065/081/084/087/092/261/264/281/284
Model 209.356/365/372/375/456/465/472/475
Model 211.056/065/070/072/082/083/087/090/256/265/282/283/287
Model 215.373/374/375
Model 216.371
Model 219.372/375
Model 220.170/173/174/175/183/184
Model 221.171/186
Model 230.471/472/475
Model 251.156/165/175
Noise from the Area of the Steering System / Power Steering Pump
If you receive customer reports in the above model vehicles of grinding or gushing noises which may be heard from the area of the steering
system/power steering pump, one of the possible causes may be in the A/C compressor belt drive.
This noise is similar to the noise produced by the power steering pump when ingesting air. This type of noise is present at both idle and higher
engine speeds, can be heard whether the steering wheel is stationary or moving and the noise frequency increases with the engine speed. The noise
intensity increases towards steering wheel end limit stops. Below sound files provide noise examples.
1. First noise example with engine running
2. Second noise example with engine running
Note:
The noise does not change by switching the A/C compressor on and off. Evacuating the refrigerant will not change the noise since the A/C
compressor belt pulley runs continuously with the engine.
Note:
Do not replace the A/C compressor belt pulley merely on suspicion. To ascertain whether the noise is caused by the A/C compressor, perform the
following test using a shorter poly-V-belt. It is absolutely essential to follow in sequence the below procedure:
1. Detach the original poly-V-belt.
2. Install poly-V-belt part number A011 997 96 92 on vehicles with M112 / M113 engines or install poly-V-belt part number A011 997 04 92 on
vehicles with M272 / M273 engines. With the shorter belt installed, the A/C compressor is not driven by the belt. The A/C compressor pulley is
by-passed) (Figure 1, 1). Route the rest of the belt the same way as the original belt (Figure 1).
3. Start the engine and listen for the complaint noise:
Correction:
4. If the complaint noise is no longer present, replace the A/C compressor belt pulley refer to the latest version of DTB P-83.55/87 (latest version)
for A/C compressor poly-v-belt pulley replacement.
5. If the complaint noise is still present, it is not due to the A/C compressor. Therefore, resolve the noise issue by following the procedure in Star
TekInfo > EDAC > Diagnostic Guides > Power Steering Diagnostic Guide (latest version) > Start > Noises in steering system.
6. Reinstall original belt.
204
Parts Information
Note:
Technical Service Bulletin # S-27_50-59G Date: 090505
A/T - Limp Home Mode/DTCs 2200/2201/2767/2768

Date: May 5, 2009
Order No.: S-B-27.50/59g
Supersedes: S-B-27.50/59f dated January 22, 2009
Group: 27.50
Revision History
g 5/5/09 Warranty Information Updated - Op Code 02-3472 Included
f 1/22/09 Revised Information (sensor ring removed as possible cause)
d 10/31/08 Warranty Information Updated Op Code 27-1255 Included
c 10/17/08 Applicable Models Updated and Remedy Revised
SUBJECT:
205
All Models Equipped with 7G-Tronic Trans.(NAG2)
2768, the condition is related to the speed sensor. To resolve, replace the electrohydraulic control module (valve body). Refer to WIS document
AR27.19-P-0200w. Refer to EPCnet for the applicable part number, being sure to regard the footnotes carefully.
Note:
May 5, 2009. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
Body - Rear Fender Corrosion

Date: May 18, 2009
Order No.: P-B-63.50/20
Group: 63
SUBJECT:
MY-All, Models 203
Bodyshell Complaints Regarding Rear Fender at Wheel Arch
Should you receive complaints regarding corrosion on the rear fender follow the procedures below.
A. Remedy 1 for Corrosion in Area A
206
1. Remove corrosion on the rear fender (1) in area A.
2. Mask off wheel arch in visible area B with clean edges.
3. Remove bulkhead on rear fender (1).
4. Detach trim on entrance longitudinal member.
5. Mask off rear bumper.
6. Apply primer filler. Use only MBUSA approved products as outlined in S-B-98.00/13P or latest version.
7. Coat wheel arch in area A with a sprayable seam sealant or paintable underfloor protection.
8. To ensure proper adhesion leave no cleaning agent residue behind. Observe all manufacturer recommendations for curing and working times of
the sealant. Mask off the wheel arch in the visual area B with clean edges for painting. Offset the tape by approximately 1 to 2 mm from the area.
9. Paint over wheel arch in area A.
10. Remove the first piece of masking tape on the wheel arch.
11. Carefully remove masking tape from the visible area B.
12. Apply cavity preservation.
13. Reinstall all removed parts.
B. Remedy 2 for Corrosion of Areas A and B
1. Remove corrosion on the rear fender 1 in the areas A and B.
2. Remove bulkhead on the rear fender.
3. Detach the trim on entrance of the longitudinal member.
4. Remove the rear bumper.
5. Remove the rear lamp unit.
207
6. Remove the trim frame on the rear window.
7. Apply the prime filler. Use only MBUSA approved products as outlined in S-B-98.00/13P or latest version.
the sealant.
10. Paint wheel fender.
C. Remedy 3a for Corrosion or Rust Through Damage in Area A and B
1. Refer to WIS document SM63.50-P-1000C.
2. In cases where areas A and B have corrosion or rust-through damage, the repair panel must be fabricated to match the damage profile and it
should be installed as a partial section. If the scope of the repair is smaller than the shaded area (Figure 2), repair stage 3 must be carried out.
NOTE:
Repair Stages Defined
a. Repair Stage 3: If the damage is equal to or smaller than the shaded area, replace the entire pictured repair panel (Figure 2).
b. Repair Stage 4: If the damage is larger than the shaded area, the repair panel must be fabricated from the entire fender.
D. Remedy 3b for Deep Damage to Outer Rear Wheel Well
1. See WIS-net document SM63.50-P-1000C.
2. In cases where severe corrosion or rust-through damage, the repair panel is acquired from the existing replacement part.
E. Remedy 4a for Severe Corrosion or Rust-Through Damage in Areas A and B
1. See In cases where areas A and B have severe corrosion or rust-through damage, see WIS-net document SM63.50-P-1000C.
2. If the scope of the repair is greater than or equal to the shaded area (Figure 2), then repair stage 4 must be carried out.
F. Remedy 4b for Deep Damage to the Outer Rear Wheel Well
2. In cases where the area of the outer rear wheel well has severe corrosion or rust-through damage, the repair panel is acquired from the existing
replacement part.
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Parts Information
Technical Service Bulletin # LI83-00_P-047480 Date: 090729
A/C - No Or Insufficient Cooling Output

NO OR INSUFFICIENT COOLING OUTPUT, PERMANENTLY OR OCCASIONALLY/DEFECTIVE REFRIGERANT LINE
Topic Number LI83.00-P-047480
Version 1
Design Group 83.00 general
Date 07-29-2009
Validity Passenger car model series with air conditioning
Reason for change
Reason for block
COMPLAINT:
No or insufficient cooling output, permanently or occasionally/defective refrigerant line.
CAUSE:
Refrigerant line (engine-side low-pressure line, from compressor to connecting point upstream of expansion valve) whose inner coating comes
loose in the flexible section of the hose, causing constriction.
Attachments
REMEDY:
Air conditioning system may not be evacuated before test steps 1. - 3., this could affect the test result.
1. Start engine, activate air conditioning on control panel (max. cold, blower setting 3), medium engine speed.
2. Connect pressure gauge to high and low-pressure side.
3. Check whether the refrigerant compressor is delivering refrigerant (limiter on belt pulley turns or pressure builds up in refrigeration circuit): If
the refrigerant, eliminate this fault.
If the refrigerant compressor builds up pressure,
4. Read off the high and low-pressure values from the pressure gauges after approx. 5 minutes.
209
If the installation space does not permit reliable temperature measurement using an infrared thermometer, continue with 6:
5. If the low pressure is noticeably high (> approx. 60psi) and the evaporator temperature is significantly too high at the same time (> approx. 50°F)
use an infrared thermometer to check the engine-side low-pressure line against the refrigerant flow direction (from compressor to connecting point
upstream of expansion valve). If there is a noticeable temperature drop in the line (Delta > 45°F),
6. Dissemble the engine-side low-pressure line (from compressor to connecting point upstream of expansion valve) and
7. Use an endoscope or the procedure described in the attachment to check the line for clear passage (checking for clear passage using welding wire
or similar is not permissible as this can damage the inner hose and cannot detect peeling anyway).
8. Replace the line if you detect and constriction. Refer to EPCNet for applicable part number.
Attachments
Symptoms
Parts
Work units
210
Validity
211
Attachments - Visual inspection of intake line for clear passage
Engine - Oil Level Message General Information

GENERAL INFORMATION ON OIL LEVEL MESSAGE IN INSTRUMENT CLUSTER
Version 1
Design Group 01.45 Oil Pan
Date 08-06-2009
Validity Valid for engines: M111, M112, M113, M166, M266, M271, M272, M273, M275, M285, OM611, OM612, OM613, OM628
Reason for change Update model designation/Supercedes SI S-B-01.45/26a and S-B-18.00/36a
Reason for block
COMPLAINT:
The attachment to this document contains detailed information on procedures and possible remedies in the event of implausible display messages
concerning the engine oil level in the Instrument Cluster (IC).
212
Specifically, it contains information on:
1. Notes on implausible display messages
2. Overview chart of the relevant switches
3. Supplemental notes on oil level measurement
CAUSE:
For causes of implausible display messages, please refer to the document in the attachment (observe correct language version).
REMEDY:
For procedures and remedies in the event of implausible display messages, please refer to the document in the attachment (observe correct language
version).
Attachments
Symptoms
Work Units
213
214
215
Validity
TIPS Information Display: Display message concerning engine oil level
216
217
Remedies for known complaints in OM642, M272 and M273 engines
218
System description on the oil sensor and oil level switch
219
220
Oil level message, oil level warnings
221
General oil level measurement
222
Procedure for "Implausible display messages"
223
224
225
Computers/Controls - DAS Software Update

DAS/XD ADD-ON 2009-08-21-1243 FOR PASSENGER CARS
Topic number LI58.40-P-048053
Version 1
Design group 58.40 Workshop equipment/MB testers
Date 09-29-2009
Validity DVD version 07/2009
Reason for change
Reason for block
Complaint:
Driver ESA/ Front passenger ESA

Model series: 203,463
Faulty CBF file produces unknown control unit in vehicles of model series 203 and model series 463 prior to model refinement;
initial startup no longer possible.
ETC
Model series: 204,212,207
SCN coding with limp-home variant is not possible
226
Cause:
For all complaints: XD and DAS diagnostic data.
Remedy:
DAS/XD add-on 2009-08-21-1243 for passenger cars.
This add-on can be installed over DAS/XD version 07/2009.
This add-on does not supersede any other add-ons and must be additionally installed.
Symptoms
Control unit/fault code
227
Validity
A/T - 722.9, Delayed Reverse Engagement

DELAYED ENGAGEMENT OF REVERSE GEAR
228
Version 1
Design Group 27.00 General
Date 06/24/2009
Validity Transmission 722.9 with code 809
Reason for change Additional procedure for remedy
Reason for block
Complaint:
When reverse is selected, the engagement sequence may be delayed.
A double jolt may occur at an interval of approx. 3 seconds after moving the gearshift lever from P to R.
The complaint occurs with electrohydraulic controller (EHS) 220 270 2406 and 220 270 2306.
These electrohydraulic controllers are installed in transmissions as of model year 2009 (code 809).
Cause:
Parameterization of adaptation values for clutch pack BR (reverse gear)
Remedy:
1. Perform software update in transmission control unit and then perform SCN coding.
It is absolutely essential to make sure that DAS version 01/09 or higher including add-on 1077 is used.
2. Then the reverse gear adaptation data must be reset using DAS (menu guide in attachment).
3. The engagement sequences for N-D and N-R must be taught in again:
NOTE:
Always remain in the gear ranges N/R/D for at least 5 sec!
Start the engine from cold,
shift 5 times N-R,
shift 5 times N-R --> warm up transmission 40°C and while doing so, exceed a speed of 50 km/h at least once.
shift 5 times N-R,
shift 5 times N-D --> warm up transmission to 70°C and while doing so, exceed a speed of 50 km/h at least once.
shift 5 times N-R,
shift 5 times N-D.
Attachment
229
Symptoms
Validity
NOTE:
230
In case of Warranty, use the table above.
231
Computer/Control System - DAS/XD Software Update

Version 1
Date 09-29-2009
Validity DAS version 07/2009
Reason for change
Reason for block
Complaint:
232
All telematics flash CUs - Model series: 204,207,212 - During control unit programming of telematics control units, the selection menu
"Component 'TV' is not installed" sometimes does not appear. During control unit programming, no symptoms are displayed on the "New software
found" screen.
CDI6 - Model series: 204,212,207 CU access not possible. CU programming from boot software cannot be performed. Initial startup cannot be
performed.
SGR - Model series: 221,195 Communication cannot be established with the radar sensors control unit (SGR).
Audio/COMAND - Model series: 164,169,211,219,245,251,230,203,463,171 Missing texts during control unit programming
SAM - Model series: 169/245 Initial startup of SAM control unit not possible for vehicles prior to YM 2008
ETC - Model series: 204,212 Communication aborted when accessing current adaptation of torque converter lockup clutch
Cause:
For all complaints: DAS data assignments.
Remedy:
DAS/XD add-on 2009-07-14-1214 for passenger cars
Symptoms
233
234
235
236
237
238
Validity
Interior - Seat Backrest Control Valve Switch Broken

BACKREST (MCS) AIR CUSHION CONTROL VALVE SWITCH BROKEN
Version 1
Design Group 91.25 Multicontour seat (MCS)
Date 07-21-2009
Validity Model series 169, 203, 209, 245
Reason for change Damage code included/Supercedes DTB P-B-91.25/123

and T-B-91.25/124
Reason for block
Complaint:
Multicontour seat backrest control valve switch broken.
Cause:
Damage due to external force, incorrect operation.
Remedy:
239
In these cases do not replace the entire control valve.
Only the broken switch should be replaced with the control valve in the installed condition.
The switch is available as a separate replacement part: A169 870 03 10
Symptoms
Parts
Attachments
Work Units
240
241
242
Validity
Attachment - Control valve, model series 169
243
244
Cell Phone - iPhone(R) Music Won't Mute During Call

!PHONE/!PHONE 3G: MUSIC PLAYBACK CAN BE HEARD DURING PHONE CALL
Version 1
Design group 82.70 Cellular telephone, voice control system (VCS)
Date 08-18-2009
Validity Model series 164, 169, 171, 203, 204, 207, 211, 212, 216, 219, 221, 245 with !phone UPCI cell phone holder (A34/15) and da
Reason for change Remedy entered/Supercedes DTB S-B-82.70/687
Reason for block
COMPLAINT:
Music playback from the !phone/!phone 3G during a phone call can be heard over the vehicle speakers. This means that the audio source is not
muted at the beginning of the phone call.
The complaint only occurs if the following boundary conditions exist:
1. The !Phone/!Phone 3G is inserted in the UPCI cell phone holder (A 34/15).
2. The UPCI cell phone holder (A 34/15) of the !Phone is connected to an !Pod interface via a data connection cable (installation instructions, see
WIS references).
3. The vehicle is equipped with (multiple-handset interface) MHI.
4. Music playback via the !Pod interface prior to the phone call
CAUSE:
!Pod interface software is faulty.
REMEDY:
Replace !Pod interface control unit (see parts note).
245
Symptoms
Parts
Work units
246
WIS-References
Validity
Steering - Squealing/Squeaking Noise When Turning

HONKING/SQUEAKING NOISE FROM AREA OF CONTROL HEAD STEERING SYSTEM WHEN STEERING
Version 1
Design Group 46.20 Steering gear
Date 06-23-2009
Validity Model 163/168, all,

Model 203/209/211 conditional implementation,
Model 220/230 without ABC, conditional implementation
247
Reason for change Steering system numbers updated
Reason for block
Complaint:
Squealing/squeaking noise when steering in both directions.
The noise can mainly be heard with the engine running and warm.
Cause:
Insufficient lubrication at radial shaft sealing ring in the control head may result in squeaking/rubbing noise
Remedy:
Add the additive Lubrizol 6178 to the power steering fluid.
NOTE:
- The additive Lubrizol 6178 may only be used for specific steering system number (refer to list below)!
No more then 50 ml mat be added!
The additive can only be used once in the steering system!
- If the additive is added to a steering system that comes after the quoted steering system number, the steering system may be damaged!
248
249
The list above shows models/steering systems or the steering system number with which the additive may be used.
Procedure
1. Check whether Lubrizol has already been added, this can be seen by a yellow dot on the steering system and power steering pump (see picture in
attachment).
2. Bring steering system to operating temperature (approx. 80°C)
3. Suction off 50 ml of steering oil.
4. Add 50 ml of Lubrizol 6178
NOTE:
Shake bottle well before pouring in
5. Start engine, increase idle speed to approx. 1200 rpm, turn steering to limit stop, hold there for approx. 1-2 seconds and then suddenly turn
steering out of the limit stop. This procedure must be performed at both limit stops until the noise can no longer be heard.
6. On the reservoir housing on the power steering pump and on the steering system, use a yellow touch-up paint pen to make a dot, as shown in the
picture (picture, refer to attachment, clean area before hand).
NOTE:
This mark is used for subsequent work on the steering system as an indication that the additive lubrizol 6178 has already been added once and may
not be added again.
250
Attachments
Symptoms
Parts
Work Units
Validity
NOTE:
251
252
253
254
Suspension - Front Axle Area Noise When Maneuvering

Knocking/creaking noises from area of front axle when maneuvering
Version 2
Design group 33.15 Axle links
Date 01-12-2010
Validity Model series 203 except 4MATIC, 171, 209, 204
Reason for change Damage code and WIS documents removed
Reason for block
Complaint:
Knocking/creaking noises from the area of the front axle when maneuvering (forwards/reverse) just before the steering reaches the limit stop.
Note:
Service brake is applied.
Cause:
Torsion of the hydro-mount in the strut rod.
When maneuvering, the hydro bushing end stop plug can collide with the inside of the outer sleeve.
In isolated cases, this surface can exhibit pinpoint wear depending on the operating conditions of the vehicle. This wear is caused by the end stop
plug resting against the outer sleeve during braking maneuvers.
As the end stop plug slides over the damaged area, fluctuations in friction pairing occur which cause the knocking/creaking noises.
Note:
The noise can generally be reproduced by driving a figure-8 in reverse. If the noises occur during this maneuver, the steering gear is not the cause
of the problem and must not be replaced. Please contact the TAC in urgent cases.
Remedy:
No remedy exists at the present time.
Symptoms
255
Validity
Engine - Oil Leaks At Back Of Engine

Camshaft caps leaking: Oil loss at rear of engine
Version 4
Design group 01.30 Cylinder head
Date 03-03-2010
Validity All models with engine 272

All models with engine 273
Cleanpoint engine for cap A000 998 5690:

Engine 273: 2739xx30268766
Engine 272: 2729xx31006851

Engine 273: 2739xx30264566
Engine 272: 2729xx30992044
256
Reason for change Supersedes DTB S-B-01.30/23b
Reason for block
Complaint:
Oil loss at rear of engine.
Note:
In isolated cases oil loss can occur at the rear caps (cover plugs) of the camshafts.
Cause:
Cap sealing ring leaking.
(In the event of borderline tolerances and under unfavorable climatic conditions the sealing ring can lose the preload necessary to seal off the oil
gallery)
Remedy:
Replace cap.
Note:
Replace all 3 or both (on engines with mechanical vacuum pump) caps.
Part number:
A000 998 55 90 (cap, small)
A000 998 56 90 (cap, large)
Symptoms
Parts
Work units
257
Validity
Interior - Front Seat Backrest Noise

Noises from backrest frame
Version 1
Design group 91.10 Front seats
258
Date 03-24-2010
Validity 203, 204, 209, 211, 219 Restriction is given in the plain text.
Reason for change Valid model designations updated / Supersedes DTB SB-91.10/112f
Reason for block
Complaint:
Noise complaints when load on backrest frame changes.
Affects the driver and front passenger seats.
Also perform the remedial action if you are performing work on
- Backrest frame (91013),
- Backrest cover (91A15, 91N15) or
- Head restraint guide rail (91A33, 91N33).
The actions must always be performed if the backrest frame is exposed to avoid follow-up repairs.
Attachments
Cause:
1. Affects all vehicles (see Figures 1, 2, 3).
1. At low temperatures (- C°), natural vibrations of the lordosis basket can result in damage to the guide wire when a person sits down in the seat.
2. Only affects vehicles produced up to September 05 (see Figure 4).
2. The Pulmaflex mat rubs on the attachment points on the backrest frame (2 attachment points on the right and 2 on the left).
3. Affects model series CL203 and 209 (see Figures 5, 6) Relative movement can produce noise problems at the bottom of the backrest.
4. Affects all vehicles of model series 211 and 219 (see Figure 7)
Noises may occur in the backrest under load due to the incorrect positioning of the circlip.
Remedy:
Note:
Even if just one of the complaints exists, you should always implement the other measures (i.e. measures 1, 2, 3 and 4), regardless of whether or not
the customer complains about these. The aim is to ensure that the customer does not return another time with complaints about noise from the seat.
Please note the restrictions, e.g. model series and production date, and implement the relevant measures. Measures are to be performed with the seat
installed.
1. First, proceed as follows (see step 1. Affects all vehicles):
- Reproduce noise caused when a person sits in seat at low temperatures.
- Remove seat-back lining - Refer to WIS document AR91.10-P-1910P (203, 209), AR91.10-P-1910CW (204), AR91.10-P-1910T (211 up to
MY05), AR91.10-P-1910TB (211 as of MY 05) or AR91.10-P-1910TX (219)
- Check whether guide wires are damaged at points where they intersect with lumbar support basket (on both right and left side). (Figure 1-
259
Lordosenkorb 1.pdf.)
- If guide wire is slightly damaged (Figure 2- Leichte Beschädigung.pdf), the damaged area must be coated with following agent: Krytox.
- If guide wire is seriously damaged (Figure 3- Starke Beschädigung.pdf), the damaged areas on the Pulmaflex mat must be rubbed down with
emery cloth, wrapped with Coroplast tape (commercially available plastic adhesive tape) and coated with Krytox.
2. Then also perform step 2 for all vehicles produced up to September 05 (see AR91.10-P-3332T):
- Detach backrest lining (already detached in step 1)
- Remove sidebag unit
- Detach Pulmaflex mat from attachment points on backrest frame
- Attach one piece of felt to each attachment point (2 on the right and 2 on the left) The exact positions are the points marked in red in the
illustration "Felting of backrest frame".
The felt must be treated with Krytox beforehand.
- After applying the felt pieces, reattach the Pulmaflex mat.
Object number of felt to be used: A0019835110
Dimensions: 25 mm wide and 2 mm thick.
3. For model series CL203 and 209 also perform the following measures:
- Seat-back lining still removed (see Figure 5). The seat is in installed position in the vehicle.
- Detach covering and spray the rivets (see Figure 6) in area between side section of frame and crossmember with grease A002 989 06 51.
4. The following measure must be implemented on all vehicles of model series 211 and 219:
Check the alignment of the circlip on the head restraint guide sleeve and correct it if necessary as shown in Figure 7 "Position of circlip".
After reattaching the cover and the seat-back lining, sit in the seat to check whether the noises are produced.
* Sufficient for 10 repairs, Submit as Local Purchase - FLS00053, Qty 1, handling is included
** Sufficient for 20 repairs, Submit as Local Purchase - SAA00213, Qty 1, handling is included
Attachments
Symptoms
260
Parts
Work units
WIS-References
261
262
263
Validity
264
Attachment - Figure 1
265
266
267
268
Interior - Front Seat Noise

Noises from seat adjuster/cushion frame
Version 1
Date 03-24-2010
Validity Model series 203, 211, 219
Reason for change Damage codes adjusted / Supersedes DTB S-B-91.10/112f
Reason for block
Complaint:
Noises from area of seat adjuster or cushion frame.
Cause:
Noises that are localized in this area of the seat (seat adjuster or cushion frame) are not caused by the seat adjusters. The component responsible is
the cushion frame or the cushion frame brackets. It is absolutely essential to not replace the seat adjuster, but instead, the cushion frame brackets.
The cushion frame brackets in vehicles produced prior to 31 March 2006 develop a burr as mileage increases, which can lead to the noise complaint
described above. The burr can be seen in the illustration attached below:
Halter Kissenrahmen.pdf
269
Affected damage codes: 91001, 91A37, 91N37.
Attachments
Remedy:
Important note:
Also perform the action if you are performing work on the seat adjustment. When the brackets are exposed during the work, the remedial action
must be performed depending on the VIN range to prevent follow-up repairs.
In these cases the seat adjusters must not be replaced.
If the above damage profile is present, replace only the relevant cushion frame brackets with object number A0009140029.
These cushion frame brackets are partially coated as of 31.03.2006 to prevent this burr from developing.
The bolted connection must always be made using a microencapsulated bolt with object number N000 000 00 4180 (hexalobular bolt MBN
10226-M6x12-8.8-MK DBL 9469).
Symptoms
Parts
Work units
270
271
Validity
272
Attachment - Burr on bracket
Interior - Grunting/Ripping Noise At Front Seat-Back

Felt pads missing after replacement of backrest frame
Version 1
Date 03-24-2010
Validity Model 211/219/203
Reason for change Attachment revised / Supersedes DTB S-B-91.10/112f
Reason for block
Complaint:
Grunting and/or ripping noise at seat-back lining.
Missing felt pads on replacement part backrest frame with part number
A 000 910 11 34
A 000 910 12 34
A 000 910 13 34
A 000 910 14 34
A 000 910 40 34
A 000 910 42 34
Cause:
273
If the felt is missing, the seat-back lining bracket collides against the backrest frame.
Remedy:
Apply felt as per gluing plan (see attachment).
Attachments
Symptoms
Parts
Work units
274
275
276
Validity
277
278
279
280
Attachment - Work Instruction "Bond felt pads to backrest"
A/T - Hard Converter Lock-Up/Hard 1-2 Shift

Hard 1-2 shift or hard torque converter lockup clutch engagement
Version 1
Design group 27.00 General
Date 04-06-2010
Validity Transmission 722.9
Reason for change Remedy revised / Supersedes DTB S-B-27.00/112
Reason for block
Complaint:
The customer complaint of "Hard shift, presumable the 1-2 shift, occurs when moving off" is often received even though the problem is hard
engagement of the torque converter lockup clutch (KUB) in the start-off process.
In order to permit a clear diagnosis, restrict the transmission to 1st gear by shifting to position 1.
If a jolt occurs at the point where the state of the torque converter lockup clutch changes from "open" to "slipping", then the cause should be sought
281
in the control of the torque converter lockup clutch.
Cause:
Control of torque converter lockup clutch engagement not optimized.
Remedy:
1. Via DAS menu item "Initial startup", perform transmission software update and then perform SCN coding.
2. Via DAS menu item "KUB adaptation", adapt the torque converter lockup clutch according to the coolant temperature and torque window.
3. Then perform a test drive.
Symptoms
Work units
Validity
A/T - Harsh Engagement From Park To Drive

Harsh engagement when changing gear range from P to D
Version 1
282
Design group 27.50 Gear assembly
Date 04-06-2010
Reason for change
Reason for block
Complaint:
When changing gear range from P to D, harsh engagement may be noticeable.
Cause:
The engagement sequences for N-D and N-R may not be optimized
Remedy:
The engagement sequences for N-D and N-R must be taught in again as follows:
Note:
shift 5 times N-R,
shift 5 times N-R,
shift 5 times N-R,
shift 5 times N-D.
Symptoms
283
Validity
Engine - Squeaking Noises From The Belt Drive

Squeaking noises from the belt drive
Version 1
Design group 13.20 Belt drive, general
Date 03-10-2010
Validity Belt drive, engine 272 and engine 273.
Reason for change
Reason for block
Complaint:
Cause:
Axial shifting (temperature-related) of the individual belt pulleys and guide pulleys can lead to squeaking noises in isolated cases.
Remedy:
Application of Krytox lubricant - belt dressing A000 989 36 60 (from lubricating kit A000 580 03 50) - one to two drops at each point to the inner
and outer side edges of the poly-V belt. Procedure:
- Bring the engine to the operating temperature (80 deg. C) and switch it off.
- Remove top front engine cover as required to get access to the poly-V-belt.
- Apply one to two drops of Krytox lubricant to the inner and outer side edges of the poly-V belt near the top idler pulley (important: only treat the
edges of the belt. If the lubricant is applied to the running surface of the belt, this can cause the poly-V belt to slip).
- Start the engine so that the lubricant can spread along the edges of the belt.
* Sufficient for 15 cars, Submit as Local Purchase - KRY00284, Qty 1, handling is included
284
Attachments
Symptoms
Parts
Work units
285
Validity
286
Attachment - Description: Apply Krytox to edges of poly-V belt
Interior - Creaking Noise From Seat Head Restraints

Noises from head restraint CAK
Version 1
Design group 91.16 Head restraints
Date 03-24-2010
Validity Model series 203, 211, 219, 221 produced up to Wk 41 (2006)
Reason for change Model designation added / Supersedes DTB S-B-91.10/ 112f
Reason for block
Complaint:
Creaking noise from CAK module in head restraint.
287
Attachments
Cause:
The plastic housings of the 6 pins in the CAK module are too large. This tolerance results in noises.
Further damage code: 91N31
Remedy:
In the case of vehicles produced since calendar week 41/2006, the shafts of the head restraint are oval in shape. This measure has been implemented
in series production.
Procedure in the case of complaints:
Replace head restraint. Do not replace guide sleeves.
Symptoms
Work units
288
289
290
291
Validity
Attachment - Affected area
292
LI80-57_P-046935 - 10/01/09
This TSB number LI80-57_P-046935, dated 10/01/09 has been superceded by TSB number LI80-57_P-0469352 , dated 10/28/09
S-82_70-686 - 04/30/09
This TSB number S-82_70-686, dated 04/30/09 has been superceded by TSB number S-82_70-686A , dated 05/18/09
S-46_30-21 - 04/06/06
This TSB number S-46_30-21, dated 04/06/06 has been superceded by TSB number S-46_30-21B , dated 05/12/09
S-46_30-21A - 02/12/08
This TSB number S-46_30-21A, dated 02/12/08 has been superceded by TSB number S-46_30-21B , dated 05/12/09
S-01_45-26 - 05/15/09
This TSB number S-01_45-26, dated 05/15/09 has been superceded by TSB number LI01-45_P-047548 , dated 08/06/09
S-03_30-08H - 04/23/09
This TSB number S-03_30-08H, dated 10/24/08 has been superceded by TSB number S-03_30-08J , dated 06/17/09
S-91_40-130 - 10/11/06
S-82_85-615 - 02/22/08
S-82_70-475 - 11/14/05
Technical Service Bulletin # S-18_00-37D Date: 081024
S-18_00-37D - 10/24/08
This TSB number S-18_00-37D, dated 10/24/08 has been superceded by TSB number S-18_00-37F , dated 06/02/09
S-82_85-544 - 03/01/07
S-46_50-34 - 03/27/06
S-27_19-82B - 07/02/08
This TSB number S-27_19-82B, dated 07/02/08 has been superceded by TSB number S-27_19-82D , dated 03/25/09
S-68_05-47 - 04/11/06
S-27_00-102A - 01/09/08
S-27_00-102 - 11/30/07
293
S-46_30-40A - 11/27/07
S-46_30-40 - 04/26/06
S-07_61-72 - 07/10/07
S-82_10-598 - 10/24/07
S-00_00-80E - 01/29/07
This TSB number S-00_00-80E, dated 01/29/07 has been superceded by TSB number S-00_00-80F , dated 10/30/08
S-00_00-80D - 11/03/06
S-00_00-80C - 04/26/06
This TSB number S-00_00-80C, dated 04/26/06 has been superceded by TSB number S-00_00-80F , dated 10/30/08
S-00_00-80B - 11/16/05
This TSB number S-00_00-80B, dated 11/16/05 has been superceded by TSB number S-00_00-80F , dated 10/30/08
S-00_00-80A - 09/27/05
This TSB number S-00_00-80A, dated 09/27/05 has been superceded by TSB number S-00_00-80F , dated 10/30/08
S-00_00-80 - 07/29/05
This TSB number S-00_00-80, dated 07/29/05 has been superceded by TSB number S-00_00-80F , dated 10/30/08
S-27_50-59B - 01/04/08
This TSB number S-27_50-59B, dated 01/04/08 has been superceded by TSB number S-27_50-59G , dated 05/05/09
S-27_50-59A - 03/16/06
This TSB number S-27_50-59A, dated 03/16/06 has been superceded by TSB number S-27_50-59G , dated 05/05/09
S-27_50-59 - 10/13/05
This TSB number S-27_50-59, dated 10/13/05 has been superceded by TSB number S-27_50-59G , dated 05/05/09
S-91_10-125 - 10/16/06
This TSB number S-91_10-125, dated 10/16/06 has been superceded by TSB number S-91_10-125C , dated 12/16/08
S-83_30-74J - 10/24/07
This TSB number S-83_30-74J, dated 10/24/07 has been superceded by TSB number S-83_30-74P , dated 06/04/09
294
Technical Service Bulletin # S-83_30-74I Date: 071008
S-83_30-74I - 10/08/07
This TSB number S-83_30-74I, dated 10/08/07 has been superceded by TSB number S-83_30-74P , dated 06/04/09
S-83_30-74H - 05/30/07
This TSB number S-83_30-74H, dated 05/30/07 has been superceded by TSB number S-83_30-74P , dated 06/04/09
S-83_30-74G - 05/08/07
This TSB number S-83_30-74G, dated 05/08/07 has been superceded by TSB number S-83_30-74P , dated 06/04/09
S-83_30-74F - 03/05/07
This TSB number S-83_30-74F, dated 03/03/07 has been superceded by TSB number S-83_30-74P , dated 06/04/09
S-83_30-74E - 02/28/07
This TSB number S-83_30-74E, dated 02/28/07 has been superceded by TSB number S-83_30-74P , dated 06/04/09
S-83_30-74D - 03/27/06
This TSB number S-83_30-74D, dated 03/27/06 has been superceded by TSB number S-83_30-74P , dated 06/04/09
S-83_30-74C - 10/26/05
This TSB number S-83_30-74C, dated 10/26/05 has been superceded by TSB number S-83_30-74P , dated 06/04/09
S-83_30-74B - 06/02/05
This TSB number S-83_30-74B, dated 06/02/05 has been superceded by TSB number S-83_30-74P , dated 06/04/09
S-83_30-74A - 02/04/05
This TSB number S-83_30-74A, dated 02/04/05 has been superceded by TSB number S-83_30-74P , dated 06/04/09
S-83_30-74 - 01/31/05
This TSB number S-83_30-74, dated 01/31/05 has been superceded by TSB number S-83_30-74P , dated 06/04/09
S-80_57-24 - 09/03/03
S-80_57-24A - 11/17/05
This TSB number S-80_57-24A, dated 11/17/05 has been superceded by TSB number LI80-57_P-0469352 , dated 10/28/09
S-80_57-24B - 01/09/08
This TSB number S-80_57-24B, dated 01/09/08 has been superceded by TSB number LI80-57_P-0469352 , dated 10/28/09
S-14_30-15C - 11/30/07
S-14_30-15B - 03/09/06
295
S-14_30-15A - 10/04/05
S-14_30-15 - 07/02/03
2008070002 - 08/15/08
This TSB number 2008070002, dated 08/15/08 has been superceded by TSB number 2008070002A , dated 08/15/08
Technical Service Bulletin # 2006110005B Date: 061201
2006110005B - 12/01/06
This TSB number 2006110005B, dated 12/01/06 has been superceded by TSB number 2006110005C , dated 08/17/08
S-53_55-87B - 11/30/07
S-53_55-87A - 08/07/07
S-53_55-87 - 05/05/07
S-18_00-17E - 06/01/06
This TSB number S-18_00-17E, dated 06/01/06 has been superceded by TSB number S-18_00-17G , dated 09/26/08
S-18_00-17D - 04/13/06
This TSB number S-18_00-17D, dated 04/13/06 has been superceded by TSB number S-18_00-17G , dated 09/26/08
S-32_25-19 - 12/30/04
This TSB number S-32_25-19, dated 12/30/04 has been superceded by TSB number S-32_25-19E , dated 06/04/08
S-32_25-19A - 03/15/06
This TSB number S-32_25-19A, dated 03/15/06 has been superceded by TSB number S-32_25-19E , dated 06/04/08
S-32_25-19B - 05/05/06
This TSB number S-32_25-19B, dated 05/05/06 has been superceded by TSB number S-32_25-19E , dated 06/04/08
S-32_25-19C - 07/18/07
This TSB number S-32_25-19C, dated 07/18/07 has been superceded by TSB number S-32_25-19E , dated 06/04/08
S-32_25-19D - 10/18/07
This TSB number S-32_25-19D, dated 10/18/07 has been superceded by TSB number S-32_25-19E , dated 06/04/08
S-10_10-112 - 08/09/06
296
S-46_25-37 - 02/01/08
S-18_00-36 - 01/01/06
S-13_22-01 - 01/07/06
This TSB number S-13_22-01, dated 01/07/06 has been superceded by TSB number S-13_22-01E , dated 10/27/08
S-13_22-01A - 11/06/07
This TSB number S-13_22-01A, dated 11/06/07 has been superceded by TSB number S-13_22-01E , dated 10/27/08
S-13_22-01B - 12/07/07
This TSB number S-13_22-01B, dated 12/07/07 has been superceded by TSB number S-13_22-01E , dated 10/27/08
S-03_30-08D - 04/16/08
This TSB number S-03_30-08D, dated 04/16/08 has been superceded by TSB number S-03_30-08J , dated 06/17/09
S-03_30-08B - 03/28/08
This TSB number S-03_30-08B, dated 03/28/08 has been superceded by TSB number S-03_30-08J , dated 06/17/09
S-03_30-08 - 08/23/07
This TSB number S-03_30-08, dated 08/23/07 has been superceded by TSB number S-03_30-08J , dated 06/17/09
P-68_20-33B - 02/02/07
This TSB number P-68_20-33B, dated 02/02/07 has been superceded by TSB number P-68_20-33C , dated 02/14/08
P-80_57-48 - 01/09/08
This TSB number P-80_57-48, dated 01/09/08 has been superceded by TSB number P-80_57-48A , dated 01/16/08
P-82_85-532 - 10/12/2006
2006110005 - 11/17/06
This TSB number 2006110005, dated 11/17/06 has been superceded by TSB number 2006110005C , dated 08/17/08
Wipers/Washers - Maintaining Wiping Quality

Lighting - Exterior Bulb Replacement Information

This TSB number P-82_10-598, dated 10/24/07 has been superceded by TSB number LI82-10_P-045451 , dated 10/01/09
Electrical - Horns Do Not Operate Correctly

Lighting - Exterior Light Bulb Replacement Information

297
Lighting - Exterior Light Bulb Replacement Info.

Interior - Rattle From Rear Seat Back Rest on Rough Road

Interior - Various Front Seat Noise Complaints

This TSB number S-91_10-112F, dated 03/20/09 has been superceded by TSB number LI91-16_P-048507 , dated 03/24/10
Interior - Noise From The Front Seats

This TSB number S-91_10-112E, dated 11/05/08 has been superceded by TSB number LI91-16_P-048507 , dated 03/24/10
Interior - Various Types Of Noises From The Front Seats

This TSB number S-91_10-112C, dated 10/06/08 has been superceded by TSB number LI91-16_P-048507 , dated 03/24/10
Interior - Various Types Of Noise From The Front Seats

Technical Service Bulletin # S-98_00-13Q Date: 100211
Paint/Body - MBUSA Approved Refinishing Products

This TSB number S-98_00-13Q, dated 02/11/10 has been superceded by TSB number S-98_00-13R , dated 03/11/10
Paint/Body - Approved Refinishing Products

This TSB number S-98_00-13P, dated 04/28/09 has been superceded by TSB number S-98_00-13R , dated 03/11/10
Technical Service Bulletin # S-98_00-13O Date: 090202
Body/Paint - MBUSA(R) Approved Refinishing Products

This TSB number S-98_00-13O, dated 02/02/09 has been superceded by TSB number S-98_00-13R , dated 03/11/10
Technical Service Bulletin # S-98_00-13N Date: 090105
Body/Paint - Approved Refinishing Materials

This TSB number S-98_00-13N, dated 01/05/09 has been superceded by TSB number S-98_00-13R , dated 03/11/10
Lighting - Moisture in Mirror Turn Signal Lamps

This TSB number P-88_70-48A, dated 05/21/07 has been superceded by TSB number P-88_70-48B , dated 05/23/08
Audio System iPhone(R)/iPod(R) Will Not Charge

Audio System - iPod(R) Won't Charge From System

Audio System - Various iPod(R) Issues

Campaign - Navigation DVD Update

This TSB number 2006110005A, dated 11/22/06 has been superceded by TSB number 2006110005C , dated 08/17/08
298
Memory System - Seat Easy Entry/Exit Feature Inoperative

This TSB number S-91_10-125B, dated 10/20/08 has been superceded by TSB number S-91_10-125C , dated 12/16/08
Interior - Easy Entry/Exit Feature Inoperative

This TSB number S-91_10-125A, dated 10/01/08 has been superceded by TSB number S-91_10-125C , dated 12/16/08
COMAND(R) - iPod Can't Be Operated With Remote Buttons

This TSB number P-82_85-544, dated 03/01/07 has been superceded by TSB number S-82_85-544A , dated 02/12/09
Audio Sys. - iPhone(R)/iPod(R) Will Not Charge

Audio System - iPhone(R)/iPod(R) Will Not Charge

Antitheft System DAS3 Diagnosis/Replacement Info.

This TSB number S-80_57-24C, dated 09/02/08 has been superceded by TSB number LI80-57_P-0469352 , dated 10/28/09
COMAND(R) - Opening/Closing Errors Or Inoperative

Restraints - Rear Seat Belt Won't Retract Properly

Interior - Various Noises Coming From The Front Seats

This TSB number S-91_10-112D, dated 10/22/08 has been superceded by TSB number LI91-16_P-048507 , dated 03/24/10
S-91_10-112A - 05/29/08
Technical Service Bulletin # S-83_30-74O Date: 090429
A/C - Various Musty/Moldy Odor Complaints

This TSB number S-83_30-74O, dated 04/29/09 has been superceded by TSB number S-83_30-74P , dated 06/04/09
Technical Service Bulletin # S-83_30-74N Date: 090415
S-83_30-74N - 04/15/09
This TSB number S-83_30-74N, dated 04/15/09 has been superceded by TSB number S-83_30-74P , dated 06/04/09
Technical Service Bulletin # S-83_30-74M Date: 090320
A/C - Various Musty/Moldy Odor Issues

This TSB number S-83_30-74M, dated 03/20/09 has been superceded by TSB number S-83_30-74P , dated 06/04/09
Technical Service Bulletin # S-83_30-74L Date: 090227
A/C - Musty/Moldy Odor Complaints

This TSB number S-83_30-74L, dated 02/27/09 has been superceded by TSB number S-83_30-74P , dated 06/04/09
Technical Service Bulletin # S-83_30-74K Date: 080925
A/C - Various Musty/Moldy Odors

This TSB number S-83_30-74K, dated 09/25/08 has been superceded by TSB number S-83_30-74P , dated 06/04/09
Technical Service Bulletin # P-83_30-74J Date: 071024
299
A/C - Musty/Mildewy/Moldy Type of Odors

This TSB number P-83_30-74J, dated 10/24/07 has been superceded by TSB number S-83_30-74P , dated 06/04/09
Technical Service Bulletin # P-83_30-74I Date: 071008
P-83_30-74I - 10/08/07
This TSB number P-83_30-74I, dated 10/08/07 has been superceded by TSB number S-83_30-74P , dated 06/04/09
A/C - System Inoperative/Indicator Flashing

This TSB number P-83_00-70C, dated 06/16/08 has been superceded by TSB number P-83_00-70D , dated 04/16/09
A/C - 'A/C OFF Lamp' Flashing/A/C Inoperative

This TSB number P-83_00-70B, dated 12/21/07 has been superceded by TSB number P-83_00-70D , dated 04/16/09
A/C - Inoperative/AC or AC Off Indicator Lamp Flashes

This TSB number P-83_00-70A, dated 10/24/07 has been superceded by TSB number P-83_00-70D , dated 04/16/09
Suspension - Front End Noise When Maneuvering

Steering/Suspension - Front Axle Knock When Parking

This TSB number P-33_15-20B, dated 12/16/08 has been superceded by TSB number LI33-15_P-0474712 , dated 01/12/10
P-33_15-20A - 12/04/08
This TSB number P-33_15-20A, dated 12/04/08 has been superceded by TSB number LI33-15_P-0474712 , dated 01/12/10
Suspension - Front Axle Knocking Noise While Parking

This TSB number P-33_15-20, dated 06/27/07 has been superceded by TSB number LI33-15_P-0474712 , dated 01/12/10
Suspension - Shock Absorber/Strut Replacement Criteria

This TSB number P-32_25-19C, dated 07/18/07 has been superceded by TSB number P-32_25-19D , dated 10/18/07
Steering - Steering Gear Leakage Information

Electrical Part Incompatibility Malfunctions

Body - Noise From Front Of Vehicle/Dash Area

This TSB number P-62_10-08B, dated 08/11/08 has been superceded by TSB number P-62_10-08C , dated 12/22/08
P-62_10-08A - 06/18/08
This TSB number P-62_10-08A, dated 06/18/08 has been superceded by TSB number P-62_10-08C , dated 12/22/08
Body - Noise From Front of Vehicle

This TSB number P-62_10-08, dated 09/28/07 has been superceded by TSB number P-62_10-08C , dated 12/22/08
300
Electrical - Power Outlet Non-Functional
M/T - First or Reverse Gear Difficult to Engage

A/T - Momentary Slip 1-2 & 2-3 Upshift At Cold Start

P-27_60-88 - 11/27/06
Technical Service Bulletin # P-27_60-61F Date: 061127
A/T - Rough Shift Quality

This TSB number P-27_60-61F, dated 11/27/06 has been superceded by TSB number S-27_60-61J , dated 11/20/08
AT - Ordering Notes For Electrohydraulic Control Unit

A/T - Correct Electro-Hydraulic Control Modules

This TSB number S-27_19-82C, dated 02/03/09 has been superceded by TSB number S-27_19-82D , dated 03/25/09
Technical Service Bulletin # P-27_60-61H Date: 070711
P-27_60-61H - 07/11/07
This TSB number P-27_60-61H, dated 07/11/07 has been superceded by TSB number S-27_60-61J , dated 11/20/08
Technical Service Bulletin # P-27_60-61G Date: 070627
P-27_60-61G - 06/27/07
This TSB number P-27_60-61G, dated 06/27/07 has been superceded by TSB number S-27_60-61J , dated 11/20/08
A/T - Electrohydraulic Control Unit Part Numbers

This TSB number S-27_19-82, dated 10/24/06 has been superceded by TSB number S-27_19-82D , dated 03/25/09
A/T - Electro-Hydraulic Control Module Identification

This TSB number S-27_19-82A, dated 06/01/07 has been superceded by TSB number S-27_19-82D , dated 03/25/09
Technical Service Bulletin # P-27_60-61I Date: 070821
A/T, 7G-Tronic Transmission - Rough Shift Quality

This TSB number P-27_60-61I, dated 08/21/07 has been superceded by TSB number S-27_60-61J , dated 11/20/08
Fuel System - Tapping Noise From Fuel Tank

This TSB number P-47_10-40A, dated 11/13/06 has been superceded by TSB number P-47_10-40B , dated 02/26/07
A/T - DTC's 2200/2201/2767/2768/Limp Home Mode

This TSB number S-27_50-59F, dated 01/22/09 has been superceded by TSB number S-27_50-59G , dated 05/05/09
A/T - Hard 1-2 Shift/Hard Converter Lock-Up

S-27_50-59E - 12/02/08
301
This TSB number S-27_50-59E, dated 12/02/08 has been superceded by TSB number S-27_50-59G , dated 05/05/09
A/T - Limp Home Mode/Codes 2200/2201/2767/2768 Set

This TSB number S-27_50-59D, dated 10/31/08 has been superceded by TSB number S-27_50-59G , dated 05/05/09
A/T - Limp Home Mode/DTC's 2200/2201/2767/2768

This TSB number S-27_50-59C, dated 10/17/08 has been superceded by TSB number S-27_50-59G , dated 05/05/09
Recall - Software Coding Errors

This TSB number 2008070001, dated 07/30/08 has been superceded by TSB number 2008070001A , dated 10/16/09
P-27_00-102 - 11/30/07
Engine Controls - Misfire Fault Code Diagnosis

Technical Service Bulletin # 2006110002C Date: 070112
2006110002C - 01/12/07
This TSB number 2006110002C, dated 01/12/07 has been superceded by TSB number 2006110002D , dated 02/02/07
A/C - Blower Motor Stops Running/DTC 9460 Set

This TSB number P-83_25-76A, dated 09/20/06 has been superceded by TSB number P-83_25-76C , dated 09/28/07
Engine Controls - MIL ON/Multiple O2 Sensor Codes Set

Engine, A/T Controls - DTC 061B After Reprogramming

2006110002A - 12/08/06
This TSB number 2006110002A, dated 12/08/06 has been superceded by TSB number 2006110002D , dated 02/02/07
Technical Service Bulletin # 2006110002B Date: 061216
2006110002B - 12/16/06
This TSB number 2006110002B, dated 12/16/06 has been superceded by TSB number 2006110002D , dated 02/02/07
Emissions - MIL ON/DTC's P2003/P2047/P0810 & P0814

This TSB number P-14_30-15C, dated 11/30/07 has been superceded by TSB number S-14_30-15F , dated 03/13/09
Engine Controls - MIL ON/Multiple Codes

Engine Controls - MIL ON/Multiple Codes Stored In ECM

Engine Surface Cleaning Recommendations/Precautions

302
A/C - Various Compressor Noises

Engine Controls - MIL ON/Codes FC1200/FC1208

This TSB number P-03_30-08, dated 08/23/07 has been superceded by TSB number S-03_30-08J , dated 06/17/09
S-01_30-31A - 01/26/10
Engine - Increased Engine Oil Consumption

This TSB number P-00_00-80E, dated 01/29/07 has been superceded by TSB number S-00_00-80F , dated 10/30/08
P-00_00-80D - 11/03/06
This TSB number P-00_00-80D, dated 11/03/06 has been superceded by TSB number S-00_00-80F , dated 10/30/08
Engine - Low Oil Level Symptoms Diagnostics

Gas/Diesel Engine - Low Oil Level Symptoms

This TSB number S-18_00-37C, dated 10/06/08 has been superceded by TSB number S-18-00-37D , dated 10/24/08
Engine - Low Oil Level Symptoms

This TSB number S-18_00-37B, dated 09/17/08 has been superceded by TSB number S-18-00-37D , dated 10/24/08
Campaign - Howling/Whining Noise From Engine

This TSB number S-13_22-01D, dated 07/10/08 has been superceded by TSB number S-13_22-01E , dated 10/27/08
S-13_22-01C - 05/13/05
This TSB number S-13_22-01C, dated 05/13/08 has been superceded by TSB number S-13_22-01E , dated 10/27/08
P-13_22-01A - 11/06/07
This TSB number P-13_22-01A, dated 11/06/07 has been superceded by TSB number S-13_22-01E , dated 10/27/08
Engine - Whining / High Pitch Whistle Noise

This TSB number P-13_22-01, dated 11/27/06 has been superceded by TSB number S-13_22-01E , dated 10/27/08
S-01_30-31 - 01/12/10
Engine - Cylinder Head Service Guidelines

Engine - Oil Leaks From The Rear Of The Cylinder Heads

303
S-01_30-23A - 05/07/09
Engine - Oil Leaks From Back Of Cylinder Head(s)

Technical Service Bulletin # S-03_30-08I Date: 090423
Engine - MIL ON/Multiple DTC's Set/Stored

This TSB number S-03_30-08I, dated 04/23/09 has been superceded by TSB number S-03_30-08J , dated 06/17/09
S-03_30-08A - 03/26/08
This TSB number S-03_30-08A, dated 03/26/08 has been superceded by TSB number S-03_30-08J , dated 06/17/09
S-03_30-08E - 04/24/08
This TSB number S-03_30-08E, dated 04/24/08 has been superceded by TSB number S-03_30-08J , dated 06/17/09
Engine - MIL ON/Multiple Camshaft Codes Stored

This TSB number S-03_30-08G, dated 10/20/08 has been superceded by TSB number S-03_30-08J , dated 06/17/09
S-03_30-08C - 04/03/08
This TSB number S-03_30-08C, dated 04/03/08 has been superceded by TSB number S-03_30-08J , dated 06/17/09
Engine Controls - MIL ON/Multiple Codes Set

This TSB number S-03_30-08F, dated 06/26/08 has been superceded by TSB number S-03_30-08J , dated 06/17/09
Instruments - Incorrect Maintenance Interval Coding

Order No.: P-B-54.30/186
Supersedes:
Group: 54
SUBJECT:
Model 199.376
Maintenance Interval Coded to 24 Months in Instrument Cluster
If you receive customer reports in the above model vehicles where the maintenance interval was mistakenly set to 24 months in the
instrument cluster, check the setting with the Star Diagnosis System (SDS) and if necessary recode the maintenance interval.
Note:
VIN and current values in this document were created using DAS simulation.
304
1. Enter the Instrumental Cluster (KIVV) with DAS (Figure 1).
2. K12 is not available the SLR, press F4 to continue (Figure 2).
3. Select the Control unit adaptations menu and confirm with F3 (Figure 3).
305
4. Select the corresponding entry and confirm selection with F3 (Figure 4).
5. Select the ASSYST settings menu and confirm with F3 (Figure 5).
6. If the menu Maintenance interval in days displays 730 days, highlight and double clic on the incorrect value. By doing so the automatic
correction function will initiate and the value will be replaced by 365 (Figure 6).
Note:

306
S-18_00-37A - 07/28/08
This TSB number S-18_00-37A, dated 07/28/08 has been superceded by TSB number S-18-00-37D , dated 10/24/08
A/C - Compressor Drive Belt Noise Issues

Instruments - Low Oil Level Messages Displayed

A/T - Upshift/Downshift Chatter or Shutter

A/C - Not Cooling/Compressor Noise

Engine - Oil Level Display and Measurement

Engine - Approved Oils Information

This TSB number S-18_00-17F, dated 07/15/08 has been superceded by TSB number S-18_00-17G , dated 09/26/08
Interior - Heat From Wheelhouse In Passenger Compartment

Date: May 4, 2007
Order No.: P-B-83.00/94
Supercedes:
Group: 83
SUBJECT:
All Model 203 / 209 Vehicles
As of Production 8/31/02
Heat from Wheelhouse Compartment Enters the Passenger Cabin
If you receive customer reports in the above model vehicles of heat entry into the passenger cabin from the wheelhouse, perform the following
procedure to resolve.
1. Remove filter housing above battery and remove housing (Figure 1, A). It is necessary to remove battery.
307
2. Remove rubber seal from engine dividing wall (Figure 2, B).
3. Remove drip molding (Figure 1, C) and replace with new drip molding part number A203 620 12 73 with rubber strip. Reinstall housing
(Figure 1, A).
4. Open the right side wiring duct and remove the duct (Figure 2, D). Replace with new cable duct part number A203 820 10 69. Ensure the
wires are routed properly in the guide.
5. Remove cover (Figure 3, E) above module box.
6. Remove front SAM and ME control units. Refer to WIS document AR07.08-P-7008P.
7. Open left wiring duct (Figure 3, F), move wiring to the side and remove the duct. Install new wiring duct part number A203 820 09 69.
Ensure that the wires are routed properly in the guide.
8. Remove the fuse and relay box. Refer to WIS document AR54.21-P-1260P, remove drip molding (Figure 4, G) and replace with new drip
molding part number A203 620 09 73 with rubber strip. Reinstall fuse and relay box.
9. Loosen foam rubber elements from old wiring ducts on the right and left sides and glue them to new wiring ducts.
10. Install rubber seal onto engine dividing wall (Figure 2, B).
308
Parts Information
Note:

Electrical - Aftermarket Tampering Malfunctions

Supersedes: S-B-54.21/234, dated July 27, 2010
Group: 54
Revision History
a 10/22/10 Additional devices and pictures added.
SUBJECT: MY- All, Models All
Malfunctions Due to Other-Make Installations
Recent attempts manipulating vehicle mileage through the use of third party electronic devices installed on Mercedes-Benz vehicles are being
reported.
There are several CAN manipulation devices on the market. Be particularly aware of two devices which are installed in tandem with the instrument
309
cluster or the EIS (Figure 1) and a circuit board which can be installed directly within the EIS (Figure 2).
If vehicle electronics malfunction, control units display implausible mileage readings, or malfunctions lack corresponding default entries; check the
vehicle for non-factory hardware. These are often installed in the interior wiring harness of the vehicle. Another example would be the TV enable
module for the COMAND APS NTG2 in Figure 3.
Possible malfunctions are:
^ Random unlocking or locking of the vehicle while driving
^ Temporary or continuous hazard warning system activation
^ Sudden mileage increase in the IC
If there is evidence that the vehicle has been tampered with (mileage altering device, aftermarket installation etc) please provide as much supporting
documents (pictures, test results, etc.) and send an email with the supporting documents to the Warranty Services Group and request that the vehicle
be put on warranty status.
Warranty will determine the correct status to be applied (usually status 8 which requires AOM review before any repairs are performed), file the
supporting documentation and add notes into our vehicle master system.
Any vehicle with a warranty status will have an alert box pop up when VMI is run to inform the dealer of this status.
Any malfunctions or subsequent damage to other parts due to the installation of foreign parts are not covered by Warranty. The repair costs should
be charged to the customer.
Chemicals/Lubrication - Multi-Grade Metal Grease Info.

Order No.: S-B-00.45/94
Group: 00
SUBJECT: MY- All, Models All
Multi-Grade Metal Grease
The multi-grade grease for metals, part # A 002 989 07 51 from the noise damping service kit A 000 580 03 50 must not come in contact with
plastic parts, otherwise the plastic can set and break.
Electrical - Voltage Drop Testing at The Fuses

Order No.: S-B-54.10/162
Supersedes:
310
Group: 54
SUBJECT:
Model 164, 171, 199, 203, 208, 209, 210, 211, 215, 219, 220, 221, 230, 251 -
Quiescent Current Test Via Voltage Drop at the Fuses
This bulletin is for rapidly pinpointing closed-circuit systems responsible for voltage drop. It involves disconnecting fuses or CAN-distributors and
measuring the voltage drop directly at the fuse.
Measuring Voltage Drop:
1. Testing must be done on the installed fuse of the circuit 30 system (control module) using a suitable multimeter (e.g. Fluke 189) in the
microvolt range.
2. For an accurate measurement, use appropriately sized pointed probes (Figure 1) to ensure sufficient contact with the opening in the fuse's
plastic housing.
NOTE:
Use probes from the electrical connection set (part no. W 220 589 00 99 00).
The quiescent current can be computed via Ohm's law from the measured voltage value and the internal resistance of the fuse measured.
Example calculation with a 30-A fuse
311
Fuse Internal resistance
Special Tools
Interior - Noises From The Front Seats

Order No.: P-B-91.10/112
Supersedes:
Group: 91
SUBJECT:
Model 203.040/052/054/056/061/064/065/076/081/084/087/092/261/264/281/284/740/747/764
Model 211.026/056/065/070/076/082/083/087/256/265/276/282/283/287
Model 219.375/376 Front Seat Noise Complaints
If you receive customer reports in the above model vehicles regarding noises from the front seats, check if the noise fits any of the six descriptions
listed below and if yes, proceed as described.
A. Noise when the load on the backrest frame changes (Model 203 only)
B. Noise between seat frame brackets and seat cushion frame
C. Noise from lower trim cover end (Model 211 and 219 only)
D. Noise from perimeter of sidebag (Model 211 and 219 only)
E. Rubbing noise between seat cushion and trim cover (Model 211 only)
F. Noise from lumbar support in backrest at subfreezing temperatures (Code 403, 404, 433 or 434 only)
Note:
Replacement of seat components for any of the noise complaints in issues A to E is not permitted. The claim in these cases will be debited.
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A. Noise When Load on Backrest Frame Changes
1. Remove backrest cover. Refer to WIS document AR91.10-P-1910P.
2. Disconnect padding support grid from the 4 suspension points (Figure 1), 2 on the right side and 2 on the left side.
3. Cut 4 pieces of felt, approximate size is 10 mm by 20 mm. Apply a generous amount of special sliding compound to the felt and then adhere
the felt to the suspension points of the padding support grid (Figure 2).
4. Reconnect the padding support grid to the 4 suspension points (2 on the right and 2 on the left).
5. Reinstall backrest cover. Refer to WIS document AR91.10-P-1910P.
B. Noise Between Seat Frame Brackets and Seat Cushion Frame - Model 203 (up to VIN A903977 and F817832) Model 211 (up to VIN
A967489 and X207037) and Model 219 (up to VIN A075885)
1. The seat frame brackets rub on the seat cushion frame and if there are burrs on the brackets, this may make noise.
2. If burrs are visible (Figure 3, circles), proceed as follows.
3. For he 211 and 219, remove the seat, refer to WIS document AR91.10-P-1000T (211) or AR91.10-P-1000TX (219).
4. Remove the brackets and replace with new brackets.
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Note:
Always install new micro-encapsulated bolts.
5. For the 211 and 219, reinstall the seat, refer to WIS document AR91.10-P-10001 (211) or AR91.10-P-1000TX (219).
C. Noise from Lower Trim Cover End Door or Tunnel Side - Models 211 and 219 only
1. The rib on the back side of the lower trim covers at the front of the seat cushion may cause a noise as it rubs on the seat cover.
2. For only the 211 remove the seat, refer to WIS document AR91.10-P-10001.
3. For only the 211 remove trim cover (Figure 4). Refer to WIS Document AR91.10-P-26001. For only the 219, remove the 120 screws located
in the corners of the storage compartment.
4. Line side of trim cover rib (Figure 5) with felt.
5. For only the 211 reinstall trim cover (Figure 4). Refer to WIS Document AR91.10-P-26001. For only the 219, reinstall the 120 screws
located in the corners of the storage compartment.
6. For only the 211 reinstall the seat, refer to WIS document AR91.10-P-10001.
D. Noise from Perimeter of Sidebag - Models 211 and 219 only
1. The hard edge of the sidebag cover may make a noise as it rubs against the seat.
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2. With a wedge, open a gap between the sidebag cover and the seat (Figure 6, arrows) and with a second wedge, apply special sliding
compound to the edge of the sidebag cover on the entire circumference.
E. Rubbing Noise Between Seat Cushion and Trim Cover - Model 211 only
1. Rubbing noise where the seat cover contacts the trim cover (Figure 7, arrows), tilt the backrest rearward.
2. Apply special sliding compound to the seat cover in this area (Figure 7, arrows).
3. Confirm that the noise is no longer present.
F. Noise from Lumbar Support in Backrest at Subfreezing Temperatures (Codes 403.404.433 or 434 only)
1. Confirm noise by actuating pneumatic bladders at sub freezing temperatures.
2. Remove backrest cover. Refer to WIS document AR91.10-P-1910P (203), AR91.10-P-19101 (211 up to MYO5), AR91.10-P-19101B (211
as of MYO5) and AR91.10-P-19101X (219).
315
3. Check if the guide wires are damaged (Figure 8) at the interface with the lumbar support basket (Figure 9).
Note:
Figure 9 shows the seat backrest frame with the seat cover and seat pad removed for clarity, it is not necessary to remove these parts to
inspect and lubricate the guide wires.
4. In case of minor damage to the guide wires, apply special sliding compound to the guide wires.
5. In the case of major damage to the guide wires (Figure 10), the complete backrest frame must be replaced. Refer to WIS Document
AR91.10-P-1060P (203), AR91.10-P-3331T (211 up to MY05), AR91.10-P-3331TA (211 as of MY05) and AR91.10-P-3331TX (219).
6. Reinstall backrest cover. Refer to WIS document AR91.10-P-1910P (203), AR91.10-P-1910T (211 up to MY05), AR91.10-P-1910TB (211
as of MY05) and AR91.10-P-1910TX (219).
316
Parts Information
317
318
In Case of Warranty
Campaign - COMAND(R)/Navigation Software Update

FILE:
SUBJECT:
MODEL 164, MODEL YEAR 2006
CHECK COMAND AND NAVIGATION SOFTWARE AND UPDATE IF NECESSARY
This Service Campaign has been initiated because DCAG has determined that on affected vehicles with code 528 or 530 (see VIN range shown
below), incorrect software may have been installed potentially leading to COMAND malfunctions. In order to proactively deal with any potential
customer complaints, dealer will check the software releases using a workshop service CD and update if necessary.
Please review the Effective Serial Number chart, and if necessary, repair the subject vehicles during the vehicle's next service.
319
Effective Serial Range
Note:
indicator.
Procedure
Note:
^ Use DAS version 05/06 or later
^ Connect battery charger
^ Turn off ignition and all electrical consumers
^ Leave Service CD and DVD in workshop
1. Connect Star Diagnosis.
2. Check versions of COMAND and Navigation software.
^ Navigate through following DAS menu: Control units/Information and communication/Audio, video, navigation and telematics.
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^ Select "COMAND..." to check COMAND software version or "NAVI..." to check Navigation software version.
^ Select "Control unit version".
3. Perform the following:
^ If COMAND software version is below 51/05, proceed to step 4 to install new COMAND software.
^ If Navigation software version is below 31/04, proceed to step 5 to install new Navigation software.
^ If neither COMAND nor Navigation software require an update, proceed to step 6.
Note:
If both COMAND and Navigation software require updating, the COMAND software must be updated first; then, the Navigation
software can be updated.
4. Install new COMAND software.
^ Insert Service CD W 203 589 04 22 00 into audio CD drive (B, Figure 1).
Note:
CAUTION!
5. Install new Navigation software.
^ Insert Service DVD W 203 589 05 22 00 into Navigation DVD drive (A).
Note:
CAUTION!
Note:
Destination memory and last destinations are cleared.
6. Recalculate vehicle position using GPS.
7. Disconnect Star Diagnosis.
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Special Tool Information
Body - Laminated Glass Chip/Crack Repair Information

Date: August, 2006
Order No.: S-B-67.00120
Supersedes: MBNA 67/2 May 1990
Group: 67
Revision History
SUBJECT:
Model All, MY All
Damage to laminated glass due to chips or cracks
If you receive customer reports in the above model vehicles of damage to any laminated glass due to chips or cracks which is not covered by the
new car warranty, this (in most cases) can now be satisfactorily and economically repaired using the NOVUS glass repair method. NOVUS
invented windshield repair and has perfected many of the procedures during the past 30 years. NOVUS glass repair is approved by DCAG and
recommended by MBUSA for use in repairs whenever possible.
Only the exterior surface of laminated glass should be repaired. Humidity or water must be totally removed before the glass repair process is
322
started. Whenever possible use either clear packaging tape or NOVUS "Keep Clean Patches" to cover the damage before rain or washing the
vehicle. If this has not been done, in most cases, it will still be possible to successfully repair the damage. Cracks up to 6 inches in length that
radiate from the impact point are also repairable.
An impact spot from the initial damage will remain visible after a successful repair. The larger the initial spot, the more it will be visible to the
customer after the repair. NOVUS uses a special polish to restore the shine to the repair, thus reducing visibility of the repair.
Additional information on glass repair and finding your nearest NOVUS repair franchisee can be found at their web site: www.Novusglass.com.
Steering - Play/Movement Explanation

Date: August 2006
Order No.: P-B-46.20/46
Supersedes:
Group: 46
SUBJECT:
MODEL 203, 209, 210, 211, 215, 220, 230
Play in the Rack and Pinion Steering System
Please note that radial movement of the steering coupling at the input of the control shaft (see figure 1, item 1) is not relevant for evaluating play in
the steering box. This does not have any influence on the operation of the rack-and-pinion steering system, or the play in the steering system and on
the driving dynamics of the vehicle. The same applies to radial movement at the rack/tie rod (see figure 1, item 2), especially when the wheels are
turned all the way to one side. In this position the rack is extended to one side and acts as a larger lever where supposed play can be felt even more
(checking play at the outer and inner joints remains the same). Radial movement when applying pressure when the rack is fully extended to one
side or the other is normal and is due to the construction of the steering system.
When quickly turning the steering wheel left/right, especially when the engine is off (no power assist), a loud clunking noise can be heard. This is
also due to the steering system's construction and is in no way evidence of play in the steering system.
In order to properly check for play, please note the following requirements:
Prerequisite: The steering column and the outer and inner joints of the tie rods must not have any play.
The actual check for play in the rack-and-pinion steering system may only be made:
- with vehicle at standstill
- with engine running (power assist of the steering must be ensured)
- with the wheels pointed straight ahead
The steering wheel must be turned slowly while watching the rims move. The rims must start to move before the steering wheel is turned at most
approx. ±1 degree. During this movement, a steady increase in pressure can be felt in the steering wheel. This delay in reaction is a result of the
elasticity of the steering system (steering connections, etc.) and is not a fault.
In order to properly evaluate play in the rack-and-pinion steering system, only the axial movement of the rack in relation to the steering box is
relevant (which is being measured by the above procedure, see Figure 2, item 3). Technical Service Bulletin # S-27_56-83 Date: 061024
A/T - Filter Part Number/Replacement Information

Date: October 2006
Order No.: S-B-27.56/83
Supersedes:
Group: 27
SUBJECT:
MODEL 164, 171, 203, 204, 209, 211, 215, 216, 219, 220, 221, 230, 251 with TRANSMISSION 722.9
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Replacement of Transmission Oil Filter
Please note that should it be necessary to install a new oil filter (e.g. at an oil change or in the event of severe contamination), only the oil filter
with the part number A 221 277 00 95 must be used.
The following needs to be observed due to the revised dimensions:
Oil pans without bevels (Figure 1 with bevel for reference) and pipes (black), as well as a grid magnet and the oil pan gasket, must be replaced by
new parts in order to be able to install the new filter.
Oil pan with bevel: A 221 270 09 12

Overflow pipe (white): A 251 271 00 97 2
Magnets: A 000 988 01 52 Oil
pan gasket: A 220 271 01 80
722.9 transmissions with a serial number of 024198 or vehicle production of 02/04 or later, have the beveled oil pan. Unnecessary replacements of
a beveled oil pan will result in warranty claim rejection or debiting. Additionally, updates of the aforementioned components can only be performed
during repairs/services which require access to these components.
This bulletin has been created and maintained in accordance with MBUSA-SLP S423QH001, Document and Data Control, and MBUSA-SLP
S424HH001, Control of Records.
Observe positioning of the 2 magnets (Figure 2).
With the oil pan with bevel and pipe (white), the new filter can be installed. If it is necessary to use magnets, only new magnets may be used.
If the grid magnet (A 220 271 00 98) is installed, it must be replaced by 2 magnets A 000 988 01 52. Observe positioning of the 2 magnets (Figure
2).
1. - Magnet (A 000 988 01 52)
If 6 magnets (round or rectangular) are installed, 4 must be removed and the other 2 positioned as in Figure 3 and 4.
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2. - Magnet, round
3. - Magnet, rectangular
Parts InformationTechnical Service Bulletin # P-88_50-53 Date: 060901
Body - Trunk Lid Lock Valet Key Retrofitting

Date: September 2006
Order No.: P-I-88.50/53
Supersedes:
Group: 88
SUBJECT:
MODEL 203.040/052/054/056/061/064/076/081/084/087/092
TRUNK LID VALET LOCK RETROFIT
WARNING
Do not disconnect the negative battery cable. Extensive reprogramming requirements are otherwise necessary. Wiring harnesses are therefore
electrically active.
Severe vehicle damage, personal injury, or death from electrical shock could result. Exercise extreme caution while executing these installation
instructions. Keep the ignition and radio powered OFF through the final test.
Note:
Retrofitting the trunk lid valet lock is a customer pay matter. Do not submit a warranty claim for retrofitting the trunk lid valet lock.
NOTICE!
Incorrect installation of connectors can result in damaged, bent pins.
Damaged, bent pins will result in component malfunction or failure.
Inspect connectors before and after installation.
A. Preparing For the Installation

1. Read these installation instructions in their entirety before proceeding.
2. Unpack and compare the installation parts against the Parts Information list in Section E.
3. Open the trunk.
4. Remove the trunk lid paneling.
^ See WIS document AR68.30-P-8150P, "Remove/install trunk lid paneling"
5. Remove the trunk lid lock.
325
^ See WIS document AR88.50-P-5020P, Remove/install and adjust trunk lid lock and striker eye"
6. Remove the trunk paneling on the left side.
^ See WIS document AR68.30-P-4600P, "Removing and installing paneling in trunk"
7. Remove the rear SAM control unit with fuse and relay module.
^ See WIS document AR54.21-P-1259P, "Remove/install SAM control unit with fuse and relay box in rear Remove/install"
B. Retrofitting the Valet Lock For the Trunk Lid

1. Remove the tab from the housing above the trunk lid lock tumbler:
a. Score the tab several times along its base (Figure 1).
b. Use side cutters to finish cutting through and removing the tab from the housing.
NOTICE!
Excessive force will crack or break plastic.
Applying excessive force while removing the tab can crack or break the plastic housing.
Do not use excessive force when removing the tab from the housing.
2. Insert the microswitch (Figure 2) for the trunk lid lock into the cavity in the left side of the housing.
3. Cut off a 1,900 mm length of brown wire.
4. Strip off 1/4 inch insulation from the ends of the brown wire.
326
5. Crimp a crimp pin onto one of the stripped-off ends of the brown wire (A, Figure 3).
6. Crimp the ground connector onto the other stripped-off end of the brown wire (B, Figure 3).
7. Cut off a 2,200 mm length of black wire.
8. Strip off 1/4 inch insulation from the ends of the black wire.
9. Crimp a crimp pin onto both stripped-off ends of the black wire (C, Figure 3).
10. Unlock the crimp lock (Figure 4) of the connector for the trunk lock microswitch.
11. Insert the pin (A, Figure 3) of the brown wire into pin 1" (A, Figure 5) of the connector for the trunk lock microswitch.
12. Insert a pin (C, Figure 3) of the black wire into pin 2" (B, Figure 5) of the connector for the trunk lock microswitch.
327
13. Lock the connector crimp lock.
14. Wrap the brown wire and black wire together with electrical tape starting 30 mm (A, Figure 6) from the connector (B, Figure 6) for the trunk
lid microswitch back 1 600 mm (C, Figure 6).
15. Reinstall the trunk lid lock.
^ See WIS document AR88.50-P-5020P, "Remove/install and adjust trunk lid lock and striker eye"
16. Connect the new wiring harness to the trunk lid lock microswitch (Figure 7).
17. Route, and secure with wire ties, the new wiring harness along the existing wiring harness running down the left side of the trunk lid (Figure
8).
18. Continue routing, and securing with wire ties, the new wiring harness along the existing wiring harness running down the left hinge bracket
328
for the trunk lid, up along the left side of the trunk interior, and down to the rear SAM control unit with fuse and relay module (Figure 9).
19. Connect the brown ground wire (B, Figure 3) of the new wiring harness to ground-point "VV6" (Figure 10), in front of the SAM control unit
with fuse and relay module.
20. Remove connector "21" (Figure 11) from the rear SAM control unit with fuse and relay module.
21. Remove the housing from connector 21."
22. Connect the black wire (C, Figure 3) of the new wiring harness to pin 18" of connector "21" (Figure 12).
23. Reinstall the housing on connector "21."
24. Reconnect connector "21" to the rear SAM control unit with fuse and relay module.
25. Reinstall the rear SAM control unit with fuse and relay module.
^ See WIS document AR54.21-P-1259P, "Remove/install SAM control unit with fuse and relay box in rear Remove/install"
C. Function Testing and Final Assembly
1. Verify proper trunk operation per the following checklist:
> With the trunk lid lock tumbler in the neutral position (A, Figure 13), verify the trunk will open when:
X Actuating the switch on the driver's side door panel
X Pressing the trunk lid button on the license plate recess
X Pressing the trunk button on the SmartKey
> With the trunk lid lock tumbler in the locked position (B, Figure 13), verify the trunk will not open when:
X Actuating the switch on the driver's side door panel
329
X Pressing the trunk lid button on the license plate recess
X Pressing the trunk button on the SmartKey
> With the trunk locked or unlocked, verify the trunk will open when:
X Pressing the trunk lid emergency release switch
2. Check the DTC memory of all installed components and components in the trunk. Identify and investigate any present DTCs. Correct the
source ofthe DTCs. Clear the DTC memory.
Note:
Powering up the newly installed system prior to version coding will set errors. Ignore these errors during the initial DTC check. If the
DTCs return after clearing, a configuration error is present. Locate and correct the error.
3. Confirm no new DTCs are present in components in the trunk.
4. Reinstall the trunk paneling on the left side.
^ See WIS document AR68.30-P-4600P, "Removing and installing paneling in trunk"
5. Reinstall the trunk lid paneling.
^ See WIS document AR68.30-P-8150P, "Remove/install trunk lid paneling"
6. Reinstall the paneling from the left side hinge bracket for the trunk lid.
^ See WIS document AR88.50-P-5120T, Remove/install hinge lever for trunk lid"
Wipers/Washers - Wipers Chattering/Noisy

Date: March 1, 2007
Supersedes: P-B-82.30/366b dated Jan. 10, 2006
Group: 82
330
Revision History
SUBJECT:
Adjusting Wiper Arms
If you receive customer reports in the above model vehicles of wipers chattering / noisy, proceed as follows.
1. Inspect wiper blades / inserts for wear and replace as needed.

2. Thoroughly clean the windshield.
3. Verify use of correct washer fluid.
4. Check washer nozzle adjustment.
5. If noises persist, proceed with steps 6 and 7.
6. Check the wiper arm angle adjustment and record values per the applicable model WIS document.
7. If required, adjust wiper arm angle.
Note:
Due to the natural aging process and wear, wiper blades should be replaced twice a year preferably in Spring and Fall (refer to Operator's
Manual).
Note:
Warranty claims for wiper blades / wiper blade inserts that are worn or damaged due to environmentally influenced reasons, abuse or physical
damage will not be accepted.
Note:
Special Tool (W211 589 02 21 00) was automatically shipped to all MB dealers as of June 2004.
Note:
Refer to Netstar message "Windshield Wiper Blades / Wiper Blade
Inserts" dated January 20, 2006.
Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair
331
In Case of Warranty
Satellite Radio - Limited Channel 184 or Lower

Group: 82
Revision History
a 10/16/06 Remedy Available

SUBJECT:
Model 171.454/456/473, As of Model Year 2005
Model203.040/052/054/056/061/064/076/081/084/087/092/261/264/281
/284/740/764, As of Model Year 2006
Model 209.356/365/375/376/456/465/475/476, As of Model Year 2005
Equipped with Satellite Radio Receiver
Audio 20 Head Unit Cannot Tune to Any Satellite Radio Channel Higher Than 184
If you receive customer reports in the above model vehicles of the Audio 20 (entry) model head unit not able to tune to any channel higher than 184
in vehicles equipped with Satellite Radio (SDAR), the head unit must be replaced according to the vehicle model listed below.
332
NOTE:
Any unnecessary replacement of an SDAR Control Module or a Head Unit will be debited accordingly.
Brakes - Squeal/Whistle When Releasing Brake Pedal

Group: 43
Revision History
a 1/16/07 Applicable Models, Series Production Dates and Part Numbers Updated
SUBJECT:
Model171.454/456/473, Up to Series Production 11/2006
Model203.040/052/054/056/061/064/065/076/081/084/087/09
Up to Series Production 11/2006
Model209.356/365/375/376/456/465/475/476, Up to Series Production 11/2006
Squealing / Whistling Noise When Releasing Brake Pedal
If you receive customer reports in the above model vehicles of a squealing or whistling noise emanating from the brake pedal area after releasing
the brake pedal, replace the brake booster with a revised part. Reference WIS document AR43.10-P-0350V (Model171) or AR43.10-P-0350P
(Model203 and 209).
The whistling noise within the brake booster is the result of air flowing between the operating chamber and vacuum chamber of the booster, caused
by increased tolerances. The increased tolerances cause air to flow over an internal edge within the booster creating vortices. These vortices can
produce a sound which may be perceived as a whistle.
NOTE:
When ordering parts please ensure to add an index 28 to the part number. For models 203 and 209 the revised part will have a Q-status of Q7 or
higher. For model 171 the revised part will have a Q-status of Q3 or higher.
Parts InformationTechnical Service Bulletin # P-15_40-60 Date: 061128
Charging System - Returning Alternators & Regulators

Order No.: P-B-15.40/60
Supersedes:
Group: 15
SUBJECT:
Model 171.454/456
Model 203.052/054/056/087/092/740
Model 209.356/372/456/472
333
Model 211.022/026/056/072/087/090/256/287
Model 215.376/379
Model 216.371/376
Model 219.372
Model 220.176/179
Model 221.171/176/179
Model 230.471/476/479
Returning Alternators and Regulators Equipped with BSS or LIN Communication
For the above model vehicles when replacing any alternator regulators and/or alternators covered under warranty, the returned part to the QEC must
be accompanied by the Control Unit Log and Alternator Test (obtained by using SDS per below instructions). Any claims submitted without this
documentation will be debited back to the dealer. No other documentation will be accepted or required.
Control Unit Log - Using Star Diagnosis 04/05 or newer access the Control Unit Log menu via SDS menu path: Control Units -> Drive -> Motor
electronics -> Control Unit Log -> Generation of Control Unit Log.
Alternator Test - Using Star Diagnosis 04/05 or newer access the Control Unit Log menu via SDS menu path: Control Units -> Drive -> Motor
electronics -> Actuations or Complete list of guided tests -> Alternator diagnosis
NOTE:
- For both documents when filling out the Customer Complaint section, please include as much detail as possible.
- For a complete description of alternator types refer to DTB P-B-15.40/56 dated Jan. 31, 2006.
- All parts will be tested. Alternators found to be working properly will be debited back to the dealer. Technical Service Bulletin #
P-07_00-57D Date: 061113
Engine Controls - MIL ON/DTC P1089 Stored in Memory

Group: 07
Revision History
d 11/13/06 Applicable Models Updated

c 6/21/06 Applicable Models / Software Version Updated
b 3/8/06 Paragraph 2 Updated
SUBJECT:
Model 171.454/456
Model 203.052/054/056/076/087/092
Model 209.356/376/456/476
Model 211.056/087/256/287
Model 221.171
Model 230.471
Check Engine Light / Engine Control Module Software Update
If you receive customer reports in the above model vehicles with check engine light activated and Diagnostic Code P1089 (fuel minor leak).
Perform leak tests as per guidelines in SDS.
If no leak is found, update engine control module software with DAS version 05/06 (or later DAS Release).
NOTE:
After the software flash, perform SCN coding. Refer to Star TekInfo Document S-B-07.61/38i dated July 24, 2006 or S-B-58.00/144b dated
July 24, 2006 for procedure. Technical Service Bulletin # P-82_85-532A Date: 061129
Diagnostic Enhancement - MCSII EDAC

Supersedes: P-B-82.85/532 dated October 12, 2006
Group: 82
Revision History
334
a 11/29/06 Addition of "Note" Pertaining to Short Test

SUBJECT:
Model 203.040/052/054/056/061/064/076/081/084/087/092/261/264/281/284/740/764
Model 209.356/365/372/375/456/465/472/475/476/477
Model 164.175/177/186/871
Model 251.165/175/177
Model Year 2005 through 2007
Diagnostic Enhancement: MCSII Enhanced Diagnostic Assistance Center "EDAC"
Mercedes-Benz USA, LLC will start the MCSII EDAC program on Monday, October 23, 2006. MBUSA has posted a diagnostic guide that
supplements information available through traditional MBUSA sources and can be found on: NetStar -> Service -> STAR TekInfo -> EDAC ->
Diagnostic Guide DVD COMAND.
Under this EDAC program, replacement of the Model Year 2005, 2006 and 2007, DVD COMAND will require authorization prior to replacement,
in accordance with the program terms summarized below.
NOTE:
Prior to calling EDAC for approval, you must have the short test containing the MOST ring configuration (not just the Head Unit), with part
numbers, software and hardware versions. EDAC will not authorize a Head Unit replacement without this information.
- The technician shall conduct an accurate assessment of the problem by using the diagnostic guide.
- ALL replacements of the 2005, 2006 and 2007, DVD COMAND will require that the dealer call the EDAC to open a case, review the
methods of diagnosis and the results. The EDAC dedicated toll free number is 1-800-997-8228 8 AM to 8 PM EST Monday to Friday.
- Upon completion of an EDAC contact, the EDAC agent will issue an authorization number in those cases where the Model Year 2005, 2006
and 2007 DVD COMAND is deemed to be malfunctioning. Due to a warranty parts return enhancement, if you submit a warranty claim that
includes a part which is covered by an EDAC project and it is found not to have an EDAC authorization number for that vehicle, a pop up
window will appear as a reminder to contact an EDAC agent for the authorization number for the repair in question. If this claim is forced
through to Warranty without the proper EDAC authorization, the claim handling fee will be debited.
- Should an authorized DVD COMAND be submitted without the specified documentation called for in the MY 2005, 2006 and 2007 DVD
COMAND Warranty Checklist (next page), the claim handling fee will be debited as of repair date October 23, 2006.
Model Year 2005, 2006 and 2007 DVD COMAND Warranty Checklist
Please follow each step PRIOR to calling the EDAC. Remember to print out all requested information and then securely affix printouts to the
replaced DVD COMAND when shipping.
Do NOT erase any stored DTC's in the DVD COMAND before returning the component.
On all pages the VIN and date must be visible.
1. Connect SDS, start DAS.

2. Apply short test.
3. Navigate to the following STAR Diagnosis Menu: Control units -> Information and communication -> Audio, video, navigation, and
Telematics -> COMAND with integral AGW -> Control unit version
4. From the "COMAND" control module print the following menu items:
a. Control unit version
b. Fault codes and corresponding freeze frame data from all fault codes in COMAND control module
c. SDS screen of guided test results (if applicable)
NOTE:
For printing wait for all information to load, and then press F11. Select "Print out of test step" and press print.
5. End DAS, disconnect SDS.
NOTE:
SEND ORIGINAL PRINTOUTS ONLY! Photocopies will NOT be accepted.
NOTE:
For the duration of this program the audio system diagnosis and return form (S-2664-99a) is not required.
335
Process OverviewTechnical Service Bulletin # P-82_30-316A Date: 070213
Wipers/Washers - Intermittent Function Operation

Group: 82
Revision History
a 2/13/07 Applicable Models / Content Revised

SUBJECT:
Model 203.040/052/054/056/061/064/065/076/081/084/087/09
As of MY04 (SA code 804)
Model 209.356/365/375/376/456/465/475/476
Model 211.026/056/065/070/076/082/083/087/256/265/276/28
Model 215.374/375/376/378/379, As of MY 03 (SA code 803)
Model 220.067/170/174/175/176/179/183/184, As of MY 03 (SA code 803)
In Addition Equipped with SA Code 345 (Rain/Light Sensor) Intermittent

Wiping Feature for the Windshield Wipers Not Functioning
336
If you receive customer reports in the above model vehicles of the intermittent wiping feature for the windshield wipers not functioning upon the
occurrence of all of the following conditions, this is due to the designed software logic of the windshield wiper system.
1. The vehicle is stationary
2. Precipitation is falling
3. Driver or front passenger door was recently opened then closed
This is normal wiper operation. When the driver or front passenger door is opened, the windshield wipers stop moving to prevent passengers who
are exiting or entering the vehicle from being splashed by wiped away water. In accordance with the design, the intermittent wiping feature
reactivates upon one of the following actions after all doors have been closed.
1. Engage transmission into reverse or drive (automatic transmission)
2. Depressing the clutch (manual transmission)
3. Temporarily switching wiper position to continuous wipeTechnical Service Bulletin # P-27_60-88A Date: 070116
A/T - Limp Home Mode/Codes 2502/2505/P0894/P2711

Group: 27
Revision History
a 1/16/07 Technical Content Revised

SUBJECT:
All Passenger Models Equipped with 722.9 Transmission (7G-Tronic) Fault Codes 2502, 2505, P0894 or P2711
If you receive reports in the above model vehicles of the automatic transmission being in limp-home mode or having no power transfer from the
transmission together with fault codes 2502, 2505 or P0894, P2711, these codes must be processed according to the vehicle symptoms. First,
attempts must be made to reproduce the problem.
If the above fault codes are stored in connection with shift quality complaints, please proceed according to the Diagnostic Tree posted on Star
TekInfo -> EDAC -> Diagnostic Guide for 722.9 NAG 2 (7G-Tronic) Transmission.
If the fault codes are stored together with loss of power transfer, proceed with the below solutions per the respective possible cause.
Cause 1: K1 piston is damaged (adaptation data for the 2-3 shift may be at the positive limit).
Solution 1: If the complaint can only be reproduced for the 2-3 upshift or if third gear can not be reached, there is a defect of the K1 piston.
- Replace the complete multi-disc clutch K1 as per the parts list.
- Reset the adaptation data.
Cause 2: Tolerance in the electrohydraulic control unit (valve body) may not be optimal.
Solution 2: If the K1 multi-disc clutch is not responsible for the concern, replace the electrohydraulic control unit (valve body) and perform initial
startup.
NOTE:
When diagnostic events lead to a transmission or valve body replacement, please refer to DTB P-B-27.00/38d for the proper completion of the
WSG pre-authorization requirements.
Parts InformationTechnical Service Bulletin # P-82_00-260B Date: 070131
Entertainment System - CD's or DVD's Won't Eject

Supersedes: P-B-82.00/260a dated August 25, 2004
Group: 82
Revision History
337

a 8/25/04 Content Updated
SUBJECT:
All Passenger Model Vehicles
Model Year 2000 through Current Model Year
CDs and DVDs May Not Be Ejected
If you receive customer reports in the above model vehicles that are equipped with COMAND with CD/DVD drives, CD changer, as well as
navigation processors with a single slot having the below symptoms, please review the possible causes listed below.
Symptoms
1. CDs / DVDs are not always pulled into the player, a light push may need to be applied.
2. CDs / DVDs are not always ejected by the player.
3. If the CD / DVD is forced in, it may not be possible to eject the disk.
4. CD / DVD player does not play the disk even if inserted correctly.
Causes
1. The disk is too thick, does not satisfy the specification thickness tolerance range of 1.1 - 1.5 mm.
2. CDs / DVDs with self-adhesive labels that may become delaminated from the disk in whole or in part due to length expansion of the material
used which results in the disk being out of thickness tolerance.
3. CDs / DVDs with diameter of 8 cm with / without an adapter resulting the in the adapter blocking the pull / eject mechanism.
NOTE:
These causes constitute misuse of the CD / DVD player that are not covered under warranty. Technical Service Bulletin #
200611005B Date: 061201
Campaign - Install Software for Navigation System

Campaign No. 2006110005, December 2006
FILE:
SERVICE:
Revision History

SUBJECT:
MODELS 164, 171, 203, 209, 211, 215, 219, 220, 221, 230, 251, X164
This Service Campaign has been initiated because DCAG has determined that certain affected vehicles (see VIN range on the following pages) may
have an earlier version navigation disc installed than that specified. This could in some cases lead to navigation directions based upon non updated
map data. Dealers will update the navigation disc in the affected vehicles as required.
Please review the Effective Serial Number chart located on the following pages, and if necessary, repair the subject vehicles during the vehicle's
next service.

- 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.
338
Effective Serial Number Range
NOTE:
indicator.
339
Procedure
NECESSARY
NOTE:
NOTE:
- Press Eject button on Navigation module.

- Visually check part number on DVD label.

- If part number is BQ 646 0216 (V 2006.1): Reinsert DVD into Navigation module; this campaign has been completed.
- If part number is not the above number: Proceed to next step to update Navigation system.
NOTE:
You must obtain Navigation DVD BQ 646 0216 (V 2006.1) by calling Navteq at 866 MB4 AMAP ( 866 624 2627). Navteq does not require
the VIN for these vehicles.

- Insert new Navigation DVD into Navigation module.
NOTE:
- Shut off vehicle upon completion of the update process.
NOTE:
The Navigation DVD must remain inside the module from this point forward in order for the Navigation system to operate correctly.
NOTE: The replaced Navigation DVD for the above models must be returned through the standard process.
NECESSARY
NOTE:
NOTE:
- Press Eject button on head unit to eject DVD from "Navigation" slot.
- Visually check part number on DVD label.

- If part number is BQ 646 0220 (V 2006.1): Reinsert DVD into Navigation drive; this campaign has been completed.
- If part number is not the above number: Proceed to next step to update Navigation system.
NOTE:
You must obtain Navigation DVD BQ 646 0220 (V 2006.1) by calling Navteq at 866 MB4 AMAP ( 866 624 2627). Navteq does not require
the VIN for these vehicles.

- Insert new Navigation DVD into Navigation drive.
NOTE:
340
- Shut off vehicle upon completion of the update process.
NOTE: The Navigation DVD must remain inside the drive from this point forward in order for the Navigation system to operate correctly.
NOTE:
The replaced Navigation DVD for the above models must be returned through the standard process.
NOTE:
You must obtain the correct DVD per VIN by filling out the form and either fax to Navteq at: 888 329 4223 or scan and email at:
mbmaps@navteq.com. For reliability, we encourage you to fax in the form. The DVD will be sequentially numbered according to the VIN you
provide in the form. If you have more than one vehicle listed in the campaign in your dealership, please submit multiple VINS in a single form,
Navteq will mail you one DVD per VIN entered.
NOTE:
- Connect battery charger
- Turn off ignition and all electrical consumers
- Turn ignition key to second position
- Follow the order of steps exactly as outlined below
CAUTION:
Ensure that slot #1 in the DVD changer is empty prior to inserting the Navigation DVD.
2. Press Button 1 of the DVD changer (A, Figure 1) and insert the Navigation DVD (part number A 221 827 30 59 (v 3.0)) into the changer
(B).
NOTE:
The update process takes approximately 30 minutes to complete. The technician is not required to be present during the process and may
perform other tasks while the process is running. The update process run time is not included in the labor time paid under this Service
Campaign.

NOTE:
This Navigation DVD is property of MBUSA; it must remain with the vehicle/customer after the update process has been completed.
Reproduction is prohibited!
Parts Information
341
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.
Repair 1 (All models except 221 - Check only)
Operation: Navigation-DVD, Check/Update if Necessary (02-5539)
Repair 2 (All models except 221 - Check and update)
Operation: Navigation-DVD, Check/Update if Necessary (02-5539)
Repair 3 (Model 221)
Operation: Battery Charger, Connect (02-5058)

Map Software for Navigation System, Update (02-5540) Technical Service Bulletin # P-47_10-40B Date: 070226
Fuel System - Tapping Noises From Fuel Tank Area

Group: 47
Revision History
b 2/26/07 Warranty Information Added

SUBJECT:
Model 203.052/054/056/087/092
Model209.356/372/456/472
Tapping Noise in the Area of the Fuel Tank
If you receive customer reports in the above model vehicles of a tapping noise in the area of the fuel tank, perform the following work instruction to
resolve:
Warning:
Risk of explosion caused by 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. Please take appropriate cautions.
342
1. Remove right rear wheel and its housing to reach the area of purge line.
2. Open purge line (Figure 1).
3. Insert restrictor in the purge line up to the red marking (Figures 2 and 3).
4. Reconnect purge line with a new clamp (Figure 4)

5. Install in reverse order.
Parts Information
NOTE:
The allowable labor operations should be used when submitting a warranty claim for this repair
In Case of Warranty
343
Operation: Restrictor between purge line and activated charcoal canister, retrofit (02-5337) Technical Service Bulletin # P-27_00-95
Date: 070329
A/T Controls - Limp Home Mode/Harsh Engagement

Order No.: P-B-27.00/95
Supersedes:
Group: 27
SUBJECT:
All Passenger Vehicles Equipped with Transmission 722.9
Trans. in Limp-Home Mode or Harsh Engagement After Programming/SCN Coding
If a vehicle equipped with a 722.9 transmission goes into limp-home mode after performing SCN coding and/or programming of the transmission
control module; or if after performing these actions the transmission engages harshly, there can be two causes for this issue. Scan the transmission
control module for the below fault / event codes.
Event Codes: 0602, 1644, 2010 and/or 2011
Note:
Do not perform a road test! This may cause transmission damage.
1. Cause 1: SCN coding was not accepted by the transmission control module. This condition can be confirmed by looking at the following
menu within the transmission control module: Transmission Control Module --> Control Unit adaptations --> SCN Coding --> Display of
coding data
If the coding reads "NO VALUE", the transmission control module must be recoded again until it is confirmed that the coding has been
accepted by the transmission control module. This is confirmed when a four digit code is displayed as a coding value.
2. Cause 2: The coding was accepted by the transmission control module, but the vehicle is in limp home mode due to the presence of the stored
fault and/or event codes. In this case, simply erase the stored codes.
Note:

Wipers/Washers - Wiper Arm Scraping/Striking Hood

Order No.: P-B-82.30/572
Supersedes:
344
Group: 82
SUBJECT:
Model 203.040/052/054/056/061/064/065/076/081/084/092
Wiper Arm Scraping/Striking Engine Hood
If you receive customer reports in the above model vehicles of the wiper arm scraping or striking the bottom side of the engine hood during wiping
sequence, this may be due to the wiper system being adjusted incorrectly. To resolve, check and adjust wiper system as per WIS document
AR82.30-P-6400-01P.
Note:

A/T - No Power Output From A/T

Supersedes: P-B-27.35/52 dated February 2, 2005
Group: 27
Revision History
SUBJECT:
No Transfer of Power from Automatic Transmission 722.9
In the above model vehicles if after replacing the electro-hydraulic control unit on automatic transmission 722.9 (7G-Tronic) you experience the
below conditions, this may be caused by an improper installation of the supply pipe for the multi-disc brake B3.
^ No gear can be selected in transmission mode "S" and there is no power flow in the transmission
^ In transmission mode "C" the vehicle can start off as usual.
To resolve, remove the electro-hydraulic control unit as described in WIS document AR27.19-P-0200w.
345
Before reinstallation, install the supply pipe (Figure 1) per WIS document AR27.19-P-0200w, step 6. Replacement parts are only necessary if the
original pipe was damaged during the original installation of the valvebody.
Parts Information
A/T - Selection Range Sensor Learning Not Possible

Group: 27
Revision History
SUBJECT:
Learning in Selection Range Sensor Not Possible After EHS Replacement
In the above model vehicles, after removing/installing the electrohydraulic control unit (EHS), learning in the selection range sensor is not possible
if the retaining bolt of the detent plate was not inserted into the plastic bracket of the selector range valve (Figure 1). During initial start-up with
Star Diagnosis, the message "The prerequisites are not fulfilled or the peripherals are not operational" is displayed, although the shift rod has been
correctly adjusted. To resolve, remove/reinstall EHS being sure to insert bolt into bracket on valve and proceed to teach the sensor using Star
Diagnosis.
346
Engine/Steering - ECO Harness Replacement Information

Date: June 26, 2007
Order No.: P-B-01.10/17
Group: 01
Revision History:
6/26/07 Initial issue
SUBJECT:
MODELS 171
(with Engine 272), 203, 209, 211, and 219 (with Engine 272 or 642)
Potentially Missing Connection to Proportioning Valve of the ECO-Power Steering Pump when Exchanging Engines
When replacing engines on vehicles with an ECO power steering pump, the wiring harness on the new engine also has to be replaced. Order the
wiring harness as outlined in Parts Information.
Note:
When replacing engines 272 or 642 on the above models, the connection of the proportioning value of the ECO-power steering pump may be
missing on the engine wiring harness of the new or reconditioned engine.
Repair Description
1. Check to see if an ECO power steering pump is installed. The ECO power steering pump has an electrical connection (see Figure 1, arrow)
and can also be recognized via the engine number (see Table 1).
2. If an ECO power steering pump is installed, replace the engine wiring harness of the reconditioned engine with the appropriate one in Parts
Information.
3. If an ECO power steering pump is not installed on the existing engine being replaced, the wiring harness must not be changed.
Warning!
The ECO power steering pump must be connected; otherwise a too light steering feel can occur around the steering wheel center position
at higher speeds, which could lead to diminished handling capacity.
347
Parts Information
Fuel System - Fuel Pump/Filter Module Replacement

Date: September 2007
Order No.: P-B-47.20/53
Supersedes:
Group: 47
SUBJECT:
MODELS 203, 209, 211, 219, 221
MODEL YEAR ALL
PROCEDURE FOR REPLACING FUEL PUMP AND FUEL FILTER MODULES
In cases of complaints involving fuel pumps or fuel filters, replace only the faulty module related to the respective component.
Replace modules in pairs only when both modules are diagnosed faulty.
The procedure above applies also in cases of complaints involving fuel level sensors.
Note:
^ Fuel level sensors on Model 221 can be replaced separately.
^ Fuel level sensors on Model 203 with PZEV fuel tank; replace the fuel tank as the fuel level float is not available separately.
^Always included the printed-out test steps with the respective faulty components when submitting a warranty return.
Drivetrain - Front Axle Grinding Noise Diagnosis

Date: July 2007
Order No.: P-B-33.20/030
Suspension
348
Group: 33
SUBJECT:
MODEL 171, 203 (except 4MATIC), 208, 209, 210 (except 4MATIC), 211 (except 4MATIC), 215, 219, 220 (except 4MATIC), 221 (except
4MATIC), 230
MODEL YEAR ALL
GUIDELINES FOR DIAGNOSING GRINDING NOISES FROM FRONT AXLE
Some wheel bearings returned to the Quality Evaluation Center (QEC) with warranty damage type "noisy," are found not defective after
testing.
To properly diagnose and to help avoid misdiagnosis, follow the guideline in cases of noise perceived to be coming from wheel bearings.
Tire noise mistaken for wheel bearing noise is also addressed in the guideline.
Refer to the following WIS documents for adjusting wheel bearing play.
^ AR33.20-P-0300V, Model 171
^ AR33.20-P-0300A, Model 203 (except 203.08/09/28/29), 208, 209, 210 (except 210.08/28), 211 (except 211.08/09/28/29), 215, 220
(except 220.08/18), 230
^ AR33.20-P-0300TX, Model 219
^ AR33.20-P-0300SX, Model 221
349
Procedure Flow Chart

Interior - Seat Noise Complaints

Date: July 31, 2007
Order No.: S-B-91.00/37
Supercedes:
Group: 91
SUBJECT:
Model Year-All
Models All
Repairs for Noise Complaints Regarding Seats
This bulletin addresses complaints regarding noisy seats. Follow the steps to ensure that the problem is fixed correctly.
A. Repair Instructions
1. To better analyze the seat noises, maintain the customer's original seat positions, including cushion angles and backrest positions. It is a good
idea to also store the customer's seat positions in vehicle memory.
350
Note:
Seat noises can depend on individual seat positions involving the backrest and cushions as well as the manner in which customers enter
and sit in the vehicle.
2. Analyze the noise problem with the customer present. Note their interpretations of various seat adjustments and resulting sounds from each
seat and back rest positions.
3. Before performing any adjustments, be sure to unbolt the seat from the vehicle while keeping the electrical seat harness connected.
4. With the seat unbolted, use the seat control switch to move the seats over the entire adjustment ranges; i.e., all the way forward, back, up,
down, etc.
5. Bolt the seat back into the vehicle. The majority of complaints will be remedied by simply loosening and refastening the seats.
6. If noise still exists, remedy with felt and lubrication as specified in the Noise Kit (see Parts Information). Use only the parts from this kit.
Engine Controls - Code 061B After Reprogramming

Supersedes: P-B-27.60/80 dated August 30, 2006
Group: 27
Revision History
Revision Date purpose
a 8/8/07 Addition of Note Pertaining to Fault Code
SUBJECT:
Model 171.454/456
Model 203.052/054/056
Model 209.356/372/456/472
Model 211.056/072/256
Model 219.372
Model 221.171
Model 230.471
After Programming Engine and/or Transmission Control Units, Fault Code 061B Stored in Transmission Control Unit
If you encounter the situation described in the above model vehicles, the cause may be a torque interface issue between the engine and
transmission control modules.
To resolve, check for and install newer software for the engine control module using SDS and perform SCN coding of the engine control
module as well. Perform quick test and erase fault code.
Note:
If the fault code 061B reappears, it can be ignored. This is not cause for any parts replacement.
Note:
If no newer software is available for the engine control module, simply perform the SCN coding of the engine control module.
Electronic Ignition Switch - Central Gateway Information

Date: May 9, 2007
351
Supersedes: P-B-80.57/30 dated October 21, 2004
Group: 80
Revision History

a 5/9/07 Applicable Models, VIN Breaks and Parts Information Updated
SUBJECT:
Model
203.040/052/054/056/061/064/076/081/084/087/092/261/264/281/284/740/764
As of VIN A705272, F607875 and R164892
Discontinuation of Central Gateway and revision of Electronic Ignition Switch
On the above model vehicles, if you encounter various fault codes during a STAR Diagnosis short test after installing a new Electronic Ignition
Switch (EIS) this is due to the fact that the Central Gateway (CGW) is no longer being installed in the above model vehicles. The CGW
functionality will now be handled by an updated EIS. When replacing the EIS, use the table shown to select the appropriate part number.
Parts Information
Restraints - SRS Lamp ON/Code 90A06 Stored

Date: August 2007
Order No.: P-B-91.60/139
Group: 91
SUBJECT:
MODEL 203
SRS warning lamp comes on and fault code 90A6 stored in restraint systems control Module (N2/7)
Failed communication between restraint system control module (N2/7) and passenger seat occupied and child seat recognition sensor (B48)
may cause fault code 90A6 to occur during system self-test.
Note:
Seat occupied recognition mats with the following part number are affected:
^& A 203 870 37 10
^ A 203 870 38 10
^ A 203 870 39 10
Do not remove/install/replace any parts. If further fault codes are stored, first process these faults and then flash the restraint systems control
module (N2/7) with DAS releases as of 03/2007:
1. Connect SDS
2. Select Main Groups/Control units/Body/AB - Airbag/Control unit adaptations/Read code and change if necessary/Test of seat mat
352
components: follow instructions in DAS.
Note:
^ As of DAS 03/2007, the software has been revised and the restraint systems control module detects the installed seat occupied
recognition mat.
^ The part number of the seat occupied recognition mat cannot be read out via DAS.
In Case Of Warranty, use the table.
Body - Interior Drafts With Sunroof Open

Date: May 17, 2007
Order No.: P-B-77.20/53
Supercedes:
Group: 77
SUBJECT:
All Model 203 Vehicles as per VINs Included in Content
Drafts in the Interior with Sliding Roof Open
If you receive customer reports in the above model vehicles of drafts in the interior when driving with the sliding roof open, this is caused by a
vacuum affect due to the roof being open. The vacuum pulls air from any opening in the interior that is not completely sealed. Follow the
procedures below to seal these areas.
A. Draft in Footwell Area from Air Leaks in Sound Deadening Material, Up to VIN A731367 and F634898:
1. Remove kick panels. Refer to WIS document AR68.20-P-2050P (driver side) and AR68.20-P-2070P (passenger side).
2. Loosen pedal assembly of parking brake and fold to the side. Brake cables do not need to be removed. Refer to WIS document
AR42.20-P-0510P.
3. On passenger side footwell, inspect sound deadening material for correct installation and cracking (Figure 1, 1).
353
5. Route electrical lines (Figure 1 - 2, 3) above sound deadening material.
6. Tape electrical lines (Figure 2 - 2, 3) to sound deadening material.
7. On driver side footwell, inspect sound deadening material for correct installation and cracking (Figure 3, 4).
9. Cover sound deadening material (Figure 4, 4) and holes (Figure 4, 5) with adhesive tape.
10. Assemble vehicle in reverse order
B. Air Leaks Between Climate System Housing and Vehicle Firewall, Up to VIN A788400 and F693171:
1. Remove battery.
2. Remove the air inlet. Refer to WIS document AR83.25-P-1401P.
354
3. Seal climate housing to firewall using adhesive tape (Figure 5, 4).
Note:
Insure the recirculation flap and humidity sensor (B 31/2) are not obstructed with adhesive tape.
4. Reassemble in reverse order
5. Perform basic programming. Refer to WIS document AR00.19-P-0200P.
C. Air Leaks from Area of C-Pillar, Up to VIN A803730 and F706981
1. Remove side bolster of rear seat backrest. Refer to WIS document AR91.12-P-1710P.
2. Apply adhesive tape to the openings in the left rear (Figure 6, arrows) and right rear (Figure 7, arrows).
D. Air Leaks from Rear Door Panel, All Vehicles
1. Remove rear door panel. Refer to WIS document AR72.12-P-1010P.
2. Disassemble power window switch strip, door lever and door handle. Refer to WIS document AF72.12-P-3100-01P.
355
3. Seal switch strip with tape (Figure 8, 1) and reinstall in door panel.
4. Apply self-adhesive insulation mat (A220 682 07 08) over large surface of door panel in are of switch strip (Figure 9).
5. Seal opening by door lever with self-adhesive insulation (A203 682 04 31) (Figure 10). Cut to make two pieces 30 mm in length.
6. Note: Insure that lever remains free to move (Figure 10, arrow).
356
7. Remove door handle and install foam rubber piece (Figure 11). Position carefully with notch (Figure 11, arrow). Refer to parts table for
applicable part number for left and right side. When foam is installed, it should cover the openings as shown in Figure 12.
8. Reassemble door panel in reverse order.
Note:
When the handle is installed the foam rubber is pressed against the openings. The foam rubber pieces must be positioned and bonded
carefully to ensure the sealing is complete.
Parts Information
Note:
357
Body - Replacement Sheet Metal With Seam Sealer

Date: July 2007
Order No.: P-B-97.00/03
Group: 97
SUBJECT:
MODELS 170, 171, 202, 203, 204, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 463
Introduction of Replacement Parts with Seam Sealant
In order to ensure a uniform quality standard, as of January 2007 sheet metal replacement parts with seam sealant will be delivered in stages via the
GLC. This affects hoods, doors, trunk lids and tailgates.
The sheet metal replacement parts for models 164, 204, and 251 have been supplied with seam sealant since their market launch.
Body/Frame - MIG Welding Requirements

Date: July 2007
Order No.: P-B-60.00/17
Group: 60
SUBJECT:
MODELS 203, 204, 208.3, 209.3, 210, 211, 216, 219, 220, 221
MIG Soldering
A. Soldering Materials for MIG Soldering
For strength reasons soldering material SG-CuAL8 (recommended wire diameter: 1.0 mm) must be used when performing MIG soldering of
connections to structural components (as described in the WIS).
The soldering material SG-CuSi3 must be used in the case of joining methods on outer paneling parts which are then to be reworked using
body solder. The soldering material SG-CuAL8 cannot be used here as it would not bind properly with the body solder on account of the
aluminum component in the soldering material.
358
Note:
Refer to WIS AH60.00-P-0024-01N for general notes on repair of vehicles with ultra-high-strength steel
B. MIG Soldering on structure components and outer paneling
On models 204, 216 and future models MIG soldering is a joining process on structure components and on exterior paneling in production.
On model 204 in the case of repair the MIG solder connections on structure components (Figure 2) are joined by a MAG weld joint. In the
process it is mandatory to observe the repair instructions in WIS.
On outer panelings (side paneling) MIG soldering can also be performed as an alternative to MAG [metal active gas] welding. For this
purpose the solder material Sg-CuSi3 must be used so that following adhesion and/or rework with unleaded tin-wash solder is ensured.
Changeover on current models:
In series production the MAG weld joint is successively replaced by a MIG-solder connection. In the process it is mandatory to observe the
corresponding repair instructions in WIS.
Outlook on new models:
On future models MIG soldering will be introduced in production as a joining method on structure components and on outer paneling. MIG
soldering will be a standard repair method on new models.
Workshop equipment:
A selection of MIG/MAG welders from various manufacturers is documented in SSEP on Star TekInfo.
Body/Frame - Rivet Replacement to Prevent Water Leakage

Supersedes: S-B-68.00/54
Group: 68
Revision:
Revised to emphasize water leakage into systems as the cause of their malfunctioning.
SUBJECT:
Model 164/203/209/211/216/219/221/251
Model Year - All
359
One-Time Use of Expansion Rivet with Sealing Function - Protecting Systems from Water
It has been observed that the sealing action of the expansion or body-bound rivet does not work once it is removed.
1. The expansion rivets become deformed after they have been removed (Figure 1).
2. They can also become cracked after they are removed (Figure 2).
3. Anytime it is necessary to remove one of these rivets, throw it out and replace it with a new one (Figure 3).
360
4. Critical installation locations are the D-pillar cover in the rear-end door on the Model 251 (Figure 3).
5. Another critical installation location is the body shell cover of the trunk lid as shown on the Model 221 (Figure 4).
6. Other locations include, among others: right rear fender on Model 211; paneling and lining of luggage compartment cover on Model 209 and
211; head protection curtain on Model 219; the A-, B- and C-Pillar paneling on Model X164; and the heater case on Model 221.
Parts Information
A/T - Throttle/Brake Pedal Application Precaution

Date: August 2007
Order No.: S-B-27.00/101
Supercedes:
Group: 27
SUBJECT:
MODEL ALL WITH TRANSMISSIONS 722.4/5/6/9
MODEL YEAR ALL
DO NOT OPERATE THE ACCELERATOR PEDAL AND BRAKE PEDAL SIMULTANEOUSLY
NOTICE!
361
Operating the accelerator pedal and brake pedal simultaneously to heat up the automatic transmission fluid more quickly for the purpose
of testing or performing repairs on the transmission has adverse consequences on the transmission and torque converter.
Thermal overload on the transmission and torque converter will result from simultaneously operating the accelerator pedal and brake pedal.
Do not operate the accelerator pedal and brake pedal simultaneously.

A/C - Control Unit is Inoperative

Date: May 9, 2007
Order No.: P-B-83.30/95
Supercedes:
Group: 83
SUBJECT:
Air Conditioning Control Units Inoperative
If during air conditioning complaint diagnosis it is determined that the air conditioning control unit may be the cause for the complaint, perform the
following additional test measures prior to component replacement. A large number of air conditioning control units have recently been returned
and once tested were found to be functioning properly. Be sure to perform the following tests to avoid claim debiting.
Normalize Actuator Motors via the Control Unit
1. Press the recirculated air and defrost buttons on the control panel simultaneously and hold for approximately 7 seconds.
2. The LED's for the recirculated air and defrost buttons will flash alternately.
3. Wait until the LED's stop flashing (approx. 30 seconds), system will set itself to defrost and the LED will be illuminated.
4. Exit the defrost mode and check all actuator motor functions.
Check Evaporator Sensor
Condensed water leaks into the evaporator sensor (B10/6) which may cause the sensor to report a temperature higher than actual. SDS may
not show an electrical failure of the sensor; however, the sensor is damaged and causes the refrigerant compressor to run for approximately
10 minutes then switch off (once per ignition cycle). To resolve, replace the evaporator sensor. Refer to EPC for applicable part number.
Note:
Operating temperature at the evaporator is between 36°F - 54°F (2°C - 12°C).
Check Pressure Sensor
1. Connect pressure gauge and SDS
2. If pressure difference between the value displayed in SDS and the actual pressure on the gauge is >2 bar, replace the pressure sensor (B12) at
the receiver/drier. Refer to EPC for applicable part number.
Note:
generated on May 9, 2007. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
362

Electrical - Connector Repair Information

Date: May 22, 2007
Supersedes: P-B-54.18/98 dated Sept. 10, 2003
Group: 54
Revision History
a 5/22/07 Applicable Models and Content Updated
SUBJECT:
All Model 171, 203, 209, 211, 219, 221, and 230 Vehicles
Work on Electrical Connectors
For the above model vehicles, please note than when disconnecting electrical couplings or connectors the battery only needs to be disconnected if
this is specified in the associated test and/or repair documents in WIS.Technical Service Bulletin # P-94_20-05C Date: 070628
Interior - Strong Oily or Vinegar Like Odors

Date: June 28, 2007
Group: 94
Revision History
363
c 6/28/07 Applicable Models, Parts and Warranty Information Updated
b 8/15/06 VIN Range and Applicable Models Updated/Warranty Information Removed
a 5/9/06 Warranty Information Updated (Addition of Op Code 83-6523)
SUBJECT:
All Model 209 Vehicles, Up to VIN F178200 and T061100
Model 211.026/056/065/070/076/082/083/087/256/265/276/282/283/287, from VIN A445800 to A967400 and X117500 to X207000
Model 219.375/376, from VIN A000001 to A075800
Odor in the Interior
If you receive customer reports in the above model vehicles regarding an odor in the interior is either a strong oily (putty) or acidic (vinegar)
or butyric acid (rancid butter) smell and other potential sources have been ruled out, the source of the odor may be the soundproofing mat on
the interior side of the transmission tunnel. This odor will be present even with the engine and HVAC turned off and becomes more intense
after the vehicle is parked for an extended period of time with the windows and sliding roof closed.
1. Pull back the carpeting on the side of the transmission tunnel.
2. Smell the exposed tunnel soundproofing mat, if there is an odor similar to the customer complaint, proceed to step 3.
3. Flex the exposed tunnel soundproofing mat, if the mat breaks when bent back and forth proceed to step 4.
4. If there is a strong odor and/or the mat breaks after a few bending movements, the tunnel soundproofing mat material must be replaced. It is
necessary to remove the AC housing. Refer to the following applicable WIS documents:
Model 203 AR83.30-P-5200P
Model 209 AR83.30-P-5200Q
Model 211 without Heater Booster: AR83.30-P-5200T
Model 211 with Heater Booster (Diesel Models Only) AR83.30-P-5200TA
Model 219 AR83.30-P-5200TX
Note:
Soundproofing mat part number A203 682 01 01 must not be installed. Refer to Parts Table for respective replacement part numbers.
5. After replacing the tunnel soundproofing mat, check adjacent areas to determine if the odor remains.
6. If the odor is detectable on adjacent areas, apply stain remover and plastic cleaner to the affected parts.
7. It the odor is still detectable on the carpet, the affected carpet panels will need to be replaced.
Parts Information
Note:
on June 28, 2007. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
364
365
Interior - Instrument Panel Rubbing/Buzzing Noises

Date: May 2007
Order No.: P-B-68.10/52
Supercedes:
Group: 68
SUBJECT:
MODEL 203
Noises at the Instrument Panel
Overview of noise sources
366
A. Rubbing noises in the area of the instrument cluster frame (1, Figure 1)
B. Buzzing noises in the area of the centerfill cover (2, Figure 1)
Note:
See individual repair procedures for relevant models.
Procedures
A. Rubbing noises in the area of the instrument cluster frame
The instrument cluster frame may rub on the instrument cluster when driving. This complaint occurs under rough road surface conditions.
1. Remove instrument cluster. (See WIS-document AR54.30-P-6015P)
2. Stick felt strip (material thickness: 0.5 - 1 mm) at the bottom of the ribs of the instrument cluster frame (Figure 2).
Note:
3. Install instrument cluster. (See WIS-document AR54.30-P-6015P)
B. Buzzing noises in the area of the centerfill cover
Buzzing noises occur due to there being too much play in the centerfill cover.
1. Remove centerfill cover. (See WIS-document AR68.10-P-1150PA)
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2. Apply felt (1, Figure 3) in order to brace the grill.
Note:
3. Install centerfill cover. (See WIS-document AR68.10-P-1150PA)
Special Tools
In Case of Warranty, use the table.Technical Service Bulletin # P-91_60-76D Date: 070725
Restraints - SRS Lamp ON/DTC's 9103 or 9123 Set

Date: July 25, 2007
368
Supersedes: P-B-91.60/76c dated Jan. 17, 2006
Group: 91
Revision History
d 7/25/07 Process and Part Numbers Updated
c 1/17/06 Process, Part No. description and Damage Code Update
b 12/19/05 Parts Quantity Updated
SUBJECT:
Model 203.040/052/054/056/061/064/065/076/081/084/087/092/261/
264/281/284/740/747/764
Model 209.356/365/375/376/456/465/475/476
SRS Light Illuminated
If you receive customer reports in the above model vehicles of the SRS light being illuminated accompanied by either of the diagnostic fault
codes listed below, perform the following procedure. Replacement of the contact spiral is not necessary. All contact spirals returned will be
subject to testing and may be debited if found to be operational.
Fault Codes:
1. Remove the Steering Wheel Module (SCM):
Note:
The battery ground cable must be disconnected. If this step is omitted, other faults may be introduced into the vehicle when cutting the
SCM harness.
2. Remove instrument panel bottom section on driver side:
^ 203 refer to WIS document AR68.10-P-1500P
^ 209 refer to WIS document AR68.10-P-1505Q
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3. Remove the SCM harness from the jacket tube by releasing lock tabs on both sides of the connector (Figure 1). If present, release harness
from retainer (Figure 2). Gently pull the harness out from under the instrument panel to gain access.
Procedures for 203/209, As of Model Year 2005:
4. The repair harness is color coded to match the car side of the harness. Pins 8 and 12 of the SCM connector are brown wires and cannot be
interchanged. Pins 5 and 11 are both green wires and cannot be interchanged. These wires should be cut and spliced one at a time to ensure
that they are connected correctly.
Cutting Procedure First Time Repair:
5. Using a Digital Multi Meter (DMM), locate the brown wire (0.75 BN) connected to terminal 8 of the SCM connector of the repair harness.
6. Locate the brown wire (0.75 BN) connected to terminal 8 of the SCM connector of the vehicle harness and cut it at the connector.
370
SCM harness wire. Braid the 15 mm stripped ends of the repair wire and SCM harness wire (Figure 3). Solder the wires in accordance with
the specified repair method in WIS document AR54.18-P-0100-06A (Figure 4 and 5).
9. Repeat steps 2 to 4 for the green wires (0.5 GN) at pin 5 and 11.
10. Cut remaining wires at the SCM connector and follow step (4) for remaining wires. The repaired harness will be significantly longer than the
original harness (Figure 6).
Note:
Use appropriate WEB ETM document to confirm pin locations and wire colors.
Cutting Procedure Previous Repair:
371
11. If the SCM connector has been previously repaired using individual repair wires, remove the insulating tape of the repaired harness. The
solder connectors should be located close to where the SCM harness comes out of the cockpit harness.
12. Using a DMM locate the brown wire (0.75 BN) connected to terminal 8 of the SCM connector of the repair harness.
13. Locate white pigtail that is spliced to the brown wire (0.75 BN) connected to terminal 8 of the SCM connector of the vehicle harness. Cut it
at the solder connector so that the white pigtail and solder connector are completely removed.
SCM harness wire. Braid the 15 mm stripped ends of the repair wire and SCM harness wire, see (Figure 3). Solder the wires in accordance
with the specified repair method in WIS document AR54.18-P-0100-06A (Figure 4 and 5).
16. Repeat steps 12 to 14 for each of the green wires (0.5 GN) at pin 5 and 11.
17. Cut remaining wires at the solder connector and follow Step 14 for remaining wires. The repaired harness will be slightly longer than the
original harness.
Note:
Use appropriate WEB ETM document to confirm pin locations and wire colors. The new repair harness needs to be spliced directly to the
vehicle harness using new solder connectors.
Assembly
18. Insulate harness and solder connectors with fabric tape.
19. Install the retainer, harness and N80 connector onto the jacket tube. Secure extra length of harness with cable tie.
Up to End of Model Year 2004:
21. Make note of pin locations and wire colors. Cut the SCM connector wires of the vehicle harness 50mm from the terminal ends.
Note:
Reference the appropriate WEB ETM document to confirm pin locations and wire colors.
22. Cut the repair wire 65 mm from each female terminal end.
23. Strip approximately 15 mm of insulation from the repair wires and the SCM harness wires. Twist the 15 mm stripped ends of the repair wires
and SCM harness wires.
24. All the repair wires are the same size (A001 540 94 05).
25. Using solder connector (A002 546 13 41), solder the repair wires (A001 540 94 05) onto the four airbag wires pins 3, 4, 5, 6, the four CAN
wires pins 10, 11, 12, 13 and the two wires for circuit 30 and 31, pins 8 and 9. Follow the specified repair method in WIS document
AR00.19-P-0100A.
26. Remove the lock on the SCM socket connector (Figure 7). Depress the lock tab on the terminal and remove one cut wire terminal at a time.
Install the appropriate repaired wire into the correct position in the socket connector.
Note:
Ensure during the reassembly of the SCM connector that all terminals are reinstalled in their correct positions. Continue the twist for
CAN wires connecting to pins 10, 11, 12, and 13. Reference the appropriate WEB ETM document to confirm pin locations and wire
colors.
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27. Insulate the solder connectors and the repaired harness with fabric tape.
28. If present, remove the reinforcement in the retainer (Figure 8) to prevent the harness from being crushed.
29. Install the retainer, harness and N80 connector onto the jacket tube.
Parts Information
Note:

A/C - Fluorescent Dye Leak Testing

Group: 83
Revision History
a 9/24/07 Updated to Include Diagnostic Tree Information
373
SUBJECT:
Air Conditioning Not Cooling / Leak Test Using Fluorescent Dye
If you receive customer reports in the above model vehicles of the air conditioning not cooling, temperature fluctuations or noisy compressor
operation, the cause could be low refrigerant level. Refer to the applicable diagnostic tree in the Vehicle Heating, Ventilation, Air Conditioning
(HVAC) Manual found on STAR TekInfo --> EDAC --> Non EDAC Guides. The refrigeration system should be checked for leakage using
fluorescent dye as per the instructions supplied with the leak detection equipment. Please refer to the MBUSA Standard Service Equipment
Program (SSEP) catalog (1-888-458-4040).
Note:
In order to ensure compatibility with all components and materials in the AC system the only approved tracer dye additive to be used is
manufactured by Spectronics Corp. /Tracer Products. If other products are used, warranty submissions could be subject to debit.
Brakes - Front/Rear Brakes Squeal

Order No.: P-B-42.10/79
Supercedes:
Group: 42
SUBJECT:
Model 171.454/456
Model 209.356/365/372/375/376/456/465/472/475/476/477
Model 215.374/375/376/379
Model 220.067/170/174/175/176/178/179/183/184
Model 230.471/474/475/476/477/479
Front / Rear Brakes Squeal When Braking
If you receive customer reports in the above model vehicles where either the front and/or rear brakes squeal, perform the following to resolve.
Note:
^ Bed in the brake pads in the course of a normal road test if new brake pads are installed. Do not perform any special "bedding-in"
operations.
^ Brake squeal does not usually necessitate the replacement of the brake disks. The only time the brake disks can potentially be the
cause of the brake squeal is when it is seriously warped or heavily scored.
^ A damping plate is adhered to the backing plate of the brake pads. This adhered joint must fix the damping plate to the backing plate
over its entire surface area in order to guarantee effective noise damping. If the adhered joint has become partially or entirely
detached and the damping plate can be lifted off as a result, the brake pads must be replaced.
^ If the brake pads exhibit signs of excessive heat (white or red discoloration at the edges), this is due to excessively high thermal stress
on the brakes (perhaps as a result of a misuse). In this case, the brake pads must be replaced because satisfactory noise damping can
no longer be guaranteed.
374
Front Brakes
1. Reproduce squealing noises when braking and ensure that the squealing noise is coming from the front wheel brake.
Note:
For vehicles with 4-piston fixed caliper brake on the front axle, continue and perform steps 2 through 4. For all other brake variants,
resume with step 5.
2. Check the version of the brake pads by comparing the designation number engraved on the backing plate (Figure 1) with the parts
information table. Replace brake pads and install the latest version if necessary.
3. Check the version of the removable damping plate (silver colored) and replace if necessary. The current version of the damping plate has
semicircular cutouts.
4. Check the version of the pressure spring. The current version of the pressure spring has retaining tabs (Figure 2). Replace the pressure spring
if necessary (corresponding to damage code 42116 36).
375
6. Apply brake paste to the pads/caliper based on the information shown for the particular application.
7. If new pads were not installed and the problem still persists, replace the brake pads. Refer to EPC for the latest part number. Ensure to follow
the above instructions (step 6) for proper greasing location per application.
8. For Model 211/215/219/220/230 vehicles, install dampers in pistons of front brake calipers. Ensure that the rounded part of the piston
damper(s) is inserted first for 4-piston fixed caliper brakes (corresponding to damage code 42186 36).
Note:
Refer to the WIS documents shown above for instructions on replacing the brake pads.
Rear Brakes
1. Reproduce squealing noises when braking and ensure that the squealing noise is coming from the rear wheel brake.
376
Figure 3 and 4
3. Apply brake paste to the pads/caliper based on the table shown above for the particular application.
4. If the problem persists replace the brake pads, refer to EPC for the latest part number. Ensure to follow the above instructions (step 3) for
proper greasing location per application.
377
Note:
Refer to the WIS documents shown for instructions on replacing the brake pads.
Parts Information
Note:
on September 20, 2007. Please refer to Netstar ?? Star TekInfo ?? Star Time for the most current labor time allowance.
378
379
380
381
382
383
384

A/C - Blower Motor Inoperative/DTC 09460 Set

Group: 83
Revision History
C 9/28/07 Work Instructions, Part Number

and Warranty Information Updated
b 3/9/07 Applicable Models and Content Updated
a 9/20/06 Addition of Note Pertaining to DTC Code 9460
SUBJECT: All 171, 203, 209, 211, 219 and 230 Models
Heater Blower Motor Stops Running
If you receive customer reports in the above model vehicles that the heater blower motor stops running, the blower motor regulator should be
385
replaced. The related symptoms for this condition are as follows:
1. During high blower demand, such as defrost or maximum cooling, the blower starts up and shuts off for approximately 90 seconds. The
blower tries to restart and may shut off again. This cycle may repeat.
2. Manual adjustment of the blower speed and the blower shuts off for 60 seconds and then restarts.
3. Once the blower has shut off by itself, cycling the ignition off and back on may allow the blower to operate again.
4. Diagnostic fault code DTC 9460 may be present.
These conditions may be caused by a high blower output requested by the climate system and the blower regulator overload protection engaging
unnecessarily. Follow the procedures below for corrective actions.
1. Replace the blower regulator as per the WIS document shown.
2. Additional procedures for 211 and 219 are shown above.
3. Following replacement, verify correct operation of the heater blower.
Parts Information
Note:
on September 28, 2007. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
386

Suspension - Shock/Strut Replacement Guidelines

Supersedes: P-B-32.25/19c dated July 18, 2007
Group: 32
Revision History
d 10/18/07 Paragraph 1 Updated (statement of Tech. Documentation and EPC)
C 7/18/07 Addition of Note Pertaining to 211/219 Airmatic Struts (Section 1)
a 3/15/06 Applicable Models and Replacement Procedure for ABC Struts Updated
SUBJECT:
All Model 124, 129, 140, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220 & 230
Replacement Procedure of Shock Absorbers and Suspension Struts
It has been noted that shock absorbers and suspension struts are repeatedly being replaced in pairs for no justifiable reason. When a repair
requires the replacement of a shock absorber or suspension strut, only replace the damaged part, unless otherwise noted in technical
documentation or the Electronic Parts Catalog (EPC).
Note:
There will be increased focus on the compliance with these rules when performing warranty parts inspection. DO NOT replace
non-damaged shock absorbers or suspension struts. Warranty claims will be denied in cases where a shock absorber or suspension strut
was replaced needlessly.
1) Guideline for Airmatic air suspension struts (Model 211, 219, 220) ABC suspension struts (Model 215, 220, 230) and ADS suspension struts
(Model 129, 140, 210)
387
Note:
Not applicable to AMG 211 and 219 Models (211.076/077/276/277 and 219.376/377)
Damage to one suspension strut does not justify the simultaneous replacement of the opposite suspension strut. This also applies to
complaints of noise, such as thumping. In such cases, thorough diagnostics to determine the responsible suspension strut should be performed
by driving each side of the vehicle on a road surface corresponding to the customer complaint. Only the affected suspension strut should be
replaced.
Prior to replacing the suspension strut in the semi-supporting systems ABC, Airmatic air suspension, or ADS, relieve the tension on the
respective suspension strut to check whether this remedies the noise complaint. To do so, loosen both the upper and lower mountings on the
rear suspension struts and retighten to the prescribed torque with the vehicle resting on its wheels.
Experience has revealed that for the front suspension strut, it is sufficient to carry out this procedure on the upper mounting only.
Since it can be assumed that a new Airmatic/ADS suspension strut installed in a high mileage vehicle, would not match with the used
suspension strut and thus impair ride comfort and or vehicle dynamics, it is then recommended that these components be replaced in pairs
only after the vehicle has reached a mileage of at least 50,000 miles (80,000 km).
In contrast to Airmatic/ADS suspension struts or conventional shock absorbers, the ABC suspension struts do not have to be replaced in pairs
at high mileages (50,000 miles /80,000 km) as the damping of the vehicle body is taken over by the active actuation of the plunger.
2a) Guidelines for conventional shock absorbers (Models 171, 203, 209, 211 and successor models)
Damage to one shock absorber does not justify the simultaneous replacement of the opposite shock absorber. This also applies to complaints
of noise, such as thumping. In such cases, thorough diagnostics to determine the responsible shock absorber should be performed by driving
each side of the vehicle on a corresponding road surface. Only the affected shock absorber should be replaced.
Since it can be assumed that a new shock absorber installed in a high mileage vehicle, would not match with the used shock absorber and
thus impair ride comfort and or vehicle dynamics, it is then recommended that these components be replaced in pairs only after the vehicle
has reached a mileage of at least 50,000 miles (~80,000 km).
2b) Guideline for conventional shock absorbers (Model 124, 129, 170, 201, 202, 208, 210)
For these models, there exist various shock absorber variants. Thus requiring that the conventional shock absorbers be replaced only in pairs.
Suspension - Front Axle Creaking Noises

Order No.: P-B-32.20/58
Supersedes:
Group: 32
SUBJECT:
Creaking Noises from Area of Front Axle When Suspension Compresses/Expands
If you receive customer reports in the above model vehicles of a creaking noise from the front axle area when the suspension is compressed or
expanded, perform the following.
Note:
This noise may be caused by the wearing out of the rubber mounts located on the front axle torsion bar. The noise may occur more at
higher temperatures.
1. Remove the lower engine paneling. Refer to WIS document AR61.20-P-1105P.
2. Remove the torsion bar on the front axle. Refer to WIS document AR32.20-P-0300P. If the vehicle has xenon headlamps, detach the linkage
from the level sensor.
3. Thoroughly clean the torsion bar.
388
4. Preinstall both rubber mounts with seal boots and slide them onto the torsion bar (Figure 1). Take note of the installation position.
5. Screw on both caps for the rubber mounts (Figures 2 and 3). Use a new bracket if the torsion bar diameters are 20 mm and 21 mm.
6. Reinstall the torsion bar and lower engine paneling in reverse order.
Parts Information
389
Note:
on November 2, 2007. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
In case of warranty, use the table.Technical Service Bulletin # P-35_30-03 Date: 071106
Drivetrain - Rear Axle Surface Corrosion

Order No.: P-B-35.30/03
Supersedes:
Group: 35
SUBJECT:
All Model 171, 203, 209, 211, 215, 219, 220, 221 and 230
Vehicles Surface Corrosion on the Rear Axle Shafts
If surface corrosion on the rear axle half-shafts/axle-shafts is noticed on the above model vehicles, the surface corrosion is aesthetic in nature and
has no influence to vehicle functionality. Parts replacement for surface corrosion is not a warrantable repair.
Engine Controls - Mil ON/DTC P0217 Stored in Memory

Order No.: P-B-07.61/78
Supersedes:
Group: 07
SUBJECT:
Model 171.454/456
Model 203.052/054/056/087/092
Model 204.054/056
Model 209.356/372/456/472
Model 211.056/072/087/090/256/287
Model 216.371
Model 219.372
Model 221.171/186
Model 230.471
Check Engine Light Illuminated / Fault Code P0217 Stored in Engine Control Unit
If you receive customer reports in the above model vehicles that the check engine light is illuminated with fault code P0217 stored in the engine
control unit, the cause may be the software in the control unit. Other possible stored fault codes may be P0868, P0872, P0190, P0208, P1347 or
P2182. To resolve, perform the following.
Note:
Vehicles produced as of 11/2005 have the modified software version installed.
1. Check the throttle valve for mechanical faults and check intake tract for residues. If there is no mechanical fault, the throttle valve actuator is
not the cause and must not be replaced. Proceed to step 2.
390
2. Program the engine control unit with the latest available ME software in DAS.
Note:

ABS/TCS - ESP Visit Workshop Displayed On I/P

Order No.: P-B-42.45/83
Supersedes:
Group: 42
SUBJECT:
All Model 203 Vehicles, As of August 1, 2001 Series Production
ESP Visit Workshop Displayed In Instrument Cluster
If you receive customer reports in the above model vehicles of "ESP - Visit Workshop" being displayed in the instrument cluster, and for vehicles
with an automatic transmission the selector lever cannot be removed from position "P" after the engine is started, and various fault codes are stored
in the relevant control units, perform the following repair.
391
Note:
In vehicles equipped with tire pressure loss warning system this function will also not be available.
The conditions listed above are caused by an inadequate ground connection at the ESP (W70) ground point (Figure 1, arrow) due to the heat
shrinkable tube protruding under the ground cable lug's attachment point.
1. Remove the excess length of the heat-shrinkable tube on the ground cable lug so that a complete ground connection can be established
(Figure 2).
Note:
Do not damage the coating on the ground cable lug. Additionally, ensure that the heat-shrinkable tube is only removed in the area of the
screw attachment point.
2. Tighten the nut on the ground bolt (W70) to 8 Nm.
Note:
generated on November 2, 2007. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.

Body - Paint Damage on Trunk Lid

392
Order No.: P-B-98.10/19
Supersedes:
Group: 98
SUBJECT:
All Model 171, 199, 203, 204, 209, 211, 216, 219, 221 and 230
Damage to Painted Surface on Trunk Lid
It has come to our attention that a large number of warranty claims have been submitted for paint repair on the trunk lid due to incorrect length
license plate attachment screws. Warranty claims with paint damage from the use of incorrect fastening hardware are not covered. The screws are to
be used for license plate installation. Please see the table shown for the correct license plate attachment screws.
Keyless Entry - LED on Transmitter Key Not Functioning

Order No.: P-B-80.35/43
Supersedes:
Group: 80
SUBJECT:
All Model 171, 202, 203, 208, 209, 210, 211, 215, 220 and 230
Equipped with Drive Authorization System (DAS3) (FBS3)
Battery Indicator (red LED) on Transmitter Key Not Functioning
If you receive customer reports on the above model vehicles that when using a new transmitter key for the first time the battery indicator is
nonfunctional (lock/unlock is unaffected), reinsert the key into the ignition a second time. Proper operation of the key is restored automatically once
the key is taught into the vehicle.
Instruments - Displaying Vehicle Voltage Instructions

393
Group: 54
Revision History
b 12/21/07 Applicable Models and Instructions Added
a 6/10/03 Applicable Models and Instructions Added
SUBJECT:
All Model 171, 203, 204, 209, 211, 215, 216, 219, 220, 221 and 230
Display of Vehicle Electrical Network Voltage in the Instrument Cluster
In the above models, electrical network voltage may be displayed through the instrument cluster's multi-function display.
For model 203 (up to MY04), 215, and 220
1. Using the steering wheel mounted multifunction buttons, ensure that the vehicle's main odometer is displayed within the instrument cluster
multifunction display.
2. Turn key to position one in the electronic ignition switch
3. Within 1.5 seconds of turning to position one, press the instrument cluster's reset button three times
4. An audible sound will be heard and the vehicle voltage will appear in multifunction display
For model 171,203 (as of MY05), 209, 211, 219, and 230
1. Using the steering wheel mounted multifunction buttons, ensure that the vehicle's main odometer, or temperature/speed display (for
209/211/219), is shown within the instrument cluster multifunction display.
3. Press the reset button on the instrument cluster three times
4. An audible sound will be heard and the vehicle voltage will appear in multifunction display
For model 204, 216 and 221
2. Ensure standard display is shown in the instrument cluster multifunction display
3. Hold down the "send" key on the steering wheel
4. While still holding the "send" key, hold down the "Ok" key on the steering wheel.
5. After approximately 3 seconds, new menu selections will appear in the multifunction display
6. Select "vehicle data" in the multifunction display
7. The vehicle voltage will appear in multifunction display
Note:
generated on December 21, 2007. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
394

Steering - Steering Gear Apparent Leakage Information

Group: 46
Revision History
a 11/27/07 Updated to Include Model 204
SUBJECT:
All 171, 203, 204, 209, 210, 211, 215, 216, 219, 220, 221 and 230 Models
Equipped with Rack-and-Pinion Steering Steering Gear Leaking Under Dust Cap on Control Head
During inspection of returned power steering racks, we have encountered cases where steering racks have been replaced due to leaking" but which
prove to exhibit merely "sweating" or a film of grease under the dust cap on the top of the control head.
If during power steering complaint diagnosis, moisture on the surface of the steering gear under the dust cap is noticed in a localized section, this is
considered sweating due to grease liquefying and not leakage.
This moisture can be caused by:
^ Grease under the dust cap to keep dirt (dust) away from the steering system.
^ Heat from the engine causes some of the grease under the cap to liquefy which produces a slight but noticeable moisture/grease film on the
surface and does not indicate leakage, nor is it a cause for power steering complaints.
395
Figures 1, 2 and 3 contain examples of steering racks that are "sweating" in this area. It can be seen that, on the sweating steering gear, only the top
of the control head is wet on one side (i.e. not all round). No droplets form (no run marks etc.) that run down the steering gear/control head. For this
reason, do not expect any contamination with grease/oil in the surrounding area or on the ground. The grease (film) adheres to the steering gear
housing.
In contrast, if the steering is genuinely leaking, the steering gear housing appears very wet, even when combined with dirt, and sometimes droplets
are formed.
Note:
Another form of leakage in the steering system is a drop in the oil level in the reservoir of the power steering pump. For this reason, the oil level
must always be checked with the dipstick when ascertaining findings.
Therefore, when assessing whether a steering gear is merely "sweating" due to liquefying grease in the area of the control head or whether it is
actually leaking, strictly adhere to the procedure described below:
1. Clean steering gear.
2. Spray or coat steering gear with a suitable leak detector spray.
396
3. Warm up the steering system by turning the steering wheel from lock to lock several times and, if necessary, perform a test drive and observe
the oil level in the power steering pump reservoir.
4. Assess steering for leaks
Note:
If leakage is found at the screw connections of the internal/external lines or at the power steering valve, repair parts are available.
Steering racks must not be replaced for this reason.
Steering - Leaks From Steering Rack

Group: 46
Revision History
C 12/19/07 Applicable Models Updated
b 3/27/06 Technical Content / Parts and Warranty Information Updated
a 8/26/05 Applicable Models / Technical Content Updated
SUBJECT:
Model 171.454/456/473
Model 203.052/054/056/061/064/065/081/084/261/264/281/284/740/747/764
Model 209.356/365/375/376/456/465/472/475/476
Model 211.026/065/070/076/082/083/265/276/282/283
Model 219.372/375/376/377
Model 230.471/472/474/475/476/477/479
Leak at Steering Rack Connection
If you encounter leakage at the steering rack connection in the above models, the cause may be damage to the sealing ring of the hydraulic lines. In
such instances, replacement of the rack will not resolve the situation. To resolve, replace the sealing ring at the steering gear connection as per the
below procedure.
1. Loosen line connection on steering gear.
Note:
If necessary, loosen line supporting bracket.
Note:
Ensure that sealing rings and supporting ring are properly seated. Supporting ring only present on high pressure line (not on model 230
and 203 up to 03/02).
Note:
There are two versions of power steering high-pressure lines. The preceding version has a slotted support ring which can be replaced
individually. The new version has a support ring which is not slotted and which cannot be replaced individually; in this case the complete
power steering high-pressure line must be replaced (see parts list).
3. Fasten line connection on steering gear with retaining plate.
Note:
Observe below torque values for screw connection.
4. Bolt, oil line clamping plate to rack-and-pinion steering
397
a. Models 203, 211.082/083/087/282/283/287 - 20 Nm
Models 171, 209, 211 except 211/082/083/087/282/283/287 - 18 Nm
b. Bolt on Clamp Plate, high-pressure line / return line to rack-and-pinion steering
Model 230 - 18 Nm
5. Bleed steering system and check for leaks. Refer to the WIS documents shown for bleeding the system / checking for leaks.
Parts Information
Note:
on December 19, 2007. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.

Wheels - Recommendation Against Chroming Alloy Wheels

Date: February 2008
Supersedes: MBNA 40/18 dated April, 1991
Group: 40
Revision History
398
a 02/2008 Updated to include current models
- 04/1991 Initial issue
SUBJECT:
All Models
Chrome Plating of Mercedes-Benz Light Alloy Wheels
Warning!
Chrome plating of Mercedes-Benz light alloy wheels is not recommended.
The reason that we do not recommend chrome plating is as follows:
When chrome plating an Mercedes-Benz light alloy wheel, the wheel must first be anodized (copper plated).
The difference in EMF (Electro-Motive Force) values between copper and aluminum results in electrolytic corrosion with aluminum being the
sacrificial metal. This will result in weakening of the base metal as well as poor adhesion of the subsequent plating, and thereby premature flaking
of the chrome finish.
Wheels of cast light alloy, with their porous surface, are even more susceptible to this condition than those of forged light alloys.
A/T - Multiple DTC's Set/Limp Home Mode

Group: 27
Revision History
SUBJECT:
All Passenger Models Equipped with 722.9 (7G-Tronic) Transmission
planetary gear set.
399
Note:
Warning!
Parts Information
Note:
400
Anti-Theft System - DAS3 Diagnostic Information

Group: 80
401
Revision History
b 1/9/08 Applicable Models and Paragraphs Three and Four Updated
a 11/17/05 Applicable Models and Paragraph Three Updated
SUBJECT:
All Model 171, 203, 204, 209, 211 and 219 Vehicles
Diagnosis and Replacement of DAS3 Components
Diagnostic procedures for the DAS3 Drive Authorization System have been revised for models listed above. Please proceed as follows when
diagnosing systems conditions.
Select Control units --> Body --> EIS --> "Guided transmitter key check" or "Guided drive authorization system check"
Select the respective guided check. A guided diagnosis follows which is used to pinpoint the component that is causing the condition. Do not
replace any component before performing this diagnosis. Always perform the diagnosis in its entirety until SDS identifies the component to be
replaced. At the end of the test steps, the user will be prompted to print the results. When submitting a claim, copies of this printout and a quick test
must accompany the parts. The warranty claim may be debited a handling charge if the printout and the quick test do not accompany the parts.
Applied diagnostic steps are stored in the EIS (Electronic Ignition Switch) and ESL (Electric Steering Lock) components. The diagnostic steps
utilized by the dealer will be electronically verified by the QEC to determine if the control unit performed the diagnostic procedure. If it is
determined that a complete diagnosis was not performed, the warranty claim may be debited a handling charge.
Both vehicle keys are required to ensure a proper diagnosis. Please be sure that both keys will be available when the repair appointment is made.
Anti-Theft System - A/T Inop After Key Programming

Supersedes: P-B-80.57/48 dated January 9, 2008
Group: 80
Revision History
SUBJECT:
Model 203.052/054/056
Model 209.356/372/375/377/456/472/475/477
Equipped with 722.9 Transmission (SA code 427)
Transmission Inoperable After Learning a New Spare Key
If you encounter an issue in the above model vehicles of the automatic transmission becoming inoperable after initializing a new spare key in the
electronic ignition switch (EIS), this may be due to the transmission control unit still performing the initialization process for the new key. To
resolve, reinsert the new key back into the EIS, switch to key position two and have key remain in EIS for approximately one hour. Do not replace
any parts for this condition!
Warning!
Ensure a battery charger is also connected.
Note:
When a key is initialized in the EIS and circuit 15 is switched on, the key is also initialized in the engine and transmission control unit. These
control units take different lengths of time to compute the drive authorization data. In most instances, the engine control unit finishes its
402
calculations in approximately 15 minutes. When the engine control unit finishes its calculations, the "vehicle computing" display in the
instrument cluster disappears, even though the calculation in the transmission control unit may not be complete. The computation of the drive
authorization data in the transmission control unit can take up to 45 minutes.
Note:

Interior - Front Center Arm Rest Loose/Falls OFF

Supersedes: P-B-68.20/33b dated February 2, 2007
Group: 68
Revision History
c 2/14/08 Note Pertaining to 203/209 Added to the beginning of this bulletin and Parts Information Updated
b 2/2/07 Content Revised and Warranty Information Updated
a 11/15/04 Applicable Models for Conditions 1 and 2 Updated
SUBJECT:
Model 203.040/052/054/056/061/064/065/076/081/084/087/092/261/264/281 /284/740/764/747
Model 209.356/365/375/376/456/465/475/476
Front Center Armrest Lid
If you receive customer reports in the above model vehicles of either of the conditions listed below, perform the respective remedy as stated.
Condition 1:
Lid for the front center armrest and storage compartment has fallen off or is not closing correctly.
Applicable Models:
203/209 MY 05 or 06, Equipped with "Flip top" armrest design
Remedy 1a:
Reinstall the lid. If the pivots or levers are not damaged do not replace the lid, reinstall lid as per WIS document AR68.20-P-2370Q (or view the
video demonstration on the MBUSA Training and Education website at http://tech_trainingdev.mbusa.com/console and latch) and then check the
lid for correct functioning. Starting October 11, 2004, lids replaced under warranty will be inspected for damage to the pivots and levers. If the
pivots and levers are found to be okay, the claim will be debited.
Note:
For 203 MY 05 or 06, if the customer is not satisfied with remedy 1a, a new armrest lid (see parts information) can be retrofitted as per WIS
document AR68.20-P-1101Q. This retrofit is customer pay.
Remedy 1b:
Inspect the bin or lid for damage. If the bin or the lid is damaged, replace the bin and lid per WIS document AR68.20-P-2150QA. If the damage
causing part is the lid, use damage code 68119. If the damage causing part is the bin, use damage code 68115 or 68118 (depending on model).
403
Condition 2 (209 only - as of MY 05):
Front center armrest latch will not open or catches when opening.
Applicable Models:
209 MY 05 or 06, Equipped with "Flip top" armrest design
Remedy 2:
This may be caused by tolerance problems in the kinematics of the latch or the latch may be broken. If this occurs, it is not necessary to replace the
entire lid.
1. Replace only the latch (Figure 1, 1).
2. Remove and install the old lock cylinder (Figure 1, 2) as per WIS document AR68.20-P-2380P.
Condition 3:
Rubbing noise from center armrest lid.
Applicable Models:
203 - up to A044555 or F026062 / 209 - up to F147223 or T044943
Remedy 3:
404
This may be due to the center armrest lid rubbing against the catch area when driving (Figure 2 for 209 or Figure 3 for 203, arrows). To resolve,
lightly grease the catch area.
Parts Information
Note:
on February 2, 2007. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
405

Tire Monitor - Tire Pressure Monitoring Inactive Message

Order No.: P-B-42.45/86
Supersedes:
Group: 42
SUBJECT:
Equipped with Sales Code 477 - Tire Loss Warning System (indirect ESP based) with Run Flat Tires
Model Year: 2005 to 2007
"Tire Pressure Monitoring Inactive" Displayed in Instrument Cluster
If you receive customer reports in the above model vehicles with the message "Tire Pressure Monitoring Inactive" displayed within the instrument
and the following fault code is stored within the ESP control unit, perform the following.
^ C1550 - Test voltage supply at control unit N47-5 (ESP and BAS control module)
Note:
This may result from an incorrect fault setting condition with the tire pressure loss warning software. If there is an under-voltage in the
ESP control unit when writing to the EEPROM (Electrically Erasable Programmable Read-Only Memory) or if an ignition change occurs
when the vehicle is moving, an invalid value can be supplied to the EEPROM check. This can produce fault code C1550 even if the ESP
control unit is OK.
1. Check power supply (> 12 V) at component N47-5 (ESP control unit) and correct any connection issues.
406
2. Check ground connection of component A7/3 (Traction system hydraulic unit) and correct any connection issues.
3. Using STAR Diagnosis perform a short test and erase fault codes
4. Cycle ignition on-off-on
5. Using STAR Diagnosis recheck for the above fault codes within ESP.
6. If no fault code is present the ESP control is OK.
7. If the fault code listed above is present, replace the ESP control module. Refer to ESP for latest part number. ESP control unit replacement is
only justifiable if the fault is currently stored and there is no under-voltage present at the ESP control or hydraulic unit.
Note:
generated on January 3, 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.

ABS/TCS - Cruise Control Message Displayed/DTR Lamp ON

Order No.: P-B-42.45/88
Supersedes:
Group: 42
SUBJECT:
All Model 203 Vehicles, as of August 2001 Production
"Speedtronic/Cruise Control, Visit Workshop!" Displayed In Instrument Cluster and / or DTR Lamp Illuminated After Engine Start and ESP
Control Unit Replacement
If after replacing the ESP control unit; "Speedtronic/Cruise Control, Visit Workshop!" is displayed in the instrument cluster and/or the DTR
indicator lamp is illuminated after the engine has been started, perform the following.
Note:
The following fault code and/or event code may be present. This is due to the incorrect ESP control unit replacement, since ESP control
407
units are not universally compatible or interchangeable.
^ ESP control unit: C1510 - Fault in CAN communication with control unit N63/1 (DTR control module)
^ Instrument cluster: 9104 - Control module DTR is not sending any data
Note:
Please refer to WIS document AR42.45-P-0820P for instructions on replacing the ESP control unit. After replacing the ESP control unit
it may be necessary to deactivate the speed-sensitive power steering via coding and activate the tire pressure loss warning system using
the "Initial Start-up" menu in STAR Diagnosis.
Parts Information
A/T - Limp Home Mode/Various Codes Set

Group: 27
Revision History
SUBJECT:
Model 171.454/456/473
Model 203.052/054/056
Model 209.356/375/456/475
Model 211.056/070/256
Model 215.375
Model 219.375
Model 220.170/175
Model 230.475
Equipped with 7G-Tronic Transmission (NAG2)
2768, the condition can be related to an unfavorable production tolerance of the speed sensor ring of the K1 shift member.
408
In such cases, the flange (Figure 1, call-out 164) should be replaced to resolve. Follow the work procedures outlined in WIS Document
AR27.51-P-0800W (Dismantling and Assembling clutch K1) as well as the other associated documents.
Note:
This work procedure only applies to the above fault codes and to transmissions with a production range of 7229xx 00 327088 to 7229xx 00
338693. For transmissions outside of the given production range, replace the electro-hydraulic control unit only. Refer to EPC for the specific
application / part number.
Parts Information
Note:
409
Paint - Adhesive Residue Removal

Order No.: S-B-98.30/22
Supersedes:
Group: 98
Subject:
All Passenger Car and Light Truck Models
Elimination of Adhesive Residues On Paint Work
410
If you receive customer reports of adhesive residues left on the paintwork from stickers which were removed on the doors and / or lift gate of new
vehicles, apply Mercedes Benz Stain remover (A001 986 28 71 10) to remove the residue. Carefully apply the stain remover using a sponge or
brush, leave it to act for a short time and then wipe off with a sponge or microfiber cloth. Also, refer to the relevant product information.
Restraints - SRS Lamp ON/Multiple Codes Set

Supersedes: P-B-91.60/65b July 22, 2004
Group: 91
Revision History
c 1/11/08 Warranty Information Updated (Model Indicators Added)
b 7/22/04 Procedure Update - Return of connectors no longer necessary
a 1/9/04 Procedure Update
SUBJECT:
Model 203
All Model Years
SRS Indicator Lamp On
If you receive customer reports in the above model vehicles that the SRS light is illuminated and diagnostic fault code(s) B1035, B1037, B103B
and/or B1039 are stored in the SRS ECU, the resistance in R12/11, R12/12, R12/20 or R12/21 ignition circuits for the sidebag squibs may be too
high. This high resistance is caused by either of the following:
^ The left front door separation point connector X35/1,
^ The right front door separation point connector X35/2,
^ The left rear door separation point connector X35/3
^ The right rear door separation point connector X35/4.
To resolve, remove connectors from the wires for sidebags in the left and right front footwells and the left and right rear entry ways and connect
wires directly. Please follow the below procedure to repair.
411
Note:
Always perform procedure on all 4 connectors.
1. Remove ignition key.
2. Remove A-pillar paneling in front foot well and door sill molding. Remove left front floor covering per WIS document AR68.20-P-2050P
and right front floor covering per WIS document AR68.20-P-2070P.
3. Remove left and right rear door sill molding.
4. Expose wiring harness. Figure 1 shows connector for front doors X35/1 (left front door separation door separation point) and X35/2 (right
rear door separation point) are similar. Wiring diagram of airbag control module with integrated E-call system can be found in WEB ETM
document 91.60-U-2101FA.
5. Remove connectors and connect wires directly with solder connectors.
a. Cut line approx. 10 mm in front of and behind connector.
b. Remove about 20 mm of fabric tape on the control unit side.
c. Strip about 15 mm of insulation from the wire.
d. Slide solder connector onto wires.
e. Twist both wire ends together, observing the wire color assignment.
f. Position solder connector in the middle and shrink it on (solder) using a heat gun.
^ Utilize wiring harness repair set W220 589 02 99 00 and heat gun part no. 458-HL1802E via the MBUSA Standard Service
Equipment Program.
g. Inspect solder connection.
h. Tape up both ends of the wires.
6. Delete fault memory with STAR DIAGNOSIS.
7. Install in the reverse order.
Parts Information
Note:
412

Steering - Flow Noises/Fluid Foaming After Repairs

Group: 46
Revision History
a 11/27/07 WIS Document Information Updated
SUBJECT:
Flow Noises from Area of Power Steering Pump and/or Foaming of Power Steering Oil in Reservoir
If you receive customer reports in the above model vehicles of flow noises from the area of the power steering pump, and/or foaming of the power
steering fluid in the reservoir following work carried out on the hydraulic steering system; this may be caused by an improper procedure followed
for filling and bleeding of the power steering fluid into the system.
To remedy, it is absolutely necessary to make sure that the procedure described in the WIS documents is strictly adhered to. In particular, it is
necessary to turn the steering to full lock-to-lock at least 30 times BEFORE STARTING THE ENGINE. If this is not done prior to starting engine,
there is a high risk of air entering the steering system, which is subsequently very difficult to eliminate.
Note:
Starting the engine prior to bleeding can cause irreparable damage to the power steering pump and will cause an air cushion to form in the
steering gear which causes noise. Once the air is ingested, the ingested air will only dissipate after driving the vehicle for at least 30 miles.
413
Refer to the chart shown for the correct WIS document reference for the proper filling and bleeding procedure of the power steering pump.
A/C - Unpleasant Odor From Air Conditioning Vents

Order No.: S-B-83.00/115
Supersedes:
Group: 83
SUBJECT:
All Model 164, 171, 203, 204, 209, 211, 215, 216, 219, 220, 221, 230 and 251
Vehicles Unpleasant Odor from Air Conditioning Vents
If you receive customer reports in the above model vehicles of an unpleasant odor coming from the air conditioning vents, the cause may not be the
air conditioning system, but an odor being circulated in the air and then perceived as coming from the air conditioning system. In the event of odor
complaints, always determine whether the odor is caused by the air conditioning system, by items in the interior compartment, or by smells from the
environment. To accurately identify odors, please reference the Odor Diagnostic Tree found on Star TekInfo --> EDAC --> Non EDAC Guides -->
Vehicle Heating, Ventilation, and Air Conditioning (HVAC) Manual.
Note:
All filters installed in the air conditioning system must be replaced in the event of an odor complaint.
Please see below for specific odor complaints and their corresponding remedies:
1. A "damp air or musty odor just after engine start" is due to the moisture that accumulates at the evaporator and gets absorbed by the air in the
evaporator housing when the blower is shut off. When the blower is activated again, the damp air is carried into the interior compartment
414
within the first few minutes. There is no fix for this, as this is due to various laws of physics. Please explain this to the customer.
2. For odors coming from the interior that are intensified in air recirculation mode, check the vehicle interior for foreign objects, contamination
or vapors. For example:
^ Food leftovers
^ Spilt fluids
^ Air outlets (e.g. for fluids that may have entered)
^ Cigarette smell/ashtrays
^ Animal hairs
^ Shoes/clothing
^ Air fresheners
^ Interior (e.g. instrument panel, door rubber seals)
^ Damping mats/materials (e.g. on firewall, transmission tunnel, spare tire well, doors) refer to Star TekInfo document P-B-94.20/05c (or
latest version)
3. Odor of chlorine/rotten eggs: Check for leaks in the bodywork, fumes entering from the engine compartment or outside environmental
sources while driving. Try to obtain ambient condition information from the customer when the complaint occurs.
4. Musty/moldy odor, refer to Star TekInfo document P-B-83.30/74j (or latest version) and T-B-83.30/91c (or latest version).
Exhaust System - Exhaust Pipe Chrome Tip Care

Date: May 14, 2008
Order No.: S-B-49.10/11
Supersedes:
Group: 49
SUBJECT:
MY-All
Models-All with Chrome Tail Pipe Finisher
The Care of Tail Pipe Finishers
Chipping damage from stones hitting tail pipe finishers cannot be prevented, but regular care of the chrome finishers can prevent ensuing corrosion
and rust from forming on the chipped areas.
To retain the gloss and appearance of the chrome on the tail pipe finishers over the life of the vehicle, observe the following:
^ Do not use alkaline or aggressive cleaners, such as wheel cleaner.
^ Particularly in the winter months, use chrome polishing paste on the tail pipe finishers.
415
Corrosion from stone chipping, rust deposits and dirt.
The replacement of the exhaust system components, such as tail pipes, tail pipe finishers or rear mufflers is not justified when proper care will
maintain the chrome.
Showing untreated left-hand side and treated right-hand side.
Warning!
In order to avoid possible serious burns or injury, wait until the rear exhaust pipes have completely cooled before applying chrome polishing
paste.
Parts Information
Interior - Interior Damage From Scent Dispensers

Order No.: S-B-68.30/75
Supercedes:
Group: 68
SUBJECT:
Surface Damage Caused by Scent Dispenser
If you receive customer reports of surface damage such as the surface coating loosening on the radio, COMAND, upper control panel or air vents,
this may be caused by the use of an aggressive interior scented product (e.g. scented oils) (Figure 1, arrows). During vehicle workshop visits, check
whether there is a scent dispenser in the vehicle and inform the customer of any consequential damage caused by the product. This type of damage
is not covered by warranty.
416
A/C - Control Module/Control Functions/Diagnostics

Date: April 4, 2008
Order No.: S-B-83.00/116
Supercedes:
Group: 83
SUBJECT:
All 164, 171, 203, 204, 209, 211, 215, 216, 219, 220, 221, 230 and 251 Vehicles
AC Control Module / Control Functions
If you receive customer reports in the above model vehicles of the below conditions, replacing the AC control module does not rectify the
problem.
1. Air conditioning not functioning:
The sensors or actuators of the climate control system that are networked to the AC bus (e.g. sun sensors or actuator motors) can completely
disable the AC bus if they are not operating. Please check the sensors, actuator motors and SDS for fault codes. If communication faults are
stored, then the operating unit is not the cause.
2. Implausible control:
The multi-zone sun sensors have a significant influence on the temperature control. The sun shining at a specific angle can result in different
outlet air temperatures and blower output on different sides of the vehicle. This effect is also possible on a cloudy day because of UV
radiation. Adjustment of the interior temperature is also heavily influenced by environmental conditions (e.g. heat from the transmission
tunnel, heat from the radio or COMAND unit influencing the in car temperature sensors). Replacing the operating unit will not change the
control response.
3. Poor control quality/cold feeling, too warm, too cold:
Condition may be due to body leaks and predominantly occurs at high speeds. At very high speeds, the refrigerant compressor output is
lowered to provide the engine with extra power; this can cause the report of "blower output too warm". Since this is a normal function,
replacing the AC control module is not a solution. The same condition can occur during rapid speed changes (heavy braking, rapid
acceleration).
4. Fogged windows:
This condition is not related to the operating unit. Possible causes include moisture in the vehicle interior, driving with the air conditioning
off or with the air condition and recirculation mode on.
Perform the following if a report regarding one of the above conditions is received:
1. Check all steps in the diagnosis tree found on Star TekInfo --> EDAC --> Non EDAC Guides --> Vehicle Heating, Ventilation, and Air
Conditioning (HVAC) Manual.
2. Erase the fault memory.
3. Perform system reset via circuit 30.
Note:
The operating unit is generally not the cause of reported concerns regarding climate control operation. Check all of the other components
in the climate control system using the diagnostic tree prior to performing work on the operating unit. Always submit the related
diagnosis printouts and findings report when submitting a warranty claim. Technical Service Bulletin # S-40_10-60 Date:
080501
Wheels/Tires - Nitrogen Usage Recommendations

Date: May 2008
Order No.: S-B-40.10/60
Supersedes:
Group: 40
417
SUBJECT:
MY-All, Models All
Nitrogen Use in Tire Inflation
Original equipment and approved replacement tires for Mercedes-Benz passenger cars and light trucks are designed to be inflated with ordinary
compressed air, which generally contains approximately 80% nitrogen. Inflation with ordinary compressed air provides the expected operating
performance for these tires so long as the operator regularly checks and maintains the air pressures as recommended by Mercedes-Benz on the
vehicle's fuel filler door or the driver-side B-pillar.
In normal vehicle use, nitrogen offers negligible benefits and is rarely cost effective. Although, the physical properties of nitrogen can reduce
inflation pressure losses due to the permeability of tire materials and thus, improve the damping behavior; the existence of several other possible
sources of leaks, such as tire/rim interface, valve, or rim/valve interface can significantly limit the effectiveness of nitrogen in maintaining tire
pressure in ordinary vehicle use.
In summary, all tires approved for use on Mercedes-Benz passenger vehicles are designed to deliver their expected performance when inflated with
ordinary compressed air. Mercedes-Benz does not require or recommend the use of nitrogen as the results and benefits derived from its use are not
in proportion to the expense. Technical Service Bulletin # P-82_10-195F Date: 080408
Lighting - Front Turn Signal(s) are Inoperative

Date: April 8, 2008
Order No.: P-B-82.10/195f
Supercedes: P-B-82.10/195e dated March 15, 2006
Group: 82
Revision History
f 4/8/08 VIN Range and Applicable Models Updated
d 2/16/06 Applicable VIN Range Added
c 7/1/03 Warranty Information Updated
b 8/2/02 Warranty Information Included
a 6/12/02 Part Number Included
SUBJECT:
Model 203.052/054/056/061/064/065/076/081/084/087/092/261/264/281/284/
740/747/764
Up to VIN A339771, F261050 and R053444
Front Turn Signal Inoperative
If you receive customer reports in the above model vehicles of the front turn signal not working, this may be due to a contact problem
between the turn signal bulb socket and the headlamp housing. In this case, perform the following repair only on the affected side of the
vehicle.
1. Remove E1e2 (left turn signal) or E2e2 (right turn signal) from the headlamp housing. Refer to WIS document no. AR82.10-P-1201P, R&R
Bulbs Headlamp Unit.
2. Check outer contacts of the bulb socket for damage. If damage is visible, repair as follows.
3. Disconnect 5-pin connector at headlamp housing.
418
^ Plug from headlamp assembly
1. Turn signal wire located in chamber 1 of existing headlamp housing connector (2)
2. Headlamp housing connector
3. Connector locking tab
4. Open pin lock (Figure 1, 3) on connector (Figure 1, 2) and "un-pin" turn signal wire (Figure 1, 1) from connector. Left side, pin 1 is
white/black. Right side, pin 1 is green/black. Refer to WIS document no. AR00.19-P-0120-02B, Removing Contacts from Sensor Connector.
5. Plug empty chamber with a rubber plug, refer to parts information section for part number.
^ Turn signal repair set
1. Turn signal wire from headlamp
4. Repair set connector
5. Turn signal bulb socket connector
6. Turn signal bulb socket ground wire
6. Remove contact housing (Figure 2, 4) from connector (Figure 2, 5) and insert "un-pinned" turn signal wire removed in step 4 (Figure 2, 1)
into chamber 2 of contact housing (Figure 2, 4) (from repair set). Prior to assembly, check individual gaskets for damage.
7. Reconnect contact housing (Figure 2, 4) with connector (Figure 2, 5). Housing must audibly click into place.
8. Connect cable eyelet (Figure 2, 6) of the repair set with the component compartment ground (Figure 3, W16/3) if repairing the left turn signal
or the component compartment ground (Figure 4, W16/4) if repairing the right turn signal.
9. Install E1e2 (left turn signal) or E2e2 (right turn signal) into the headlamp housing.
10. Re-connect connector (Figure 1, 2) with headlamp housing.
11. Attach repair harness set along the original harness with two cable ties in such a way that the harness will not be abraded and /or cause any
noise.
Parts Information
419
Note:
on April 8, 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
In Case of Warranty, use the table.Technical Service Bulletin # S-68_05-74 Date: 080408
Garage Door Opener - Range Too Short/Can't Program

Date: April 8, 2008
Order No.: S-B-68.05/74
Supercedes:
Group: 68
SUBJECT:
All Model 129, 140, 163, 164, 170, 171, 202, 203, 204, 208, 209, 210, 211, 215, 216, 220, 221, 230, 251 and 463 Vehicles
Garage Door Opener Cannot Be Programmed and/or Range is Too Short
If you receive customer reports in the above model vehicles that the handheld garage door transmitter cannot be programmed into the integrated
garage door opener transmitter (inside the rearview mirror) or that the range of the integrated garage door opener transmitter is too short, refer to
the remedies below depending on the symptom encountered.
Symptom 1:
Integrated garage door opener buttons are already preprogrammed.
Remedy 1:
Before a handheld transmitter can be programmed, a reset must be performed on the integrated garage door opener. To do so, press and hold down
buttons 1 and 3 on the integrated garage door opener simultaneously for approx. 20 seconds until the LED begins to flash rapidly (also refer to the
operating instructions for the vehicle).
Symptom 2:
Garage door transmitter frequency or coding technology is not compatible with vehicle system.
Remedy 2:
Order and install a universal receiver for the opener installed in your home via the HomeLink hotline.
Note:
If you have further questions relating to the garage door opener, compatibility, programming of the regional code, synchronization or ordering
of a universal receiver, visit Internet site: www.homelink.com or contact the HomeLink toll-free hotline 1-800-355-3515.
Symptom 3:
Handheld transmitter uses a rolling code system.
Remedy 3:
It may be necessary to learn the code now stored to the integrated garage door transmitter into the garage door opener's receiver because they are
now out of sync. (Refer to the garage door opener on how to learn a transmitter into the receiver.)
Symptom 4:
Distance when programming handheld transmitter to integrated garage door opener is too small/too large or programming time is terminated too
soon.
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Remedy 4:
Pay attention to the distance when programming. The distance varies between 5 cm and 30 cm depending on the system. Several programming
attempts may be necessary; every attempted setting position should be maintained for at least 15 seconds.
Symptom 5:
Timeout time of hand transmitter exceeded (switches off after approx. 20 sec).
Remedy 5:
Attempt learning the handheld transmitter into the vehicle again.
Symptom 6:
Timeout time of integrated garage door opener exceeded (switches off after approx. 60 sec).
Remedy 6:
Change the position of the hand transmitter and then start programming again.
Symptom 7:
On vehicles with infrared coated glass, the openers which use 390MHz have no range; however 300MHz is OK in same vehicle. (Sears/Liftmaster
openers used 390MHz up until 2005.)
Remedy 7:
Construct a passive repeater antenna from a piece of RG174 coaxial cable (locally sourced) to resolve the issue.
a) Cut a piece of coaxial cable (locally sourced) approximately 152 cm long.
b) Strip 18.5 cm of the outer shield from each end, leaving center conductor insulator intact (Figure 1).
c) Remove mirror from vehicle and open the mirror.
d) Remove cover on left A-pillar.
e) One end of the cable is cable tied to the garage door opener antenna in the mirror (Figure 2).
f) Route the cable above the headliner and place the other end of the cable along the edge of the glass on left side of the windshield (Figure 3).
g) Reinstall the mirror and test the range of opener.
h) Replace panels
Interior - Seats are Dirty/Stained

Order No.: S-B-91.18/151
Supersedes:
Group: 91
SUBJECT:
421
All Passenger and Light Truck Models Dirty Seats
If seat covers are stained/dirty caused by food, perspiration, skin peeling, creams, dirt from clothing, dust, inadequate or non-existent care of the
seat covers, or color bleeding from clothing or sheepskin covers, based on the type of seat covering perform the recommended action below to
resolve.
Note:
Leather covers are natural products that are subject to a natural aging process, and therefore might behave differently under different
temperature conditions.
Genuine leather covers:
Wipe down with a damp cloth and allow to dry. Be careful not to soak the leather especially in perforated areas. After they have been cleaned, treat
the leather covers with leather care foam (A001 986 59 7110).
Imitation leather covers:
Clean using approximately 1% mild soap solution and water with a damp cloth and allow to dry.
Alcantara covers:
Clean using only a damp cloth. It is important to treat complete sections of the covers, e.g. an entire side bolster or the entire cushion surface,
otherwise visible edges (cleaned vs. non cleaned areas) will be noticeable. When needed Alcantara covers can also be cleaned using a very soft
brush.
Steering - Power Steering Diagnostic Tips

Date: March 2008
Supercedes: P-B-46.25/37
Group: 46
Revision History
a 03/03/08 Additional Models Added
SUBJECT:
MODELS 129, 140, 163, 164, 170, 171, 199, 202, 203, 204, 208, 209, 210, 211, 215, 216, 219, 220, 221, 230, 251, 463
Processing of Steering System Complaints
For any Power Steering Complaint, please always refer to the latest version of the EDAC Diagnostic Guide found on Star TekInfo. It
includes all the latest bulletins repair information.
1.) Complaints about noise from the vicinity of the hydraulic steering system:
Many complaints about noise from the steering system, particularly during the colder seasons, can be caused by the fluid level in the power
steering pump reservoir being too low, without the system having a leak.
Depending on the reservoir, small shortages are sufficient to cause the pump to take in air or foaming fluid, which then produces noises. As a
result, if a complaint is received about noise when the engine is running, such as hissing, gushing or humming from the vicinity of the pump,
first check the fluid level in the reservoir.
If the fill level is only slightly lower i.e. just under the relevant specified marking, correct this before performing any other work on the
steering system and reassess the vehicle.
To prevent this type of effect, we recommend always filling the fluid level in the power steering pump reservoir to "Maximum" for the
corresponding temperature, particularly during winter inspections or other relevant vehicle checks.
2.) Information on replacing the power steering pump in the case of steering system leaks:
The power steering pump does not have to be replaced if the hydraulic steering system is leaking and the vehicle was driven a short distance
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without power steering fluid in the reservoir. Driving without power steering fluid for up to 30 miles does not damage the power steering
pump. Without fluid, it is not placed under any stress (pressure buildup) compared to normal operation.
The residual fluid in the pump is sufficient to provide an adequate lubricating film. After repairing the steering system, perform a function
and noise check on the steering system, including the power steering pump. In the case of leaks, the location of the leak is to be indicated
with a wax pen if the complete component, such as steering racks and pumps, are replaced.
3.) General information on warranty return parts:
It is crucial to attach a detailed description of the damage profile to be able to specifically investigate the damaged part and initiate remedial
measures if necessary. We urge dealers to fully utilize the warranty text field to provide as much information as possible on the reasons for
the replacement of specific components, particularly power steering racks and pumps.
The reason for replacement of a steering rack or pump must be included on all warranty claims.
Warranty claim text will be compared to the subject vehicle's Warranty history. If it becomes apparent in the review that an existing repair
method (i.e. fluid level corrected, a repair kit, etc.) has not been utilized prior to replacing a power steering rack or pump this claim will be
subject to charge back.Technical Service Bulletin # P-91_16-153 Date: 080326
Restraints - Passenger Head Restraint Moves Sporadically

Order No.: P-B-91.16/153
Supersedes:
Group: 91
SUBJECT:
Passenger Head Restraint Moves Sporadically
If you receive customer reports in the above model vehicles of the passenger seat head restraint sporadically moving by itself, this may be caused
by a software discrepancy between the seat control unit and the weight sensing seat. To resolve, disable the Not occupied position of passenger
head restraint coding via Star Diagnosis menu path: Control units --> Seats and doors --> ESA passenger-Electric seat adjustment front passenger
(with memory) --> "Diagnosis as per factory specifications".
Note:
The menu "Diagnosis as per factory specifications" is protected by a password. The password can be obtained via the TAC Hotline. A quick test
will be needed to obtain a password. Enter the password via Star Diagnosis menu path, as shown above.
Note:
In Case of Warranty, use the table.Technical Service Bulletin # S-32_25-19E Date: 080604
Suspension - Shock/Strut Replace Guidelines

Date: June 4, 2008
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Supersedes: P-B-32.25/19d and T-B-32.25/20b dated October 18, 2007
Group: 32
Revision History
e 6/4/08 Replacement Procedure & Applicable Models Updated
d 10/18/07 Paragraph 1 Updated (statement of Tech. Documentation and EPC)
c 7/18/07 Addition of Note Pertaining to 211 / 219 Airmatic Struts (Section 1)
a 3/15/06 Applicable Models and Replacement Procedure for ABC Struts Updated
SUBJECT:
All Model 124, 129, 140, 163, 164, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 216, 219, 220, 221, 230, 251 and 463 Vehicles
Replacement Procedure of Shock Absorbers and Suspension Struts
It has been noted that shock absorbers and suspension struts are repeatedly being replaced in pairs for no justifiable reason. When a repair
requires the replacement of a shock absorber or suspension strut, only replace the damaged part, unless otherwise noted in technical
documentation or the Electronic Parts Catalog (EPC).
Note:
There will be increased focus on the compliance with these rules when performing warranty parts inspection. DO NOT replace
non-damaged shock absorbers or suspension struts. Warranty claims will be denied in cases where a shock absorber or suspension strut
was replaced needlessly.
1) Guideline for Airmatic air suspension struts (Model 164, 211, 219, 220, 221, 251), ABC suspension struts (Model 215, 216, 220, 221, 230),
and ADS suspension struts (Model 129, 140, 210)
Note:
Not applicable to AMG 211 and 219 Models (211.076/077/276/277 and 219.376/377)
Damage to one suspension strut does not justify the simultaneous replacement of the opposite suspension strut. This also applies to
complaints of noise, such as thumping. In such cases, thorough diagnostics to such cases, thorough diagnostics to determine the responsible
suspension strut should be performed by driving each side of the vehicle on a road surface corresponding to the customer complaint. Only the
affected suspension strut should be replaced.
Prior to replacing the suspension strut in the semi-supporting systems ABC, Airmatic air suspension, or ADS, relieve the tension on the
respective suspension strut to check whether this remedies the noise complaint. To do so, loosen both the upper and lower mountings on the
rear suspension struts and retighten to the prescribed torque with the vehicle resting on its wheels.
Experience has revealed that for the front suspension strut, it is sufficient to carry out this procedure on the upper mounting only.
Since it can be assumed that a new Airmatic/ADS suspension strut installed in a high mileage vehicle, would not match with the used
suspension strut and thus impair ride comfort and or vehicle dynamics, it is then recommended that these components be replaced in pairs
only after the vehicle has reached a mileage of at least 50,000 miles (~ 80,000 km). In the cases where a strut may have been previously
replaced, the mileage differential between struts must be at least 50,000 miles (~ 80,000 km) in order to replace in pairs.
In contrast to Airmatic/ADS suspension struts or conventional shock absorbers, the ABC suspension struts do not have to be replaced in pairs
at high mileages (50,000 miles / 80,000 km) as the damping of the vehicle body is taken over by the active actuation of the plunger.
2a) Guidelines for conventional shock absorbers (Models 171, 203, 209, 211 and successor models)
Damage to one shock absorber does not justify the simultaneous replacement of the opposite shock absorber. This also applies to complaints
of noise, such as thumping. In such cases, thorough diagnostics to determine the responsible shock absorber should be performed by driving
each side of the vehicle on a corresponding road surface. Only the affected shock absorber should be replaced.
Since it can be assumed that a new shock absorber installed in a high mileage vehicle, would not match with the used shock absorber and
thus impair ride comfort and or vehicle dynamics, it is then recommended that these components be replaced in pairs only after the vehicle
has reached a mileage of at least 50,000 miles (~ 80,000 km). In the cases where a strut may have been previously replaced, the mileage
differential between struts must be at least 50,000 miles (~ 80,000 km) in order to replace in pairs.
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2b) Guideline for conventional shock absorbers (Model 124, 129, 163, 164, 170, 201, 202, 208, 210, 251, 463)
For these models, there exist various shock absorber variants. Thus requiring that the conventional shock absorbers be replaced only in pairs.
Campaign - Engine V-Belt Guide Pulley Replacement

FILE:
SUBJECT:
Models 164, 164.8, 171, 203, 209, 211, 216, 219, 221, 230, and 251
With Engine 272 or 273, Model Years 2006 - 2007
Replace V-Belt Upper Guide Pulley
A 08/15/08 Revision to warranty information
- 08/15/08 Initial release
This Service Campaign has been initiated because Daimler AG (DAG) has determined that a V-belt upper guide pulley optimized for noise
reduction is available. The dealer will replace the V-belt upper guide pulley at the next workshop visit.
^ 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.
Procedure
1. Remove engine cover.
2. Remove plastic cap (A, Figure 1) covering pulley bearing and discard.
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3. Remove V-belt (A, Figure 2) from pulley (arrow); refer to WIS for models:
^ 164/164.8/251: AR13.20-P-0001GZA.
^ 171: AR13.22-P-1202VA.
^ 203/209: AR13.22-P-1202QB.
^ 211/219: AR13.20-P-0001TS.
^ 216/221: AR13.20-P-0001SX.
^ 230: AR13.22-P-1202RX.
Note (regarding above WIS instructions):

^ Do not remove V-belt from engine.
^ Do not replace belt tensioner.
4. Replace guide pulley (arrow, Figure 2), torque guide pulley bolt to: 35 Nm.
Note:
Do not reinstall cap (A, Figure 1).
5. Assemble in reverse order.
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
Warranty InformationTechnical Service Bulletin # P-26_50-02A Date: 080616
426
M/T - Hard To Engage 1st or Reverse/Shifter Sticking
Date: June 16, 2008
Group: 26
Revision History
a 6/16/08 Applicable Models Updated (204 Added)
SUBJECT:
Model 170.449/465
Model 171.454/456
Model 203.040/052/054/056/061/064/261/264/740/747/764
Model 204.054
Equipped with Manual Transmission 716 Only First or Reverse Gears Difficult to Engage from Neutral and/or During 1-2 Up-Shift Shifter May
Catch Between Gears
If you receive customer reports in the above model vehicles of first or reverse gears being difficult to engage from neutral and/or the shifter
catching between gears during 1-2 up-shift, this may be due to insufficient lubrication of the transmission input shaft not allowing the clutch disc to
move freely.
Note:
Prior to removing the transmission, first confirm that the shifter console is properly adjusted.
^ For vehicles produced up to June 2000, refer to WIS AR26.60-P-0635-02D
^ For vehicles produced after June 2000, refer to WIS AR26.60-P-0635-02E
Proceed as indicated below only after the adjustment of the shifter console has been ruled out as the cause of the concern.
1. Remove the transmission.
2. Lightly grease the transmission input shaft around the splines with heat resistant lubricant (anti-size).
Warning!
It is critical that no grease gets onto any of the clutch friction surfaces.
3. Reinstall the transmission.
Body - Door Frame Corrosion

Date: July 7, 2008
Order No.: P-B-72.00/88
Supersedes:
Group: 72
SUBJECT:
Corrosion Complaints Concerning Door Frames
If you receive customer reports in the above model vehicles of corrosion in the area of the door frame, outside door panel or lower inside of door,
follow the procedures below to resolve.
Determining the repair scope
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1. In the event of a customer complaint, all the doors must be checked for signs of corrosion.
2. Open the doors to be checked. Detach rubber seal at top and bottom of door. Clean rubber seal.
3. Perform visual inspection for corrosion (Figure 1, A and B). Select remedy according to damage profile.
4. In area Figure 1, C, use mirror to check for corrosion. Select remedy according to damage profile. (Figure 1).
Repair Remedy Overview
1. Corrosion in non-visible area (Figure 1, B and C) under rubber seal, refer to WIS document AR97.00-P-1001F (repair stage 1).
2. Corrosion also in visible area (Figure 1, A) where paint can be touched up, refer to WIS document AR97.00-P-1002F (repair stage 2).
3. Corrosion also in visible area where paint cannot be touched up on outside door panel near door handle and central trim strip or spot
corrosion on lower inside of door, which can be touched up with a brush with no additional painting work, refer to WIS document
AR97.00-P-1003F.
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4. Corrosion effects in area (Figure 2, E) after cutting off the fold or in visible area where paint cannot be touched up on outside door panel and
corrosion on lower inside of door which cannot be touched up with a brush. (Figures 3 & 4), doors must be replaced. Wax inside of door
frames and window frames then install rubber seals.
Refer to WIS documents as shown above.
Parts Information
Note:
In the case of warranty, please damage code to the failed component. In the event of a sublet repair, please refer to Section 6.25.16 of the
Warranty Policies and Procedures manual.
Body/Lighting - Moisture in Mirror Turn Signals

Date: May 23, 2008
Supersedes: P-B-88.70/48a dated May 21, 2007
Group: 88
Revision History
429
b 5/23/08 Addition of Note Pertaining to Model 204, Parts and Warranty Information
SUBJECT:
Moisture in Additional Turn Signal Lamp(s) in Rearview Mirrors
If you receive customer reports regarding moisture or water inside the additional turn signal lamp(s) (Figure 1), please advise the customer that
surfaces fog up whenever they are cold and come in contact with warmer, humid air. An example of this is the mirror in the bathroom which often
fogs up after showering because the warm humid air from the shower may condense on the colder surface of the mirror. The same occurs to the
additional turn signal lamps. Water vapor that is normally present within the lamp housing may condense on the colder surface in the surrounding
area which typically is the lens as the ambient temperature decreases. Any fogging will typically disappear after 1 or 2 hours during the day
depending on temperature and humidity. This condition is normal operation and does not call for repair. If there is any indication of greater
moisture in the housing, please check for external damage to the housing that may be the cause of the condition. Damage to other than production
defect in the housing is not covered by warranty.
Note:
For Model 204 vehicles, produced up to 08/2007 (up to VIN A064140 and F057431), there may be isolated cases of the turn signal lamp in the
outside mirror housing exhibiting a crack at the edge (weld seam), in these cases the turn signal lamp must be replaced must be replaced.
Parts Information
Note:
on May 23, 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
Technical Service Bulletin # 2006110005C Date: 080817
Campaign - Navigation System Disc Update

FILE:
Revision History
C 8/17/08 Navi DVD part numbers updated, note added and revised in parts information
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SUBJECT:
MODELS 164, 171, 203, 209, 211, 215, 219, 220, 221, 230, 251, X164
431
This Service Campaign has been initiated because DCAG has determined that certain affected vehicles (see VIN range shown above) may have an
earlier version navigation disc installed than that specified. This could in some cases lead to navigation directions based upon non updated map
data. Dealers will update the navigation disc in the affected vehicles as required.
Please review the Effective Serial Number chart shown above, and if necessary, repair the subject vehicles during the vehicle's next service.
Parts Information
NOTE:
^ Due to the multiple Navigation DVD released annually, there may be a newer Navi DVD version than the one referenced in this Campaign
Bulletin. Please use the latest Navigation DVD available from Navteq. MUBSA will update this bulletin to reflect latest Navi DVD part
numbers as they become available.
^ Repairs performed using any other part(s) than the ones in this Bulletin 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.
432
Procedures A - C
NECESSARY
Note:
Note:
^ Press Eject button on Navigation module.
^ If part number is BQ 646 0232: Reinsert DVD into Navigation module; this campaign has been completed.
NOTE:
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^ Insert new Navigation DVD into Navigation module.
Note:
The DVD is automatically detected and the update process starts. Shut off vehicle upon completion of the update process.
Note:
The Navigation DVD must remain inside the module from this point forward in order for the Navigation system to operate
correctly.
Note:
NECESSARY
Note:
Note:
^ Press Eject button on head unit to eject DVD from "Navigation" slot.
^ If part number is BQ 646 0226: Reinsert DVD into Navigation drive; this campaign has been completed.
NOTE:
^ Insert new Navigation DVD into Navigation drive.
Note:
^ Shut off vehicle upon completion of the update process.
Note:
The Navigation DVD must remain inside the drive from this point forward in order for the Navigation system to operate correctly.
Note:
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NOTE:
^ You must obtain the correct DVD per VIN by filling out the form shown above and fax to Navteq. For reliability, we encourage
you to fax in the form. The DVD will be sequentially numbered according to the VIN you provide in the form. If you have
more than one vehicle listed in the campaign in your dealership, please submit multiple VINs in a single form, Navteq will mail
you one DVD per VIN entered.
Note:
^ Connect battery charger and turn OFF ignition and all electrical consumers
^ Turn ignition key to second position
CAUTION!
Ensure that slot # 1 in the DVD changer is empty prior to inserting the Navigation DVD.
435
2. Press Button 1 of the DVD changer (A, Figure 1) and insert the Navigation DVD BQ 646 0233 into the changer (B).
Note:
The update process takes approximately 30 minutes to complete. The technician is not required to be present during the process and
may perform other tasks while the process is running. The update process run time is not included in the labor time paid under this
Service Campaign.
Note:
This Navigation DVD is property of MBUSA; it must remain with the vehicle/customer after the update process has been
completed. Reproduction is prohibited!
Lighting - Auto Lamps/Rain Sensor Malfunctions

Order No.: S-B-82.30/634
Supersedes:
Group: 82
SUBJECT:
All Model 164, 171, 203, 204, 209, 211, 215, 216, 219, 220, 221, 230 and 251 Vehicles Equipped with Rain/Light Sensor (SA Code 345)
Auto On/Off Driving Lights and/or Rain/Light Sensor not Functioning Properly
If you receive customer reports in the above model vehicles that the auto on/off and/or rain/light sensor is not functioning properly, the cause may
be one of the following:
^ The windshield is not a genuine Mercedes-Benz part
^ The rain/light sensor is not the correct part
^ No adaptation or coding was performed on the rain/light sensor
Perform the following procedure to remedy the issue:
1. Verify that the windshield is indeed a genuine Mercedes-Benz part (the genuine parts have the Mercedes-Benz three-pointed star on them).
2. Verify that the correct rain/light sensor is installed by performing a quick test.
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3. Perform adaptation and parameterization of the Rain/light sensor via DAS. In most vehicles, the process in DAS is as follows: Control Units
--> Body --> OCP - Overhead control panel --> Control unit adaptations --> Rain/light sensor --> Parameterization and windshield
adaptation.
4. If applicable, follow guided tests in Star Diagnosis.
Note:
Please submit all damaged parts along with an initial and final quick test. Costs for components submitted without a documented fault
code WILL NOT BE REIMBURSED.
Note:
generated on September 16. 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance labor
time allowance.
Interior - Rear Seat Back Rest Rattling Noises

Date: July 2, 2008
Group: 91
Revision History
a 7/2/08 Part Number Corrected
SUBJECT:
Model 203.052/054/056/076/087/092
Noise from Rear Backrest While Driving on Rough Roads
If you receive customer reports in the above model vehicles about a rattling noise coming from the rear backrest lock when driving on rough roads,
this may be caused by a slight displacement of the backrest. To resolve, slightly lift the rear shelf and apply self-adhesive foam block (30 x 20 x 13
mm) onto the cross member in the body shell (Figure 1).
437
Note:
Do not remove backrest. Do not use felt strips.
Parts Information
Note:
Parking Assist System - Erroneous Activation

Group: 54
a 9/17/08 Applicable Models Updated / Note Added (cause and remedy)
SUBJECT:
All Models Equipped with Parktronic (SA Code 220)
Erroneous Parktronic Activation
Parktronic, the optional vehicle parking assist system, can be erroneously activated with or without warning tones by the following conditions as
noted below.
Note:
The causes mentioned can lead to complaints that may be unduplicatable at the workshop. The workshop technician should thoroughly
inspect the Parktronic sensors for interferance, cleanliness, and proper orientation.
1) Accessory license plate frames installed on the front bumper.
2) Incorrect front license plate orientation.
3) Other detachable accessories that are located within range of the Parktronic sensors.
4) Decreased vehicle ride height, resulting in an echo from the ground.
5) Snow, slush, hail, and sleet.
6) Heavy rain
7) A gush of water, running down the vehicle's hood over the Parktronic sensors when the vehicle is braking.
8) Sensors heavily soiled.
9) Extraneous ultrasonic sources such as air brakes, jackhammer, etc.
10) In ground electrical induction loops, located at traffic lights or in basement garages.
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11) Waste heat, from excessively heated engines (exhaust), forms in front of the vehicle when stopped.
Note:
Replacing sensors or control modules will not resolve the false activation. The sensitivity of the Parktronic system is a result of its design,
and is required for accurate operation. Please inform the customers accordingly. Additionally, present to the customer the information
contained within the vehicle's operating instructions, concerning Parktronic operation.
Note:
In cases where the sensors have been replaced/repainted previously, incorrect painting (Figure 1, incorrect) of the sensor may lead to
erroneous readings. Painting the entire front of the sensor changes its vibration characteristics. These altered vibration characteristics may
lead to erroneous readings and random triggering of the system. To remedy, paint the sensors in the provided box (Figure 2). If the box is
not available, mask off the sensor accordingly.
Engine - Test For Increased Oil Consumption

Supersedes: P-B-00.00/80e and T-B-00.00/81e dated January 29, 2007
Group: 00
439
Revision History
SUBJECT:
Model 164.186, Up to Engine Serial No. 272 967 30 053879
Model 171.454/456, Up to Engine Serial No. 272 9xx 30 058705
Model 203.052/054/056/087/092, Up to Engine Serial No. 272 9xx 30 053555
Model 209.356/456, Up to Engine Serial No. 272 9xx 30 053555
Model 211.056/087/256/287, Up to Engine Serial No. 272 9xx 30 052208
Increased Engine Oil Consumption
If you receive customer reports in the above model vehicles regarding increased oil consumption based on the below repeated oil level messages in
the instrument cluster, the cause may be due to incomplete engine break-in process.
- Add 1 Quart Oil When next Refueling (Model 211 until production date 06/2005)
- Check Engine Oil Level When Next Refueling (Models 164, 171, 203 and 209 as of production start up and 211 as of production date
06/2005)
NOTE:
As of engine production date February 2005 and engine serial numbers listed above, modified piston ring set has been introduced in
series. The M272 is equipped with an oil level switch. Therefore, no values relating to oil consumption can be read out using SDS or
DAS. Oil refilling between oil change intervals is normal and does not necessarily mean oil consumption has increased.
If the customer's information indicates that the oil consumption is less than 2000 miles/quart; e.g. 2500 miles/quart no further measures are
necessary as that level of consumption is within specification. If oil consumption is greater than 2000 miles/quart; e.g. 1700 miles/quart, perform
oil consumption measurement by weight as follows.
1. Check engine for external oil loss; e.g., oil leaks.
2. Pre-condition the engine of the vehicle by completing the break-in process of the engine as follows:
a. Check the oil level and correct level if necessary.
b. Drive the vehicle for 1 hour under high load and high engine speed (between 4,000 and 6,000 rpm) appropriate for the local conditions
and circumstances.
c. Vary the engine speeds during the road test.
NOTE:
If possible perform this test on interstate type roads where speeds of 55 - 65 mph can be obtained and use the appropriate
transmission gears to maintain engine speed of 4000 to 6000 rpm.
3. Oil consumption measuring drive:
a. Prepare oil consumption measuring drive according to the attached work instructions.
b. Measuring drive should be performed by customer until the oil level warning reappears in the instrument cluster.
c. Determine oil consumption as per work instructions and document calculation on the attached test sheet.
NOTE: Customer should maintain his or her driving style during the entire measuring drive.
4. Limits And Engine Repair Criteria:
NOTE:
Replacing the valve stem seals does not provide an effective remedy to this condition. Therefore valve stem seals must not be replaced.
The engine break-in process depends strongly on the usage conditions and driving style of the customer, and in some cases, the break-in
process can extend to greater than 6500 miles.
a. If mileage is less than 6500 miles and the measured oil consumption is greater than 750 miles/quart; e.g. 600 miles/quart, adjust oil
level to MAX (14.95 lbs. of oil by weight) and continue to observe oil consumption up to mileage reading of at least 6500 miles.
NOTE: Document oil level and mileage reading.
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b. If mileage is between 6500 miles and 13,000 and the measured oil consumption is greater than 2000 miles/quart; e.g. 1700
miles/quart, repair only with a complete engine replacement.
c. The procedure for vehicles with a mileage higher that 13,000 miles is described in WIS document AR18.00-P-0025QB.
NOTE:
- Oil consumption of up to 2000 miles/quart is considered to be within specification.
- Do not replace any engines which have not gone through an oil consumption measuring drive. The filled out test sheet must be
enclosed with any returned engine. Any claims submitted that have not followed the above procedures or do not have full
documentation will be denied.
- The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has
been generated on October 30, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time
allowance.
In Case of Warranty
Operation: Engine, check for oil leak(s)/loss (01-1010)

Oil consumption test drive, perform (18-1010)
Flex. Service plus - oil/filter change, perform (00-1212)
Engine - exchange, (engine w/ auto. trans. removed) (01-4015)
Engine - exchange, (engine w/ man. trans. removed) (01-4011)
Engine - exchange (01-4010)
441
M272 Oil Consumption Measurement By Weighing Method
Preparation:
Equipment Requirement:
- Scales with 0.01 lb. accuracy.
- Oil Container with 10-liter capacity (Oil drain pan with spout as oil container for this purpose is recommended)
- Stop watch
Procedure:
Weigh Engine Oil (At Start of Oil Consumption Measuring Drive)
1. After pre-conditioning the engine to operating temperature (90 degrees C coolant temperature), raise vehicle on lifting platform.
2. Weigh the empty and clean oil container as "TARE".
3. Open oil filter cap and pull out oil filter.
4. Remove engine lower encapsulation and open oil drain plug.
5. Allow engine to drain into the oil container for 15 minutes.
6. Place the container with drained oil on scales and weigh.
7. Adjust the weight of the oil in the container to 14.95 lbs.; e.g. if "TARE" = 2.55 lbs fill up the container with oil up to the combine weight of
17.50 lbs. (14.95 lbs. + 2.55 lbs.)
8. Pour the engine oil back into the engine.
9. Re-install back the oil filter and oil filler cap.
10. Record the weight of the oil in pounds as m1 and the mileage odometer reading of the vehicle as s1.
Have the customer perform the oil consumption measuring drive.
Weigh Engine Oil (At End of Oil Consumption Measuring Drive)
11. Customer arrives at workshop after oil level warning message is displayed in the instrument cluster.
12. Lift vehicle on lifting platform with engine at operating temperature (90 degrees C coolant temp.).
13. Weigh empty oil container in pounds as "TARE".
14. Open oil filler cap and pull out oil filter.
15. Remove under engine encapsulation and open oil drain plug.
16. Allow engine to drain into the oil container for 15 minutes.
17. Place the container with drained oil on scales and record combined weigh in lbs. as M.
18. Record weight of drained oil in pounds as m2; i.e., m2 = M - "TARE".
442
19. Calculate oil consumption as described in test sheet.
Power Steering - Fluid Filling/Bleeding Precautions

Group: 46
Revision History
SUBJECT:
Flow Noises from Area of Power Steering Pump and/or Foaming of Power Steering Oil in Reservoir
If you receive customer reports in the above model vehicles of flow noises from the area of the power steering pump, and/or foaming of the power
steering fluid in the reservoir following work carried out on the hydraulic steering system; this may be caused by an improper procedure followed
for filling fluid and bleeding of the hydraulic power steering system.
To remedy, it is absolutely necessary to make sure that the procedure described in the WIS documents is strictly adhered to. In particular, it is
necessary to turn the steering to full lock-to-lock at least 30 times BEFORE STARTING THE ENGINE. If this is not done prior to starting engine,
there is a high risk of air entering the steering system, which is subsequently very difficult to eliminate.
NOTE:
Starting the engine prior to bleeding can cause irreparable damage to the power steering pump and will cause an air cushion to form in the
steering gear which causes noise. Once the air is ingested, the ingested air will only dissipate after driving the vehicle for more than 30 miles.
443
Refer to the chart for the correct WIS document reference for the proper filling and bleeding procedure of the power steering pump.
Engine - MIL ON/Multiple Camshaft Codes Set

DTB

Order No.: S-B-03.30/08h
Supersedes: S-B-03.30/08g dated October 20, 2008
Group: 03
444
SUBJECT: Model 164.172/186/871/886

Model 171.454/456
Model 203.052/054/056/087/092
Model 204.054/056/081
Model 209.356/372/456/472
Model 211.056/072/087/090/256/287
Model 216.371
Model 219.372
Model 221.171/186
Model 230.471
Model 251.156/165
Equipped with M272 or M273 Engine
Check Engine Light On / Fault Codes 0059, 0060, 0063, 0064, 0271, 0272, 0275, 0276, 1200 and/or 1208 Stored in ME-SFI Control
Module / Camshaft Adjustment Solenoid Leaking Oil
If you receive customer reports of the check engine light being illuminated and the following fault code scenario is found in the above model
vehicles, follow the applicable procedure below to resolve.
Fault Code Scenario 1: DTC 1200 and/or 1208 are stored in ME-SFI control module. The fault codes are recorded as current and stored in the
fault memory. When the fault memory is erased and the engine is restarted, the fault codes reoccur immediately. This is due to the positioning of
the camshafts of the right cylinder bank relative to the crankshaft being impaired by a worn sprocket on the balance shaft on engine M272 or by a
worn guide (idler) gear for the timing chain on engine M273.
Applicable Models (Not Applicable to Model 204): Equipped with M272 Engine Up to Serial No. 2729..30 468993 or M273 Engine Up to Serial
No. 2739..30 088611
Procedure 1:
a. Perform a visual inspection for wear of teeth on sprocket of balance shaft (M272) or of guide (idler) gear for timing chain (M273) by
removing the timing case cover on the engine.
NOTE: When inspecting the component, refer to Figure 1 for an example of a damaged gear.
b. To repair engine, replace the balance shaft on engine M272 or to replace the guide (idler) gear of chain drive on engine M273 as per WIS
instructions...
NOTE: When replacing the balance shaft on engine M272 the counterweight must also be replaced. The balance shaft and counter weight
are specific to engine designation. Order parts accordingly.
c. Replace the engine oil pump.
445
d. Replace the chain tensioner.
e. Change engine oil and filter.
f. Drive with engine at high load and rpm for approx. 15 miles.
g. After completed step f, change engine oil and filter once more.
h. Replace all four of the camshaft adjustment solenoids with A272 051 01 77.
Fault Code Scenario 2: One or more of the fault codes 0059, 0060, 0063, 0064, 0271, 0272, 0275, and 0276 are stored in ME-SFI control module.
The fault codes are recorded as current and stored in the fault memory. These codes are caused by a malfunctioning camshaft adjustment solenoid.
Procedure 2: Diagnose each DTC as per Star Diagnosis. If it is determined the solenoid is faulty, replace with solenoid A272 051 01 77 as per
appropriate WIS instructions.
NOTE (Applicable to Procedure 2): Only replace the solenoid that has a corresponding fault code. Copy of the SDS short test must accompany
returned parts. If the documentation is missing or does not support the diagnosis, the warranty claim may be debited.
Fault Scenario 3: Camshaft adjustment solenoid is leaking oil, no fault codes current or stored.
Procedure 3: Replace solenoid sealing ring with A019 997 37 45.
NOTE: It is not necessary to replace the solenoid assembly if it is leaking oil.
Parts Information
In Case of Warranty
Operation: Scenario 1:
Ground cable-elec. system battery, D&C (when separating elec. connectors) (54-7989)
Ground cables on both batteries remove/install (when disconnecting elect. connectors w/o accidental contact protection) (54-7991)
Ground cables on both batteries remove/install (when disconnecting elect. connectors w/o accidental contact protection) vehicles as of
modification year (54-7992)
Ground cable to battery negative terminal replace vehicle as of modification year (54-7996)
Timing chain cover-(engine removed), R&R (01-8005)
Timing chain cover-R&R (engine removed) (01-0000)
Timing chain cover, R&R / seal (01-8000)
Engine compartment panels-bottom (all), R&R (61-1069)
Engine compartment panel, bottom-front & rear part, R&R (61-1070)
Engine compartment trim at bottom, remove/install (61-1105)
Front engine compartment paneling, remove/install (vehicle with offroad package) (61- 1101)
Manual transmission, D&C from engine (engine with transmission removed) (26-2200)
Autom. Transmission, R&R (engine with transmission removed) (27-2110)
446
Engine balancing shaft R&R/replace as required (03-0000)
Engine oil pump - (main/lower oil pan removed), R&R/replace (18-6022)
Engine oil pump - R&R/replace as required (oil pan removed) (18-6023)
Engine oil pump - (engine removed), R&R/replace if required (18-6025)
Solenoid units-(all) var. valve time-cam control mech, replace (05-7290)
Wheel alignment, check (40-6500)
Front wheel toe angle adjust (with vehicle alignment check) (40-4064)
Oil change, perform (00-6555)
Road test (00-9151)
Additional to road test (00-0000)
Scenario 2:
Test program-after short test, perform (54-1012)
Scenario 3:
447
448
449
Suspension - Rear Axle Knocking Noises

Order No.: P-B-32.20/69
Supersedes:
Group: 32
SUBJECT:
VIN Range A279000 up to A283305 and F213965 up to F214690
Knocking Noise from Rear Axle
450
If you receive customer reports in the above model vehicles of a knocking noise from the rear axle area during normal driving operation, inspect the
torsion bar link rod (Figure 1, 6k, circle) at the top of the attachment point to wheel carrier for axial play and replace the corresponding bolt if
necessary. Refer to WIS document AF32.20-P-1500AG.
NOTE:
Torque for bolt -- link rod to wheel carrier 40 Nm (WIS document BA32.20-P-1005-04C).
Parts Information
NOTE:
In Case of Warranty
Operation: Replace torsion bar link bolt (32-0000)
Body - Sunroof Excess Lift Control Function

Order No.: GP-B-77.20/26a
Supersedes: P-B-77.20/26 dated July 21, 2004
Group: 77
Revision History
SUBJECT:
451
Model 203.040/052/054/056/061/064/065/076/081/084/087/092/740/747/764, as of
A678820 and F580316
Model 203.261/264/281/284, as of F580139
Model 209.356/365/372/375/376/377, as of F12458
Excess Lift Control Function for Tilting/Sliding Roof
As of the above production cut offs, the tilting/sliding roof now incorporates an excess lift control feature similar to that on the 215 and 220 model
vehicles. With this feature, when closing the roof from the open position using the one-touch feature, the roof closes, stops and then briefly tilts up
and closes again. Closing from the tilt up position can reduce wind noise with the roof closed and while driving at high speeds.
In cases where the overhead control panel (OCP, N70) needs to be replaced, the excess lift control function must be reprogrammed using SDS as
the default configuration for spare parts is to have the excess lift control feature inactive.
Parts Information
A/T - Limp Home Mode/Multiple Codes Stored

Supersedes: P-B-27.00/102a and T-B-27.00/103a, dated January 9, 2008
Group: 27
Revision History
SUBJECT:
All Models Equipped with 722.9 (7G-Tronic) Transmission
planetary gear set.
NOTE:
452
WARNING:
Parts Information
NOTE:
453
454
In Case of Warranty

Oil pan on auto. trans. remove/install/seal, repl. if necessary veh. with 722.9 trans. (27-7033)
Oil level auto. trans. (after leak test), check/correct veh. with 722.9 trans. (27-1256)
Automatic transmission (veh. with 722.9 trans), R&R (27-2029)
Auto. transmission - (transmission removed), replace (27-2150)
Control unit - ... code (after short test), perform (54-0992)
Adaptation perform (27-1047)
Analysis form, fill out (02-3472)
Engine Controls - MIL ON/Multiple O2 Sensor DTC's Set

DTB

Supersedes: S-B-49.00/12 dated August 18, 2008
Group: 27.49
SUBJECT: Model 164.172/186/871/886

Model 171.454/456
Model 203.040/052/054/056/092/087/740
Model 204.054/056/081
455
Model 209.356/372/456/472
Model 211.056/072/087/090/256/287
Model 215.376/379
Model 216.371/376/379
Model 219.372
Model 220.176/179
Model 221.171/176/179/186
Model 230.471/476/477/479
Model 251.156/165
Engine Running Characteristics / Check Engine Light Activated
If you receive customer reports in the above model vehicles about engine running characteristics, and the check engine light is activated by stored
oxygen sensor faults, this may be due to the below causes. To resolve, perform a new diagnostic test for the oxygen sensor, available as of DAS
DVD 09/07.
Causes
- Mixture formation not ideal
- Line connection of oxygen sensor incorrect
- Oxygen sensor heater defective
NOTE: Copy of the SDS short test and all tests performed must accompany returned parts. If the documentation is missing or does not
support the diagnosis, the warranty claim may be debited.
456
457
In Case of Warranty

O2 sensor - left before catalyst, replace (after test) (07-5210)
O2 sensor - right before catalyst, replace (after test) (07-5212)
O2 sensor - left after catalyst, replace (after test) (07-5211)
O2 sensor - right after catalyst, replace (after test) (07-5213)
458
Engine - Grinding/Howling/Whining Noises

DTB

Supersedes: S-B-13.22/01d dated July 10, 2008
Group: 13
459

Noise Coming From Front of Engine
If you receive customer reports in the above model vehicles of a RPM dependent grinding, howling, whining or high pitch whistle noise coming
from the front section of the engine, this noise maybe caused by a faulty upper idler pulley. The noise can no longer be heard when the poly-V belt
is removed. To resolve, replace the upper idler pulley with a new unit (Figure 1). The pulley is supplied with a mounting bolt, dust cover, flat
spacer washer and a black plastic retainer (plastic assembly protection) that holds the assembly together.
NOTE: Revised instruction: It is not necessary to remove the spacer before installation. The black plastic retainer will assist in centering the flat
spacer washer and pulley on the mounting lug (Figure 2).
Parts Information
In Case of Warranty
460
Operation: Guide pulley A - V-belt, replace (13-3350)
Engine - Air Filter Replacement Precautions

Order No.: S-B-09.10/30
Group: 09
SUBJECT:
MY- All, Models 164, 171, 203, 204, 209, 211, 216, 219, 221, 230, 251, and 463 (with Engine 272 or 273)
Installing Air Filters
An improperly installed air filter assembly can cause the air mass sensor to receive turbulent, instead of laminar air flow due to air leakage at the
sealing ring (4c, Figure 1). This in turn can cause 0745, 0749, 2091, or 2095 ME fault codes.
A. Procedure for Installing Air Filters
1. Apply lubricant to the retaining clip (4b, Figure 1) and the sealing ring (4c, Figure 1).
NOTE:
Apply only a thin layer of lubricant to the ring to avoid getting any on the HFM-SFI (hot film air mass sensor fuel injection system).
461
2. Fit the air filter housing (4, Figure 2) on the HFM-SFI while checking that the sealing ring (4c, Figure 1) is correctly positioned.
3. Fit retaining clips (4b, Figure 1) on the support (4a, Figure 1). If necessary, adjust by positioning retaining clips (4b, Figure 1) precisely.
4. Before pressing the raining clips in, ensure that the air filter housing is correctly set on the HFM-SFI.
NOTE:
Check that the sealing ring (4c, Figure 1) is correctly positioned and realign it if necessary. The housing may have to be shifted slightly
toward the radiator. Check that there is no gap between the air filter housing (4, Figure 2) and the ME-SFI [ME] (motor electronic
sequential multiport fuel injection/ignition system) control unit at the firewall end and that they are both parallel and aligned evenly.
5. Press the air filter housing (4, Figure 3) evenly into the support (4a, Figure 3) without applying excessive force. If unsuccessful, start again at
step 2.
7. Install the hose (3, Figure 2) for the air pump at the air filter housing (4, Figure 3) so that the arrows on the hose (3, Figure 2) and the air
filter housing (4, Figure 3) point towards each other.
8. Install the left and right intake air ducts (2, Figure 3). Inspecting for any cracks, do not pull on the braided hose. Pull or press the vinyl ring
only. Sealing rings must make contact over the entire surface.
9. Fit the front engine cover on the vehicle.
Parts Information
Interior - Power Seats Intermittent Operation/Inop.

DTB
462

Group: 91

Electrical Seat Position Adjustment (ESA) Not Working or Working Intermittently
If you receive customer reports in the above model vehicles that the electrical seat position adjustment (ESA) is not working or working
intermittently, first follow normal diagnostic procedures to determine if it is a problem with the fuse, seat switch or ESA control unit. Before
replacing the ESA control unit, follow the below diagnostic procedure as many ESA control units are unnecessarily replaced.
1. Check the part number of the ESA, the following only applies to part numbers A211 820 15 26, A211 820 16 26, A211 820 01 26, A211 820
02 26, A211 820 40 85 and A211 820 41 85.
2. Check that the fuse is okay. If not, replace fuse, verify seat functions normally and end test
3. Check with SDS that the seat is normalized in both directions,
i. Up to the middle of model year 2005, this can be checked with SDS by performing a quick test and then checking and clearing codes.
Then with SDS, select the seat with the fault and with activations, move the seat through the full range of motion.
ii. As of the middle of model year 2005, perform a Quick Test. If the seat is not normalized, there will be a displayed after the line ESA
driver - Electric seat adjustment driver (with memory) or ESA passenger - Electric seat adjustment front passenger (with memory). This
is an indication that an event code has been stored. To view the event code, press F8 and then normalize using activations as described for
vehicles up to the middle of model year 2005.
4. If a normalization error is stored without the corresponding Hall effect sensor error, the seat must be adjusted in both directions. This insures
the Hall effect sensor error is reset. If there are no Hall effect sensor errors stored, it is sufficient to normalize the seat. Normalize seat with
SDS by following the path: Control units -> Seats and doors -> ESA driver -> Electric seat adjustment driver (with memory) -> Control unit
adaptations and then repeat if necessary for the passenger seat by selecting ESA passenger -> Electric seat adjustment front passenger (with
memory) -> Control unit adaptations. If no Hall effect sensor error is stored, skip to step 9.
5. Using SDS, perform the following for each seat adjustment direction
i. Read status
ii. Delete error
iii. Activate motor in either direction for at least 2 seconds
iv. Read status
v. Activate motor in the opposite direction for at least 2 seconds
vi. Read status
6. If Hall effect sensor errors are still present, remove seat cushion according to WIS Document AR91.10- P-1070P (203/209) and for Model
211 refer to Group 91.10 for correct document based on Model Year and seat options of vehicle.
7. The electrical connectors for this function must be checked for loose contacts and the wires checked for short circuits. Disconnect the
affected motor and Hall effect sensor. Check for the following:
i. a short circuit between the Hall effect sensor signal and ground wires
ii. a short circuit between the Hall effect sensor signal and motor line 1
iii. a short circuit between the Hall effect sensor signal and motor line 2
iv. a short circuit between the Hall effect sensor ground and motor line 1
v. a short circuit between the Hall effect sensor ground and motor line 2.
463
8. All resistance measurements must be greater than 1 Mohm
9. Check the rest current with a Digital Multimeter, this can be done at the fuse (use fuse adapter Special Tool W140 589 12 21 00). The
following rest currents are measured with an electrical system voltage between 10 and 15 volts. With the CAN inactive, backrest locked and
seat not moving <300 micro A, with the CAN inactive, door switches held closed, backrest folded and seat not moving <20 mA and with the
CAN active and seat not moving <200 mA. If okay, go to step 12.
10. If the rest currents are greater than the above values, remove the following plugs one at a time to locate the cause of the high rest current.
i. Plug 11 - violet - Dynamic driving seat, if present
ii. Plug 8 - white - Head restraint and backrest switch, Coupes and Cabriolets only
iii. Plug 7 - pink - Backrest release switch, Coupes and Cabriolets only
iv. Plug 6 - orange - Backrest angle and head restrain height motors
v. Plug 5 - brown - Height adjustment motor at front of seat cushion
vi. Plug 4 - black - Fore/aft adjustment motor
vii. Plug 3 - green - Height adjustment motor at rear of seat cushion
viii.Plug 1 - black - CAN Bus and steering column adjustment motors
11. If the rest currents remain greater than the above values after all the above plugs have been removed, 2 the ESA control module must be
replaced. Normalize seat, verify seat functions normally and end test. Please specify parts by VIN using EPCnet (Group 91/200).
12. The ESA control unit is good, continue to diagnose the system.
NOTE: The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has
been generated on September 26, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty

Fuse - specify location, replace (54-1286)
Front passenger seat cushion, R&R (91-5028)
Electric seat adjustment test, perform (91-0000)
Power seat memory control module - front pass. seat, replace (after test) (91-6690)
464
Cell Phone - iPhone(R) Address Book Not Loading

Order No.: S-B-82.70/666
Supersedes:
Group: 82
SUBJECT:
465
Model 164.122/172/175/177/186/822/871/886, MY 2006 - 2008
Model 171.454/456/473, MY 2005 - 2008
All Model 203 Vehicles, MY 2005 - 2008 (Except 203.065 and 203.747)
All Model 209 Vehicles, MY 2005 - 2009
All Model 211 Vehicles, MY 2004 - 2008 with COMAND Head Unit (528 or 530) Model 216.371/376/377/379, MY 2007 - 2009
Model 219.372/377 2006 - 2008
Model 221.171/176/179/186/177 MY 2007 - 2009
Model 230.470/471/472/474/475/476/477/479 MY 2005 - 2008
Model 251.122/156/165/175/177 MY 2006 - 2008
Model 463.249/271, MY 2007 - 2008 Apple iPhone or iPhone 3G Address Book Not Loading In vehicles Equipped With Hands-free Telephone
and Blue Tooth Cradle (HFP-Puck)
If you receive customer reports in the above model vehicles equipped with a hands-free blue tooth cradle HFP-Puck that the address book did not
load (only with Apple iPhone or iPhone 3G), this may be caused by a software error in the iPhone itself. The remedy is revised software for the
iPhone, which is currently being developed by the Apple Corporation. Please do not replace any parts, the solution is forthcoming and this DTB
will be revised accordingly.
NOTE:
For model vehicles (MY 05 - 08) which use a hands-free Bluetooth Puck (HFP), the iPhone 3G will not fit on the current iPhone Cradle, the
dimensions between phones are different. Please look for specific communication from MB-Accessories regarding a new iPhone 3G specific
cradle.Technical Service Bulletin # S-18-00-37D Date: 081024
Engine - Low Oil Level Symptom Diagnostics

DTB

Supersedes: S-B-18.00/37c dated October 6, 2008
Group: 18

Equipped with M156, M272, M273 or M642
Engines Low Oil Level Symptoms
NOTE: This document supersedes the following previously published DTBs.

T-B-01.45/20 dated September 19, 2007
P-B-18.00/31c dated February 1, 2007
T-B-18.00/32a dated August 21, 2006
T-B-18.00/33b dated March 27, 2007
P-B-18.00/35a dated July 26, 2007
P-B-18.40/34 dated May 8, 2007
1. Model 203.087/092 and 211.087/287, Equipped with M272 - Erroneous IC Warning Display "Check Engine Oil Level at Next Service Stop":
Oil level warning message frequently appears in the instrument cluster, however the oil level correct on the dipstick, the cause may be the
incorrect oil data record stored in the ASSYST control unit (Model 211), or instrument cluster (Model 203). To resolve, perform the
following procedures.
466
Message:
"Pour in one liter of oil at next refueling stop" (Model 211 4MATIC with M272 up to 6/2005) "Check oil level at next refueling stop"
(Model 211 4MATIC as of 6/2005 and Model 203 4MATIC with M272 as of production startup)
1a. Adaptation of Modified Oil Data Record with SDS 10/06 or Later
Model 203 4MATIC with M272 Engine, up to VIN F886321: Control Units -> Information and communication -> ICM - Vehicle code
12 / NO -> CU adaptations -> select code 807 -> select national version select M272 all-wheel drive change status 3 "or higher" confirm
selection.
Model 211 4MATIC with M272 Engine, up to VIN X218820
- Check whether CGW programming is possible by using SDS: Control units -> Body -> CGW -> Control Unit adaptations -> Control
Unit programming. If yes, perform control unit programming and then perform parameterization in ASSYST. If no, perform
parameterization in ASSYST.
- Perform parameterization in ASSYST by using SDS: Start Control -> Units -> Information and communication -> ASSYST -> CU
adaptations -> select engine M272 -> Select national version -> Select engine for ASSYST M272 Model 211 all-wheel drive
"National version" status 5 or higher.
1b. Check Oil Dipstick Marking on Handle (Model 203 / 211 up to Engine No. 2729..30467144)
NOTE: As of February 2, 2007, Section 1b of this DTB must not be performed on the following vehicles which are covered under
Service Campaign No. 2007010010
Model 203.087 - Serial Nos. AF725595 to F864624

Model 203.092 - Serial Nos. F725472 to F885088
a. Oil dipstick with marking 27214 is correct.
b. Oil dipstick with different marking should be replaced with part number A272 010 14 72.
c. Check whether quantity of engine oil in engine corresponds to specification in WIS.
2. Model 164.186 - Erroneous IC Warning Display "Check Engine Oil Level at Next Service Stop" Confirm engine type coding in ASSYST
using the current issue of SDS: Control unit -> Information and Communication - ASSYST Active Service System -> Control Unit
Adaptations -> Engine Type - Code to correct engine type.
measure.
3a. Vehicles Up to VIN No. A213990 / Production Date 12/20/2006 - Check and correct oil level where necessary by adding 0.3 liter oil at
PDI or at the customers "1st Visit" for all newly sold GL450 vehicles. Refer to WIS document AP-18.00-P-0101GZ. Costs are to be
charged using the warranty code 00001 70.
3b. Check Oil Dipstick Marking on Handle - Oil dipstick with marking 27314 is correct. Oil dipstick with different marking should be
replaced with part number A273 010 14 72. New specification for quantity of engine oil in engine is 9.0 liters with filter change.
3c. Vehicles with VIN No. A213991 up to A235524 / Production Date 2/9/2007
NOTE: Do not automatically add 0.3 liters of oil; check dipstick first.
Oil dipstick with marking 27314 is correct. Oil dipstick with different marking should be replaced with part number A273 010 14 72.
New specification for quantity of engine oil in engine is 9.0 liters with filter change.
4. Model 221.186, Equipped with M273 Engine and 4-Matic, Erroneous IC Warning Display "Check Engine Oil Level at Next Service Stop" -
Update oil data record in ASSYST using SDS: Control unit Information and Communication ASSYST Control Unit Adaptations SCN coding
Perform SCN online coding Work through steps 1-3 in SDS to perform SCN coding.
5. Model 209/211/219, Equipped with M156 Engine, Oil Level Warning Message "Add 1 liter engine oil at next refueling stop" or "Check oil
at next refueling stop" in Instrument Cluster / Oil Level on Dipstick is OK - Perform the following steps.
a. Check the coding of the engine model designation and oil data set of the ASSYST control unit in SDS -> Control units -> Information
and communication -> ASSYST -> Control unit adaptations -> Engine type -> Engine type M156 E63 Version for rest of world Status: 3
has been recognized -> Information and communication -> ASSYST PLUS -> Control unit adaptations -> Control module reset
467
b. Check installed oil dipstick and replace if necessary. The correct oil dipstick is identifiable by the red handle and by the code 156 16
c. Check oil level and correct if necessary.
6. Model 164.122/822 (up to VIN A261645) and 251.122 (up to VIN A059019), "Check oil at next refueling stop" Warning in Instrument
Cluster - If you receive customer reports that at speeds above 75 mph the instrument cluster displays - Check engine oil level at next
refueling stop, the cause may be the position of the oil level switch.
NOTE: Condition only relevant when the oil level is significantly above "min".
a. To resolve, install a lengthened bracket (7 mm) for the oil level switch (part number A642 018 27 40) and check software in the Central
Gateway. For Model 164 vehicles, the data records in software version 30A9 (and higher) are OK and for Model 251 vehicles, the data
records in software version 30AA (and higher) are OK. SDS path: Control units -> Information and communication -> ASSYST ->
Control unit log. The software description in the ECU control unit log from ASSYST (not ASSYST Plus). In the Line "Variant code", the
first 4 characters "00 01..." gives you the information on the above mentioned software (Figure 1). If the software is incorrect, look for
the latest software with DAS.
b. Replace the oil level switch as per step 7.
7. All Passenger and Light Truck Models, Equipped with Engine M156, M272, M273 or M642 (Up to engine no. 642 xxx 40 673486), Faulty
Oil Level Switch - If after performing the applicable remedy(s) 1 through 6 stated within this document, the issue has not been resolved, the
cause may be a malfunctioning oil level switch. Perform the following.
a. Check the oil level using the dipstick.
b. If the oil level is confirmed between the "MIN" and the "MAX" marks on the dipstick, replace oil level switch with part number A001
153 11 32 as per the applicable WIS document.
NOTE: For Engines M272, M273 and M642 - If there is any deformation of the stamped steel bottom section of the oil pan after
removal, it must be replaced. Refer to EPCnet for applicable part number.
c. It is possible to install the switch upside down. For correct installation refer to Figure 2.
Parts Information
468
In Case of Warranty

Control unit - .... code (after short test), perform (54-0992) Panels all, below all, engine R&R (Operation Code: 94-5305, 61-1069,
61-1070, 61-1071, 61-1072, 61-1075, 61-1105, 61-1110 or 61-1128)
Engine oil level / oil quality sensor, R&R/replace (18-4110)
469
Engine Controls - Misfire Diagnostic Information

Supersedes: P-B-07.61/72 and T-B-07.61/73 dated July 10, 2007
Group: 07
470
Revision History
SUBJECT:
Model 129.068
Model 163.154/157/172/175
Model 164.172/175/186/871/886
Model 170.465
Model 171.454/456
Model 202.029
Model203.040/052/054/056/061/064/081/084/087/092/261/264/281/284/740/764
Model 204.054/056
Model 208.365/370/465/470
Model 209.356/365/372/375/456/465/472/475
Model 210.065/070/082/083/265/282
Model 211.056/065/070/072/082/083/087/090/256/265/282/283/287
Model 215.375
Model 216.371
Model 219.372/375
Model 220.067/070/083/170/175/183/184
Model 221.171/186
Model 230.471/475
Model 251.156/165/175
Model 463.249
Diagnosis in DAS for Misfire Fault Codes
If you receive customer reports in the above model vehicles concerning combustion misfiring, process the faults using the guided diagnosis in DAS.
A guided diagnosis program for the fault codes listed below is available in DAS as of DVD 03/2007.
471
472
473
474
NOTE:
Only parts indicated by the SDS test may be replaced. The engine control unit must not be replaced in the case of the fault codes listed below. If
the guided test does not indicate there is a malfunctioning ignition coil, do not replace the ignition coil. All other components being replaced
and requested by the QEC for inspection must be accompanied by full supporting documentation (i.e. control unit log, short test and fault code /
freeze frame data from other related control modules). If the documentation is missing or does not support the diagnosis, the warranty claim
may be debited.
Electrical - Horn Replacement Information

Supersedes: S-B-54.35/193 dated Feb. 21, 2008
475
Group: 54
Revision History
SUBJECT:
Up to April 2008 Production
Replacing the Fanfare Horns
If you receive customer reports in the above model vehicles of the horn not functioning correctly, and it is due to corrosion, replace both the tweeter
(510 Hz) and the woofer (420 Hz) even if only one horn is defective. Refer to vehicle specific WIS documentation for replacement instructions.
Steering/Suspen. - Stabilizer Threads Pulled From Axle

Group: 33
Revision History
SUBJECT:
Model 203.040/052/054/056/061/064/065/076/261/264/740/747/764
Model 209.356/365/372/375/376/377/456/465/475/476/472/477
Threads for Front Stabilizer Bar Mounting Bracket Pulled Out of Axle Carrier
If you identify pulled threads on the front axle stabilizer bar mounting bracket, while removing the stabilizer bar, the cause may be due to
manufacturing tolerances which were not optimized in the tap/drill process.
To resolve, install a M8x1.25 x 16 mm Heli-Coil insert (follow instructions included with the Heli-Coil 8 mm repair kit) into the front axle carrier
and replace the existing bolts so that the specified torque can be achieved when tightening the stabilizer bar mounting bracket. Refer to WIS
document number AR32.20-P-0300P for further information.
Parts Information
NOTE:
476
In Case of Warranty
Operation: Stabilizer bar mounts modification (32-0000)
A/T - Harsh 1-2/3-2 And 2-1 Shifts

Supersedes: P-B-27.60/61i dated August 21, 2007 and T-B-27.60/62i dated Dec. 4, 2007
Group: 27
Revision History
SUBJECT:
All Models with Automatic Transmission 722.9, 7G-Tronic (NAG2) Uncomfortable Shift Quality of 1-2, 3-2 and 2-1 Gear shifts
If you receive customer reports in the above model vehicles of rough 1-2, 3-2 and 2-1 gearshifts, this may be due to the specific gear not being fully
adapted or there could also be a mechanical cause as well. To resolve, perform the following diagnostic sequence.
1. Reproduce the complaint and identify the affected shifts using Star Diagnosis.
2. Print out adaptation data in the form of a transmission control unit log (do not reset the adaptation values).
3. Re-adapt the problem shift using the adaptation process in Star Diagnosis and print a post process transmission control unit log.
NOTE:
For downshifts, the vehicle must coast to a stop without braking in order for adaptation to occur.
For upshifts, the vehicle must be driven and shifted within the valid torque window (green zone in torque display in Star Diagnosis).
If the condition still exists after adaptation, compare adaptation values before and after adaptation test drive. If the values for the filling times of
these shift operations are close to the negative limit of -20 cycles (between -15 and -20), but move further into the negative with further adaptation,
this may have the following cause / remedy.
Cause A - An incorrectly installed retaining ring for return spring B1 or B3.
Remedy A:
1. Remove the transmission
2. Disassemble multi-disk brake B1& B3
3. Remove / install / replace retaining ring and disk spring. Refer to test/repair work procedure in WIS document AR27.50-P-0870W and
AR27.50-P-0890W.
477
NOTE:
There are two different versions of the B1 and B3 multi-disk brake. It is essential to ensure that the retaining ring is ordered correctly.
Refer to Figures 1 through 3 and the parts table, identification groove on the inside/outside of the plate supports.
4. When assembling, insure that the anti-twist locks are correctly positioned! (See Figure 4: Correct positioning of anti-twist lock for thrust
bearing).
478
Cause B- Warped disks of the B1. This can be determined by placing them on a flat surface - they do not lie flat and are uneven.
Remedy B
1. Replace disks of B1, disk spring and retaining ring.
Parts Information
NOTE:
479
In Case of Warranty
Operation: Road test, perform (00-9151)
480
Short test, perform (54-1011)
Oil level - auto. trans. (after leak test), check/correct vehicle w/ 722.9 trans. (27-1256)
Adaptation, perform (27-1047)
Automatic transmission (vehicle with 722.9 trans.), R&R (27-2029)
Auto. trans. (722.6/722.9) - K1/K2/K3/B1/B2/B3/Freewheel, D&A/repl. parts as required transmission removed) (27-9999)
A/T - Shudder On Upshifts/Downshifts

DTB

Group: 27
SUBJECT: Model 203.052/054/056/087/092

Model 209.356/372/456/472
Equipped with Transmission 722.6 / 722.9
Shift Chatter/Shutter While Upshifting/Downshifting
If you receive customer reports in the above model vehicles of shift chatter / shutter while upshifting/downshifting, the cause may be water inside
the automatic transmission as the result of an incorrectly positioned water outlet. Please perform the following procedure to resolve.
1. Check the transmission oil for signs of water contamination (white/pink discoloration of the oil).
2. If there is visible contamination of the transmission oil, clean the transmission oil pan and flush out the transmission by following the
procedure described in WIS document AR27.55-P-0100A.
3. Correct the position of the water outlet (A) and secure using a tie strap (B) as shown in Figure 1.
NOTE:
- Series production vehicles have been resolved as of VINs:
203 - A934352 or F864291 or E025775
209 - F212532 or T078387
- The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been
generated on March 30, 2007. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty
Operation: Oil change - automatic transmission 722.6, replace (00-6556)

Automatic transmission and torque converter, flush (27-4863)
Water outlet to correct position, perform (67-0000)
481
Campaign - Automatic Trans. Pilot Bushing Replacement

Campaign No. 2008120008
December 2008
FILE:
SERVICE:
PARTS:
GROUP I OF INFORMATION _ PARTS & ACCESSORIES BINDER
SUBJECT:
Models 203/ 209/ 211/ 219/ 230/ 463
Replace Pilot Bushing at Electrohydraulic Unit
This service campaign has been initiated because Daimler AG has determined that on affected vehicles the transmission pilot bushing may leak.
Dealer will replace the transmission pilot bushing at the next workshop visit.
- 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.
Procedure
CAUTION:
Ensure the temperature of the transmission is not higher than 50 degrees C prior to starting repairs.
NOTE:
If the vehicle has not been operated in a while, run the engine to fill the torque converter with transmission fluid to reduce the amount of fluid
that will run out when the pilot bushing is removed.
1. Remove underbody paneling.
2. Disconnect electrical connector at transmission.
482
NOTE:
Remove heat shield (arrow, Figure 1) if equipped.
3. Remove pilot bushing mounting bolt (Figure 2); remove pilot bushing.
NOTE:
When removing the pilot bushing, catch any transmission fluid that might leak out.
4. Install new pilot bushing and reassemble in reverse order.
- Torque pilot bushing mounting bolt to 3 Nm.
- Torque heat shield bolt to 6 Nm.
5. Reassembly in reverse order.
NOTE:
Ensure the transmission is cold (approx. 25 degrees C) prior to performing step 6.
483
6. Remove breakaway locking tab from dipstick and check fluid level (with engine running and transmission in P); the fluid level must be
between the min and max marks (A, Figure 3).
- Refill transmission fluid to correct level.
- Install new lock pin on cap.
Special Tools
NOTE:
The above-listed Special Tools have been previously released to all dealers and should already be in your Special Tool inventory.
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
484
NOTE:
- To claim a repair performed during an A or B Maintenance or other necessary warranty repair requiring removal of underbody paneling, use
Repair 1.
- To claim a repair performed independently of an A or B Maintenance or other necessary warranty repair requiring removal of underbody
paneling, use Repair 2.
Lighting - License Plate Bulb(s) Burned Out

Supersedes: P-B-82.10/398a dated Jan. 26, 2005
Group: 82
Revision History
SUBJECT:
License Plate Bulb(s) Burned Out
If you receive customer reports in the above model vehicles that one or both license plate bulbs is burned out, a resistor wiring harness is available
to reduce the voltage at the license plate bulbs. Check the vehicle history file to confirm that a resistor wiring harness for the license plate bulbs has
not been previously installed. If it has not, install a resistor wiring harness for each license plate lamp and replace the burnt out bulb(s) per the
below procedure.
1. Remove license plate lamps.
2. Remove trunk lid lining.
485
3. Disconnect plug from each license plate illumination socket (Figure 1, 1).
4. Install resistor wiring harness (Figure 2) between the disconnected plug and license plate illumination socket on each side.
5. Cover plug socket with foam sleeve (Figure 2) included with each resistor wiring harness.
6. Fasten the rest of each adapter cable to the trunk lid with felt (Figure 1, 2).
7. Reinstall trunk lid lining
8. Replace burnt out license plate bulb(s)
9. Reinstall license plate lamps
If a license plate resistor wiring harness was previously installed, only replace the burned out bulb(s).
Parts Information
NOTE:
In Case of Warranty
Operation: Wire harness adapter - license plate lamps, install (02-4542)
Keyless Entry - Various Malfunctions

486
Order No.: S-B-80.00/53
Supersedes:
Group: 80
SUBJECT:
MY- All, Models All
Replace Battery in Transmitter Key
In the event of complaints about the function of the vehicle key, first check for and remove any soil or grease from the battery or battery contacts
using the lint-free cloth and alcohol.
NOTE:
To ensure faultless contact, do not touch the batteries on their contact sides. Technical Service Bulletin # P-62_10-08C Date: 081222
Interior - Noise From The Center Of The Dash

Group: 62
Revision History
SUBJECT:
Model 203.052/054/092/056/087
Model 209.356/365/372/375/376/377/456/465/472/475/476/477
Noise Front of Vehicle / Dash Area
If you receive customer reports in the above model vehicles of noise from the center of the dash area, this may be caused by a portion of the ME
wiring harness contacting the plastic guide on the partition wall or the harness not properly positioned in the harness retainer clip (Figure 1).
Perform the procedure below to resolve.
1. Remove the air filter housing. Refer to WIS document AR09.10-P-1150QB.
487
2. Remove cowl drain tube on drivers side (Figure 2, arrow), unclip plastic cover clips (Figure 2, circle) and partially remove the harness from
the plastic guide.
3. Wrap the ME wiring harness with felt tape (A001 983 23 10) where it fits into the plastic guide on the partition wall (Figure 3).
4. Wrap the end of the felt tape on the harness near the clip location with fabric tape (Figure 3).
5. Insert 10 mm x 10 mm square piece of felt tape between partition wall cover and all screw clips (Figure 1, circles - 2 shown).
6. Check the ME wiring harness at the clip location (Figure 3), reposition the harness to fit properly into the retainer clip.
7. Apply special sliding compound (A000 989 36 60) to felt tape in the area where the harness is in contact with the plastic guide.
8. Reassemble in reverse order.
Parts Information
NOTE:
In Case of Warranty
Operation: Noise in front of vehicle / dash area, eliminate (62-0000)
488
Accessories - Can't Program Garage Door Opener

Group: 68
Revision History
SUBJECT:
Garage Door Opener Cannot be Programmed
If you receive customer reports in the above model vehicles of the integrated garage door opener on the interior rearview mirror or overhead control
panel unable to accept coding from a hand-held garage door transmitter, this may be caused by the integrated garage door opener being
preprogrammed. You can determine if the system has been preprogrammed by pressing a signal transmitter button. The indicator lamp will
illuminate but will not flash. To resolve, please refer the customer to the instructions noted in the Operator's Manual on erasing the integrated
remote control memory. Attached is a copy of the instructions that can be provided to the customer.
NOTE:
The enclosed procedure cannot be claimed under Warranty.
Instructions on Resetting the Integrated Remote Control Memory

1. Switch on the ignition.
2. Simultaneously press and hold down the outer signal transmitter buttons (Figure 1 or 2, 2 and 4) for approximately 20 seconds until the
indicator lamp (Figure 1 or 2, 1) flashes rapidly. Do not hold for longer than 30 seconds.
3. The codes of all three channels are erased.
489
4. Program integrated garage door opener as per the instructions outlined in the Operator's Manual.
WARNING:
Before programming the integrated remote control to a garage door opener or gate operator, make sure people and objects are out of the
way of the device to prevent potential harm or damage. When programming a garage door opener, the door moves up or down. When
programming a gate operator, the gate opens or closes. Do not use the integrated remote control with any garage door opener that lacks
safety stop and reverse features as required by U.S. federal safety standards (this includes any garage door opener model manufactured
before April 1, 1982). A garage door that cannot detect an object - signaling the door to stop and reverse does not meet current U.S.
federal safety standards. When programming a garage door opener, park the vehicle outside the garage. Do not run the engine while
programming the integrated remote control. Inhalation of exhaust gas is hazardous to your health. All exhaust gas contains carbon
monoxide (CO), and inhaling it can cause unconsciousness and possible death.
Vehicle - Approved Service Products On WIS

DTB

Group: 47

Equipped with FSS / FSS+ or MB Maintenance System
Approved Service Products
NOTE: As of July 15, 2008, information on approved service fill oils can be found on WIS-Net.
Locate the Search Aid for Specifications for Operating Fluids (BB00.40-P-0900A) within WIS-net, by entering the number in the Document
number field and clicking Enter (Figure 1).
Please note the specified engine oils by engine type are listed in BB00.40-P-0223-02A and relevant sheets for Engine Oil in search results are
229.3, 229.5 and 229.51. Transmission fluid sheets have a 236.X number.
490
Electrical - Auxiliary Power Outlet Inoperative

Group: 54
Revision History
SUBJECT:
Model 203.052, from VIN E019387 up to VIN E021112
Power Outlet Nonfunctional / Missing Relay
If you receive customer reports in the above model vehicles of a nonfunctional power outlet (cigarette lighter), the Rear Signal Acquisition and
Actuation Module (SAM) may be missing a relay and/or fuse.
1. Check for missing relay in slot "F" and/or missing fuse (15 A) in slot "12" on Rear SAM (N10/2) (Figure 1).
2. If required, install new relay in slot "F" and new fuse (15 A) in slot "12" on Rear SAM (N10/2)
Parts Information
generated on November 18, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty
Operation: Fuse - specify location, replace (54-1286)
491
Memory Systems - Easy Entry/Exit Feature Is Inoperative

Order No.: S-B-91.10/125c
Supersedes: S-B-91.10/125b dated Oct. 20, 2008
Group: 91
Revision History
SUBJECT:
All 164, 171, 203, 209 and 251 Vehicles, Equipped with Memory Seats (Code 275)
All 211, 219 and 230 Vehicles
Easy Entry/Exit Feature for Seat Position Not Functioning
If you receive customer reports in the above model vehicles regarding the easy entry/exit feature for the seat position not functioning, this may be
due to prior replacement of the instrument cluster (A1) on vehicles up to production date 06/01/2005. This can be corrected by installing one of the
following seat ECU (N32/1 or N32/2) part numbers and programming the ECU with SDS release 09/06 or newer.
Models 164, 171, 219 and 251: Control units with the following part numbers should only be programmed and coded with SDS release 09/2006 or
later.
A211 820 11 85 A211 820 85 85 A211 870 05 85 A211 870 49 85
Model 203 without Central Gateway (CGW or N93): Control units with the following part numbers are to be replaced with A211 870 46 26 and
then programmed and coded with SDS release 09/2006 or later. Control units with part number A211 870 46 26 should only be programmed and
coded with SDS release 09/2006 or later.
A203 820 15 26 A211 820 01 26 A211 820 40 85 A211 820 11 85

A211 820 85 85 A211 870 05 85 A211 870 49 85
Model 203 with Central Gateway (CGW or N93) and Model 211: Control units with the following part numbers are to be replaced with A211 870
46 26 and then programmed and coded with SDS release 09/2006 or later.
A203 820 15 26 A211 820 01 26 A211 820 40 85
A211 820 11 85 A211 820 85 85 A211 870 05 85 A211 870 49 85
Model 209: Control units with the following part numbers are to be replaced with A211 870 46 26 and then programmed and coded with SDS
release 09/2006 or later.
A203 820 15 26 A211 820 01 26 A211 820 40 85
A211 820 89 85 A211 870 17 26 A211 870 46 26
NOTE:
On model 209 vehicles produced prior to 03/2004, the control units cannot be programmed in the vehicle. Instead, the control units must first be
installed and programmed in a model 211 vehicle, or a model 203 vehicle as of 08/2003, then installed in the 209 vehicle.
Model 230: Control units with the following part numbers are to be replaced with either A230 820 60 26 A230 820 61 26 (or equivalent
superseding parts) and then programmed and coded with SDS release 09/2006 or later.
492
A230 820 05 26 A230 820 06 26 A230 820 32 26 A230 820 33 26

A230 820 43 26 A230 820 44 26
Parts Information
NOTE:
on October 20, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty

Power seat control module - for driver seat, replace (seat cushion removed) (91-6687)
Control unit - .... code (after short test), perform (54-0992)
493
Restraints - Head Restraint Height Adjuster Is Inop.

DTB

Group: 91

Electric Head Restraint Height Adjuster Not Functioning
If you receive customer reports in the above model vehicles that the electric head restraint height adjuster is not functioning, the printed circuit
board (PCB) at the motor may have broken due to tension applied to it by the wiring harness. Fault code 9203, hall sensor of component M27m4
(Head restraint raise/lower motor) is faulty, may also be present.
1. Remove the head restraint height adjuster per WIS document AR91.29-P-1432P (203 and 209) or AR91.29-P-1432T (211).
2. Use a cable tie to secure wiring harness to strut (Figure 1, arrow)
3. Guide wiring harness behind top transverse wire (Figure 2, arrow)
4. Reinstall the head restraint height adjuster per WIS document AR91.29-P-1432P (203 and 209) or AR91.29-P-1432T (211).
Parts Information
494
generated on September 26, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty

Power seat motor - driver headrest adjustment, replace (91-6042)
Power seat motor - front passenger headrest adjustment, replace (91-6092)
A/C - No Or Low A/C Cooling Performance

Order No.: S-B-83.55/118
Supersedes:
Group: 83.55
SUBJECT:
Defective Refrigeration Circuit / Refrigerant Compressor
If you receive customer reports in the above model vehicles related to "no or low AC cooling performance", it may be due to a locked refrigerant
compressor, a broken torque limiter on the refrigerant compressor, the refrigeration circuit blocked or an electrical defect in the refrigerant
compressor. To remedy any of these issues please proceed with the following.
Note:
495
This document is intended as a supplement to the SDS function test "Refrigerant circuit test". Only perform repair and replacement work on the
refrigerant circuit if the SDS refrigerant circuit test was unsuccessful and you have received appropriate instructions in the SDS function test.
Prerequisites:
1. Before parts can be replaced, the exact quantity of the refrigerant in the refrigeration circuit must be determined by evacuating the system. When
returning parts be sure to indicate the exact amount of refrigerant in the circuit and any other findings by the technician. If the filling capacity is not
indicated, warranty claims may be rejected.
2. If the fill level of the refrigerant circuit is too low, parts should only be replaced if the torque limiter is broken.
3. If the fill level of the refrigerant circuit is too low and the torque limiter is damaged, the leak test (Test 6 "Leak in refrigeration circuit") must be
performed using the "Technology Guide Vehicle Climate Control" located in SDS SDMedia first and then the system must be refilled and checked.
If the amount of refrigerant in the circuit is less than 80% of the normal level, it is too low. Inadequate fill levels may be the cause of the air
conditioning shutting down or malfunctioning.
Remedy A - Broken Torque Limiter:
1. Ensure the alternator freewheel (when applicable) is not damaged and that the belt pulley of the refrigerant compressor rotates in the belt drive.
2. If the alternator freewheel is blocked, replace the alternator freewheel. For refrigerant compressors with a replaceable belt pulley, replace the belt
pulley only, otherwise replace the refrigerant compressor. Refer to EPCNet for applicable part number.
3. If the alternator freewheel is not blocked and black refrigerant/oil is evacuated from the system, replace the AC compressor. Refer to EPCNet for
applicable part number.
Remedy B - Blockage in the Refrigeration Circuit
2. Inspect along the AC lines to check for blockage at the points with marked temperature differences.
3. Identify and replace the blocked components in the refrigeration circuit. Refer to EPCNet for applicable part number.
Remedy C - Electrical Defect in Refrigerant Compressor
2. After ruling out a short circuit in the actuation and ground wiring, replace the refrigerant compressor only. Refer to EPCNet for applicable part
number.
Note:
^ Always empty the oil from the new refrigerant compressor before installing.
^ When completely refilling the system, ensure the quantity of oil and refrigerant is correct (refer to WIS document BF83.00-Z-9999AZ). Take
into consideration whether individual components or the entire refrigerant circuit are to be replaced.
^ Always perform a leak test on the system after changing the refrigerant circuit but before filling it with refrigerant.
Note:
496
497
498
499
In Case of Warranty, use the tables above.
A/C - A/C Lamp Flashing/A/C Inoperative

Group: 83
Revision History
SUBJECT:
All Model 171, 203, 209, 211, 216, 219 and 221 Vehicles
AC or AC Off Indicator Lamp Flashes After Actuation / Air Conditioning Not Functioning
If you receive customer reports in the above model vehicles of the AC or AC Off indicator lamp flashing and the air conditioning is not operating,
the cause could be the coding of the climate system control module. Follow the instructions below to overcome the specification parameter in the
refrigerant level logic circuit.
1. Process any fault codes in the climate system and repair as necessary.
2. Confirm refrigerant level by performing a Refrigerant Circuit Test as per SDS and following instructions for corrective actions.
3. Only after steps 1 and 2 are completed, use Star Diagnosis to deactivate the fill level control as per the instructions listed below.
Model 203: Control unit groups --> Body --> EZS - Electronic ignition switch --> Control unit adaptations --> Read coding and change if necessary
--> Climate control --> Standard setting: Climate control --> Refrigerant level check --> Set to Inactive
Model 216/221: Main groups --> Control units --> Air conditioning --> AAC - Automatic air conditioning (Interior CAC bus) --> Read coding and
change if necessary --> Control unit adaptations --> Workshop coding --> Refrigerant level check --> Set to Deactivated
500
501
Model 171, 211 and 219: If the fluid level control is still active, there will be a menu item in 'Main groups' labeled 'Check for necessary coding
measures' (Figure 1). Process this menu item to deactivate the coding of the fluid level controls (Figure 2 and 3). If the fluid level control is already
inactive, this additional menu item will not appear when "Main groups" is selected (Figure 4).
Note:
If the fluid level control has already been deactivated and the vehicle has the symptoms described, there is a fault that has not been corrected and
further diagnosis is necessary. Refer to applicable diagnostic trees in the Vehicle Heating, Ventilation, Air Conditioning (HVAC) Manual found on
STAR TekInfo --> EDAC --> Non EDAC Guides.
Note:
502
Engine Controls - Engine Won't Start When Hot

Order No.: S-B-54.21/215
Supersedes:
Group: 54
SUBJECT:
All Models Equipped with Engine M272 and M273
Engine Cannot Be Started When Engine is Hot but Will Start After Engine has Cooled
If you receive customer reports in the above model vehicles that the engine cannot be started when the engine is hot but will start after the engine
has cooled and there are no Diagnostic Trouble Codes stored in the ME control unit, check the signal to the fuel pump relay from the ME Control
unit (12VDC with Key in position "1" N3/10 pin 17 + and pin 4). If no signal is found, check the wiring from the ME control unit to the fuel pump
relay. If the wiring checks out, it may be due to an open circuit in the ME control unit. In this case, replace the ME control unit and retest the signal
to the fuel pump relay. Refer to EPCnet for applicable part number.
Note:
A copy of the short test and all tests performed must accompany returned parts. If the documentation is missing or does not support the diagnosis,
the warranty claim may be debited.
Note:
503
COMAND(R) - Inoperative Or Opening/Closing Errors

Group: 82
Revision History
504
SUBJECT
Central Display Opening/Closing Errors or Inoperative, Voice Control Does Not Respond To User's Commands (Hands-free Conversation) and/or
Other Party May Not Hear Driver's Conversation
If you receive customer reports in the above model vehicles having any of the conditions below, it may be due to an incorrect
installation/mating/contact of the iPod Interface Cable (Refer to Figures 1-4 above) with the COMAND head unit connector.
To remedy, replace the iPod Interface Cable. Refer to the appropriate section of WIS Documents shown above.
505
Conditions
^ Central display opens and closes by itself or inoperative
^ Voice control system may not respond to driver's commands due to head unit connector contacts not mating securely as a result, the connection
to the microphone is lost
^ iPod playback intermittently inoperative
^ Back up camera (B84/3) intermittently inoperative
^ Intermittently the instrument cluster and audio/COMAND display fan motor M4/13 inoperative
^ Left or right side speakers intermittently not producing sound
^ COMAND head unit external fan not operating
Note:
When connecting the iPod Interface Cable to the wiring harness of the Head Unit, please make sure that all individual connections are securely
fastened as it is possible individual pins may pass unnoticed. Please ensure that you hear the "click" when mating the connectors and visually
inspect both sides of the connector for proper contact. Where possible, please perform a continuity check on the iPod Interface Harness.
Parts Information
Note:
Steering - Leaks At Steering Gear/Hose Junction

Order No.: P-B-46.20/16e
Supersedes: P-B-46.20/16d dated Nov. 10, 2008;

P-B-46.20/10c dated Dec. 19, 2007
Group: 46
506
Revision History
SUBJECT:
Models 171, 203, 204, 209, 211, 215, 216, 219, 220, 221, 230
Leaks at the Steering Gear Control Head Connection to High or Low Pressure Lines or Leaks at Internal Steering Lines of the Control Head
Connection to Steering Gear Housing
If you receive customer reports in the above model vehicles of leakage at the steering gear control head connection of high and low pressure lines
or from the internal steering lines at the connection between the control head and the steering housing, this may be caused by damage to a
respective O-ring at the control head or steering housing. Follow the below to resolve.
Note:
It is not necessary to replace the entire rack-and-pinion steering system. The O-rings are now available as separate parts or as part of repair kits.
Repair A (Model 171, 203, 204, 209, 211, 215, 216, 219, 220, 221 and 230)
To replace the O-rings of the affected connections at the steering gear control head to the high or low pressure steering lines, it is necessary to seal
both lines at the same time, due to the common retaining plate for both lines. Proceed as follows.
1. Loosen line connection on steering gear. Refer to applicable WIS documents shown above.
Note:
If necessary, loosen line supporting brackets.
Note:
Ensure that sealing rings and supporting ring are properly seated. Supporting ring only present on high pressure line.
Note:
There are two versions of power steering high-pressure lines. The preceding version has a slotted support ring which can be replaced individually.
The new version has a support ring which is not slotted and which cannot be replaced individually; in this case the complete power steering high
pressure hose must be replaced (refer to EPC to specify correct high pressure hose).
3. Fasten line connection on steering gear with retaining plate. Fasten any loosened line supporting brackets and reinstall any removed panelings.
Note:
Observe torque values for screw connection. Refer to WIS documents for specifications.
4. Bleed steering system and check for leaks. Refer to the DTB S-B-46.30/40b (or latest version).
Repair B (Model 203, 204, 209, 211, 215, 219 and 220):
To remedy leaks at the connections of internal lines between the steering gear head and the steering housing individually, replace the short or long
507
internal oil lines and respective seals. Proceed as follows.
1. Remove the steering gear from the vehicle as described in the WIS documents as shown above.
2. Replace internal pipelines from control head to steering gear housing. Refer to applicable WIS document as shown above.
3. Reinstall the power steering gear as described in the WIS documents listed under step 1 based on the respective model.
4. Toe adjustment after removal/reinstallation of the steering gear is NOT necessary. (Refer to latest version of DTB P-B-46.20/28
Note:
508
Parts Information
Note:
509
510
Wheels - Approved Alloy Wheel Cleaning Product

Order No.: S-B-40.10/66
Group: 40
SUBJECT:
MY-All, Models All
Approved Alkaline MB Wheel Cleaner for Light Alloy Disk Wheel
511
Any under top coat discoloration which occurs on vehicle wheel bolts (Figure 1) and light alloy disk wheels (Figures 2 - 4) can indicate that the
wheels have been cleaned with an acid-containing product. Harsh, non-recommended products diffuse through the top coat and leave behind visible
run-like tracks on the wheel finish as well.
Any wheels returned with such damage will not be covered by warranty.
NOTE:
Use only the approved alkaline MB wheel cleaner in parts information below. Ensure that all cleaning products and care systems are acid-free as
well.
Parts Information
512
Wheels/Tires - Alloy Wheel Radial Crack Information

Order No.: S-B-40.10/69
Group: 40
SUBJECT:
MY-All, Models All
Radial Crack in Light Alloy Disk Wheel
Through inspection of returned warranty parts, it has become evident that light alloy disk wheels are being replaced under warranty for radial
cracks. This type of damage is attributable to driving over obstacles and resulting punctures. The rim flange becomes deformed and a radial crack
occurs immediately or later due to the vehicle's operating load. This type of damage is not covered under warranty.
Low section tires also significantly contribute to mechanical damage because of their lower side wall height and the possibility of a crack can be
exacerbated by low tire inflation pressure.
For safety reasons, a tire should be replaced after it has been punctured to preclude internal fabric damage of the tire carcass.
Electrical - Battery Maintenance Information

Order No.: S-B-54.10/213
Supersedes:
Group: 54
SUBJECT:
MY- All, Models 164, 171, 199, 203, 204, 209, 211, 216, 219, 221, 230, 251, 463
Battery Maintenance
The vehicle battery must be checked periodically on vehicles that remain inactive for extended periods of time. The maximum allowable time
between performing battery checks is 4 weeks. In the event that a vehicle is going to be stored for more than 4 weeks, it is recommended to
disconnect the ground lead at the battery. This will prevent battery discharge by quiescent current (rest current) draw from the vehicle's
no-load current consumers.
NOTE:
If it is deemed necessary to charge the on-board electrical system battery and the vehicle is equipped with more than one battery, then the
starter battery must also be charged. On vehicles with more than one battery, ground leads should be disconnected from all batteries
equipped on the vehicle including the on-board electrical system battery, starter battery and the auxiliary/additional battery (G1/7).
Check the battery voltage of the on-board electrical system battery via the instrument cluster or multimeter, as described in
AR54.10-P-1132A. A battery should be charged when the measured voltage drops below 12.2 V.
If the vehicle has been inactive for 6 months or longer, prior to putting the vehicle back in service, the batteries must be charged to counteract
any effect of self-discharge. If equipped, the auxiliary/additional battery (G1/7) does not need to be recharged, just reattach the ground lead
for this battery.
513
NOTE:
The instrument cluster displays a white battery symbol with the text "Visit Workshop," if the auxiliary/additional battery voltage is < 11.5
V.
If the auxiliary/additional battery is < 11.5 V and > 6.0 V, this battery will be charged by the Front SAM (N10/1) at a charge rate of 150 mA,
when the engine is running or STAR Diagnosis is left connected and set to charge the auxiliary battery. If the measured voltage of the
auxiliary/additional battery is < 6.0 V, the battery should be replaced.
Battery maintenance is the responsibility of the dealer for all new vehicles in dealer inventory. Batteries replaced and claimed as warranty
while the vehicle is in dealer inventory, other then auxiliary/additional batteries, are subject to debit. Additionally, the customer is responsible
for battery maintenance when vehicles remain inactive for extended periods of time. Technical Service Bulletin # S-14_30-15F
Date: 090313
Emissions - Multiple Codes Set/MIL ON

Group: 14
Revision History
SUBJECT
Check Engine Light with DTC P2003, P2047, P0810 and P0814 Stored in Engine ECU
If you receive customer reports in the above model vehicles of the check engine light coming on and codes P2003 (M112, M113, M275), P2047
(M271), P0810 (M272, M273), P0814 (M272, M273) are stored in the engine control module memory, please perform the below procedure.
1. Air Pump Relay
514
This condition may be caused by a malfunctioning air pump relay. When the secondary air pump relay malfunctions, the air pump may be actuated
beyond the maximum permissible operating time. This overload may lead to failure of the secondary air injection pump and results in a malfunction
in the secondary air injection system. Proceed as follows:
Note:
If diagnosis reveals a malfunctioning air injection pump, refer to step 1.2.
1.2 If the secondary air pump is determined to be defective remove/replace secondary air pump and air pump relay (refer to WIS document:
AR14.30-P-7251QB).
1.3 If it is determined that only the relay is defective, replace the relay only and retest the secondary air injection function chain with SDS.
1.4 Program engine control module.
2. Check Valve for Vacuum Actuation of Air Pump
515
This condition may be caused by a malfunctioning check valve in the vacuum line (Figure 1) to the air pump switch over valve. When the check
valve malfunctions, vacuum flow to the diverter valve is restricted preventing it from opening. Proceed as follows.
2.2 If the air pump can be activated with SDS but the function chain test fails, the vacuum flow between the air pump switchover valve and the
diverter valve may be restricted preventing the diverter valve from opening.
2.3 Check vacuum supply (Figure 2) at the diverter valve. If vacuum is < 500mbar, change check valve.
Note:
Copy of the SDS short test and all tests performed must accompany returned parts. If the documentation is missing or does not support the
diagnosis, the warranty claim may be debited.
Note:
When ordering a replacement relay order the part number of the relay being removed. The parts system will deliver the current version of the
ordered part.
Parts Information
Note:
516
517
Audio System - AM/FM Interference With Rear Defogger ON

Supersedes: P-B-82.60/227 dated Feb. 26, 2003
Group: 82
Revision History
518
SUBJECT:
All Model 202, 203, 208, 209, 210, 211, 215, 219 and 220 Vehicles
Equipped with Radio/TV Window Antenna
AM/FM Reception Interference When Rear Window Heater is Switched On
If you receive customer reports in the above model vehicles of AM/FM or TV reception interference when the rear window heater is switched on,
this may be caused by one or more interruptions in the heat conductor in the rear window which may cause interference in the FM/AM bands. To
remedy, perform the following.
Note:
Use a battery trickle charger
At ambient temperature, the rear window heater needs to be turned on continuously for approx. 45 minutes at 13.8V. Since the heating period is
regulated depending on the outside temperature, it is necessary to switch off the rear window heater every 5 minutes manually and turn it back on
again immediately.
This procedure eliminates transition resistance at the contacts of the heated rear window. If interference is still present, detach the connecting lines
of the rear window heater from the rear window and connect them to a resistive load (50-60W light bulb = approx. 240 Ohms). If there is no longer
any radio interference present while the ohmic load is connected, the antenna in the rear window is malfunctioning and the rear window needs to be
replaced. Refer to EPCnet for applicable part number. Refer to WIS AF67.29-P-1130AG for further instructions.
Note:
Cell Phone - Calls Dropped Or Cut Off

Group: 82
Revision History
SUBJECT:
Telephone Calls Being Cut Off or Dropped
If you receive customer reports in the above model vehicles for telephone calls being dropped or disconnected even with adequate signal strength,
please read the below information on possible causes.
1. Dead Zones - Depending on the location and the respective network provider, 100% network coverage may not be present. Network coverage
519
can vary at the same location depending on the network provider. When crossing from an area with network coverage to an area without network
coverage, reception may drop to zero and the call may be cut off, even though the phone or head unit may still continue to show signal strength.
There are many things that can diminish "dead zones" and weather is a large contributor.
2. Switching Cells - While driving, the telephone transfers from network cell to the next network cell. Sometimes switching between cellular towers
can also cause calls to be dropped. This can be fixed by the customer's service provider (Verizon, Sprint, Alltel, Cingular, T-Mobile, etc.). If
customers experience dropped calls on a regular basis along the same route, they should take note of the cross streets or address and contact their
service provider and describe where the drops are taking place and time of day.
3. Cells Operating at Full Capacity - While driving, the telephone transfers from network cell to the next network cell. Each cell can only process a
maximum number of calls. If the vehicle with an active call transfers to a cell operating at full capacity, the cell cannot handle the call and it will be
dropped. The call is cut off even though the head unit and/or telephone may be showing full signal strength and anywhere from 1 to 5 bars.
These are network problems and not related to the vehicle; replacing components will NOT resolve the complaint.
Interior - Leather/Wood Steering Wheel Imperfections

Order No.: P-B-46.10/68
Supersedes:
Group: 46
SUBJECT:
Without Leather or Wood/Leather Steering Wheels (Codes 280 and 289)
Noticeable Steering Wheel Imperfections
520
If you receive customer reports in the above model vehicles of steering wheel imperfections such as crimps, bursts or scrunches felt on the outside
surface of the steering wheel, this may be caused by foam (used in the steering wheel manufacturing process) escaping the mold and creating bursts
(Figure 1 and 2, A) on the outside surface. These bursts or scrunches are not entirely removed during finishing work. To remedy, very carefully
remove any such imperfections on the steering wheel (Figure 1, A) using a sharp utility knife (Figure 3, B).
Note:
Extreme care must be exercised when removing steering wheel imperfections. Use only a new, sharp blade of the utility knife when cutting off any
imperfections refer to Figure 3. Do not cut steering wheel (Figure 4) or cut with a blade at an angle (Figure 4). If it is determined that it is
impossible to remove steering wheel imperfections, the steering wheel should be replaced.
Note:
Body - Windshield/Rear Window Body Seam Corrosion

521
Order No.: P-B-67.00/24
Supersedes:
Group: 67
SUBJECT:
MY-All, Model 129, 140, 170, 202, 203, 208, 209, 210, 211, 215, 220, 230
Corrosion of Weld Seam on Sealing Flange of Windshield and/or Rear Window
If after the removal of the front or rear glass in the above model vehicles, corrosion of the weld seam flange is noted in either the front or rear
(Figure 1), repair the corrosion. Clean the sealing flange as it must be free of dust and grease.
In addition, perform any new paintwork according to guidelines from Mercedes-Benz using repair materials and instructions of approved paint
vendors.
Restraints - Seat Belts Don't Retract Properly

Supersedes: P-B-91.40/130 and T-B-91.40/131 dated October 11, 2006
Group: 91
Revision History
a 3/19/09 Parts Information Updated
SUBJECT:
All Model 164, 171, 203, 209, 211, 219, 220, 221, 230 and 251
Seat Belt Does Not Roll Up Correctly
If you receive customer reports in the above model vehicles of the front or rear seat belts not rolling up fully, the cause could be dirt deposits on the
seat belt guide due to a soiled seat belt. Cleaning the belt guide and seat belt should restore proper function of the seat belt retraction.
To resolve, perform the following.
522
1. Clean the belt guide using MB Plastic Cleaner (Figures 1 and 2).
2. Clean the seat belts using MB Car Shampoo mixed with water, MB Textile Carpet/Fabric Care or clean, lukewarm water and soap. Do not treat
the belt with any other cleaning agents.
3. Extend belt and allow to air dry. Do not dry at temperatures above 175°F (80°C) or in direct sunlight. Do not bleach or dye.
Note:
If these instructions are not followed, proper retraction of the seat belt may be impaired.
Note:
This repair cannot be claimed under warranty.
Parts Information
A/T, M/T - Flywheel/Flexplate Replacement Information

Order No.: S-B-03.30/11
Supersedes:
523
Group: 03
SUBJECT:
MY- All, Models All with Engine 272 with Transmission 722.6/9, Engine 273 with Transmission 722.9, Engine 272 with Transmission 722.6
Flywheel/Flexplate Replacement Procedure
The following must be observed when replacing the flywheel/flexplate in vehicles with engine 272 and transmission 722, as well as vehicles with
engine 273 and transmission 722.
Flywheel/Flexplate Replacement Procedure
1. Spacer washer A 273 032 00 52 must be installed between the new flywheel/flexplate A 273 030 03 12 and the crankshaft.
2. Spacer plate A 112 032 02 52 must be installed between the bolt heads and the flywheel/flexplate.
NOTE:
The screw-in depth of bolts A 007 990 88 04 in the flywheel/flexplate plate may be insufficient due to unfavorable tolerances; and
therefore, the torque converter must be fastened to the new flywheel/flexplate using bolts N 007 984 010 036 and washers A 327 990 06
40.
This procedure is to be followed until further notice.
Parts Information
A/T - Electro-Hydraulic Control Module ID/Ordering

Supersedes: S-B-27.19/82c, February 3, 2009
Group: 27
Revision:
Parts information for models 230, 209, 211, and 215.
SUBJECT:
MY-All, Models 164, 171, 203, 209, 211, 215, 216, 219, 220, 221, 230, 251 (with Transmission 722.9)
Ordering Correct Transmission Electro-Hydraulic Control Modules
Effective immediately, use only the following Parts Information when replacing a transmission electro-hydraulic control module.
NOTICE!
On some models, it is crucial to consider any fault codes for the respective model year and the presence of an auxiliary oil cooler. It is therefore
necessary to inspect models with (marked **) or without auxiliary oil coolers (marked *) before ordering the transmission electro-hydraulic control
unit when the vehicle production date is after 01/2007. The auxiliary oil cooler in models with Engine 273 and Engine 642 is in front of the radiator
and air-conditioning condenser and is connected in series with the existing oil/water cooling system of the radiator. Failure to comply may prevent
Star Diagnosis from correctly programming and coding the valve body.
Note:
This Parts Information reflects only correct part number information for use should transmission electro-hydraulic control module replacement be
necessary. This Parts Information does not serve to determine that the correct or latest version transmission electro-hydraulic control module is
installed, nor does it justify parts replacement.
524
Note:
Use the most current version Star Diagnosis software along with all necessary add-ons.
525
526
Parts Information
A/C - Various Compressor Noise With A/C ON

Group: 83
527
Revision History
SUBJECT
Replacement of Refrigerant Compressor Belt Pulley Due to Noise Complaints If you receive customer reports in the above model vehicles of noises
at the refrigerant compressor with air conditioning activated and deactivated, the cause could be a defective belt pulley or belt pulley bearing. The
pulley and pulley bearing can be diagnosed and replaced with the compressor still installed in the vehicle by following the procedures below.
1. Locate the noise by duplicating the conditions under which the complaint occurred.
2. If there is also a cooling performance complaint, the noise could be caused by low refrigerant level, perform a Refrigerant Circuit Test as per
SDS and follow instructions for corrective actions.
3. Before the belt pulley on the refrigerant compressor is replaced, verify that the following components in the belt drive are not the source of the
noise and repair as required.
^ Alternator
^ Power steering pump
^ Guide pulleys / tensioner pulleys
^ Water pump
4. If there is a whining noise that is RPM-dependant which is present with the air conditioning on AND off and is determined to be caused by the
tensioner pulleys, guide pulleys or refrigerant compressor, continue with step 5.
Note:
Make sure that the AC is SHUT OFF! On the push button unit, select "AC off" then "OFF" to turn the Climate System off, then select climate
system on. The compressor should now be off. To see more details on the various push button units, please refer to the climate book, section 2.1 for
each model.
Engines M112/113/272/273
5. Remove the poly-V-belt from the refrigerant compressor.
528
6. Install shorter belt to bypass the compressor. Route belt as shown in Figure 1.
Engines M112/113 - 20 x 2315 to 2325 mm (A011 997 86 92 or A 011 997 96 92)

Engines M272/273 - 20 x 2330 to 2340 mm (A011 997 04 92)
Note:
A short test belt for OM642 is currently not available.
Note:
The belts can be sourced locally or by MB part number. The belts must be purchased to diagnose AC compressor pulley noise and are not to be
submitted on a warranty claim.
7. Run the engine with the short belt installed. If the noise is still present, check whether the tensioner and/or guide pulleys are the source of the
noise. Replace as necessary the defective tensioner and/or guide pulleys.
8. If the noise is no longer present, allow the engine to cool and proceed to step 10.
9. Replace the compressor pulley as follows.
Note:
It is not necessary to remove the compressor or evacuate the refrigeration circuit. Refer to WIS document AR83.55-P-7685B
10. Remove the pulley-V-belt. Determine if the diameter of the pulley is 100 mm or 110 mm.
11. Raise the vehicle and remove the lower engine compartment paneling.
529
12. Refer to Figure 2 for component number references. Remove the belt pulley circlip (Figure 2, Part 6). With plastic belt pulleys, it is possible to
insert a screwdriver under the circlip (Figure 2, Part 6) and pry it out of the groove.
13. Remove hub (Figure 2, Part 1) using a socket and counter hold tool W112 589 07 40 00. Use a small magnet to remove flat washer from shaft.
Note:
There are two versions of the compressor shaft, a 7mm hex and one with two flats. The shaft with two flats requires the use of socket W112 589 02
09 00. To loosen 7mm hex head, ensure that proper METRIC tool is utilized. To loosen the pulley:
Warning!
It is not a left hand thread!
Method A (Preferred and shown in picture above): Hold the compressor shaft stationary and turn the drive hub counter clockwise to loosen (Figure
3a). Turn the hub clockwise to tighten.
Method B: Hold the drive hub stationary and turn the compressor shaft clockwise to loosen. Turn counter clockwise to tighten.
14. Remove snap ring (Figure 2, Part 4) for pulley bearing.
15. Remove belt pulley (Figure 2, Part 2) from the end of compressor housing.
Note:
Do not apply a pulling force in an axial direction to the refrigerant compressor shaft.
Components damaged due to improper repair procedures may be subject to debit.
530
Assemble the rubber dampers (Figure 2, Part 5) into new pulley the as shown in example A in Figure 4 and Figure 5. Make note of the direction of
the curvature of the rubber dampers and install them over the reinforcing webs in the pulley, not in the spaces between the webs.
16. Install new belt pulley (Figure 2, Part 2) onto the end of compressor housing. Make sure it is the same diameter as the original, 100 mm, 110
mm.
17. Install the snap ring (Figure 2, Part 4) for pulley bearing with its flat side facing the refrigerant compressor. Make sure the snap ring is seated
correctly in the groove.
Note:
Use snap ring pliers with 90° tips that have a minimum reach of 19 mm (0.75").
18. Install washer (Figure 2, Part 3). Make sure it is flat against the shoulder of the shaft.
19. Install hub (Figure 2, Part 1) so the drive fingers are inserted into the gaps between the ends of the rubber dampers. Screw the hub onto the
compressor shaft clockwise and torque to 35 nm. The hub continues to tighten when in the compressor is in operation.
20. Install circlip (Figure 2, Part 6) into the belt pulley. Make sure it is seated in the groove of the pulley.
21. Install a new standard length poly-V-belt. Start engine and verify correct belt operation.
22. Install lower engine paneling.
Special Tools
531
Parts Information
Note:
November 20, 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
532
533
Tire Monitor System - Steel Valve Stem Cap Precautions

Order No.: S-B-40.15/65
Group: 40
SUBJECT:
MY-2001 - Present, Models - All (With Tire Pressure Monitoring System)
Steel Valve Caps on Vehicles with Tire Pressure Monitoring Systems
Important Information
On all vehicles equipped with direct reading TPMS systems, that is with wheel pressure sensors, and their corresponding aluminum valve stems; it
is not advisable to install steel or chrome valve stem caps as the subsequent electrolysis may make it impossible to remove the valve cap at a later
time. Such damage is not covered by warranty.
Body - New Window Glazing Adhesive Repair Kit

Order No.: S-B-67.00/25
Supersedes:
Group: 67
534
SUBJECT:
MY-All, Models All
New Window Glazing One-Component Adhesive Repair Kit
Since January 2004, all MB plants use a higher grade adhesive to bond windows. To match the quality of this adhesive, the glazing repair kits for
replacing windows have been improved. It is no longer a two-component item and is without the booster component.
In addition, the new repair kit is to be used to glue the fixed glass cover on model 203.7 and 211.0 panoramic roofs.
NOTE:
The special tool is recommended for squeezing all of the sealant out of the kit's cartridge.
Parts Information
Special Tools
Audio System - Various iPod(R) Concerns

Supersedes: S-B-82.60/629 dated June 26, 2008
Group: 82
Revision History
SUBJECT:
All Model 164 / 203 / 209 Vehicles, as of Model Year 2005
All Model 171 / 251 Vehicles, as of Model Year 2006
All Model X204 Vehicles, as of Model Year 2010
All Model 211 Vehicles, as of Model Year 2004, Equipped with COMAND (528 or 530)
All Model 216 / 219 / 221 / 463 Vehicles, as of Model Year 2007
Equipped with iPod Interface System or Media Interface System (Option Code 518)
Various iPod Issues: iPod Battery Discharge, No Data Display, Slow Reaction When Listening to Audio Books
If you receive customer reports in the above model vehicles of the conditions below, this may be due to old iPod Software which must be updated
535
via Apple's Website.
^ iPod Battery discharged after a continuous lengthy use of iPod in vehicles (3-5 continuous hours).
^ Display illumination of iPod does not go out after docking the iPod connector.
^ Track display on the head unit (only in vehicles equipped with Media Interface) or instrument cluster does not correctly show the track number
and title.
^ Cluster or head unit do not display iPod data completely.
^ Pod-casts are intermittently not displayed.
^ Slow iPod reaction when listening to audio books.
^ iPod does not charge while connected to the vehicle's iPod Interface Cable or Media Interface.
Note:
In certain cases, you may need to reset the iPod if it locks up during operation. When the iPod does not charge while connected to the interface,
this may be caused by insufficient battery voltage at the iPod Interface Module. For this, make sure the voltage across PIN 1 and PIN 11 of the
iPod Interface Module Cable-set is > 10V, otherwise perform a continuity check and make sure the kit is correctly installed using the
corresponding WIS Document.
Apple Website Support Notes:
The Customer needs to ensure the iPod Software is up to date. For current iPod Application Software and supported iPod models, navigate to this
official Apple Website:
http://support.apple.com/kb/HT1353?
To find the correct iPod Application Software version for the iPod, navigate to this official Apple Website:
http://docs.info.apple.com/article.html?artnum=60984-en
Audio System - Various iPod(R) Malfunctions

Supersedes: P-B-82.85/544 and T-B-82.85/545 dated March 1, 2007
Group: 82
Revision History
a 2/12/09 Step 1 and Damage Code Updated
SUBJECT
iPod Intermittently Cannot Be Operated or Controlled Using Steering Wheel Controls, Delayed Response on Instrument Cluster Display, iPod
536
Volume Too Low Compared to Other Audio Sources
If you receive customer reports in the above model vehicles equipped with iPod Interface Kit of the below iPod conditions, this may be due to
incorrectly loaded MP3 files from the user's music library onto the iPod, the Aux level of the iPod is too low or a CAN communication error
between the head unit and the instrument cluster. To resolve, follow the diagnostic steps below.
^ Cannot be controlled by the multifunction steering wheel controls.
^ A delayed response (sometimes up to 2 minutes) in display of the track information or the radio station on the instrument cluster.
^ The iPod volume is too low in comparison to other Audio sources such as the CD or CD changer.
Step 1 - Compare Audio Volume of Identical Tracks from the iPod and an Audio CD
Note:
To complete step 1, you need a computer, an internet connection, iTunes, CD-R Compact Disc, a CD burner with reliable CD burning software set
to a lower burning speed (8x) with data verification option checked.
^ Using a reliable internet connection, log onto the website: www.mercedes-benz.tv/mixedtape
^ When the page loads, select the menu "Mixed Tape Music Magazine".
^ Select "MP3 Download"
^ Select "MP3 Download" again (note that the Album is in a "zip" format
^ Save and unzip the file onto a local folder on your Computer
^ Insert a blank CD-R in you CD burner start the burning software and burn the selected track from your computer onto the CD-R.
^ When the burn process is complete, copy the track from your computer (NOT from the CD-R) onto your music library in iTunes.
^ From iTunes, pull this track onto the iPod (make sure you have the MP3 format checked in your iTunes burning preferences).
^ On the iPod, scroll to Settings --> Sound check --> OFF
^ Adjust the iPod to max, connect the iPod and adjust head unit's volume to any desired level.
^ Scroll to the acquired iPod track and inspect the volume.
^ Insert the burned CD-R and play the same track on the Head Unit CD player, compare the audio levels of both tracks from the iPod and CD
player.
If no significant volume difference is noted between both audio sources from the iPod and the Audio CD-R, then any reported concern for volume
difference may be caused by an incorrect burning process or using a poor quality audio source file.
If a significant volume difference is noted, proceed to step 2 prior to any replacement of the iPod Interface Module.
Step 2 - Adjust the Aux Output Volume Level
^ Use the MFS buttons to select the iPod menu (Aux) in the instrument cluster (IC)
^ Simultaneously, hold down the down-arrow + Tel hang-up MFS buttons for about 8 seconds, the IC displays the words "DIAG" on the top and
"SW.." on the bottom --> wait 5 seconds, the IC displays "DIAG", "HW.." --> wait another 5 seconds --> "DIAG", "Vol..."
Within 5 seconds of the "DIAG", "Vol" display appearing, you can press the up or down arrow to adjust the Aux output volume. Make sure it is set
to the loudest --> wait 5 seconds without pressing any MFS buttons --> the display will return to iPod main screen automatically.
If necessary replace the iPod Interface Module with part number B6 782 42 52 (or later). Reference the applicable WIS documents listed below and
adjust the Aux output volume level after replacement per the below procedure.
Note:
If the vehicle is equipped with the latest iPod interface Module, you can use the procedure to adjust the Aux volume output.
537
Instructions to Remove the Head Unit and iPod Interface Module
Parts Information
Note:
Steering - Speed Sensitive Steering Malfunctions/DTC's

Group: 46
Revision History
538
a 2/4/09 Applicable Models Updated. Content Revised, Parts and Warranty Info. Updated
SUBJECT:
Models 164, 171, 203, 209, 211, 215, 216, 219, 220, 221, 230, 251 with code 213 (Speed Sensitive Power Steering - Parameter Steering)
Speed Sensitive Power Steering (Parameter Steering) Malfunction
If you receive customer reports in the above model vehicles of malfunctioning Speed Sensitive Power Steering (Parameter Steering), this may be
due to the following causes.
1. Speed sensitive power steering valve, electrical malfunction.
2. Electrical connection on speed sensitive power steering valve damaged or broken.
As a result, the fault codes above may be stored in the ESP control unit.
To resolve issues, replace the speed sensitive power steering valve with a new part as per the below procedure.
Note:
It is not necessary to replace the entire rack-and-pinion steering system.
1. Remove steering gear as per respective WIS document shown above.
2. Remove loose dirt from steering gear and clean area around speed sensitive power steering valve. Do not use any cleaning agents!
Important!
Ensure that the utmost cleanliness is maintained at the work area during the following steps!
3. Unscrew bolts (Figure 1, 2) attaching speed sensitive power steering valve (Figure 1, 1).
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4. Replace the speed sensitive power steering valve (Figure 1, 1). Ensure that the new sealing ring is seated properly. Attach speed sensitive power
steering valve (Figure 1, 1) by screwing in bolts (Figure 1, 2), observe torque (5 Nm +/- 0.3 Nm).
5. Install steering gear, refer to the respective WIS document as stated in Step 1
Note:
There are two versions of power steering high pressure lines that must be detached when removing steering gear. The earlier version has a slotted
support ring, which can be replaced individually. The new version does not have a slotted support ring. In this case, the complete power steering
high pressure line must be replaced (see parts list).
6. Check steering for leaks.
7. Check speed sensitive - parameter function using the DAS, read out fault memory and erase if necessary.
A toe adjustment after removing/installing the steering gear is no longer necessary according to the latest findings (refer to the latest version of the
DTB P-B-46.20/28).
Note:
Parts Information
Note:
February 4, 2009. Please refer to Netstar --> Star Teklnfo --> Star Time for the most current labor time allowance.
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Drivetrain - Axle Mount Service Guidelines

Date: March 4, 2009
Order No.: S-B-35.00/08
Group: 35
SUBJECT:
MY-All, Models All
Repairing Self-Locking Threaded Axle Mount Connections
Self-locking screws/bolts with thread-lock must always be replaced. As described in the WIS-net document AH00.00-N-0001-01A, it is mandatory
that the nut threads on the axle mount be recut and blown out with compressed air.
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Adhesive residue in the threads affects the strength of the bolt even when the correct tightening torque and angle is applied. The bolt may bend and
eventually break. Any consequent vehicle damage would not be covered under warranty.
See WIS-net document AH00.00-N-0001-01A for notes on self-locking nuts and bolts.
A/C - Musty/Moldy Odor Issues

Date: June 4, 2009
Order No.: S-B-83.30/74p
Supersedes: S-B-83.30/74o dated April 29, 2009
Group: 83
Revision History
SUBJECT:
All Model 164, 171, 203, 204, 209, 211, 215, 216, 219, 220, 221, 230 and 251 Vehicles
Air Conditioning Musty/Moldy Odor Complaints
Under certain environmental conditions, typically in a hot and humid climate, the vehicle may emit a musty/moldy odor from the air conditioning
system. This may be more noticeable when starting the vehicle due to residual condensation on the evaporator and on the interior surface of the
heater box.
If you receive customer reports in the above model vehicles regarding a musty/moldy odor from the air conditioning system, the evaporator should
be cleaned using Mercedes-Benz Contra Sept and the interior using the "ultrasonic atomizer", refer to WIS document AR83.30-P-5556A. For the
best lasting results, follow the instructions provided below.
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1. Remove all filters installed in the air conditioning system. The following filter may be fitted: Pollen filter, dust filer, combination filter or active
charcoal filter.
2. Clean evaporator with Mercedes-Benz Contra Sept as per WIS document AR83.30-P-5555T.
Contra Sept is applied using a spray gun attached to a long probe. It is imperative to have as much of the evaporator sprayed with the cleaner by
moving the probe in / out and up / down inside the case. It may be necessary to bend the probe in order to gain access. The cleaner is applied and
allowed to dry. Refer to Figure 1a for spraying angle recommendation.
Note:
After cleaning the evaporator, a second treatment has to be conducted. After completion of section A (ContraSept), refer to section B (Wynns).
Parts Information
Note:
543
544
A. ContraSept Cleaning Procedure

A. ContraSept Cleaning Procedure:
Caution!
Wear safety glasses and respiratory protection when spraying cleaner.
^ Spray the evaporator in a 90° angle.
^ Move up and down, left and right to reach all areas of the evaporator
^ Do not rotate the probe to reach other areas of the evaporator. This will change the spraying angle and the cleaning effect will diminish.
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Warning!
Do not exceed the manufacturer's recommended maximum air pressure as stated on the label affixed to the pressure cup (Figure 1b). Excessive air
pressure could cause the canister to explode and potentially cause personal injury. The recommended pressure to clean the evaporator effectively is
120psi.
Additional Procedures - Model 203 / 209
1. Equipped with ACC climate system Option Code 580 - It is necessary to drill a 15mm hole in the climate housing to access the evaporator with
the spray probe. The location for drilling the hole is described in WIS document AR83.30-P-5555-01A and Figure 1, A1 and B1.
2. A white foam block may be mounted to the housing between the blower motor and the main section of the case, see (Figure 2). On these
546
housings, there is an alternate location of the hole as shown in Figure 1, A2 and B2.
Figure 3 - bend probe as shown
3. Bend the shorter of the two probes (Figure 3). Move the probe up and down as well as side to side to ensure the entire evaporator is sprayed with
the cleaner. Plug hole after cleaning with seal plug A110 987 10 44 64.
4. Using the instructions below check the "REHEAT" setting. It should be set to "Anti-icing". Control Units --> Body --> EIS --> Control unit
adaptations --> Read coding and change if necessary --> Climate control Standard setting: Climate control --> REHEAT mode --> Change From:
"Standard" to: "Anti-icing protection"
Mercedes-Benz Contra Sept product as described above, a Biocide coated evaporator entered production as of VIN A731368 and F634900 (203)
and F144091 and T042954 (209). In this case, this part can be installed in earlier vehicles. Be sure to thoroughly clean the inside of the heater box
and make sure the drain tubes are not clogged before reassembling the system.
Additional Procedures - Model 211
1. Using the instructions below check the "REHEAT" setting. It should be set to "Fixed value". Control Units --> Air Conditioning --> C-AAC,
AAC --> Control unit adaptations --> Read coding and change if necessary --> Workshop coding --> Evaporator-Control (REHEAT mode) -->
Change From "Humidity-dependent (SERIES)" To: "Fixed value"
Mercedes-Benz Contra Sept product as described above, a new slanted heater box bottom which allows the condensation to drain better and a
coated evaporator entered production as of VIN A675828 and X171590. In this case, these parts can be installed in earlier vehicles. Be sure to
thoroughly clean the inside of the heater box and make sure the drain tubes are not clogged before reassembling the system.
Note:
Replacement of the heater box bottom and evaporator on the 211 and replacement of the evaporator on the 203 and 209 can only be claimed if the
Mercedes-Benz Contra Sept treatment has already been performed. Dealers must claim which option was performed in the text of the claim.
Procedure for 164 and 251
Caution!
Wear safety glasses and respiratory protection when drilling hole and spraying cleaner.
1. Clean the evaporator with MercedesBenz Contra Sept as per WIS document AR83.30-P-5555T and the additional information in this document.
2. To clean the driver side of the evaporator, the spray probe is inserted into the hole for the evaporator temperature sensor as described in WIS
document AR83.30-P-5555T, Step 4.1.
3. To clean the passenger side of the evaporator, the spray probe is inserted into a 15 mm hole that needs to be drilled in the climate housing as
described in Steps 4 through 6.
4. Remove the cover below the instrument panel on the passenger side and fold carpet down. Refer to WIS document AR68.10-P-1520GZ (164) or
AR68.10-P-1520RT (251).
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5. Location of hole is shown in Figures 4 and 5. The hole should be centered in the triangular shaped section of the climate housing as shown in
Figure 5.
6. Drill a 15mm hole in small increments using a mechanical drill stop to limit how far the drill bit penetrates the climate housing. A collar type drill
stop, a piece of rubber hose or tape can be used as the drill stop.
Warning!
The drill bit cannot be allowed to penetrate the housing more than 13mm or damage to the evaporator could occur. When the drill bit breaks
through the housing it has a tendency to pull inward. This is why a drill stop is necessary.
7. Bending of the probe may be required to be able to spray all parts of the evaporator. Move the probe up and down as well as side to side to
ensure the entire evaporator is sprayed with the cleaner.
8. Follow the remainder of instructions in WIS document AR83.30-P-5555T. Reassemble vehicle in reverse order. Do not replace any filter back
into the system!
Warning!
Do not exceed the manufacturer's recommended maximum air pressure as stated on the label affixed to the pressure cup (Figure 3). Excessive air
pressure could cause the canister to explode and potentially cause personal injury.
B. Wynns Treatment
B. Wynns Treatment
1. Warm up vehicle with air conditioning switched off for a minimum of 30 minutes in order to dry out the climate housing and ducts. Set the
climate control to the following settings:
Blower speed 2-3
Heat to maximum
Recirculation activated
Air distribution to the footwell
All doors, windows and sliding roof closed
Note:
AC compressor does not turn off immediately when the AC Off is selected at the control module. In order to ensure the compressor is off, use the
following instructions:
Select AC Off
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Select Climate System Off
Select Climate System On. The AC compressor will now be off.
2. Remove all filters installed in the climate system. This could include dust, activated charcoal or combination filters.
3. Close the recirculation flap for cleaning using SDS.
For 171, 204, 211, 219, 216, 221, 164 and 251 models follow path: Control Units --> Air Conditioning --> C-AAC, AAC --> Actuations -->
Closing air recirculation flap for cleaning --> Select recirculation.
For 203 and 209 models, follow path: Functions performed by more than one control unit --> Body --> Climate control --> Climate control -->
C-AAC --> Actuations
The system will come out of recirculation when SDS is disconnected from the vehicle.
Note:
This menu item is not available in SDS for all vehicles. On these vehicles, recirculation must be manually selected on the control module.
4. Place the Wynn's(R) AIRCOMATIC(TM) Ultrasonic Cleaning System in the passenger footwell. Insert the hose in the luggage net and orient the
end of the hose to insure the output from the device is sucked into the footwell vents.
5. Start engine, AC off, press recirculation button, select lowest blower speed and set the temperature(s) to minimum.
Note:
The compressor must not be running.
6. Install one container of Wynn's(R) AIRCO-CLEAN(TW) in the Wynn's system.
7. Plug in the Wynn's system and check that it is running.
8. Close all doors and windows.
9. When the fog stops coming out of the Wynn's(R) system (after approximately 20 minutes), the dispersion process has been completed.
10. When the cleaning procedure is finished, switch engine off, turn off the Wynn's(R) system and leave windows and doors closed for
approximately 1 hour.
11. Open doors and trunk lid/tailgate.
12. Open the air recirculation flap again if the automatic recirculation function has been deactivated by coding, and set the recirculated air function
to "unimited" again.
13. Restart engine, switch on A/C, select the highest blower speed and set the temperature(s) to minimum.
14. Allow system to run for about 10 minutes. The cleaning process is now complete.
15. After cleaning, install new filters.
16. If cleaning the interior does not remedy the complaint, please refer to the following documents: SI83.00-P-0004A and SI83.30-P-0008A.
Engine - Low Oil Level Symptoms/Diagnostics

Date: June 2, 2009
Supersedes: S-B-18.00/37e dated March 20, 2009
Group: 18
Revision History
549
f 6/2/09 Model 211 Production Information Included to Steps 1a and 4
e 3/20/09 Step 6 Revised
d 10/24/08 Damage Type Revised - Step 7
c 10/6/08 Warranty Information Updated - Step 7 Op Code 18 4110
b 9/17/08 Warranty Information - Step 7 Updated
a 7/28/08 Updated Step 3a (removed reference to 229.5 and 229.51 oil) and Step 7
SUBJECT:
Equipped with M156, M272, M273 or M642 Engines
Low Oil Level Symptoms
1. Model 203.087/092 and 211.087/287, Equipped with M272 - Erroneous IC Warning Display "Check Engine Oil Level at Next Service Stop": Oil
level warning message frequently appears in the instrument cluster, however the oil level correct on the dipstick, the cause may be the incorrect oil
data record stored in the ASSYST control unit (Model 211), or instrument cluster (Model 203). To resolve, perform the following procedures.
Message:
"Pour in one liter of oil at next refueling stop" (Model 211 4MATIC with M272 up to 6/2005) "Check oil level at next refueling stop" (Model 211
4MATIC as of 6/2005 and Model 203 4MATIC with M272 as of production startup)
1a) Adaptation of Modified Oil Data Record with SDS 10/06 or Later
Model 203 4MATIC with M272 Engine, up to VIN F886321: Control Units --> Information and communication --> ICM --> Vehicle code 12 / NO
--> CU adaptations --> select code 807 --> select national version --> select M272 all-wheel drive change status 3 "or higher" --> confirm selection.
Model 211 4MATIC with M272 Engine, up to VIN X218820 (up to production September 2006). As of approximately October 2006, vehicles
were produced with modified oil data record.
^ Check whether CGW programming is possible by using SDS: Control units --> Body --> CGW --> Control Unit adaptations --> Control Unit
programming. If yes, perform control unit programming and then perform parameterization in ASSYST. If no, perform parameterization in
ASSYST.
^ Perform parameterization in ASSYST by using SDS: Start Control Units --> Information and communication --> ASSYST --> CU adaptations
--> select engine M272 --> Select national version --> Select engine for ASSYST M272 Model 211 all-wheel drive "National version" status 5 or
higher.
1b) Check Oil Dipstick Marking on Handle (Model 203 / 211 up to Engine No. 2729..30467144)
Note:
As of February 2, 2007, Section 1b of this DTB must not be performed on the following vehicles which are covered under Service Campaign No.
2007010010
a) Oil dipstick with marking 27214 is correct.
b) Oil dipstick with different marking should be replaced with part number A272 010 14 72.
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c) Check whether quantity of engine oil in engine corresponds to specification in WIS.
2. Model 164.186 - Erroneous IC Warning Display "Check Engine Oil Level at Next Service Stop"
Confirm engine type coding in ASSYST using the current issue of SDS:
Control unit --> Information and Communication --> ASSYST Active Service System --> Control Unit Adaptations --> Engine Type --> Code to
correct engine type.
measure.
3a) Vehicles Up to VIN No. A213990 / Production Date 12/20/2006 - Check and correct oil level where necessary by adding 0.3 liter oil at PDI
or at the customers "1st Visit" for all newly sold GL450 vehicles. Refer to WIS document AP-18.00-P-0101GZ. Costs are to be charged using
the warranty code 00001 70.
3b) Check Oil Dipstick Marking on Handle - Oil dipstick with marking 27314 is correct. Oil dipstick with different marking should be replaced
with part number A273 010 14 72. New specification for quantity of engine oil in engine is 9.0 liters with filter change.
3c) Vehicles with VIN No. A213991 up to A235524 / Production Date 2/9/2007
Note:
Do not automatically add 0.3 liters of oil; check dipstick first.
Oil dipstick with marking 27314 is correct. Oil dipstick with different marking should be replaced with part number A273 010 14 72. New
specification for quantity of engine oil in engine is 9.0 liters with filter change.
4. Model 221.186, Equipped with M273 Engine and 4-Matic, Erroneous IC Warning Display "Check Engine Oil Level at Next Service Stop"
Vehicles Up to Production Date end of 03/2007 (as of 04/2007 vehicles produced with modified oil data record) - Update oil data record in
ASSYST using SDS: Control unit --> Information and Communication --> ASSYST --> Control Unit Adaptations --> SCN coding --> Perform
SCN online coding --> Work through steps 1-3 in SDS to perform SCN coding.
5. Model 209/211/219, Equipped with M156 Engine, Oil Level Warning Message "Add 1 liter engine oil at next refueling stop" or "Check oil at
next refueling stop" in Instrument Cluster / Oil Level on Dipstick is OK - Perform the following steps.
a) Check the coding of the engine model designation and oil data set of the ASSYST control unit in SDS --> Control units --> Information and
communication --> ASSYST --> Control unit adaptations --> Engine type --> Engine type M156 E63 Version for rest of world Status: 3 has been
recognized --> Information and communication --> ASSYST PLUS --> Control unit adaptations --> Control module reset
b) Check installed oil dipstick and replace if necessary. The correct oil dipstick is identifiable by the red handle and by the code 156 16
c) Check oil level and correct if necessary.
6. Model 164.122/822 and 251.122, "Check oil at next refueling stop" Warning in Instrument Cluster
If you receive customer reports when driving at constant speeds ranging from 60 to 75 mph the instrument cluster displays "Check engine oil level
at next refueling stop", the cause may be:
a) the position of the oil level switch,
b) a malfunctioning oil level switch,
c) incorrect oil data record coded into the instrument cluster.
Note:
Condition only relevant when the oil level is significantly above "min".
To Resolve:
164.122/822 up to VIN A261645
251.122 up to VIN A059019
a) Install a lengthened bracket (7mm) for the oil level switch (part number A642 018 27 40).
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164.122/822 from VIN A261645 up to A425120 (prod. 06/2008)

251.122 from VIN A059019 up to A086462 (prod. 06/2008)
164.122/822 as of A425120 (prod. 06/2008)

251.122 as of VIN A086462 (prod. 06/2008)
7. All Passenger and Light Truck Models, Equipped with Engine M156, M272, M273 or M642 (Up to engine no. 642 xxx 40 673486), Faulty Oil
Level Switch - If after performing the applicable remedy(s) 1 through 6 stated within this document, the issue has not been resolved, the cause may
be a malfunctioning oil level switch. Perform the following.
a) Check the oil level using the dipstick.
b) If the oil level is confirmed between the "MIN" and the "MAX" marks on the dipstick, replace oil level switch with part number A001 153 11
32 as per the applicable WIS document.
Note:
For Engines M272, M273 and M642 If there is any deformation of the stamped steel bottom section of the oil pan after removal, it must be
replaced. Refer to EPCnet for applicable part number.
552
c) It is possible to install the switch upside down. For correct installation refer to Figure 5.
Parts Information
Note:
553
554
Engine - Multiple DTC's Set/MIL ON

Date: June 17, 2009
Supersedes: S-B-03.30/08i dated April 29, 2009
Group: 03
555
Revision History
SUBJECT:
Check Engine Light On / Fault Codes Current and/or Stored in ME-SFI Control Module / Oil Leaking at Camshaft Adjustment Solenoid
If you receive customer reports of the check engine light being illuminated and one of the following Fault Code Scenarios (no corresponding Fault
Codes in Scenario 3) is found in the above model vehicles, follow the applicable procedure below to resolve.
Note:
Corresponding protocols (i.e. ME Control Module log file related to DTC code) must always be included with any returned parts as indicated on the
Warranty Return Form Printout Matrix (RFPM). If the documentation is missing or does not support the diagnosis, the warranty claim may be
debited.
Note:
Flashing the ME Control Module will not resolve these issues and is unnecessary at this point.
Note:
Mobil Training Coach (MTC) "M272 Engine Timing" can be referred to when performing repairs. However, this DTB takes precedence in terms of
technical and warranty content as well as referred WIS documents. Any parts specified in the DTB or in referenced WIS documents should be
replaced accordingly (e.g. seals, gaskets or bolts and screws as required).
Note:
When preparing / cleaning any surfaces for resealing, extreme care must be taken not to damage surfaces with sharp tools. It is absolutely not
permissible to use any abrasive materials (i.e. sand paper, abrasive pads, etc.) for cleaning resalable surfaces. Proper application of sealant is a must
as excessive sealant can result in damage to the engine (refer to MTC listed in the note above). Failure to follow these precautions could result in
severe and permanent engine damage.
556
Special Tools
Note:
Always refer to EPC for the latest parts information and use the correct VIN number when specifying parts.
Parts Information
Note:
June 17, 2009 Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
557
558
559
560
561

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DTC 1200 and/or 1208 is/are present in ME-SFI control module. The fault codes are recorded as current and/or stored in the fault memory. When
the fault memory is erased and the engine is restarted, the fault codes reoccur immediately. This is due to the positioning of the timing chain driven
camshafts relative to the crankshaft and can be caused by a worn sprocket on the balance shaft on engine M272 or by a worn guide (idler) gear for
the timing chain on engine M273. Figure 1, 2 and 3 show extremely worn sprocket gears. Figure 4, for comparison, shows a new sprocket gear.
Note:
563
In rare cases, a stretched timing chain might be the reason for the DTC fault codes when the sprocket does not exhibit any signs of wear.
Applicable Models (Not Applicable to Model 164.156, 204 or 216.386): Equipped with M272 Engine Up to Serial No. 2729..30 468993 or M273
Engine Up to Serial No. 2739..30 088611.
The material for the balance shaft sprocket and the timing chain guide wheel (idler) was modified on engines past the serial numbers listed above.
Procedure 1 (Follow all steps and the order as described):
a) Perform a visual inspection for any wear of the teeth (damage profile) on the sprocket of the balance shaft (M272) or of the guide (idler) gear
for timing chain (M273) by removing the timing case cover on the engine. Refer to WIS instructions AR01.40-P-8000* (* - applies to a specific
model designation e.g. AR01.40-P-8000SX models 221, 216). Ensure the use of the Special Tool W001 589 81 09 00 when removing /
installing timing case cover.
Note:
Refer to Figure 1 through 3 for examples of damaged / worn sprocket profile. Refer to Figure 4 for example of a new gear (for comparison).
b) Only if worn (sprocket teeth profile damaged), replace the balance shaft on engine M272 or replace the guide (idler) gear of the chain drive on
engine M273 as per WIS instructions AR03.20-P-1000* (* - applies to a specific model designation e.g. AR03.20-P-1000VA model 171).
Note:
Cylinder heads are not needed to be removed.
Note:
When performing repair, pay attention to cleanliness. Remove any debris, shavings and contaminants.
Note:
When replacing the balance shaft on engine M272, the counterweight must also be replaced. The balance shaft and counter weight are specific to
engine designation. Order individual parts and kits specifically to a VIN number.
c) Replace the engine oil pump. Refer to WIS instructions AR18.10-P-6020* (* - applies to a specific model designation).
d) Replace the chain tensioner.
Caution!
New timing chain tensioner must be installed and only after the engine head covers (valve covers) are installed / bolted on. Failure to observe that,
will result in the over tightening the timing chain which will ultimately lead to engine head damage. Noted the timing chain tensioner is a single use
part. Once the tensioner is installed, it cannot be taken out or readjusted, doing so will result in over tightening of the timing chain as well.
e) Change engine oil and filter.
Note:
Use inexpensive, appropriate engine oil from MB sheet 229.1 and 229.3 for this step.
f) Drive with engine at high load and rpm for approx. 15 miles.
g) After 15 miles, drive, change engine oil and filter once more. Use appropriate engine oil from MB sheet 229.5 in this step.
h) Replace all four of the camshaft adjustment solenoids with A272 051 01 77 this step applies only to Scenario 1.

One or more of the fault codes 0059, 0060, 0063, 0064, 0271, 0272, 0275, and 0276 is/are present in ME-SFI control module. The fault codes are
recorded as current and/or stored in the fault memory. If current and/or stored, these codes are caused by a malfunctioning camshaft adjustment
solenoid.
Applicable Models: Equipped with M272 Engine Up to Serial No. 2729..30 759427 or M273 Engine Up to Serial No. 2739..30 193592. Engines
produced after serial nos. listed above are already equipped with improved camshaft adjustment solenoids (A272 051 01 77).
Procedure 2:
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Diagnose each DTC as per Star Diagnosis. If it is determined the solenoid is faulty, replace with solenoid A272 051 01 77 as per appropriate WIS
instructions. Refer to WIS instructions AR05.20-P-7295* (* - applies to a specific model designation e.g. AR05.20-P-7295RTB model 251).
Note:
For this scenario only, replace the solenoid that has a corresponding fault code. Copy of the SDS short test and ME Control Module log file related
to DTC code must accompany returned parts. If the documentation is missing or does not support the diagnosis, the warranty claim may be debited
(i.e. only two Fault Codes but all four solenoids are changed or low voltage situation might result in a code to be stored but not current).

Fault Scenario 3:
Camshaft adjustment solenoid is leaking oil, and no Fault Codes are current or stored in the ME Control Module. Determine the cause of the leak.
The solenoid can be leaking from under the sealing ring or through the harness connector.
Procedure 3:
a) If the leak appears to be between the solenoid and the cylinder head replace solenoid sealing ring (Figure 5, 145).
b) If the leak is from the electrical connector, replace the solenoid (Figure 5, 140).
Note:
Provide description of where the leaking occurred and mark the replaced solenoid.
Brakes - Brake Pad Paste Usage

Date: June 16, 2009
Order No.: S-B-42.10/110
Supersedes:
Group: 42
SUBJECT:
MY-All, Models All
Brake Pad Paste Usage
565
When performing repair or maintenance work on the brake system it is imperative that only the specified brake pad paste is used. Different models
and brake variants may use different types of brake paste (Figures 1-3). Please reference any corresponding LIs, DTBs and or WIS document
566
AR42.10-P-0161-01B for paste type and application location. Do not apply too much paste, only a light coating of brake paste is required when
instructed.
Warning!
Under no circumstances should aftermarket brake paste or anti-squeal type chemicals be used on brake components. These chemicals are not
approved by Mercedes-Benz, and their affect on brake components is unknown.
Warning!
Never apply brake paste or any other chemicals to the brake pad friction surfaces.
Note:
Failure to follow guidelines for proper brake paste usage may result in brake noise issues.
Parts Information
Steering, A/C - Grinding/Gushing Noises

Date: May 12, 2009
Supersedes: S-B-46.30/21a dated Feb. 12, 2008
Group: 46
Revision History
b 5/12/09 Parts Information Updated / Sound Files Included
a 2/12/08 Applicable Models, Content, Parts and Warranty Information Updated
SUBJECT:
Model 163.154/157/172/174/175
Model 164.172/175/186/871/886
Model 171.454/456/473
Model 203.052/054/056/061/064/065/081/084/087/092/261/264/281/284
Model 209.356/365/372/375/456/465/472/475
Model 211.056/065/070/072/082/083/087/090/256/265/282/283/287
Model 215.373/374/375
Model 216.371
Model 219.372/375
Model 220.170/173/174/175/183/184
Model 221.171/186
Model 230.471/472/475
Model 251.156/165/175
Noise from the Area of the Steering System / Power Steering Pump
If you receive customer reports in the above model vehicles of grinding or gushing noises which may be heard from the area of the steering
system/power steering pump, one of the possible causes may be in the A/C compressor belt drive.
This noise is similar to the noise produced by the power steering pump when ingesting air. This type of noise is present at both idle and higher
engine speeds, can be heard whether the steering wheel is stationary or moving and the noise frequency increases with the engine speed. The noise
intensity increases towards steering wheel end limit stops. Below sound files provide noise examples.
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1. First noise example with engine running
2. Second noise example with engine running
Note:
The noise does not change by switching the A/C compressor on and off. Evacuating the refrigerant will not change the noise since the A/C
compressor belt pulley runs continuously with the engine.
Note:
Do not replace the A/C compressor belt pulley merely on suspicion. To ascertain whether the noise is caused by the A/C compressor, perform the
following test using a shorter poly-V-belt. It is absolutely essential to follow in sequence the below procedure:
1. Detach the original poly-V-belt.
2. Install poly-V-belt part number A011 997 96 92 on vehicles with M112 / M113 engines or install poly-V-belt part number A011 997 04 92 on
vehicles with M272 / M273 engines. With the shorter belt installed, the A/C compressor is not driven by the belt. The A/C compressor pulley is
by-passed) (Figure 1, 1). Route the rest of the belt the same way as the original belt (Figure 1).
3. Start the engine and listen for the complaint noise:
Correction:
4. If the complaint noise is no longer present, replace the A/C compressor belt pulley refer to the latest version of DTB P-83.55/87 (latest version)
for A/C compressor poly-v-belt pulley replacement.
5. If the complaint noise is still present, it is not due to the A/C compressor. Therefore, resolve the noise issue by following the procedure in Star
TekInfo > EDAC > Diagnostic Guides > Power Steering Diagnostic Guide (latest version) > Start > Noises in steering system.
6. Reinstall original belt.
Parts Information
Note:
568
Engine - Cylinder Wall Inspection

Date: May 19, 2009
Order No.: S-B-01.00/27
Group: 01
SUBJECT:
MY-All, Models with Engines 112, 113, 137, 272, 273, 275
Cylinder Barrel Inspection
Cylinder Wall Inspection
If engine complaints regarding noises, overheating, or oil consumption arise, visually inspect the mounted cylinder head with a light probe and
endoscope (bore scope). If visual inspection with an endoscope is not sufficient, consult the following documents in WIS: "Check compression
pressure" and "Check cylinder leakage" before removing the cylinder head (WIS documents AR01.00-P-1300, AR01.00-P-0200, AR01.00-P-1200,
AR01.40P9201AA, etc.).
When inspecting Silitec barrels with a light probe it is absolutely essential to observe all possible scenarios before removing an engine or replacing
a crankcase. Section A describes acceptable cylinder barrel wear and section B describes the cases where cylinder barrels are deemed unacceptable
and the crankcase should be replaced.
Ideal (Normal) Cylinder Wall Condition
569
The ideal is a matte gray surface, no honing pattern, and a dry cylinder barrel without polished sections or mirror polished flats. Individually assess
any irregularities (Figure 1).
Note:
Do not replace crank case based on suspicions only. Perform checks and / or repairs according to published WIS, DTBs, and other official
documents. If other than crankcase components are determined to be a cause of complaint, replace only affected components.
Note:
Use only approved methods to remove any carbon deposits when performing a repair. Do not use any sand paper, abrasive pads or disks or grinding
and sanding tools. Use only approved fuel additives. Dealers might be debited when performing unapproved or incorrect repairs as well as when
unnecessarily replacing parts.
Deviations
DEVIATIONS
A. Cylinder Wall Deviations from Normal Wear Where Crankcase Can Continue to be Used For any deviations from normal wear and tolerance
values, document the direction of the leakage while checking the leak tightness of the cylinder (in the direction valve or in the direction of the
crankcase). In the case of deviating compression pressure values, in particular when not achieving the installation tolerance/new values (measured
with a compression recorder), one should check for indications of a fluid lock (e.g. wet piston crown, wet air filter, water-oil-glycol residues).
In the following cases of deviation, continue to use the crankcase.
1. Individual or Fields of Score Marks
In cases where individual or fields of score marks (Figure 2), (usually caused by residual waste or soiling through back pulsation of particle from
the catalytic converter or the exhaust system), continue to use the crankcase.
2. Ring Shaped Imprints
570
In cases where upper and lower reversal range of piston rings (Figure 3), continue to use the crankcase.
3. Brown Coloration at Upper Cylinder
In cases where brown coloration (Figure 4) (oil varnish) over large areas of the cylinder barrel, (which indicates that the engine has been driven at a
high temperature level); continue to use the crankcase.
4. Pressure Gloss Marks and Smooth Spots
In cases where individual blank points (Figure 5), as on the middle of the cylinder or around the cylinder head bolts or an all-round impression at
the piston ring reversing point above and below; continue to use the crankcase.
5. Optical Stripes, Friction Marks
571
In cases where dry friction marks (Figure 6), which cannot be felt, which start from the first, second or third piston ring and run out after approx. 30
mm; continue to use the crankcase.
NOTE:
These traces of friction marks which occur principally around the cylinder head bolts and on pressure side are not a problem provided they are
smoothed. They are caused by soot particles and oil film being washed off by fuel as a result of frequent cold starts associated with short-distance
driving.
6. Imprint on Valve Cooling Bore for an 8- and 12- Cylinder Engine
In cases where the cooling bore in the crankcase shows a different coloration (Figure 7) than the cylinder barrel; continue to use the crankcase.
B. Deviations Necessitating Replacing the Crankcase
572
1. Corrugated Wear of the Cylinder Barrel In cases where the cylinder barrel surface has a washboard appearance (Figure 8), partially or all around;
do not use the crankcase anymore.
2. Roughened Mottling, Friction Scoring
If friction eroded marks or streaks (Figure 9) are observed starting from the first, second or third piston ring and taper down to the cylinder bottom,
the cylinder barrel is unusable and the crankcase should no longer be used.
3. Piston seizure, eroded areas on the ring
Most of cylinder wall perceptibly roughened over the entire length (Figure 10). Material deposits and perceptible scoring marks on cylinder wall
and at piston skirt. The cylinder barrel is unusable and the crankcase should no longer be used.
573
Brakes - Caliper Bolt Replacement Information

Date: June 16, 2009
Order No.: S-B-42.10/111
Supersedes:
Group: 42
SUBJECT:
MY-All, Models All
Self-Locking Brake Caliper Bolt Replacement
When performing repair or maintenance work on the brake system it is imperative that the corresponding instructions contained within WIS be
followed. If the brake caliper (front or rear) requires removal then the self-locking bolts (caliper support to steering knuckle / wheel carrier) will
require replacement. Reference WIS document AH00.00-N-0001-01A. Refer to EPC for the proper part number per application.
Note:
Do not reuse self-locking bolts.
Cell Phone - Bluetooth(R)/Cell Phone Diagnostic Tool

Date: 5/18/2009
Supersedes: S-B-82.70/686, April 30, 2009
Group: 82
Revised: Tool Release Messages are on STAR TekInfo under MB Special Tools
SUBJECT:
MY2005 to the Present, Models All
Telephone and Bluetooth Adapter Diagnosis and Test Tool W203 589 07 63 00 and Warranty Return Requirements
This is a follow-up to the "February 2009 Tool Release" message, which is located under MB Special Tools on STAR TekInfo.
All dealers must use special tool W203 589 07 63 00 to test and diagnose any telephone and Bluetooth-related conditions on all vehicles equipped
with the hands-free blue tooth telephone system.
The special tool can test the following telephone functions:
^ Pairing capability, cradle line voltage checks
574
^ Testing whether the customer's cellular phone is on the approved list http://www.mbusa-mobile.com or http://www.wireless4mb.com
^ Testing the data connection between Bluetooth cradle and the vehicle's telephone control unit (MHI)
^ Testing the data connection between Bluetooth phone and vehicle's integrated Bluetooth system (non-MHI vehicles)
To perform the test, follow the path: Select proper chassis --> Control Unit --> Information & Communication --> Audio, video, navi and
telematics --> select Ctel --> control unit actuations --> Test of Telephony (test Adapter required) --> Test of Function (Full Procedure).
Please reference the Netstar Message above for a detailed description on the tool and its capabilities.
Any request for a cradle replacement must be accompanied by the required documentation, which is outlined below.
HFP Cradle Replacement Required Documentation:
^ A screen shot/print copy of the test protocol clearly showing one of the results negative
^ Telematics control unit log
^ Place all documentation with the returned inoperative unit to the, QEC.
Should a component be sent to the QEC without the specified documentation, the claim handling fee will be debited as of release date of this
Service Bulletin.
QEC reserves the right to review the documented diagnosis forms with each claim.
Lighting - Xenon Headlamp Brightness Explanation

Date: May 18, 2009
Order No.: S-B-82.10/680
Group: 82
SUBJECT:
All Models 140, 163, 164, 170, 171, 202, 203, 204, 208, 209, 210, 211, 215, 216, 219, 220, 221, 230, and 251 Equipped with Xenon Headlamps
Headlamp Color and/or Brightness Difference When Changing Xenon Bulb
You may receive customer reports regarding the above model vehicles after replacing one xenon bulb. Headlamps will have a visible color
difference between the two when only one bulb is replaced.
Explain to the customer that in situations where only one bulb is replaced:
^ There is a perceptible color difference for the first 100 hours when comparing new bulbs with those that have been in service for some time.
^ Once this "breaking-in period" has passed, the color becomes bluer and resembles that of the older bulb.
Wipers/Washers - Wiping Quality Maintenance

Date: June 2, 2009
Order No.: S-B-82.35/ 621a
Supersedes: S-B-82.35/621, May 2008
Group: 82
Revision History
a 6/2/09 Part Numbers added.
- 5//08 Initial issue
575
SUBJECT:
MY-All, Models-All
Windshield Washer System: Maintaining Wiping Quality and Controlling Noise
Consult this document to help the customer improve the wiping quality on their vehicle windshields.
NOTICE!
Always consider the windshield, wiper arm, wiper blade and windshield washer system as a matched system that works together. Recommend only
Mercedes-Benz genuine parts and cleaner to the customer to ensure the best possible wiping system and to maintain the surface quality of the
windshield itself.
A. Windshield Surface Quality
1. Pollution, chipping, scratches, chemical additives at carwash facilities and even the wrong cleaning fluid can create an irregular windshield
surface that will either cause noise or an ineffective wiping action.
2. Use Mercedes Benz cleaning solution part A 001 986 38 71 for a typical windshield cleaning or A 000 986 40 71 for a more intense cleaning.
3. Consider windshield replacement at customer expense if the surface is marred enough to create wiping problems.
B. Wiper Arm Quality
1. Check the angle of the wiper arms as per appropriate WIS documentation. Wiper arm adjustment outside the specified tolerance will cause noise
and wiping complaints. Only use the Mercedes-Benz approved wiper adjustment tool.
2. Check for the wiper arm physical damage. Replace the wiper arm when necessary:
^ Clinch bolt loose
^ Locking lug bent
^ Change in spring length (alters the contact pressure)
3. If complaints are related to rattling, whistling, or chirping noises, check the mounting of the wiper arm. Loose wiper arms can lead to excessive
rubbing.
C. Wiper Blade Quality
1. Wiper blades may degrade more quickly when:
^ Exposed to severe environmental influences such as heat cold, ice, snow, ozone, UV radiation
^ Not used for extended periods of time (wiper profile deformation)
^ Dirt and foliage falls on the wipers when they are in the rest position
^ Unsuitable cleaning agents or methods are applied.
2. Customer induced actions that will degrade the wiper more quickly are:
^ Ripping wiper blades from a frozen windshield. This action damages the microedge. In isolated cases the rubber profile may be disconnected. Do
not loosen wiper blades from the windshield with an ice scraper. Use a de-icer to melt the ice and snow.
^ Using wiper blades on an icy windshield. Use an ice scraper to clear away all ice.
^ Bending or adjusting the actual blade in any manner.
3. A worn or damaged wiper blade may lead to increased lines and noises. Before replacing a wiper blade examine for defects and perform a system
check on the wiper arm and windshield.
D. Windshield Washer System
1. During any amount of rainfall, use the windshield washer system to pre-clean before fully using the wipers.
2. Check all nozzles and openings of the washer fluid system for calcification or lime deposits and clean if necessary.
3. Ensure correct water/fluid mixing ratio is used. Using the incorrect mixing ratio in cold temperatures can cause damage to the windshield
576
washer system.
4. Adjust any faulty nozzle settings.
Parts Information
Special Tools
Body/Frame - Tail Lamp Cutout Tool Information

Date: May 5, 2009
Order No.: P-B-64.00/02
Supersedes:
Group: 64
SUBJECT:
MY-All, Model 203, 204, 209, 211
Special Tool for Creating Mounting Holes for Tail Lamp Cutout
Fit problems may occur when replacing the rear fender or tail lamp cutout. Adapt all mounting holes with the special embossing tool below.
Special Tools
A/T - Limp Home Mode/DTCs 2200/2201/2767/2768

Date: May 5, 2009
Order No.: S-B-27.50/59g
Supersedes: S-B-27.50/59f dated January 22, 2009
577
Group: 27.50
Revision History
g 5/5/09 Warranty Information Updated - Op Code 02-3472 Included
f 1/22/09 Revised Information (sensor ring removed as possible cause)
d 10/31/08 Warranty Information Updated Op Code 27-1255 Included
c 10/17/08 Applicable Models Updated and Remedy Revised
SUBJECT:
All Models Equipped with 7G-Tronic Trans.(NAG2)
2768, the condition is related to the speed sensor. To resolve, replace the electrohydraulic control module (valve body). Refer to WIS document
AR27.19-P-0200w. Refer to EPCnet for the applicable part number, being sure to regard the footnotes carefully.
Note:
May 5, 2009. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
Audio System - Copy Protected CD Information

Date: May 5, 2009
Order No.: S-B-82.60/690
Supersedes:
Group: 82
SUBJECT:
All Passenger Car and Light Truck Models, As of Model Year 2005
Faulty Playback of Copy Protected CDs
578
Certain companies in the music industry have been enforcing Digital Rights Management (DRM) to protect their produced music from being
copied. As a result of this implementation, some music CDs or tracks in the CDs may not be recognized (played) by Mercedes-Benz media players
(head units, CD changers). A reason for this condition is copy-protection encoding algorithms of the subject CD do not match the industry standard.
Please note this condition is not caused by Mercedes Benz medial players and therefore head units, changers and other media players cannot be
replaced due to this condition. Prior to diagnostics, inspect the subject CDs and their labels for any indication of copy-protection on the CD and
advice customers of this information.
Brakes - Brake Component Corrosion Information

Date: June 15, 2009
Order No.: S-B-42.10/109
Supersedes:
Group: 42
SUBJECT:
MY-All, Models All
Corrosion of Brake Components
579
Corrosion protection coatings for brake components and hardware may be damaged and or stripped away (Figures 1 and 2) if highly concentrated
acid-based cleaners are used. Once the corrosion protection is damaged or removed the brake components and or hardware can begin to corrode.
These acid-based chemicals (Figure 3) are typically found in wheel cleaners, but may also be found in other general high strength cleaning
solutions. It is imperative that only approved Mercedes-Benz paint care products and cleaners be used. Reference WIS document
AP98.30-P-8070-06Y for approved paint care products and Mercedes-Benz Service Bulletin S-B-40.10/66 for an approved alkaline wheel cleaner
for light alloy wheels.
Note:
Components damaged by cleaning solutions are not covered under warranty.
Body - Rear Fender Corrosion

Date: May 18, 2009
Order No.: P-B-63.50/20
Group: 63
SUBJECT:
MY-All, Models 203
Bodyshell Complaints Regarding Rear Fender at Wheel Arch
Should you receive complaints regarding corrosion on the rear fender follow the procedures below.
A. Remedy 1 for Corrosion in Area A
580
1. Remove corrosion on the rear fender (1) in area A.
2. Mask off wheel arch in visible area B with clean edges.
3. Remove bulkhead on rear fender (1).
4. Detach trim on entrance longitudinal member.
5. Mask off rear bumper.
6. Apply primer filler. Use only MBUSA approved products as outlined in S-B-98.00/13P or latest version.
the sealant. Mask off the wheel arch in the visual area B with clean edges for painting. Offset the tape by approximately 1 to 2 mm from the area.
9. Paint over wheel arch in area A.
10. Remove the first piece of masking tape on the wheel arch.
11. Carefully remove masking tape from the visible area B.
B. Remedy 2 for Corrosion of Areas A and B
1. Remove corrosion on the rear fender 1 in the areas A and B.
2. Remove bulkhead on the rear fender.
3. Detach the trim on entrance of the longitudinal member.
4. Remove the rear bumper.
5. Remove the rear lamp unit.
581
6. Remove the trim frame on the rear window.
7. Apply the prime filler. Use only MBUSA approved products as outlined in S-B-98.00/13P or latest version.
the sealant.
10. Paint wheel fender.
C. Remedy 3a for Corrosion or Rust Through Damage in Area A and B
1. Refer to WIS document SM63.50-P-1000C.
2. In cases where areas A and B have corrosion or rust-through damage, the repair panel must be fabricated to match the damage profile and it
should be installed as a partial section. If the scope of the repair is smaller than the shaded area (Figure 2), repair stage 3 must be carried out.
NOTE:
Repair Stages Defined
a. Repair Stage 3: If the damage is equal to or smaller than the shaded area, replace the entire pictured repair panel (Figure 2).
b. Repair Stage 4: If the damage is larger than the shaded area, the repair panel must be fabricated from the entire fender.
D. Remedy 3b for Deep Damage to Outer Rear Wheel Well
2. In cases where severe corrosion or rust-through damage, the repair panel is acquired from the existing replacement part.
E. Remedy 4a for Severe Corrosion or Rust-Through Damage in Areas A and B
1. See In cases where areas A and B have severe corrosion or rust-through damage, see WIS-net document SM63.50-P-1000C.
2. If the scope of the repair is greater than or equal to the shaded area (Figure 2), then repair stage 4 must be carried out.
F. Remedy 4b for Deep Damage to the Outer Rear Wheel Well
2. In cases where the area of the outer rear wheel well has severe corrosion or rust-through damage, the repair panel is acquired from the existing
replacement part.
582
Parts Information
Vehicle - Maintenance Systems Overview

Date: July 30, 2009
Order No.: S-B-00.20/91
Supersedes:
Group: 00
SUBJECT:
MY1998 -
Present
Models All
Maintenance Systems Overview
This bulletin provides an overview of the various maintenance systems that have been used in Mercedes-Benz vehicles since 1998. The document
explains which maintenance system is used by model, describes the service differences between them, and how they are determined. It is crucial
that the Mercedes-Benz Maintenance Sheets and the Mercedes-Benz Maintenance Booklet be referenced for specific maintenance requirements.
Refer to www.startekinfo.com under the menu headings "Maintenance Sheets" and or "Operator Manuals."
Different onboard vehicle maintenance system nomenclatures were used in US specific documents compared to WIS and the vehicle's instrument
cluster display. Reference the table above for system identification.
Maintenance System: FSS (Flexible Service System)
Model Years: MY1998 - MY2004
Models: 129, 140, 163, 170, 202, 203, 208, 209, 210, 215, 220, 230, 463
With the FSS maintenance system there is a minor or major service designated as "A" or "B" respectively. If the last service performed was an
A-service, than the next service will be a B-service. For subsequent services; if the distance driven since the last B-service is less (<) than 14,000
miles, than an A-service should be performed. Consequently; if the distance driven since the last B-service is greater or equal than 14,000 miles,
than another B-service should be performed. Service intervals are based on oil quality, which is determined by the vehicle's oil quality sensor.
583
MY1998 - MY1999 the instrument cluster service reminder displays one wrench (figure 1). Any additional work to the respective A or B service
scope is calculated using the maintenance sheet.
As of MY2000 - MY2004, there is one or two wrenches displayed within the instrument cluster (Figure 2) indicating "A" or "B" service
respectively. Any additional work to the respective A or B service scope is still calculated using the maintenance sheet. (Figure 2)
Maintenance System: FSS + (Flexible Service System Plus)

Model Years: MY2003 - MY2004
Model: 211
The entire service scope is calculated by the FSS +. With this maintenance system there is no minor "A" or major "B" services. Service intervals are
based on oil quality which is determined by the vehicle's oil quality sensor.
The maintenance service time will be indicated by showing a service type A through type H in the multi-function display and possibly followed by
a "+" symbol (Figure 3). Types A through H are classified based on estimated time needed to perform the maintenance service, ranging from
Service A (approximately 1 hour) to Service H (approximately 8 hours). The plus "+" symbol indicates that the brakes need to be inspected as well,
based on system calculations.
Note:
The alphabetic designations (A, B, C....H) do not represent minor or major services more commonly known as Service A and Service B. Instead
these codes strictly represent an estimated amount of time required to perform the corresponding service.
Maintenance System: MBMS (Mercedes-Benz Maintenance System)
Model Years: MY2005 - Present
Models: 163, 164, 171, 199, 203, 204, 207, 209, 211, 212, 215, 216, 219, 220, 221, 230, 251, 463
The MBMS uses various instrument cluster displays and intervals. Refer to model specific information below.
^ Model 163, 199, 203, 209, 215, 220, 230, 463
The MBMS indicates a minor or major service by displaying one or two wrenches within the instrument cluster's multifunction display (Figure 2)
indicating "A" or "B" service respectively, similar to the FSS system. Additional work is calculated using the maintenance sheet. The difference
from FSS is that the service interval is not based on oil quality. Fixed Intervals 10,000 miles (AMG models and 12 - cylinder engine only) or
13,000 miles (all other models).
^ Model 164, 171, 211, 216, 219, 221 and 251
The service scope is calculated by the MBMS. The maintenance service times will be indicated by showing a service type A through type H in the
multi-function display. Types A through H are classified based on estimated time needed to perform the maintenance service, ranging from Service
A (approximately 1 hour) to Service H (approximately 8 hours). Fixed Intervals - 10,000 miles (199, AMG models, 12 - cylinder, and 642 diesel
engines only) or 13,000 miles (all other models and 648 diesel engine).
Note:
The alphabetic designations (A, B, C....H) do not represent minor or major services more commonly known as Service A and Service B. Instead,
these codes strictly represent an estimated amount of time required to perform the corresponding service.
584
^ Model 204, 207, 212
With the MBMS there is a minor or major service designated as "A" or "B" respectively. The instrument cluster displays "AX" or "BX", where "X"
is a one-digit number representing the additional work. Additional work is determined using the Mercedes-Benz Maintenance Sheet. Fixed
Intervals - 10,000 miles (except MY2008 204 13,000 miles).
Note:
As of 2009 a new 10,000 mile maintenance strategy was implemented for all models and engine variants. Service is divided by "Required" and
"Recommended" at each interval. Refer to the Mercedes-Benz Maintenance Sheets and the Mercedes-Benz Maintenance Booklet for specific model
requirements. Refer to www.startekinfo.com under the menu heading "Maintenance Sheets" and or "Operator Manuals".
The chart shown above provides an easy and quick method of determining the type of maintenance system, instrument cluster display, and interval
based on model and model year.
A/C - No Or Insufficient Cooling Output

NO OR INSUFFICIENT COOLING OUTPUT, PERMANENTLY OR OCCASIONALLY/DEFECTIVE REFRIGERANT LINE
Version 1
Design Group 83.00 general
Date 07-29-2009
Validity Passenger car model series with air conditioning
Reason for change
585
Reason for block
COMPLAINT:
No or insufficient cooling output, permanently or occasionally/defective refrigerant line.
CAUSE:
Refrigerant line (engine-side low-pressure line, from compressor to connecting point upstream of expansion valve) whose inner coating comes
loose in the flexible section of the hose, causing constriction.
Attachments
REMEDY:
Air conditioning system may not be evacuated before test steps 1. - 3., this could affect the test result.
1. Start engine, activate air conditioning on control panel (max. cold, blower setting 3), medium engine speed.
2. Connect pressure gauge to high and low-pressure side.
3. Check whether the refrigerant compressor is delivering refrigerant (limiter on belt pulley turns or pressure builds up in refrigeration circuit): If
the refrigerant, eliminate this fault.
If the refrigerant compressor builds up pressure,
4. Read off the high and low-pressure values from the pressure gauges after approx. 5 minutes.
If the installation space does not permit reliable temperature measurement using an infrared thermometer, continue with 6:
5. If the low pressure is noticeably high (> approx. 60psi) and the evaporator temperature is significantly too high at the same time (> approx. 50°F)
use an infrared thermometer to check the engine-side low-pressure line against the refrigerant flow direction (from compressor to connecting point
upstream of expansion valve). If there is a noticeable temperature drop in the line (Delta > 45°F),
6. Dissemble the engine-side low-pressure line (from compressor to connecting point upstream of expansion valve) and
7. Use an endoscope or the procedure described in the attachment to check the line for clear passage (checking for clear passage using welding wire
or similar is not permissible as this can damage the inner hose and cannot detect peeling anyway).
8. Replace the line if you detect and constriction. Refer to EPCNet for applicable part number.
Attachments
Symptoms
586
Parts
Work units
Validity
587
Attachments - Visual inspection of intake line for clear passage
Engine - Oil Level Message General Information

GENERAL INFORMATION ON OIL LEVEL MESSAGE IN INSTRUMENT CLUSTER
Version 1
Design Group 01.45 Oil Pan
Date 08-06-2009
Validity Valid for engines: M111, M112, M113, M166, M266, M271, M272, M273, M275, M285, OM611, OM612, OM613, OM628
Reason for change Update model designation/Supercedes SI S-B-01.45/26a and S-B-18.00/36a
Reason for block
COMPLAINT:
The attachment to this document contains detailed information on procedures and possible remedies in the event of implausible display messages
concerning the engine oil level in the Instrument Cluster (IC).
588
Specifically, it contains information on:
1. Notes on implausible display messages
2. Overview chart of the relevant switches
3. Supplemental notes on oil level measurement
CAUSE:
For causes of implausible display messages, please refer to the document in the attachment (observe correct language version).
REMEDY:
For procedures and remedies in the event of implausible display messages, please refer to the document in the attachment (observe correct language
version).
Attachments
Symptoms
Work Units
589
590
591
Validity
TIPS Information Display: Display message concerning engine oil level
592
593
Remedies for known complaints in OM642, M272 and M273 engines
594
System description on the oil sensor and oil level switch
595
596
Oil level message, oil level warnings
597
General oil level measurement
598
Procedure for "Implausible display messages"
599
600
601
Engine - Surface Cleaning Recommendations/Precautions

Order No: S-B-01.10/29a
Supercedes: S-B-01.10/29, July 30, 2009
Group: 01
Revision History
a 9/30/09 Updated footnotes 1 and 2, in parts information.
SUBJECT:
MY-All, Engines 112, 113, 272 and 273
Cleaning Sealing Surfaces
When performing any engine repair or maintenance work where cleaning sealing surfaces is recommended, such as cylinder head cover removal or
installation, always follow the methods described below.
It is important to remember to never use abrasive cloths, pads, paper or any sanding procedures to remove silicon residue. In addition, never use
any sharp-edged tools or wire brushes that will damage the sealing surfaces.
602
Note:
When preparing and cleaning any surfaces for resealing, extreme care must be taken. Consequent damage resulting from not following the
prescribed methods for cleaning will not be covered by the warranty.
Note:
Use only approved methods to remove any carbon deposits when performing a repair. Do not use any sand paper, abrasive pads or disks or sanding
tools. Use only approved fuel additives. Dealers might be debited when performing unapproved or incorrect repairs as well as when unnecessarily
replacing parts.
Note:
Proper application of sealant is a must as excessive sealant can result in damage to the engine (refer to MTC "M272 Engine Timing"). Failure to
follow these precautions could result in severe and permanent engine damage.
Sealant Removal Procedure
1. Using a rag, wipe away all operating fluids (oil) and any other residue from sealing surface.
2. Observing all manufacturer application directions for product application, spray Loctite 7200 (or substitute as indicated in the parts information
below) on all sealing surfaces and let alone for 10 to 30 minutes.
3. Using a soft (plastic or wood) scraper, scrape away any loosened silicone sealant and wipe with a rag.
4. Note that the sealing surface should now feel even with a visible deposit of silicon sealant remaining (Figure 1). The surface should not be
metallic bright.
5. Thoroughly clean the sealing surface (follow product label directions) with Loctite 7063 (or substitute as indicated in the parts information
below) cleaning spray. Wipe surface when still wet with a dry, clean cloth and blow with compressed air.
6. The Loctite spray should be fully blown off before applying the new silicone sealant (the surfaces must be completely dry); otherwise, leaks may
occur.
Parts Information
Computers/Controls - DAS Software Update

603
Version 1
Date 09-29-2009
Reason for change
Reason for block
Complaint:
Driver ESA/ Front passenger ESA

Model series: 203,463
Faulty CBF file produces unknown control unit in vehicles of model series 203 and model series 463 prior to model refinement;
initial startup no longer possible.
ETC
Model series: 204,212,207
SCN coding with limp-home variant is not possible
Cause:
Remedy:
DAS/XD add-on 2009-08-21-1243 for passenger cars.
Symptoms
604
Validity

FILE:
605
SUBJECT:
Models 164, 164.8, 171, 203, 204, 209, 211, 215, 216, 219, 220, 221, 230, 251, 463

Procedure
Note:
Note:
606
Note:
607
Note:
608
A/T - 722.9, Delayed Reverse Engagement

DELAYED ENGAGEMENT OF REVERSE GEAR
Version 1
Design Group 27.00 General
Date 06/24/2009
Validity Transmission 722.9 with code 809
Reason for change Additional procedure for remedy
Reason for block
Complaint:
When reverse is selected, the engagement sequence may be delayed.
A double jolt may occur at an interval of approx. 3 seconds after moving the gearshift lever from P to R.
The complaint occurs with electrohydraulic controller (EHS) 220 270 2406 and 220 270 2306.
These electrohydraulic controllers are installed in transmissions as of model year 2009 (code 809).
Cause:
Parameterization of adaptation values for clutch pack BR (reverse gear)
Remedy:
1. Perform software update in transmission control unit and then perform SCN coding.
It is absolutely essential to make sure that DAS version 01/09 or higher including add-on 1077 is used.
2. Then the reverse gear adaptation data must be reset using DAS (menu guide in attachment).
3. The engagement sequences for N-D and N-R must be taught in again:
NOTE:
shift 5 times N-R,
shift 5 times N-R --> warm up transmission 40°C and while doing so, exceed a speed of 50 km/h at least once.
shift 5 times N-R,
shift 5 times N-R,
shift 5 times N-D.
Attachment
609
Symptoms
Validity
NOTE:
610
611
Recall - ECM Update For EVAP Diagnostics

FILE:
SUBJECT:
Models 164, 171, 203, 209, 251
Software Calibration Number (SCN) Coding - Engine Control Module This Recall Campaign has been initiated because Daimler AG (DAG), the
manufacturer of Mercedes-Benz vehicles, has determined that between May, 2006 and June, 2007, due to a software error, the vehicles fuel tank
leak diagnosis system may have been inadvertently deactivated during a visit to the workshop. This may cause the affected vehicles to fail to meet
the statutory requirements for Inspection/Maintenance (emissions inspection). Dealers will re-code the Software Calibration Number (SCN) -
612
Engine Control Module to correct this situation.
Shown in this bulletin is sample copy of a letter which owners of the affected vehicles will receive.
Approximately 12,848 vehicles are involved.
NOTE REGARDING CUSTOMER REIMBURSEMENT
Reimbursement to customers for repairs performed prior to this recall: If the customer already paid to have this recall campaign condition repaired
and provides adequate documentation to support their claim of a non-warranty repair of this item, they may be eligible to receive reimbursement.
Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement is limited to the amount the repair of a non illuminating check
engine malfunction indicator lamp (MIL would have cost if completed by an authorized Mercedes-Benz dealer under this campaign.
Submit a warranty claim, utilizing Damage Code 54952468 as a sublet, utilizing the sublet code of "SUB." Sublet repairs require dealer text as
stated in the Warranty Policies and Procedures Manual. Repair date should be the date that the customer paid for the repair.
Note:
Please note the claim submitted for customer reimbursement will not close the campaign (if still open). If the customer is still in possession of the
vehicle with an open campaign, please arrange to close the campaign in the usual manner as described in this bulletin. this bulletin.
Procedure
Note:
^ Use DAS/XENTRY 06/09 with all associated patches or higher.
^ Follow the steps exactly as described in DAS/XENTRY.
2. Follow the DAS path below to SCN code Engine control module:
Control units/Drive/ME 9.7/Control unit adaptations/Variant coding/SCN coding
613
Note:
^ The label is being mailed to dealers prior to the launch of this Recall Campaign. Additional labels are available as literature through NetStar free
of charge (order# P-BQ-AEM-LBL)
614
4. California dealers only: Print Proof of Correction form as shown above and fill out as also above shown in Figure 2.
Note:
615
616
Computer/Control System - DAS/XD Software Update

Version 1
Date 09-29-2009
Validity DAS version 07/2009
Reason for change
617
Reason for block
Complaint:
All telematics flash CUs - Model series: 204,207,212 - During control unit programming of telematics control units, the selection menu
"Component 'TV' is not installed" sometimes does not appear. During control unit programming, no symptoms are displayed on the "New software
found" screen.
CDI6 - Model series: 204,212,207 CU access not possible. CU programming from boot software cannot be performed. Initial startup cannot be
performed.
SGR - Model series: 221,195 Communication cannot be established with the radar sensors control unit (SGR).
Audio/COMAND - Model series: 164,169,211,219,245,251,230,203,463,171 Missing texts during control unit programming
SAM - Model series: 169/245 Initial startup of SAM control unit not possible for vehicles prior to YM 2008
ETC - Model series: 204,212 Communication aborted when accessing current adaptation of torque converter lockup clutch
Cause:
For all complaints: DAS data assignments.
Remedy:
Symptoms
618
619
620
621
622
623
Validity
Interior - Seat Backrest Control Valve Switch Broken

BACKREST (MCS) AIR CUSHION CONTROL VALVE SWITCH BROKEN
Version 1
Design Group 91.25 Multicontour seat (MCS)
Date 07-21-2009
Validity Model series 169, 203, 209, 245
Reason for change Damage code included/Supercedes DTB P-B-91.25/123

and T-B-91.25/124
Reason for block
Complaint:
Multicontour seat backrest control valve switch broken.
Cause:
Damage due to external force, incorrect operation.
Remedy:
624
In these cases do not replace the entire control valve.
Only the broken switch should be replaced with the control valve in the installed condition.
The switch is available as a separate replacement part: A169 870 03 10
Symptoms
Parts
Attachments
Work Units
625
626
627
Validity
628
629
Cell Phone - iPhone(R) Music Won't Mute During Call

!PHONE/!PHONE 3G: MUSIC PLAYBACK CAN BE HEARD DURING PHONE CALL
Version 1
Design group 82.70 Cellular telephone, voice control system (VCS)
Date 08-18-2009
Validity Model series 164, 169, 171, 203, 204, 207, 211, 212, 216, 219, 221, 245 with !phone UPCI cell phone holder (A34/15) and da
Reason for change Remedy entered/Supercedes DTB S-B-82.70/687
Reason for block
COMPLAINT:
Music playback from the !phone/!phone 3G during a phone call can be heard over the vehicle speakers. This means that the audio source is not
muted at the beginning of the phone call.
The complaint only occurs if the following boundary conditions exist:
1. The !Phone/!Phone 3G is inserted in the UPCI cell phone holder (A 34/15).
2. The UPCI cell phone holder (A 34/15) of the !Phone is connected to an !Pod interface via a data connection cable (installation instructions, see
WIS references).
3. The vehicle is equipped with (multiple-handset interface) MHI.
4. Music playback via the !Pod interface prior to the phone call
CAUSE:
!Pod interface software is faulty.
REMEDY:
Replace !Pod interface control unit (see parts note).
630
Symptoms
Parts
Work units
631
WIS-References
Validity
Lighting - Exterior Light Bulb Replacement

REPLACING EXTERIOR LIGHT BULB
Version 3
Design group 82.10 Exterior lights
Date 10-01-2009
Validity All Model 163, 164, 171, 203, 209, 211, 215, 219, 220,
230 and 251 Vehicles
632
Reason for change LI did not match DTB from which it was created. (Main remedy for repair was missing.) / Supersedes DTB SB-82.10/598b
Reason for block
Complaint:
Replacing Exterior Light Bulbs
Cause:
N/A
Remedy:
If you receive customer reports of exterior bulbs requiring replacement, only long life bulbs are to be used as replacement bulbs.
Refer to Table 1 for applicable models.
Note [i]:
In cases where a new tail lamp housing (which does not have long-life bulbs) is being installed, replace the bulbs with long life bulbs.
Note [i]:
This information has been generated on October 30, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time
allowance.
Attachments
Symptoms
633
Parts
Work units
634
Validity
Attachment - Table 1
635
Body - Windshield/Window Glass Bonding System
Date: July 23, 2009
Order No.: S-B-67.10/27
Supercedes:
Group: 67
Subject:
MY-All, Models All
Introduction of Improved Single-Component Windshield/Window Bonding System
A. Advantages Of Narrower Nozzle
1. A narrower nozzle affords easier application and produces a more accurate bead for going around components, such as a center high-mounted
brake lamp.
2. The yield of the cartridge has been increased by 63 cm and covers all windshield and window scopes. This eliminates the need for a second
cartridge.
3. There is less soiling in the inner headliner.
B. New Applicator Sticks Include a Primer and an Activator (Figure 2)
1. New applicator sticks ensure quicker application in a precise width with a reliable one-time use.
636
3. Wait Time After Windshield or Window Installation
1. When performing a windshield or window install, wait at least two hours after using the new application kit. This is a reduced wait time from
older kits.
Parts Information
Steering - Squealing/Squeaking Noise When Turning

HONKING/SQUEAKING NOISE FROM AREA OF CONTROL HEAD STEERING SYSTEM WHEN STEERING
Version 1
Design Group 46.20 Steering gear
Date 06-23-2009
Validity Model 163/168, all,

Model 203/209/211 conditional implementation,
Model 220/230 without ABC, conditional implementation
Reason for change Steering system numbers updated
Reason for block
Complaint:
Squealing/squeaking noise when steering in both directions.
The noise can mainly be heard with the engine running and warm.
Cause:
Insufficient lubrication at radial shaft sealing ring in the control head may result in squeaking/rubbing noise
Remedy:
Add the additive Lubrizol 6178 to the power steering fluid.
NOTE:
- The additive Lubrizol 6178 may only be used for specific steering system number (refer to list below)!
No more then 50 ml mat be added!
The additive can only be used once in the steering system!
637
- If the additive is added to a steering system that comes after the quoted steering system number, the steering system may be damaged!
638
The list above shows models/steering systems or the steering system number with which the additive may be used.
Procedure
1. Check whether Lubrizol has already been added, this can be seen by a yellow dot on the steering system and power steering pump (see picture in
attachment).
2. Bring steering system to operating temperature (approx. 80°C)
3. Suction off 50 ml of steering oil.
4. Add 50 ml of Lubrizol 6178
NOTE:
Shake bottle well before pouring in
5. Start engine, increase idle speed to approx. 1200 rpm, turn steering to limit stop, hold there for approx. 1-2 seconds and then suddenly turn
steering out of the limit stop. This procedure must be performed at both limit stops until the noise can no longer be heard.
6. On the reservoir housing on the power steering pump and on the steering system, use a yellow touch-up paint pen to make a dot, as shown in the
picture (picture, refer to attachment, clean area before hand).
NOTE:
This mark is used for subsequent work on the steering system as an indication that the additive lubrizol 6178 has already been added once and may
not be added again.
639
Attachments
Symptoms
Parts
Work Units
Validity
NOTE:
640
641
642
643
Lighting - Automatic Lights Switch OFF Too Late

DRIVING LIGHTS SWITCH OFF TOO LATE OR ON TOO EARLY (BLUE SKY EFFECT)
Version 1
Design Group 82.10 Exterior lights
Date 09-10-2009
Validity Models 203 as of 06/2003, 169, 245, 215, 216, 209, 219, 211, 164, 251, 220, 221, 230, 171. With rain/light sensor (RLS)
Reason for change
Reason for block
Complaint:
The customer complains that, under a cloudless, blue sky (away from direct sunlight), the driving lights switch off too late when the rotary light
switch is in the "Auto" (automatic) position.
Cause:
Under a blue sky, the sensor interprets the ambient brightness as being too dark due to its physical operating principle (blue sky effect). The reason
for this is that the sensor measures light in the infrared range, and range of light occurs less then usual under a cloudless sky.
Remedy:
Please advise the customer of the technical limitations in this special situation.
NOTE:
Replacement of the rain/light sensor (RLS) is not justified and does not remedy the complaint!
Symptoms
Work Units
644
Validity
Suspension - Front Axle Area Noise When Maneuvering

Knocking/creaking noises from area of front axle when maneuvering
Version 2
Design group 33.15 Axle links
Date 01-12-2010
Validity Model series 203 except 4MATIC, 171, 209, 204
Reason for change Damage code and WIS documents removed
Reason for block
645
Complaint:
Knocking/creaking noises from the area of the front axle when maneuvering (forwards/reverse) just before the steering reaches the limit stop.
Note:
Service brake is applied.
Cause:
Torsion of the hydro-mount in the strut rod.
When maneuvering, the hydro bushing end stop plug can collide with the inside of the outer sleeve.
In isolated cases, this surface can exhibit pinpoint wear depending on the operating conditions of the vehicle. This wear is caused by the end stop
plug resting against the outer sleeve during braking maneuvers.
As the end stop plug slides over the damaged area, fluctuations in friction pairing occur which cause the knocking/creaking noises.
Note:
The noise can generally be reproduced by driving a figure-8 in reverse. If the noises occur during this maneuver, the steering gear is not the cause
of the problem and must not be replaced. Please contact the TAC in urgent cases.
Remedy:
No remedy exists at the present time.
Symptoms
646
Validity
Antitheft System - DAS3 Diagnosis/Replacement Info.

DIAGNOSIS AND REPLACEMENT OF DAS3 COMPONENTS (KEY, EIS, ESL)
Version 2
Design group 80.57 Drive authorization systems (DAS)
Date 10-28-2009
Validity All Model 164, 171, 203, 204, 207, 209, 211, 212, 219
and 251 Vehicles
Reason for change Added applicable models / Supersedes DTB SB-80.57/24c
Reason for block
Complaint:
Diagnostic procedures for the DAS3 Drive Authorization System have been revised for models listed above. Please proceed as follows when
diagnosing systems conditions.
Cause:
647
N/A
Remedy:
Select Control units -> Body -> EIS -> "Guided transmitter key check" or "Guided drive authorization system check"
Select the respective guided check. A guided diagnosis follows which is used to pinpoint the component that is causing the condition. Do not
replace any component before performing this diagnosis. Always perform the diagnosis in its entirety until SDS identifies the component to be
replaced. At the end of the test steps, the user will be prompted to print the results. When submitting a claim, copies of this printout and a quick test
must accompany the parts. The warranty claim may be debited a handling charge if the printout and the quick test do not accompany the parts.
Applied diagnostic steps are stored in the EIS (Electronic Ignition Switch) and ESL (Electric Steering Lock) components. The diagnostic steps
utilized by the dealer will be electronically verified by the QEC to determine if the control unit performed the diagnostic procedure. If it is
determined that a complete diagnosis was not performed, the warranty claim may be debited a handling charge.
Note:
Both vehicle keys are required to ensure a proper diagnosis. Please be sure that both keys will be available when the repair appointment is made. If
this is not possible, ensure you have the correct diagnosis path when conducting diagnosis in SDS.
Symptoms
648
649
Validity
Computers/Control - DAS/XD Add-On 2009-10-09-1280

Version 1
650
Date 11-25-2009
This add-on is dependent on the following add-ons: 1266, 1274
Reason for change
Reason for block
Complaint:
ETC
Model series:
171, 203, 209, 211, 219, 230
The new transmission control unit VGS3NAG2 could not previously be programmed.
ETC
Model series: 204, 216, 221
ETC
Model series: 221
Control unit programming for hardware object number 0335457332 reports: "The following control unit software versions are available for control
unit programming: 0094484910" After control unit programming, the control unit cannot be started up.
CDI
Model series: 212
Control unit programming for software object number 6519030700 reports: "No newer control unit software found".
Cause:
Remedy:
DAS/XD add-on 2009-10-09-1280 for passenger cars:
This add-on can be installed over DVD version 09/2009.
This add-on is dependent on the following add-ons: 1266, 1274
Symptoms
651
652
Validity
Computer/Controls - DAS/XD 2009-10-05-1274

Version 1
Date 11-25-2009
Reason for change
Reason for block
Complaint:
ETC
Model series: 171, 203, 209, 211, 215, 219, 220, 230, 463
CDI
Control unit programming for hardware object numbers 651 901 26 00 and 651 901 25 00 reports: "No newer control unit software found". New
software for actuation of piezo injectors.
Cause:
Remedy:
653
Symptoms
654
Validity
Computer/Controls - DAS/XD Add-On 2009-10-05-1271

Version 1
Date 11-25-2009
Reason for change
Reason for block
Complaint:
655
All flashable CUs
Model series: 129, 163, 164, 168, 169, 170, 171, 199, 203, 204, 208, 209, 210, 211, 215, 216, 219, 220, 221, 230, 240, 245, 251, 451, 461, 463
3 fault messages displayed during SCN coding
IC
Fault messages during automatic initial startup
FSCM212
Model series: 204
FSCM212 is not shown in the quick test and in the control unit list
All flashable CUs
FDOK redocumentation of CVN is not performed during SCN coding - SCN coding on vehicles with China variant of COMAND not possible. -
Enabling offline control unit programming not possible.
Cause:
Remedy:
Symptoms
656
657
658
659
Validity

Version 1
Date 11-25-2009
Reason for change
Reason for block
Complaint:
Audio or Comand
Model series: 169,245,164,251,171,203,211,219,463
Initial startup cannot be completed with Audio20
ABR
Model series: 216
Control unit programming cannot be performed.
CDI6
Model series: 164, 254
Unknown variant of CDI control unit.
SCR
Test prerequisites incomplete - Faults during actuations
660
Teleaid
PRL update nonfunctional
AAC
Special function for eliminating coding problem after software programming

CDI6BIN5
Actuation cannot be started
Cause:
Remedy:
Symptoms
661
Validity

Version 1
662
Date 11-25-2009
Reason for change
Reason for block
Complaint:
Audio or COMAND
Model series: 169, 245, 164, 251, 171, 203, 211, 219, 463+37
Initial startup cannot be completed with Audio20
ABR
Model series: 216
Control unit programming cannot be performed.
CDI6
Unknown variant of CDI control unit.
TGW2
Test of mobile phone Bluetooth adapter (HFP cradle) results in faulty test result
Teleaid
PRL update nonfunctional
ETC
1. Display of adaptation data
Cause:
Remedy:
Symptoms
663
664
Validity

Version 1
Date 12-16-2009
Reason for change
Reason for block
Complaint:
SCR
Guided test does not work
COMAND
Model series: 203, 219, 211, 164, 251, 463, 230, 171, 245, 169
Navigation actual values cannot be displayed.
COMAND
Impossible to create a control unit log for telematics.
SCR
The SCR is missing from the list of control units.
Diesel, transmission CUs
Model series: 212
665
New diesel and transmission control units cannot be commissioned. CU programming: CAN TO errors are logged FSCU212
Test "Fuel pressure and internal leak tightness" cannot be performed, selection of FSCU in model series 204
DCU-LF, DCU-RF, DCU-LR, DCU-RR
Model series: 221
Coding in diagnostics per factory specifications is not possible STH stationary heater with remote control
If fault codes are stored in the fault memory, the following message appears in DAS when the initial startup is performed: "sst file not found".
Initial startup is aborted.
ETC
Model series: 171
Not possible to flash from VGS2 to VGS3 after EHS replacement. ABS traction systems. Model series: 461 Variant coding in control unit variant
0x0001 not possible
Cause:
Remedy:
This add-on does not supersede any other add-ons and must be additionally
installed.
Symptoms
666
667
668
Validity
669

Version 1
Date 2-16-2009
Reason for change
Reason for block
Complaint:
ME9.7
Model series: 171, 203, 209, 211, 219, 221, 216, 230, 164, 251, 463
Engine warning lamp is currently on or was on according to customer, and a delay fault of the camshaft adjuster is current or stored in the engine
control unit.
CDI D
Model series: 204
Fault memory cannot be erased
ETC
Diagnosis as per factory specifications is possible without a password.
ETC
CDID
Model series: 204
Actuations faulty and some cannot be performed.
Cause:
Remedy:
670
Symptoms
671
Validity
Computers/Controls - DAS/XD Add-On 2009-11-27-1321

Version 1
Date 01-07-2010
Reason for change
672
Reason for block
Complaint:
ME9.7
Model series: all except 168, 169, 245 and smart
control unit.
CDI D
Model series: 204
ETC
ETC
1. Display of adaptation data for development department as text file
2. Activation of control unit 3. Correction programming in Diagpass and XD modified for hotline cases
CDID
Model series: 204
Cause:
Remedy:
Symptoms
673
Validity
674
Computers/Controls - DAS/XD Add-On 2009-12-03-1314

Version 1
Date 01-07-2010
Reason for change
Reason for block
Complaint:
ETC, model series: 203,211,221 Diagnosis as per factory specifications is possible without a password.
ETC
SIM4CNG
Model series: 211
Coding of engine control unit not possible.
TSGVL9, TSGVR9, TSGHL9, TSGHR9, TSGML9, TSGMR9
Model series: 221
Coding in diagnosis per factory specifications is not possible

SRS/airbag
Model series: X204
If the SM for the X204 cannot be successfully completed in the first run (e.g. communication problem, OBD connector disconnected etc.), it is not
possible to repeat the initial startup procedure (fault message -99 after CU programming).
Cause:
Remedy:
Symptoms
675
676
Validity
Steering - Approved Hydraulic Fluids

Order No.: S-B-46.25/70
Group: 46
SUBJECT:
MY-All, Models 124, 129, 140, 163, 164, 170, 171, 199, 202, 203, 204, 207, 209, 210, 211, 212, 215, 216, 219, 220, 221, 230, 251, 463
Approved Hydraulic Fluids for Steering Systems
Only use the following approved fluids in the event of hydraulic steering system repairs:
Hydraulic fluid A according to sheet 236.3; hydraulic fluid B according to sheet 345.0; and hydraulic fluid C according to sheet 344.0 (see Parts
Information below).
677
Parts Information
BULLETIN OBSOLETE - REFER TO BULLETIN S-01_30-23B

Supersedes: S-B-01.30/31a, January 22, 2010
Group: 01
Revision History
b 2/3/10 Bulletin No Longer Applicable
a 1/22/10 Bulletin text modified
SUBJECT:
All Passenger and Light Truck Models, Equipped with Engine M272 / 273
Up to approx. June 2008 Production
Oil Seepage from Back of Cylinder Head Interim Repair Method - INTERIM REPAIR METHOD IS NO LONGER VALID - BULLETIN IS NO
LONGER APPLICABLE
678
The interim repair method for this situation is no longer valid. The provision under this bulletin is no longer applicable.
Please refer to DTB S-B-01.30/23b for repair solution.
Engine - Oil Leaks At Back Of Engine

Camshaft caps leaking: Oil loss at rear of engine
Version 4
Design group 01.30 Cylinder head
Date 03-03-2010
Validity All models with engine 272

All models with engine 273

Engine 273: 2739xx30268766
Engine 272: 2729xx31006851

Engine 273: 2739xx30264566
Engine 272: 2729xx30992044
Reason for change Supersedes DTB S-B-01.30/23b
Reason for block
Complaint:
Oil loss at rear of engine.
Note:
In isolated cases oil loss can occur at the rear caps (cover plugs) of the camshafts.
Cause:
Cap sealing ring leaking.
(In the event of borderline tolerances and under unfavorable climatic conditions the sealing ring can lose the preload necessary to seal off the oil
gallery)
Remedy:
Replace cap.
Note:
Replace all 3 or both (on engines with mechanical vacuum pump) caps.
Part number:
A000 998 55 90 (cap, small)
A000 998 56 90 (cap, large)
Symptoms
679
Parts
Work units
680
Validity
Engine - Misfire Or Oil Consumption Service Guidelines

Supersedes: S-B-01.30/28 June 8, 2009
Group: 01
Revision History
a 3/29/10 Bulletin text modified
SUBJECT:
MY-All, All Models Equipped with M272 and M273 Engines
Cylinder Head-Related Complaint Guidelines
If you receive customer reports regarding vehicles equipped with Engine 272 or 273 related to a misfire or oil consumption, follow the guidelines
herein to determine further actions.
Perform checks and / or repairs according to published WIS (such as, AH01.00-P-0300-01VA), DTB (such as S-B-07.61/72a - misfire codes; DTBs
and LIs in group 18 or 01 related to oil consumption) and other official documents.
Note:
Do not replace cylinder heads based on suspicion alone and follow the guidelines to make a proper determination. Only the compression and leak
down test values taken from engines at operating temperature could be taken for consideration. Proper inspection of combustion chamber requires
MB Special Tools approved Borescope.
Note:
Use only approved methods to remove any carbon deposits when performing a repair. Mechanical carbon deposit cleaning (and use of any sand
paper, abrasive pads or disks or sanding tools) is not allowed under warranty and cylinder heads should not be removed to do that. Use only
approved fuel additives - Keropur part # A000 989 25 45 12. Dealers might be debited when performing unapproved or incorrect repairs as well as
when unnecessarily replacing parts.
Note:
If the guideline test steps are inconclusive, revert to the SDS guided test as indicated by the DTB S-B-07.61/72a and / or properly determine a root
cause of the complaint.
681
682
683
Complaint Process Guidelines (Pages 2-4) shown above.
Engine - Cylinder Head Cover Leak Information

Date: April 2, 2010
Order No.: S-B-01.20/32
Supersedes:
Group: 01
SUBJECT: All Models with M272 and M273 Engines
Cylinder Head Cover Leaks
Recent field inspections of suspected cylinder head cover oil leaks, have revealed that unnecessary resealing is being performed where leaks do not
exist. A significant number of other procedures have incorrect damage codes applied to cylinder head covers.
In cases of customer complaints of oil leakage, it is essential to determine the actual source. A proper remedy should be applied to avoid repeat
repairs and unnecessary workshop visits (refer to other publications on the subject). "Oil sweating" in most cases is not a cause for concern. Refer
to LI01.30-P-048997.
684
It is also crucial to apply the correct damage and operation codes on warranty claims.
The new generation of Mercedes-Benz engines have chemical sealers (sometimes referred to as "formed-inplace gaskets") applied to sealing
surfaces by robots during the engine assembly process. This engine sealing technique called the RTV (Room Temperature Vulcanizing) uses the
silicone rubber compound. This precise and uniform application of silicone at the factory insures proper adhesion and a leak tight connection that
very rarely leaks.
During necessary engine resealing repairs, care must be taken in preparing surfaces and applying silicone compound. Do not clean surfaces with
any abrasive materials or sharp tools. Only approved Loctite cleaning spray must be used when prepping engine surfaces (refer to published
documentation on the subject, such as bulletin S-B-01.10/29(x)).
Only 1 millimeter (+/- 0.2 mm) thick silicone bead should be applied uniformly to one side of sealing surfaces on a precise pattern (refer to Figure 1
and 2 and / or WIS doc AH01.30-P-1000-08V). A small amount of oil should be applied to camshaft bearings. Sealing surfaces must be assembled
within 10 minutes of sealant application.
Interior - Front Seat Backrest Noise

Noises from backrest frame
Version 1
685
Date 03-24-2010
Validity 203, 204, 209, 211, 219 Restriction is given in the plain text.
Reason for change Valid model designations updated / Supersedes DTB SB-91.10/112f
Reason for block
Complaint:
Noise complaints when load on backrest frame changes.
Affects the driver and front passenger seats.
Also perform the remedial action if you are performing work on
- Backrest frame (91013),
- Backrest cover (91A15, 91N15) or
- Head restraint guide rail (91A33, 91N33).
The actions must always be performed if the backrest frame is exposed to avoid follow-up repairs.
Attachments
Cause:
1. Affects all vehicles (see Figures 1, 2, 3).
1. At low temperatures (- C°), natural vibrations of the lordosis basket can result in damage to the guide wire when a person sits down in the seat.
2. Only affects vehicles produced up to September 05 (see Figure 4).
2. The Pulmaflex mat rubs on the attachment points on the backrest frame (2 attachment points on the right and 2 on the left).
3. Affects model series CL203 and 209 (see Figures 5, 6) Relative movement can produce noise problems at the bottom of the backrest.
4. Affects all vehicles of model series 211 and 219 (see Figure 7)
Noises may occur in the backrest under load due to the incorrect positioning of the circlip.
Remedy:
Note:
Even if just one of the complaints exists, you should always implement the other measures (i.e. measures 1, 2, 3 and 4), regardless of whether or not
the customer complains about these. The aim is to ensure that the customer does not return another time with complaints about noise from the seat.
Please note the restrictions, e.g. model series and production date, and implement the relevant measures. Measures are to be performed with the seat
installed.
1. First, proceed as follows (see step 1. Affects all vehicles):
- Reproduce noise caused when a person sits in seat at low temperatures.
- Remove seat-back lining - Refer to WIS document AR91.10-P-1910P (203, 209), AR91.10-P-1910CW (204), AR91.10-P-1910T (211 up to
MY05), AR91.10-P-1910TB (211 as of MY 05) or AR91.10-P-1910TX (219)
686
- Check whether guide wires are damaged at points where they intersect with lumbar support basket (on both right and left side). (Figure 1-
Lordosenkorb 1.pdf.)
- If guide wire is slightly damaged (Figure 2- Leichte Beschädigung.pdf), the damaged area must be coated with following agent: Krytox.
- If guide wire is seriously damaged (Figure 3- Starke Beschädigung.pdf), the damaged areas on the Pulmaflex mat must be rubbed down with
emery cloth, wrapped with Coroplast tape (commercially available plastic adhesive tape) and coated with Krytox.
2. Then also perform step 2 for all vehicles produced up to September 05 (see AR91.10-P-3332T):
- Detach backrest lining (already detached in step 1)
- Remove sidebag unit
- Detach Pulmaflex mat from attachment points on backrest frame
- Attach one piece of felt to each attachment point (2 on the right and 2 on the left) The exact positions are the points marked in red in the
illustration "Felting of backrest frame".
The felt must be treated with Krytox beforehand.
- After applying the felt pieces, reattach the Pulmaflex mat.
Object number of felt to be used: A0019835110
Dimensions: 25 mm wide and 2 mm thick.
3. For model series CL203 and 209 also perform the following measures:
- Seat-back lining still removed (see Figure 5). The seat is in installed position in the vehicle.
- Detach covering and spray the rivets (see Figure 6) in area between side section of frame and crossmember with grease A002 989 06 51.
4. The following measure must be implemented on all vehicles of model series 211 and 219:
Check the alignment of the circlip on the head restraint guide sleeve and correct it if necessary as shown in Figure 7 "Position of circlip".
After reattaching the cover and the seat-back lining, sit in the seat to check whether the noises are produced.
* Sufficient for 10 repairs, Submit as Local Purchase - FLS00053, Qty 1, handling is included
** Sufficient for 20 repairs, Submit as Local Purchase - SAA00213, Qty 1, handling is included
Attachments
Symptoms
687
Parts
Work units
WIS-References
688
689
690
Validity
691
692
693
694
695
Interior - Front Seat Noise

Noises from seat adjuster/cushion frame
Version 1
Date 03-24-2010
Validity Model series 203, 211, 219
Reason for change Damage codes adjusted / Supersedes DTB S-B-91.10/112f
Reason for block
Complaint:
Noises from area of seat adjuster or cushion frame.
Cause:
Noises that are localized in this area of the seat (seat adjuster or cushion frame) are not caused by the seat adjusters. The component responsible is
the cushion frame or the cushion frame brackets. It is absolutely essential to not replace the seat adjuster, but instead, the cushion frame brackets.
The cushion frame brackets in vehicles produced prior to 31 March 2006 develop a burr as mileage increases, which can lead to the noise complaint
described above. The burr can be seen in the illustration attached below:
Halter Kissenrahmen.pdf
696
Affected damage codes: 91001, 91A37, 91N37.
Attachments
Remedy:
Important note:
Also perform the action if you are performing work on the seat adjustment. When the brackets are exposed during the work, the remedial action
must be performed depending on the VIN range to prevent follow-up repairs.
In these cases the seat adjusters must not be replaced.
If the above damage profile is present, replace only the relevant cushion frame brackets with object number A0009140029.
These cushion frame brackets are partially coated as of 31.03.2006 to prevent this burr from developing.
The bolted connection must always be made using a microencapsulated bolt with object number N000 000 00 4180 (hexalobular bolt MBN
10226-M6x12-8.8-MK DBL 9469).
Symptoms
Parts
Work units
697
698
Validity
699
Attachment - Burr on bracket
Interior - Grunting/Ripping Noise At Front Seat-Back

Felt pads missing after replacement of backrest frame
Version 1
Date 03-24-2010
Validity Model 211/219/203
Reason for change Attachment revised / Supersedes DTB S-B-91.10/112f
Reason for block
Complaint:
Grunting and/or ripping noise at seat-back lining.
Missing felt pads on replacement part backrest frame with part number
A 000 910 11 34
A 000 910 12 34
A 000 910 13 34
A 000 910 14 34
A 000 910 40 34
A 000 910 42 34
Cause:
700
If the felt is missing, the seat-back lining bracket collides against the backrest frame.
Remedy:
Apply felt as per gluing plan (see attachment).
Attachments
Symptoms
Parts
Work units
701
702
703
Validity
704
705
706
707
Attachment - Work Instruction "Bond felt pads to backrest"
A/T - Hard Converter Lock-Up/Hard 1-2 Shift

Hard 1-2 shift or hard torque converter lockup clutch engagement
Version 1
Design group 27.00 General
Date 04-06-2010
Reason for change Remedy revised / Supersedes DTB S-B-27.00/112
Reason for block
Complaint:
The customer complaint of "Hard shift, presumable the 1-2 shift, occurs when moving off" is often received even though the problem is hard
engagement of the torque converter lockup clutch (KUB) in the start-off process.
In order to permit a clear diagnosis, restrict the transmission to 1st gear by shifting to position 1.
If a jolt occurs at the point where the state of the torque converter lockup clutch changes from "open" to "slipping", then the cause should be sought
708
in the control of the torque converter lockup clutch.
Cause:
Control of torque converter lockup clutch engagement not optimized.
Remedy:
1. Via DAS menu item "Initial startup", perform transmission software update and then perform SCN coding.
2. Via DAS menu item "KUB adaptation", adapt the torque converter lockup clutch according to the coolant temperature and torque window.
3. Then perform a test drive.
Symptoms
Work units
Validity
Audio Sys. - iPod(R)/iPhone(R) Will Not Charge

iPod/iPhone 3G is not charged
Version 3
709
Design group 82.60 Radio, audio/video systems
Date 03-18-2010
Validity Model 164, 169, 171, 203, 204, 207, 209, 211, 212, 216, 219, 221, 230, 245, 251 with media interface (code 518) or retrofitted
Reason for change Model designation added
Reason for block
Complaint:
1. Apple iPod or iPhone 3G is not charged when used on media interface (code 518).
Affected consumer cables:
A001 827 65 04 (supplied with ECE straight connector)

A204 827 04 04 (iPod cable with straight connector)
A001 827 70 04 (supplied with ECE straight connector)
A001 827 68 05 (iPod cable with straight connector)
B6 782 45 26 (supplied with ECE angled connector)
B6 782 45 25 (iPod cable with angled connector)
A204 827 05 04 (supplied with USA straight connector)
A001 827 69 04 (supplied with USA straight connector)
B6 782 45 27 (supplied with USA angled connector)
2. Apple iPod or iPhone 3G is not charged when used with the iPod interface kit (Mercedes-Benz Accessories retrofit).
Affected iPod interface kits:
B6 782 2890
B6 782 4239
B6 782 4246
B6 782 4253
B6 782 4254
B6 782 4258
B6 782 4094
Cause:
Discontinuation of the 12V charging circuit by the Apple Corporation in Apple iPhone 3G and iPod Nano 4G, iPod Touch 2G and iPod classic
120GB.
Note:
Previous iPod/iPhone generations could be charged with 5V and 12V. The iPods/iPhones listed above and future generations can only be charged at
5V.
Note on model series 221, 216:
Due to the power management in model series 221 and 216, the iPod/iPhone is charged only when the engine is running in vehicles with iPod
interface kit installed.
Note:
The change in charging circuit from [5v/12v] to 5v is Apple Corporation responsibility and not Mercedes-Benz/Daimler AG. Any unnecessary
replacements will be debited.
Remedy:
1. Replace iPod consumer cable (see parts note).
Note:
Occasionally, the message "Charging not supported with this accessory" appears on the display of the iPod Nano even though the iPod Nano is
being charged. This message can be ignored if the charging symbol of the iPod nano indicates that the rechargeable battery is being charged (see
picture in attachment).
2. Replace iPod cable set of iPod interface kit (see parts note).
710
Note:
The iPod interface kits listed are not approved for the iPhone 3G or iPod Nano 4G, iPod Touch 2G and iPod classic 120GB.
Note:
Older iPods can be charged with both the old and new consumer/charging cables.
Note:
Occasionally, the message "Charging not supported with this accessory" appears on the display of the iPod Nano even though the iPod Nano is
being charged. This message can be ignored if the charging symbol of the iPod Nano indicates that the rechargeable battery is being charged (see
picture in attachment).
Attachments
Symptoms
Parts
Work units
711
712
713
Validity
Attachment - iPod charging symbol

Technical Service Bulletin # S-98_00-13R Date: 100311
Paint/Body - MBUSA Approved Refinishing Products Update

Order No.: S-B-98.00/13R
714
Supersedes: S-B-98.00/13Q, February 2010
Group: 98
Revision R: Edits to Spies Hecker and Standox Products
Subject:
MY-All, Models All, MBUSA Approved Refinishing Products
Glasurit and R-M (BASF), Spies Hecker, Standox, and Global (PPG) paint products are currently approved as refinishing products for
Mercedes-Benz vehicles.
MBUSA approved refinishing products from Glasurit, R-M, Spies Hecker, Standox, and Global are listed.
General Information can be obtained by contacting the supplier directly at the corporate headquarters listed above or by contacting your local
distributor.
MBUSA requires that only approved paint refinishing products and procedures be used on any warranty repair work. Documentation regarding this
must be submitted. Do not submit warranty claims to MBUSA for any repairs on refinished areas.
715
716
MBUSA Approved Standox(TM) Products
717
718
MBUSA Approved Spies Hecker Products
719
720
MBUSA - Approved Glasurit Reference Products
721
722
NBUSA - Approved PPG Refinishing Products
MBUSA - Approved R-M(R) Refinishing Products
Computers/Controls - DAS/XD add-on 2010-01-15-1348

Version 1
Date 03-05-2010
Reason for change
Reason for block
723
Complaint:
Audio or COMAND
Model series: 164, 169, 203, 211, 219, 230, 245, 251
Testing with Bluetooth test adapter not possible.
CDI6BIN5
Model series: 164
CU access not possible
CDI6_EU5
Model series: 461
CU programming cannot be performed.
Product overview
Model series: All
Model designation 212.224, in the field from April, is not yet available as production data.
ELC
Model series: 212
When the "AIRMATIC" control unit is accessed, "Unknown control unit variant" is displayed and initial startup and level
calibration is not possible. / The "AIRMATIC" control unit is displayed although the system is not installed.
ME
Incomplete testing behind fault codes 0230 and 0234, menu items for ethanol operation are not displayed
Audio/COMAND
Model series: 204, 212, 207, 197
XENTRY must be rebooted after manual coding and initial startup.
Cause:
Remedy:
Symptoms
724
Validity
Computers/Controls - DAS/XD add-on 2010-02-03-1352

Version 1
725
Date 03-05-2010
Reason for change
Reason for block
Complaint:
COMAND/audio
Model series: 169, 245, 203, 211, 219, 164, 251, 230
Automatic programming of the MOST members when programming COMAND or audio is not available.
Media interface
Programming of media interface inoperative.
IC
Dashes in trip computer after SCN coding
IBGAS
Model series: 211
Programming of the IBGAS interface box is not possible
Audio or COMAND
Model series: 463
Control unit programming for hardware object number 4638700989 reports: "No newer control unit software found".
IC
Model series: 221
Control unit programming for several hardware object number reports: "The following control unit software versions are available for control unit
programming: ..." After control unit programming, the control unit cannot be started up.
Cause:
Remedy:
Symptoms
726
Validity
Computer/Controls - XD/DAS Add-On 2009-11-27-1321

Version 1
Date 03-23-2010
Reason for change
Reason for block
Complaint:
727
ME9.7
Model series: all except 168, 169, 245 and smart
control unit.
CDI D
Model series: 204
ETC
ETC
CDID
Model series: 204
Cause:
Remedy:
Symptoms
728
729
730
731
Validity
A/T - Harsh Engagement From Park To Drive

Harsh engagement when changing gear range from P to D
Version 1
Design group 27.50 Gear assembly
Date 04-06-2010
Reason for change
Reason for block
Complaint:
When changing gear range from P to D, harsh engagement may be noticeable.
Cause:
The engagement sequences for N-D and N-R may not be optimized
Remedy:
The engagement sequences for N-D and N-R must be taught in again as follows:
Note:
shift 5 times N-R,
shift 5 times N-R,
shift 5 times N-R,
shift 5 times N-D.
Symptoms
732
Validity
Engine - Squeaking Noises From The Belt Drive

Version 1
Design group 13.20 Belt drive, general
Date 03-10-2010
Validity Belt drive, engine 272 and engine 273.
Reason for change
Reason for block
Complaint:
Cause:
Axial shifting (temperature-related) of the individual belt pulleys and guide pulleys can lead to squeaking noises in isolated cases.
Remedy:
Application of Krytox lubricant - belt dressing A000 989 36 60 (from lubricating kit A000 580 03 50) - one to two drops at each point to the inner
and outer side edges of the poly-V belt. Procedure:
- Bring the engine to the operating temperature (80 deg. C) and switch it off.
- Remove top front engine cover as required to get access to the poly-V-belt.
- Apply one to two drops of Krytox lubricant to the inner and outer side edges of the poly-V belt near the top idler pulley (important: only treat the
edges of the belt. If the lubricant is applied to the running surface of the belt, this can cause the poly-V belt to slip).
- Start the engine so that the lubricant can spread along the edges of the belt.
* Sufficient for 15 cars, Submit as Local Purchase - KRY00284, Qty 1, handling is included
733
Attachments
Symptoms
Parts
Work units
734
Validity
735
Attachment - Description: Apply Krytox to edges of poly-V belt
Interior - Floor Mat Safety Information

Order No.: S-B-68.00/81
Group: 68
SUBJECT: MY-All, Models All
Floor Mat Safety
We are sure you are aware of recent events that have prompted another OEM to issue recalls involving several million vehicles. One of the issues
being focused on by NHTSA is the possibility that the floor mats in these vehicles may interfere with accelerator or brake pedal movement.
Given the critical safety concerns involved, we'd like to take this opportunity to remind our dealers of the proper procedures for installing floor
mats in our vehicles so they may properly communicate this information to our customers:
^ Any existing floor mats should be removed prior to installing new floor mats. Never install floor mats on top of existing floor mats.
^ Floor mats must be secured using the MB floor mat fixation system. We do not recommend using aftermarket floor mats that are not compatible
with this fixation system. For additional information, please refer to the installation instructions included with floor mat sets.
^ Floor mats are model specific. Only install floor mats designed for a specific model and model year. Do not install floor mats if you are unsure of
the model application.
^ Ensure that the driver's mat is installed in the driver's foot area - passenger mat in the passenger foot area.
736
^ Ensure that floor mats are installed correctly - not upside down!
^ Floor mats should be checked periodically for proper fastening and to insure that the floor mat is not interfering with pedal movement.
^ We strongly recommend only using Genuine Mercedes-Benz floor mats. These are the only floor mats approved for use in Mercedes-Benz
vehicles.
^ Only Genuine Mercedes-Benz floor mats utilize the factory-approved fixation system.
Adhering to these recommendations can help to prevent potentially dangerous situations for our customers. This notice applies to both carpet and
all-season floor mats.
Interior - Creaking Noise From Seat Head Restraints

Noises from head restraint CAK
Version 1
Design group 91.16 Head restraints
Date 03-24-2010
Validity Model series 203, 211, 219, 221 produced up to Wk 41 (2006)
Reason for change Model designation added / Supersedes DTB S-B-91.10/ 112f
Reason for block
Complaint:
Creaking noise from CAK module in head restraint.
Attachments
Cause:
The plastic housings of the 6 pins in the CAK module are too large. This tolerance results in noises.
Further damage code: 91N31
Remedy:
In the case of vehicles produced since calendar week 41/2006, the shafts of the head restraint are oval in shape. This measure has been implemented
in series production.
Procedure in the case of complaints:
Replace head restraint. Do not replace guide sleeves.
Symptoms
737
Work units
738
739
740
Validity
Attachment - Affected area
741
Restraints - Air Bag Durability And Reliability
Date: June 11, 2010
Order No: S-B-91.60/193
Group: 91
Subject:
MY-All, Models All
Airbag Durability and Reliability
The air bag SRS control module (N2/2) does not have a set shelf life and will normally be reliable for the life of a Mercedes-Benz vehicle.
NOTE:
With 164, 216, 221, 251 and newer, the airbag control unit can be reset five times. With models 202, 210 and newer, the airbag control unit can be
reset three times.
Earlier models would have to have their airbag control unit and triggered restrain components changed only after an accident.after an accident.
AT - Electrohydraulic Control Unit Order Notes Update

Date: June 14, 2010
Order No: S-B-27.19/118A
Supercedes: S-B-27.19/118, April 29, 2010
Group: 27
Revision History
a 6/14/10 Procedure 2-3 ordering notes modified
SUBJECT:
MY-All, Transmission 722.9 in Models 164, 171, 203, 204, 207, 209, 211, 212, 215, 216, 219, 220, 221, 230, 251, 463
Ordering Notes for Electrohydraulic Control Unit
The following information clarifies how to determine the correct electrohydraulic control units.
A. Procedure 1a
742
1. Diagnosis on the vehicle is possible:
2. To determine the correct EHS part number, the currently installed EHS should first be read out with the Star diagnosis.
a. Xentry Diagnostics:
^ via the path "Control units view" - "Current quick test" - "Fully integrated transmission control" - "EHS part number".
^ Ordering the new EHS with this read out part number.
b. DAS:
^ "Quick test">"EGS > electronic transmission control serial number".
^ Ordering the new EHS with this read out serial number.
B. Procedure 1b
Diagnosis on the vehicle is no longer possible, as the control unit no longer responds. Therefore, the number must be read off directly by the
EHS and the ordering process is started with this number.
C. Procedure 2
1. Read out part number A 220 270 14 06
2. This part number was replaced by A 220 270 13 06 or by A 220 270 18 06, depending on the vehicle model range.
For this the following must be observed for correct ordering:
Model 209, 211, 215, 219, 220, 230 with transmission 722.901
A 220 270 14 06 replaced by
A 220 270 31 06
Model 209 with transmission 722.902 and engine 642.910 up to 5/31/2007
^ A220 270 14 06 replaced by
^ A 220 270 21 06 replaced by
^ A220 270 29 06
Model 209 with transmission 722.902 and engine 642.910 as of 6/1/2007
A220 270 19 06 replaced by
A220 270 32 06
Model 164, 251 with transmission 722.901
A 220 270 27 06
Model 164, 203 with transmission 722.902
A 220 270 27 06
743
Model 171, 209, 211, 219 and 230.471 with transmission 722.904
A 220 270 27 06
Model 221 with transmission 722.906
A 220 270 27 06
Model 171 with transmission 722.907
A 220 270 27 06
D. Procedure 3
1. Read out the part number A 220 270 12 06
2. For this the following must be observed for correct ordering:
^ Model 219.356, 171.456 with transmission 722.906 up to and including model year 2005 (code 805)
A 220 270 12 06.
^ For all other baumusters/model designations (except 219.356, 171.456) order with the read off part number A 220 270 12 06
A 220 270 31 06
Audio System - Radio Interruption Information

Order No.: S-B-80.57/56
Group: 80
SUBJECT:
MY-All, Models 129, 163, 164, 170, 171, 199, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 219, 220, 221, 230, 251, 463
Interruptions in Radio-Operated Vehicle Systems
In the frequency range of the transmitter key or KEYLESS-GO, many other radio-operated Systems can also be transmitting and with a stronger
signal. Systems such as, radio frequency headphones, radio thermometer, garage door opener, alarm systems, etc. can prevent or interrupt
unlocking, locking, and engine starting via a KEYLESS-GO.
Fortunately, in parallel with radio remote control, most MB vehicles also have infrared remote control, so that even with radio disturbance, the
transmitter key will unlock and lock at short range. Exceptions are the 163 and the 170 as they do not have additional infrared remote control, but
the mechanical key will always work.
Advise customers that taking a vehicle key is always recommended as it is conceivable that a criminal might use a radio interferer to block the
locking of a vehicle. Locking is ensured by 3-signal flashing.
744
Paint - Clearcoat With Higher Scratch Resistance
Date: August 2010
Order No.: S-B-98.00/28
Group: 98
SUBJECT:
Models 164,170,171, 203, 204, 207, 209, 211, 212, 215, 216, 219, 220, 221, 230, 251, 463
Clearcoat Paint Systems with Higher Scratch Resistance
Since June 2002, starting with the model 215, clear paint Systems with higher scratch resistance came into use. The changeover took place in the
following years and was completed by mid 2004.
From June 2002 up to 06/30/2010 with a few exception (see Table) all vehicles with a more scratch resistant clear paint system, are marked with a
"C" in front of the paint code on the model plate.
As since 2005 on all models only the scratch resistant clear paint systems are always used, the identification "C" is deleted as of 7/1/2010.
In the table below, the data for the production changeover and marking are once again listed for the period 2002 up to June 2010.
Special protection vehicles (Guard) were painted with conventional dual-component Systems up to 01/2005 The changeover to the new scratch
resistant systems took place in 02/2005. As of this time all vehicles are also marked with a "C".
In collaboration with all of our approved paint partners suitable paint repair systems have been developed for the new clearcoat paints with
improved scratch resistance and these have been approved after comprehensive on-road testing.
All the paint partners we approve have incorporated the repair instructions and materials to be used in their repair guidelines.
These can be found on the After-Sales paint technology internet page.
The paint specialists of these companies are also available to help you on site, if required. Please remember to ensure without fail, that only these
approved refinish systems are used for paint repair.
745
This also always applies to Mercedes-Benz service operations that out source their paint work to external paint operators.
These Mercedes-Benz service operations are responsible for ensuring that only the approved refinish systems are used.
The application methods have not been changed.
The plastic attachment parts continue to be coated with conventional 2-K-clear coats. In the case of repair we recommend the scratch resistant
repair systems for plastic parts.
The existing sanding and polishing process has been changed. These techniques for scratch resistant paint are described in the work instructions
AR98.00-P-0012A.
The process and auxiliary materials to be used and the required workshop equipment are specified in detail.
Training courses on offer
Please remember that our paint and polish partners offer a wide variety of training courses on repair materials and processes, which are normally
free of charge.
According to our knowledge the training capacities of the paint suppliers are underutilized. We therefore ask you to take advantage of the
qualifications of the paint specialists within the market. This is the only way of ensuring a smooth repair procedure, which provides customer
satisfaction with proven Mercedes-Benz quality.
If you have any questions contact your Technical Representative.
For more information please refer the table above.
1
Computers and Control Systems: Initial Inspection and Diagnostic Overview
GF07.10-P-1030V Smooth Engine Running Analysis, Function
To protect the catalytic converters from thermal overload through combustion misfirings and in order to keep the exhaust emission values, the
engine operation is continuously monitored. If smooth engine running analysis in the ME-SFI [ME] control unit detects combustion misfiring, the
fuel injection valves affected are no longer actuated after a certain number of misfiring.
The following combustion misfiring causes are detected:

- Ignition system
- Injection system
- Engine, mechanical aspects (e. g. fresh air, valve seat, valve springs)
- Fuel shortage
For smooth engine running analysis the signal supplied by the Hall sensor is analyzed exactly in respect of time uniformity between the individual
2
combustions by means of a comprehensive mathematical method.
Each individual combustion must produce a characteristic acceleration at the flywheel. In case of combustion misfirings, the flywheel mass rotates
slightly slower until the next ignition (short variations in torque).
The following factors are taken into account:

- Engine speed, engine load
- Engine temperature
- Recognition of uneven road surface
- Synchronization of fuel injection and firing order
- Fuel reserve signal
- Sensor wheel adaptation takes place.
1. Engine speed, engine load

A comparative value for the time between two combustions is calculated from these two parameters.
2. Engine temperature
If engine is cold, several combustion misfires are allowed temporarily.
3. Recognition of uneven road surface

The wheel speed signal is sent via the CAN data bus from the traction systems control unit (even run). On poor road surfaces (washboard
roads) the smooth engine running analysis is set less sensitive. Vibrations transmitted through the drive train may have a negative influence
on the smooth operation analysis at certain engine speeds and load states.
4. Synchronization of fuel injection and firing order

The cylinder recognition is required for fault storing and evaluation.
5. Fuel reserve signal

If combustion misfires are detected, a fault is stored if the fuel tank level is too low. Combustion misfires due to fuel starvation are detected
via this additional information.
6. Sensor wheel adaptation

After sensor adaptation is performed, the smooth engine running analysis becomes more sensitive and can be adapted to the specific smooth
running properties of the engine.
During a deceleration phase (uniform smooth running) the smooth running analysis stores the particular smooth running properties of the
engine. These are required as a comparison parameter for misfire detection.
Misfire counter
The following information is entered in the fault memory:

- Total of all misfirings
- Misfiring of specific cylinders
- Misfiring at "emission limit"
- Misfiring "harmful to catalytic converter"
1
Computers and Control Systems: Reading and Clearing Diagnostic Trouble Codes
AD00.00-P-2000-04A Connect STAR DIAGNOSIS and read out fault memory
2
3
1 Connect STAR DIAGNOSIS (0100) to diagnostic socket, on the data link connector (X11/4) or on the data link connector (1.3) (X11/22).
2 Switch on ignition.
3 Start the Diagnosis Assistance System.
4 In the "Model" menu, select the sub menu "Other model series".
5 Go through the instructions on the screen:
^ Enter the control unit version
^ Read out fault memory and erase
^ Readout actual values
^ Perform actuations
^ Adaptation of control units
6 Disconnect STAR DIAGNOSIS (0100).
Stored faults which may be caused by disconnecting cables or by simulation during testing operations must be deleted in the diagnostic
trouble code memory following completion of the operations.
1
Computers and Control Systems: Component Tests and General Diagnostics
AH07.00-P-3003-01A Notes Regarding Test Conditions When Testing Engine Output and Exhaust
Gas
AH07.00-P-3003-01A Notes regarding test conditions when testing engine output and exhaust gas
Traffic regulations/test conditions

^ Secure front wheels, (retainer locks with 100 mm distance in front of front wheels).
^ Check rear wheel tire pressure, adjust to specified pressure.
^ Check trunk capacity, remove any heat-sensitive and heavy objects.
^ Cool off vehicle with blower (Minimum output 15,000 m3/h). Direct air flow at radiator and underside of vehicle (oil pan, exhaust, 3-way
catalytic converter, tires). Maintain a distance of approx. 1 m between blower and vehicle.
^ The driven period is to be limited solely to the time required to read off the instruments (approx. 5 seconds for the output dynamometer;
approx. 20 seconds for the exhaust test).
^ On vehicles fitted with a 3-way catalytic converter the work procedure is to be interrupted immediately when any signs of combustion
interference appear, because otherwise the 3-way catalytic converter may be damaged.
Unless an explicit performance complaint has been issued, it is enough to perform the test at max. 100 km/h or 120 km/h.
Comply with test specifications and the following sequence:

^ Warm up
^ Performance test Continue for exhaust emission test only
^ Exhaust test at wide-open throttle, upper part throttle, lower part throttle
^ Idle speed
^ Exhaust test at idling
The full-throttle tests (power output, exhaust) are to be performed immediately after warming the engine up, as long as the tire pressure is still low,
as the temperature rises most markedly during these measurements.
Two repetitive measurements are permitted after adjustment operations. A break of 45 minutes must be made before any further measurements are
made to allow the overall major assembly to cool down.
AH42.00-P-0001-06A Notes on Testing Electronic Components and Systems For Damage Resulting
From an Accident
AH42.00-P-0001-06A Notes on testing electronic components and systems for damage resulting from an accident
Treating BAS parts in crashed vehicles

The brake booster must be replaced if, owing to the extent of damage to the vehicle, the brake booster has been displaced from its original
position or shows signs of contact with other components. Indications of this are e.g.:
^ Hydraulic lines kinked
^ leaking connections at master brake cylinders
^ Cables or plug connections damaged
^ brake booster housing shows signs of damage
The system should always be checked in accordance with the Diagnosis Manual.
AH42.00-P-0001-06B Notes on Testing Electronic Components and System For Damage Resulting
From an Accident
AH42.00-P-0001-06B Notes on testing electronic components and system for damage resulting from an accident
Handling ESP/SBC parts on vehicles involved in an accident

If, because of the extent of the damage to the vehicle or the position and external appearance of the hydraulic unit after the accident, it is obvious
that the hydraulic unit has sustained a heavy shock, it must be renewed.
Indications of this are e.g.:

^ Hydraulic lines kinked
^ Connections on hydraulic unit leaking
^ Cables or plug connections damaged
^ Metal block of hydraulic unit shows signs of damage
^ Hydraulic unit detached from its bracket and cannot be easily reinstalled
Even if none of these are applicable the system must still be subjected to a rigorous function test.
The solenoid valves and pump must be checked with the help of the corresponding test steps of the diagnosis manual or the Diagnosis Assistance
System (DAS).
2
Testing and repair work

^ All operations which concern the electronic accelerator (EFP) are described in the group 07 (ME-SFI, Engine control monolith, common rail
diesel injection).
1
Computers and Control Systems: Mode 6 Data
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A L L Diagnostic Trouble Codes ( DTC ): Diagnostic Trouble Code Descriptions
ME 9.7 - Engine 272 [1 of 3]

ME 9.7 - Engine 272 [1 of 3]
P-Code MB DTC Brief Description
P0010 279 Component Y49/5 (Right camshaft intake solenoid) has an open circuit in the wiring. (P0010)
P0010 740 Continuous camshaft adjustment ( RIGHT ): Incorrect position of the intake camshaft (P0010)
P0013 67 Component Y49/7 (Right camshaft exhaust solenoid) has an open circuit in the wiring. (P0013)
P0013 71 Component Y49/6 (Left camshaft exhaust solenoid) has an open circuit in the wiring. (P0013)
P0014 59 Continuous camshaft adjustment ( RIGHT ): Incorrect position of the exhaust camshaft (P0014)
P0016 1205 Constant adjustment of intake camshaft of right cylinder bank in direction 'Advanced' (P0016)
P0016 1206 Constant adjustment of intake camshaft of right cylinder bank in direction 'Retarded' (P0016)
P0016 1207 Constant adjustment of intake camshaft of right cylinder bank in direction 'Advanced' (P0016)
P0016 1208 Constant adjustment of intake camshaft of right cylinder bank in direction 'Retarded' (P0016)
P0017 1197 Constant adjustment of exhaust camshaft of right cylinder bank in direction 'Advanced' (P0017)
P0017 1198 Constant adjustment of exhaust camshaft of right cylinder bank in direction 'Retarded' (P0017)
P0017 1199 Constant adjustment of exhaust camshaft of right cylinder bank in direction 'Advanced' (P0017)
P0017 1200 Constant adjustment of exhaust camshaft of right cylinder bank in direction 'Retarded' (P0017)
P0018 1209 Constant adjustment of intake camshaft of left cylinder bank in direction 'Advanced' (P0018)
P0018 1210 Constant adjustment of intake camshaft of left cylinder bank in direction 'Retarded' (P0018)
P0018 1211 Constant adjustment of intake camshaft of left cylinder bank in direction 'Advanced' (P0018)
P0018 1212 Constant adjustment of intake camshaft of left cylinder bank in direction 'Retarded' (P0018)
P0019 1201 Constant adjustment of exhaust camshaft of left cylinder bank in direction 'Advanced' (P0019)
P0019 1202 Constant adjustment of exhaust camshaft of left cylinder bank in direction 'Retarded' (P0019)
P0019 1203 Constant adjustment of exhaust camshaft of left cylinder bank in direction 'Advanced' (P0019)
P0019 1204 Constant adjustment of exhaust camshaft of left cylinder bank in direction 'Retarded' (P0019)
P0020 283 Component Y49/4 (Left camshaft intake solenoid) has an open circuit in the wiring. (P0020)
P0020 744 Continuous camshaft adjustment ( LEFT ): Incorrect position of the intake camshaft (P0020)
P0024 63 Continuous camshaft adjustment ( LEFT ): Incorrect position of the exhaust camshaft (P0024)
P0030 443 Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Open circuit (P0030)
P0031 442 Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Short circuit to ground (P0031)
P0032 441 Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Short circuit to positive (P0032)
P0036 427 Heating of component G3/6 (Right O2 sensor, after TWC [KAT]) : Open circuit (P0036)
P0037 426 Heating of component G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit to ground (P0037)
P0038 424 Heating of component G3/5 (Left O2 sensor, after TWC [KAT]) : Heating capacity is too low. (P0038)
P0040 600 O2 sensors upstream TWC : Plug connections of the O2 sensors are wrongly connected. (P0040)
P0041 1360 O2 sensors downstream TWC : Plug connections of the O2 sensors are wrongly connected. (P0041)
P0050 447 Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Open circuit (P0050)
P0051 446 Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Short circuit to ground (P0051)
P0052 445 Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Short circuit to positive (P0052)
P0056 431 Heating of component G3/5 (Left O2 sensor, after TWC [KAT]) : Open circuit (P0056)
P0057 430 Heating of component G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit to ground (P0057)
P0058 429 Heating of component G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit to positive (P0058)
P0068 1349 The measured air mass is implausible compared to the position of the throttle valve. (P0068)
P0071 1599 Plausibility error between signal of temperature sensor in intake pipe and signal of outside temperature sensor (P0071)
P0071 1600 Plausibility error between signal of temperature sensor in intake pipe and signal of outside temperature sensor (P0071)
P0072 2070 Component B14 (Ambient temperature display temperature sensor) has a short circuit to ground. (P0072)
P0073 2069 Component B14 (Ambient temperature display temperature sensor) has a short circuit to positive. (P0073)
P0101 2181 The air mass measured by hot film MAF sensor is too low. / The cycle duration of the HFM signal is too long. (P0101)
P0101 2182 The air mass measured by the hot film MAF sensor is too high. / The cycle duration of the HFM signal is too short.
(P0101)
P0102 1347 B2/5 (Hot film mass air flow sensor) : Open circuit / Short circuit to ground or to positive (P0102)
P0104 1345 B2/5 (Hot film mass air flow sensor) : Loose contact with low frequency (P0104)
P0104 1346 B2/5 (Hot film mass air flow sensor) : Loose contact with high frequency (P0104)
P0106 1913 B28 (Pressure sensor) : Implausible value (P0106)
2
P0107 1910 B28 (Pressure sensor) : Short circuit to ground (P0107)
P0108 1909 B28 (Pressure sensor) : Short circuit to positive or open circuit (P0108)
P0111 2029 The value of component B2/5b1 (Intake air temperature sensor) is implausible. (P0111)
P0111 2030 The value of component B2/5b1 (Intake air temperature sensor) is implausible. (P0111)
P0111 2032 The value of component B2/5b1 (Intake air temperature sensor) does not change. (P0111)
P0112 2025 Component B2/5b1 (Intake air temperature sensor) has a short circuit to ground. (P0112)
P0113 2026 Component B2/5b1 (Intake air temperature sensor) has a short circuit to positive or an open circuit. (P0113)
P0115 405 Component Y16/2 (Heating system shutoff valve) has a short circuit to positive. (P0115)
P0115 406 Component Y16/2 (Heating system shutoff valve) has a short circuit to ground. (P0115)
P0115 407 Component Y16/2 (Heating system shutoff valve) has an open circuit in the wiring. (P0115)
P0116 860 B11/4 (Coolant temperature sensor) : Shunt fault / Sensor characteristic curve (P0116)
P0116 1461 B11/4 (Coolant temperature sensor) : Coolant temperature is too high. (P0116)
P0116 1462 B11/4 (Coolant temperature sensor) : Coolant temperature is too low. (P0116)
P0116 1463 The engine temperature from the engine control module is implausible. Signal voltage is implausible. (P0116)
P0116 1464 The engine temperature from the engine control module is implausible. Shunt fault / Sensor characteristic curve (P0116)
P0117 858 B11/4 (Coolant temperature sensor) : Short circuit to positive / Open circuit (P0117)
P0117 859 B11/4 (Coolant temperature sensor) (P0117)
P0118 857 B11/4 (Coolant temperature sensor) : Short circuit to ground (P0118)
P0118 2066 Component B11/4 (Coolant temperature sensor) has a short circuit to positive or an open circuit. (P0118)
P0122 162 M16/6 (Throttle valve actuator) : Actual value potentiometer 1 : Short circuit to ground (P0122)
P0123 161 M16/6 (Throttle valve actuator) : Actual value potentiometer 1 : Short circuit to positive or open circuit (P0123)
P0128 856 Component Y110 (Three-disk thermostat valve) jams in opened position. : Coolant temperature rises too slowly. (P0128)
P0130 573 G3/4 (Right O2 sensor, before TWC [KAT]) : Voltage is too high. (P0130)
P0130 574 G3/4 (Right O2 sensor, before TWC [KAT]) : Voltage is too low. (P0130)
P0135 433 Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Short circuit to positive / Resistance of sensor heater
too low (P0135)
P0135 436 Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Heating capacity is too low. (P0135)
P0136 550 G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit to ground (P0136)
P0136 552 G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit between signal line and line to sensor heater (P0136)
P0138 549 G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit to positive / Resistance of sensor heater too low (P0138)
P0139 511 G3/6 (Right O2 sensor, after TWC [KAT]) : Aging (P0139)
P0140 551 G3/6 (Right O2 sensor, after TWC [KAT]) : Discontinuity of signal line (P0140)
P0141 420 Heating of component G3/6 (Right O2 sensor, after TWC [KAT]) : Heating capacity is too low. (P0141)
P0141 425 Heating of component G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit to positive (P0141)
P0150 577 G3/3 (Left O2 sensor, before TWC [KAT]) : Voltage is too high. (P0150)
P0150 578 G3/3 (Left O2 sensor, before TWC [KAT]) : Voltage is too low. (P0150)
P0155 437 Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Short circuit to positive / Resistance of sensor heater
too low (P0155)
P0155 440 Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Heating capacity is too low. (P0155)
P0156 554 G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit to ground (P0156)
P0156 556 G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit between signal line and line to sensor heater (P0156)
P0158 553 G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit to positive / Resistance of sensor heater too low (P0158)
P0159 515 G3/5 (Left O2 sensor, after TWC [KAT]) : Aging (P0159)
P0160 555 G3/5 (Left O2 sensor, after TWC [KAT]) : Discontinuity of signal line (P0160)
P0170 1047 Lambda control, before TWC right : Control implausible (P0170)
P0170 1048 Lambda control, before TWC right (P0170)
P0171 337 Self-adaptation of mixture formation for enrichment at partial load for the right cylinder bank is above the permissible
limit. (P0171)
P0171 745 Self-adaptation of mixture formation for enrichment at idle for the right cylinder bank is above the permissible limit.
(P0171)
P0171 1046 Lambda control, before TWC right : Lambda control is at rich stop. (P0171)
P0172 338 Self-adaptation of mixture formation for enleanment at partial load for the right cylinder bank is below the permissible
limit. (P0172)
P0172 746 Self-adaptation of mixture formation for enleanment at idle for the right cylinder bank is below the permissible limit.
(P0172)
P0172 1045 Lambda control, before TWC right : Lambda control is at lean stop. (P0172)
P0173 1051 Lambda control, before TWC left : Control implausible (P0173)
P0173 1052 Lambda control, before TWC left (P0173)
P0174 341 Self-adaptation of mixture formation for enrichment at partial load for the left cylinder bank is above the permissible limit.
(P0174)
P0174 749 Self-adaptation of mixture formation for enrichment at idle for the left cylinder bank is above the permissible limit.
(P0174)
P0174 1050 Lambda control, before TWC left : Lambda control is at lean stop. (P0174)
P0175 342 Self-adaptation of mixture formation for enleanment at partial load for the left cylinder bank is below the permissible limit.
(P0175)
P0175 750 Self-adaptation of mixture formation for enleanment at idle for the left cylinder bank is below the permissible limit.
(P0175)
3
P0175 1049 Lambda control, before TWC left : Lambda control is at rich stop. (P0175)
P0201 303 The injection valve output stage of cylinder 1 detects a line discontinuity. (P0201)
P0219 E1821 Fault present in control module Transmission (P0219)
P0222 166 M16/6 (Throttle valve actuator) : Actual value potentiometer 2 : Short circuit to ground (P0222)
P0223 165 M16/6 (Throttle valve actuator) : Actual value potentiometer 2 : Short circuit to positive or open circuit (P0223)
P0261 302 The injection valve output stage of cylinder 1 detects a short circuit to ground. (P0261)
P0262 301 The injection valve output stage of cylinder 1 detects a short circuit to positive. (P0262)
P0300 629 Misfiring (P0300)
P0301 633 Misfiring of cylinder 1 : Damages TWC (P0301)
P0301 634 Misfiring of cylinder 1 : Worsening of exhaust emission values (P0301)
P0301 636 Misfiring of cylinder 1 : Worsening of exhaust emission values after engine start (P0301)
P0324 493 The knock control has a malfunction. (P0324)
P0325 504 Component A16/1 (knock sensor 1, right) has an electrical fault. (P0325)
P0327 502 Component A16/1 (knock sensor 1, right) has a short circuit to ground. (P0327)
P0328 501 Component A16/1 (knock sensor 1, right) has a short circuit to positive. (P0328)
P0330 508 Component A16/2 (knock sensor 2, left) has an electrical fault. (P0330)
P0332 506 Component A16/2 (knock sensor 2, left) has a short circuit to ground. (P0332)
P0333 505 Component A16/2 (knock sensor 2, left) has a short circuit to positive. (P0333)
P0335 703 B70 (Crankshaft Hall sensor) : Check wiring of signal line and voltage. (P0335)
P0336 117 Number of teeth on sensor rotor too high or too low or wiring error (P0336)
P0336 119 No tooth space on sensor rotor detected or wiring error (P0336)
P0336 120 Tooth space on sensor rotor temporarily not detected or wiring error (P0336)
P0339 704 B70 (Crankshaft Hall sensor) : Check wiring of signal line and voltage. (P0339)
P0340 771 The camshaft Hall sensors were not detected. ( B6/4 (Left intake camshaft Hall sensor) | B6/5 (Right intake camshaft Hall
sensor) | B6/6 (Left exhaust camshaft Hall sensor) | B6/7 (Right exhaust camshaft Hall sensor) ) (P0340)
P0341 755 B6/5 (Right intake camshaft Hall sensor) : The alternation frequency of the signal value is implausible. (P0341)
P0341 756 B6/5 (Right intake camshaft Hall sensor) : The time of the signal value change is implausible. (P0341)
P0342 754 B6/5 (Right intake camshaft Hall sensor) : Short circuit to ground (P0342)
P0343 753 B6/5 (Right intake camshaft Hall sensor) : Short circuit to positive or open circuit (P0343)
P0346 759 B6/4 (Left intake camshaft Hall sensor) : The alternation frequency of the signal value is implausible. (P0346)
P0346 760 B6/4 (Left intake camshaft Hall sensor) : The time of the signal value change is implausible. (P0346)
P0347 758 B6/4 (Left intake camshaft Hall sensor) : Short circuit to ground (P0347)
P0348 757 B6/4 (Left intake camshaft Hall sensor) : Short circuit to positive or open circuit (P0348)
P0351 981 Ignition coil primary current of cylinder 1 is too high. (P0351)
P0351 982 Ignition coil primary current of cylinder 1 is too low. (P0351)
4
P0351 983 Signal fault of ignition coil diagnosis of cylinder 1 (P0351)
P0351 984 Ignition coil primary current of cylinder 1 alternates between too high and too low. (P0351)
P0351 1015 The control line to the ignition coil of cylinder 1 has an open circuit. (P0351)
P0351 1016 The output stage to ignition coil of cylinder 1 detects an electrical fault. (P0351)
P0366 763 B6/7 (Right exhaust camshaft Hall sensor) : The alternation frequency of the signal value is implausible. (P0366)
P0366 764 B6/7 (Right exhaust camshaft Hall sensor) : The time of the signal value change is implausible. (P0366)
P0367 762 B6/7 (Right exhaust camshaft Hall sensor) : Short circuit to ground (P0367)
P0368 761 B6/7 (Right exhaust camshaft Hall sensor) : Short circuit to positive or open circuit (P0368)
P0391 767 B6/6 (Left exhaust camshaft Hall sensor) : The alternation frequency of the signal value is implausible. (P0391)
P0391 768 B6/6 (Left exhaust camshaft Hall sensor) : The time of the signal value change is implausible. (P0391)
P0392 766 B6/6 (Left exhaust camshaft Hall sensor) : Short circuit to ground (P0392)
P0393 765 B6/6 (Left exhaust camshaft Hall sensor) : Short circuit to positive or open circuit (P0393)
P0410 810 Malfunction of secondary air injection at right bank of cylinders (function chain) (P0410)
P0410 814 Malfunction of secondary air injection at left bank of cylinders (function chain) (P0410)
P0412 1071 Y32 (Air pump switchover valve) : Open circuit (P0412)
P0413 1069 Y32 (Air pump switchover valve) : Short circuit to positive (P0413)
P0414 1070 Y32 (Air pump switchover valve) : Short circuit to ground (P0414)
P0418 1067 Relay for air pump : Open circuit (P0418)
P0422 942 The efficiency of the right catalytic converter is insufficient. (function chain) (P0422)
P0422 946 The efficiency of the left catalytic converter is insufficient. (function chain) (P0422)
P0442 1081 Purge control system has slight leak / Leak in hose connection or shutoff valve of activated charcoal canister (P0442)
P0444 851 Y58/1 (Purge control valve) : Open circuit / Switchover valve permanently closed (P0444)
P0446 959 Component Y58/4 (Activated charcoal canister shut-off valve) has an open circuit in the wiring. (P0446)
P0446 1097 Mechanical defect or component Y58/4 (Activated charcoal canister shut-off valve) is permanently open (P0446)
P0446 1098 Mechanical defect or component Y58/4 (Activated charcoal canister shut-off valve) is permanently open (P0446)
P0447 957 Component Y58/4 (Activated charcoal canister shut-off valve) has a short circuit to positive. (P0447)
P0448 958 Component Y58/4 (Activated charcoal canister shut-off valve) has a short circuit to ground. (P0448)
P0451 1301 B4/3 (Fuel tank pressure sensor) : Short circuit to positive (P0451)
P0451 1302 B4/3 (Fuel tank pressure sensor) : Short circuit to ground (P0451)
P0451 1303 B4/3 (Fuel tank pressure sensor) : Open circuit (P0451)
P0451 1304 B4/3 (Fuel tank pressure sensor) : Signal implausible (P0451)
ME 9.7 - Engine 272 [2 of 3]
ME 9.7 - Engine 272 [2 of 3]
P0452 970 Tank pressure sensor diagnosis : Short circuit to ground (P0452)
P0453 969 Tank pressure sensor diagnosis : Short circuit to positive (P0453)
P0455 1085 Major leak in purge system / Hose in system not connected or filler cap open (P0455)
5
P0456 1089 Purge control system has a slight leak (minor leak) (P0456)
P0458 850 Y58/1 (Purge control valve) : Short circuit to ground / Switchover valve permanently open (P0458)
P0459 849 Y58/1 (Purge control valve) : Short circuit to positive / Switchover valve permanently closed (P0459)
P0460 353 B4 (Fuel level sensor) (P0460)
P0506 2190 The idle speed is too low during catalytic converter warm-up. (P0506)
P0507 2189 The idle speed is too high during catalytic converter warm-up. (P0507)
P0513 E1124 Start enable of DAS not sent : See fault codes in control unit EZS (P0513)
P0562 866 Voltage supply of component Motor electronics / Battery voltage too low (P0562)
P0562 E1797 Fault present in control module Transmission : Battery voltage too low (P0562)
P0563 865 Voltage supply of component Motor electronics / Battery voltage too high (P0563)
P0563 E1793 Fault present in control module Transmission : Battery voltage too high (P0563)
P0597 155 Component Y110 (Three-disk thermostat valve) has an open circuit in the wiring. (P0597)
P0598 154 Component Y110 (Three-disk thermostat valve) has a short circuit to ground. (P0598)
P0599 153 Component Y110 (Three-disk thermostat valve) has a short circuit to positive. (P0599)
P0604 916 Control module has an internal error. (P0604)
P0607 435 The electronic analysis system for the O2 sensor in the engine control unit is defective. (P0607)
P0607 439 The electronic analysis system for the O2 sensor in the engine control unit is defective. (P0607)
P0607 868 Voltage supply of component Motor electronics / Battery voltage too low for ADC (P0607)
P0620 365 Operational fault of component G2 (generator) (P0620)
P0638 193 M16/6 (Throttle valve actuator) : Mechanical fault (P0638)
P0638 212 M16/6 (Throttle valve actuator) : The component was replaced without performing throttle valve adaptation. (P0638)
P0638 228 M16/6 (Throttle valve actuator) : Throttle valve jamming (iced up) (P0638)
P0651 93 B37 (Accelerator pedal sensor) : Power supply (P0651)
P0726 876 The input signal of the engine speed has a malfunction. (P0726)
P1999 2185 The idle speed with warm engine is above the permissible range limit. (P1999)
P1999 2186 The idle speed with warm engine is below the permissible range limit. (P1999)
P2004 521 Diagnosis of tumble flap 'Intake manifold' : Short circuit to ground of sensor lines / Tumble flap shafts stick in the actuated
position. (P2004)
P2005 524 Diagnosis of tumble flap 'Intake manifold' : Short or open circuit in sensor lines / Mechanical fault of one actuating lever /
Sensor faulty, replace sensor. (P2005)
P2006 522 Diagnosis of tumble flap 'Intake manifold' : Open circuit of sensor lines / Tumble flap shafts stick in the nonactuated
position. (P2006)
P2008 1075 Y22/6 (variable intake manifold switchover valve) : Open circuit (P2008)
P2008 1187 Y22/9 (Intake manifold tumble flap switchover valve) : Open circuit (P2008)
P2009 1074 Y22/6 (variable intake manifold switchover valve) : Short circuit to ground (P2009)
P2009 1186 Y22/9 (Intake manifold tumble flap switchover valve) : Short circuit to ground (P2009)
6
P2010 1073 Y22/6 (variable intake manifold switchover valve) : Short circuit to positive (P2010)
P2010 1185 Y22/9 (Intake manifold tumble flap switchover valve) : Short circuit to positive (P2010)
P2072 1313 Throttle valve jamming (iced up) (P2072)
P2088 278 Component Y49/5 (Right camshaft intake solenoid) has a short circuit to ground. (P2088)
P2089 277 Component Y49/5 (Right camshaft intake solenoid) has a short circuit to positive. (P2089)
P2090 66 Component Y49/7 (Right camshaft exhaust solenoid) has a short circuit to ground. (P2090)
P2090 70 Component Y49/6 (Left camshaft exhaust solenoid) has a short circuit to ground. (P2090)
P2091 65 Component Y49/7 (Right camshaft exhaust solenoid) has a short circuit to positive. (P2091)
P2091 69 Component Y49/6 (Left camshaft exhaust solenoid) has a short circuit to positive. (P2091)
P2092 282 Component Y49/4 (Left camshaft intake solenoid) has a short circuit to ground. (P2092)
P2093 281 Component Y49/4 (Left camshaft intake solenoid) has a short circuit to positive. (P2093)
P2101 185 M16/6 (Throttle valve actuator) : Output stage (P2101)
P2101 200 M16/6 (Throttle valve actuator) : Position Throttle valve (P2101)
P2101 216 M16/6 (Throttle valve actuator) : Throttle valve adaptation is faulty. (P2101)
P2122 77 Check potentiometer of component B37 (Accelerator pedal sensor). Hall sensor 1 : Short circuit to ground or open circuit
(P2122)
P2123 73 Check potentiometer of component B37 (Accelerator pedal sensor). Hall sensor 1 : Short circuit to positive (P2123)
P2127 85 Check potentiometer of component B37 (Accelerator pedal sensor). Hall sensor 2 : Short circuit to ground or open circuit
(P2127)
P2128 81 Check potentiometer of component B37 (Accelerator pedal sensor). Hall sensor 2 : Short circuit to positive (P2128)
P2135 160 M16/6 (Throttle valve actuator) : Actual value potentiometer 1 or 2 has failed. (P2135)
P2135 164 M16/6 (Throttle valve actuator) : There is a comparison error between actual value potentiometers 1 and 2. (P2135)
P2135 168 M16/6 (Throttle valve actuator) : There is a comparison error between actual value potentiometers 2 and 1. (P2135)
P2138 89 B37 (Accelerator pedal sensor) : Voltage of Hall sensor 1 does not agree with voltage of Hall sensor 2. (P2138)
P2138 904 The values from the position sensors of the accelerator pedal are implausible in relation to each other. (P2138)
P2158 E0925 CAN signal 'Vehicle speed at front axle' from control unit Traction systems is implausible. (P2158)
P2158 E0927 CAN signal 'Vehicle speed at front axle' from control unit Traction systems is implausible. (P2158)
P2176 204 The safety fuel shutoff is active. (P2176)
P2176 217 M16/6 (Throttle valve actuator) : The throttle valve is jamming or is stiff. (P2176)
P2176 218 M16/6 (Throttle valve actuator) : The throttle valve is jamming or is stiff. (P2176)
P2176 224 M16/6 (Throttle valve actuator) : Perform throttle valve adaptation. (P2176)
P2195 775 The signal of the oxygen sensor upstream of the catalytic converter of the right cylinder bank is shifted towards 'Lean'.
(P2195)
P2196 776 The signal of the oxygen sensor upstream of the catalytic converter of the right cylinder bank is shifted towards 'Rich'.
(P2196)
P2197 779 The signal of the oxygen sensor upstream of the catalytic converter of the left cylinder bank is shifted towards 'Lean'.
(P2197)
P2198 780 The signal of the oxygen sensor upstream of the catalytic converter of the left cylinder bank is shifted towards 'Rich'.
(P2198)
P2227 1365 Sensor 'Ambient pressure' in control module Motor electronics : Implausible value (P2227)
P2228 1362 Sensor 'Ambient pressure' in control module Motor electronics (P2228)
P2229 1361 Sensor 'Ambient pressure' in control module Motor electronics (P2229)
P2237 565 G3/4 (Right O2 sensor, before TWC [KAT]) : Voltage is too high. (P2237)
P2237 567 G3/4 (Right O2 sensor, before TWC [KAT]) : Open circuit (P2237)
P2237 568 G3/4 (Right O2 sensor, before TWC [KAT]) : Signal voltage is implausible. (P2237)
P2240 569 G3/3 (Left O2 sensor, before TWC [KAT]) : Voltage is too high. (P2240)
P2240 571 G3/3 (Left O2 sensor, before TWC [KAT]) : Open circuit (P2240)
P2240 572 G3/3 (Left O2 sensor, before TWC [KAT]) : Signal voltage is implausible. (P2240)
P2257 1066 Relay for air pump : Short circuit to ground (P2257)
P2258 1065 Relay for air pump : Short circuit to positive (P2258)
7
P2279 620 Check intake tract for unmetered air. (P2279)
P2300 1014 The control line to the ignition coil of cylinder 1 has a short circuit to ground. (P2300)
P2301 1013 The control line to the ignition coil of cylinder 1 has a short circuit to positive. (P2301)
P2414 908 G3/4 (Right O2 sensor, before TWC [KAT]) : Signal implausible (P2414)
P2415 912 G3/3 (Left O2 sensor, before TWC [KAT]) : Signal implausible (P2415)
P2421 1077 Mechanical defect or component Y58/1 (Purge control valve) is permanently open (P2421)
P2421 1078 Mechanical defect or component Y58/1 (Purge control valve) is permanently open (P2421)
P2422 954 Mechanical defect or component Y58/4 (Activated charcoal canister shut-off valve) permanently closed (P2422)
P2440 817 The secondary air valve (cylinder bank 1) is jammed open. (P2440)
P2442 821 The secondary air valve (cylinder bank 2) is jammed open. (P2442)
P2505 1105 The voltage at relay 'Circuit 87' is too high. (P2505)
P2505 1106 The voltage at relay 'Circuit 87' is too low. (P2505)
P2505 1108 The voltage at relay 'Circuit 87' is too low. (P2505)
P2539 2157 Component B4/7 (Fuel pressure sensor) has an electrical fault. (P2539)
P2541 2173 Component B4/3 (Fuel tank pressure sensor) has a short circuit to ground. (P2541)
P2542 2169 Component B4/3 (Fuel tank pressure sensor) has a short circuit to positive. (P2542)
P2610 E1593 The engine off time has an implausible value. (P2610)
- 230 Due to a possible leak in the intake air system, an implausible signal was received from oxygen sensor 1 (cylinder bank
1).
- 234 Due to a possible leak in the intake air system, an implausible signal was received from oxygen sensor 1 (cylinder bank
2).
- 237 The request for fan output is implausible.
- 327 This fault can be ignored and erased.
- 449 The electronic analysis system for the O2 sensor in the engine control unit is defective. (P064D)
- 453 The electronic analysis system for the O2 sensor in the engine control unit is defective. (P064E)
- 485 Power output limited because of excessively high temperature of coolant
- 489 Relay 'Fuel pump'
- 537 B2/5 (Hot film mass air flow sensor)
8
- 693 M4/7 (Engine and AC electric suction fan with integrated control) : Output stage
- 773 The signal of the oxygen sensor upstream of the catalytic converter of the right cylinder bank is shifted towards 'Lean'.
(P2A00)
- 774 The signal of the oxygen sensor upstream of the catalytic converter of the right cylinder bank is shifted towards 'Rich'.
(P2A00)
- 777 The signal of the oxygen sensor upstream of the catalytic converter of the left cylinder bank is shifted towards 'Lean'.
(P2A03)
- 778 The signal of the oxygen sensor upstream of the catalytic converter of the left cylinder bank is shifted towards 'Rich'.
(P2A03)
- 872 The torque calculation of the control unit has a malfunction. (P061B)
- 940 S9/1 (Stop lamp switch)
- 1061 The load limit is active.
- 1101 B14 (Ambient temperature display temperature sensor) : Short circuit to positive
- 1102 B14 (Ambient temperature display temperature sensor) : Short circuit to ground
- 1103 B14 (Ambient temperature display temperature sensor) : Open circuit in wiring
- 1104 B14 (Ambient temperature display temperature sensor) : Plausibility error
- 1305 Component Y10/1 (Power steering pump pressure regulator valve) has a short circuit to positive.
- 1306 Component Y10/1 (Power steering pump pressure regulator valve) has a short circuit to ground.
- 1307 Component Y10/1 (Power steering pump pressure regulator valve) has an open circuit in the wiring.
- 1337 Alternator serial interface
- 1367 Control module has an internal error.
- 1389 Air injection diagnosis
- 1425 Wheel speed signal is implausible.
- 1857 Ratio of HFM signal to intake manifold pressure is too high.
- 1858 Ratio of HFM signal to intake manifold pressure is too low.
- 1921 SBC : Undervoltage supply
- 2013 CAN bus OFF : Short circuit Engine CAN bus
- 2017 CAN bus OFF : Short circuit Powertrain-Bus
- 2021 CAN bus OFF : Short circuit Engine CAN bus
- 2037 Fault during the mixture adaptation (multiplicative or additive) bank 1
- 2041 Fault during the mixture adaptation (multiplicative or additive) bank 2
- 2045 Physical fill level fault: upper limit exceeded
- 2046 Physical fill level fault: upper limit exceeded (tank 2)
- 2048 Physical fill level fault: signal implausible
- 2053 PremAir sensor : Short circuit to positive
- 2054 PremAir sensor : Short circuit to ground
- 2056 PremAir sensor has exceeded the upper range limit.
- 2060 Wrong installation location of the PremAir sensors
- 2064 Coding of the PremAir sensors is implausible.
- 2065 Component B11/4 (Coolant temperature sensor) has a short circuit to ground.
- 2071 B14 (Ambient temperature display temperature sensor) : No CAN message. (U0155)
- 2089 The mixture in the right cylinder bank is too lean in the partial load range.
ME 9.7 - Engine 272 [3 of 3]
ME 9.7 - Engine 272 [3 of 3]
- 2090 The mixture in the right cylinder bank is too rich in the partial load range.
- 2091 The mixture in the right cylinder bank is too lean when idling.
- 2092 The mixture in the right cylinder bank is too rich when idling.
- 2093 The mixture in the left cylinder bank is too lean in the partial load range.
- 2094 The mixture in the left cylinder bank is too rich in the partial load range.
- 2095 The mixture in the left cylinder bank is too lean when idling.
- 2096 The mixture in the left cylinder bank is too rich when idling.
9
- 2165 The idle speed is too high during catalytic converter warm-up.
- 2166 The idle speed is too low during catalytic converter warm-up.
- 2177 The power supply at the input of the engine control unit has a sporadic malfunction.
- 2193 Open circuit in right oxygen sensor upstream of TWC [KAT] (lambda control was switched off). (P2A00)
- 2197 Open circuit in left oxygen sensor upstream of TWC [KAT] (lambda control was switched off). (P2A03)
- 2225 The left fuel level sensor has a short circuit to positive.
- 2226 The left fuel level sensor has a short circuit to ground.
- 2227 The left fuel level sensor has an electrical fault.
- 2234 The coolant temperature is implausible relative to the intake air temperature.
- 2237 Coolant temperature sensor 1 has a malfunction.
- 2281 The input for the digital crash signal has a short circuit to positive.
- 2285 The CAN signal from circuit 15 does not match the signal via the hardware line. ( Signal via CAN = 0 )
- 2289 The CAN signal from circuit 15 does not match the signal via the hardware line. ( Signal via hardware line = 0 )
- 2305 G3/6 (Right O2 sensor, after TWC [KAT]) : Time between rich and lean switching too long.
- 2307 G3/6 (Right O2 sensor, after TWC [KAT]) : Time between rich and lean switching too long.
- 2309 G3/5 (Left O2 sensor, after TWC [KAT]) : Time between rich and lean switching too long.
- 2311 G3/5 (Left O2 sensor, after TWC [KAT]) : Time between rich and lean switching too long.
- 2313 Torque control has a malfunction.
- 2333 Self-adjustment of the mixture formation of the right cylinder bank is erratic.
- 2337 Self-adjustment of the mixture formation of the left cylinder bank is erratic.
- 2341 The right fuel level sensor has a short circuit to positive.
- 2342 The right fuel level sensor has a short circuit to ground.
- 2343 The right fuel level sensor has an electrical fault.
- 2349 Component G3/4 (Right O2 sensor, before TWC [KAT]) has a malfunction.
- 2350 Component G3/4 (Right O2 sensor, before TWC [KAT]) has a malfunction.
- 2353 Component G3/3 (Left O2 sensor, before TWC [KAT]) has a malfunction.
- 2354 Component G3/3 (Left O2 sensor, before TWC [KAT]) has a malfunction.
- 2357 The control line to component M4/7 (Engine and AC electric suction fan with integrated control) has Short circuit to
positive.
- 2358 The control line to component M4/7 (Engine and AC electric suction fan with integrated control) has Short circuit to
ground.
- 2359 The control line to component M4/7 (Engine and AC electric suction fan with integrated control) has Open circuit.
- 2360 Overtemperature or undervoltage at component M4/7 (Engine and AC electric suction fan with integrated control)
- 2365 Component M4/7 (Engine and AC electric suction fan with integrated control) has a malfunction.
- 2373 Actuation of the radiator shutters has a malfunction.
- 2377 The position of the exhaust camshaft (cylinder bank 2) deviates from the specified value during cold start.
- 2381 The position of the intake camshaft (cylinder bank 2) deviates from the specified value during cold start.
- 2385 The position of the intake camshaft (cylinder bank 1) deviates from the specified value in direction 'Retarded' during cold
10
start.
- 2389 The position of the intake camshaft (cylinder bank 2) deviates from the specified value in direction 'Retarded' during cold
start.
- 2393 Ignition angle setting has a malfunction during a cold start.
- 2397 The ignition angle setting has a malfunction during cold starting (partial load operation).
- 2401 The pressure sensor/pressure switch of the evaporative emission control system has a malfunction.
- D600 The control unit software 'CODE' and 'DATA' do not comply.
- D601 Control unit software 'CODE' missing or is corrupt.
- D606 Control unit software 'DATA' missing or is corrupt.
- E0009 CAN signal 'Torque request' from control unit Air conditioning is implausible.
- E0025 CAN signal 'Torque request' from control unit Distronic is implausible.
- E0113 CAN signal 'Stop lamp' from control unit Traction systems is implausible.
- E0257 One or more signals sent from control unit Traction systems via the CAN bus is implausible.
- E0297 CAN signal 'Torque request' from control unit Traction systems is implausible.
- E0386 CAN message from control module N15/3 (Electronic transmission control (ETC [EGS])) : Coding error.
- E0733 CAN signal 'Fuel tank level' from control unit A1 (Instrument cluster) is implausible.
- E0845 CAN signal 'Torque request' from control unit Transmission is implausible.
- E0929 CAN signal 'Vehicle speed' from control unit Traction systems is implausible.
- E0931 CAN signal 'Vehicle speed' from control unit Traction systems is implausible.
- E0961 The filler cap is not closed.
- E1285 One or more signals sent from control unit Distronic via the CAN bus is implausible.
- E1289 CAN signal 'Stop lamp' from control unit Traction systems is implausible.
- E1293 No CAN message was received from control unit N93 (Central gateway control unit).
- E1297 This fault can be ignored and erased.
- E1309 Fault or disturbance in CAN message from control unit Traction systems
- E1317 One or more signals sent from control unit N73 (EIS [EZS] control unit) via the CAN bus is implausible.
- E1321 No CAN message was received from control unit N73 (EIS [EZS] control unit).
- E1353 No CAN message was received from control unit A1 (Instrument cluster).
- E1373 No CAN message was received from control unit Traction systems.
- E1377 One or more signals sent from control unit N80 (Steering column module) via the CAN bus is implausible.
- E1381 No CAN message was received from control unit N80 (Steering column module).
- E1393 One or more signals sent from control unit N51/2 (ABC control module) via the CAN bus is implausible.
- E1397 No CAN message was received from control unit N51/2 (ABC control module).
- E1401 One or more signals sent from control unit Transmission via the CAN bus is implausible.
- E1405 No CAN message was received from control unit Transmission. (U0101)
- E1409 One or more signals sent from control unit Transmission via the CAN bus is implausible.
- E1413 Monitoring of signal 'Torque request' by control unit Distronic has stopped.
- E1417 Monitoring of signal 'Torque request' by control unit Traction systems has stopped.
- E1421 Monitoring of signal 'Torque request' by control unit Transmission has stopped.
- E1433 No CAN message was received from control unit N15/5 (Electronic selector lever module (ESM [EWM])) or A80
(Intelligent servo module for DIRECT SELECT).
- E1436 One or more of the signals transmitted by control unit N15/5 (Electronic selector lever module (ESM [EWM])) or A80
(Intelligent servo module for DIRECT SELECT) via the CAN bus are implausible.
- E1437 No CAN message was received from control unit Air conditioning.
- E1441 One or more signals sent from control unit Air conditioning via the CAN bus is implausible.
- E1665 Fault present in control module Transmission
11
- E1865 No CAN message was received from control unit N118 (Fuel pump control module).
- E1869 One or more signals sent from control unit PSM Parameterizable Special Module via the CAN bus is implausible.
- E1893 No CAN message was received from control unit N82 (Battery control module).
- E1897 Timeout of the PremAir temperature signal
- E2051 CAN signal 'Fuel tank level' from control unit A1 (Instrument cluster) is implausible.
- E2081 No CAN message was received from control unit N118 (Fuel pump control module). (U0109)
- E2137 A/C compressor2 : CAN transmission error of signal from component AC compressor ( Toggle error / Parity error )
- E2201 One or more of the signals transmitted by control unit N15/5 (Electronic selector lever module (ESM [EWM])) or A80
(Intelligent servo module for DIRECT SELECT) via the CAN bus are implausible.
- E2321 The engine off time has an implausible value.
Transmission Control Module Codes
ETC2 (722.9) [7-Gear] as of 2005
DTC TEST SCOPE
0218 Temperature of gear oil is too high.
0604 Component Y3/8n4 (Fully integrated transmission control (VGS) control unit) is defective.
060C Component Y3/8n4 (Fully integrated transmission control (VGS) control unit) is defective.
061B The internal engine torque computation performed in component Y3/8n4 (Fully integrated transmission control (VGS) control unit) is
faulty.
062F Component Y3/8n4 (Fully integrated transmission control (VGS) control unit) is defective.
0642 The voltage supply of the speed sensors is faulty. ( Undervoltage )
0643 The voltage supply of the speed sensors is faulty. ( Overvoltage )
0705 Component Y3/8s1 (Selection range sensor (VGS)) is defective.
0706 Check component Y3/8s1 (Selection range sensor (VGS)).
0712 The signal from component Y3/8s2 (Transmission oil temperature sensor (VGS)) is implausible. ( Undervoltage )
0713 The signal from component Y3/8s2 (Transmission oil temperature sensor (VGS)) is implausible. ( Overvoltage )
0716 The transmission input shaft has rotated at excessive rpms.
0717 The signal from component Y3/8n1 (Turbine speed sensor (VGS)) is not available.
12
0718 Component Y3/8n1 (Turbine speed sensor (VGS)) is defective.
0720 Mechanical fault of component Drive train
0721 The transmission output speed signal is implausible when compared to the wheel rpm signal.
0722 The signal from component Y3/8n3 (Output speed sensor (VGS)) is not available.
0723 Component Y3/8n3 (Output speed sensor (VGS)) is defective.
0741 Actuation of torque converter lockup clutch is not possible.
0742 Engaging of torque converter lockup clutch not permitted.
0748 The internal electrical check of component Y3/8y2 (K1 clutch control solenoid valve (VGS)) has failed.
0778 The internal electrical check of component Y3/8y5 (B1 brake control solenoid valve (VGS)) has failed.
0893 Hydraulic fault in transmission (disengaging shift element does not disengage).
0894 The gear is implausible or the transmission is slipping.
2216 Check component Y3/8s1 (Selection range sensor (VGS)). The adaptation sequence occurred outside the valid range.
2711 Hydraulic fault in transmission (engaging shift element does not engage).
2759 The internal electrical check of component Y3/8y8 (Torque converter lockup clutch control solenoid valve (VGS)) has failed.
2766 Excessive rpms have occurred at component Y3/8n2 (Internal speed sensor (VGS)).
2767 The signal from component Y3/8n2 (Internal speed sensor (VGS)) is not available.
2768 Component Y3/8n2 (Internal speed sensor (VGS)) is defective.
2783 The friction power of the torque converter lockup clutch is too high.
2805 The signals of the range selector sensor are implausible in comparison to the signals from the electronic selector lever module.
2810 The internal electrical check of component Y3/8y1 (Working pressure control solenoid valve (VGS)) has failed.
13
C001 CAN controller: CAN bus OFF
C002 CAN controller: CAN bus OFF
C300 Component Y3/8n4 (Fully integrated transmission control (VGS) control unit) is defective.
E0513 The CAN signal for start enable sent to the drive authorization system by transmission control is missing or invalid.
E0562 The voltage supply of circuit 87 has undervoltage.
E0563 The voltage supply of circuit 87 has overvoltage.
E0602 Control module Y3/8n4 (Fully integrated transmission control (VGS) control unit) is not coded.
E1644 The variant coding of component Y3/8n4 (Fully integrated transmission control (VGS) control unit) is implausible or no coding.
E1707 Function shutoff of system due to excessive temperature and overvoltage
E2638 Engine control does not allow any torque intervention by transmission control.
E2806 Component Y3/8s1 (Selection range sensor (VGS)) is not learned.
EC100 No CAN message was received from control unit Engine management.
EC103 No CAN message was received from control unit N15/5 (Electronic selector lever module (ESM [EWM])).
EC121 No CAN message was received from control unit N47-5 (ESP and BAS control module).
EC126 One or more messages from control unit N80 (Steering column module) are not available on the CAN bus.
EC141 No CAN message was received from control unit N73 (EIS [EZS] control unit).
EC155 No CAN message was received from control unit A1 (Instrument cluster).
EC164 No CAN message was received from control unit N22 (AAC [KLA] control and operating unit).
EC167 No CAN message was received from control unit N73 (EIS [EZS] control unit) or N93 (Central gateway control unit).
EC401 One or more signals sent from control unit Engine management via the CAN bus is implausible.
EC404 No CAN message was received from control unit N15/5 (Electronic selector lever module (ESM [EWM])).
EC415 One or more signals sent from control unit N47-5 (ESP and BAS control module) via the CAN bus is implausible.
EC423 One or more signals sent from control unit A1 (Instrument cluster) via the CAN bus is implausible.
EC424 One or more signals sent from control unit N22 (AAC [KLA] control and operating unit) via the CAN bus is implausible.
EC428 No CAN message was received from control unit N80 (SCM [MRM] control unit).
EC429 No CAN message was received from control unit N80 (Steering column module).
EC431 One or more signals sent from control unit N73 (EIS [EZS] control unit) via the CAN bus is implausible.
ED10B No CAN message was received from control unit Engine management.
ED139 No CAN message was received from control unit N80 (SCM [MRM] control unit).
ED13A No CAN message was received from control unit N80 (SCM [MRM] control unit).
ED400 No CAN message was received from control unit Engine management.
14
ED407 No CAN message was received from control unit N47-5 (ESP and BAS control module).
ED40A No CAN message was received from control unit N47-5 (ESP and BAS control module).
ED40B No CAN message was received from control unit N47-5 (ESP and BAS control module).
ED40C No CAN message was received from control unit N47-5 (ESP and BAS control module).
ED420 No CAN message was received from control unit N15/5 (Electronic selector lever module control unit).
ED504 One or more signals sent from control unit N80 (Steering column module) via the CAN bus is implausible.
ED507 One or more signals sent from control unit Engine management via the CAN bus is implausible.
ED508 One or more signals sent from control unit N15/5 (Electronic selector lever module (ESM [EWM])) via the CAN bus is implausible.
ED50B One or more of the signals transmitted by control unit N73 (EIS [EZS] control unit) or N93 (Central gateway control unit) via the CAN
bus are implausible.
Electronic Selector Lever Codes
Version 203 Electronic Selector Lever Codes
DTC Test scope
EP1860 The right rear wheel rpm signal sent from the traction system via the CAN bus is implausible.
EP1861 The left rear wheel rpm signal sent from the traction system via the CAN bus is implausible.
EP1876 The signals sent by control unit N47-5 (ESP and BAS control module) for the wheel speeds and the braking torque are not available on
the CAN bus.
EP2000 The braking torque value sent from the traction system via the CAN bus is implausible.
EP2001 The signal sent by control unit N73 (EIS [EZS] control unit) for the stop lamp status is not available on the CAN bus.
EP2010 The braking signal sent from the traction system via the CAN bus is implausible.
EP2012 The brake signal from control unit N47-5 (ESP and BAS control module) is not available on the CAN bus.
P1750 The supply voltage of the control unit is too low (undervoltage).
P1832 The output stage in control module N15/5 (Electronic selector lever module control unit) has Short circuit.
P1833 The output stage in control module N15/5 (Electronic selector lever module control unit) has Open circuit.
P1856 Selector lever position detection has failed.
P1875 CAN communication with other control units installed in this vehicle is not possible.
P1910 The supply voltage of the control unit is too high (overvoltage).
P2002 The tip switch in the floor-mounted shift has a short circuit to ground.
P2003 The tip switch in the floor-mounted shift has an open circuit.
P2004 The tip switch in the floor-mounted shift has a short circuit to positive.
P2005 The voltage value of the touch pushbutton is implausible.
P2006 The voltage value of the touch pushbutton is implausible.
P2007 Control unit N15/5 (Electronic selector lever module control unit) is defective.
15
1
A L L Diagnostic Trouble Codes ( DTC ): P Code Charts
P0014
Continuous camshaft adjustment ( RIGHT ): Incorrect position of the exhaust camshaft (P0014)
Possible cause:
- Exhaust camshaft of right cylinder bank

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 1: Exhaust camshaft of right cylinder bank
1. Exhaust camshaft of right cylinder bank

Warning!Communication with ECU required.
P0015
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

P0024
Continuous camshaft adjustment ( LEFT ): Incorrect position of the exhaust camshaft (P0024)
Possible cause:
- Exhaust camshaft of left cylinder bank

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 1: Exhaust camshaft of left cylinder bank
1. Exhaust camshaft of left cylinder bank

2
P0025
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Component Y49/7 (Right camshaft exhaust solenoid) has an open circuit in the wiring. (P0013)
Possible cause:
- Y49/7 (Right camshaft exhaust solenoid)

- Voltage supply via component Z7/38 (Circuit 87 M1i connector sleeve)
Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 1: Power supply
Test 2: Check component Y49/7 (Right camshaft exhaust solenoid).
1. Power supply
Voltage supply via component Z7/38 (Circuit 87 M1i connector sleeve)
Possible cause and remedy
- Check voltage supply according to wiring diagram.
2. Check component Y49/7 (Right camshaft exhaust solenoid).
Test 2.1: Test actuation of component Y49/7 (Right camshaft exhaust solenoid).
Test 2.2: Test current consumption of component Y49/7 (Right camshaft exhaust solenoid).
2.1. Test actuation of component Y49/7 (Right camshaft exhaust solenoid).

Test prerequisite
- Engine at idle
- Vehicle stationary
- Coolant temperature > 80° C
- Time since engine start> 60 s
Status of relevant actual value:
- Temperature of coolant:Warning! Communication with ECU required.
Note
- After the actuation it may be necessary to erase the fault memory!
3
Proceed to 'Actuation' with F2
2.2. Test current consumption of component Y49/7 (Right camshaft exhaust solenoid).
Figure legend
- A -ConnectionTest cable 35-pin socket box

- 001 -Sockets of component N3/10 (ME-SFI [ME] control unit)
- 05 -35-pin socket box
- 108 -Test cable 266 589 01 63 00
- N3/10 (ME-SFI [ME] control unit)
- II 1-63ConnectionTest cable
- III 64-126ConnectionTest cable
Warning!
- Connection A of test cable 108 may NOT be connected to connection B of the 126-pin socket box (050).
Continue to test with button F2
Test sequence
- Measure direct current with multimeter between sockets [F.4] 100 and [M.24] 24 of the 126-pole socket box tester.
- Switch on ignition.
Testing of maximum power consumption may be conducted for no longer than 5 s.Specified value
- Amperage[1.0...1.8] A
Question
- Is the measurement value OK?
YES
The measurement value is OK.End of test
NO
The measurement value is not OK.Possible cause and remedy
- N10/1f43 (Fuse 43)

- Line from component Y49/7 (Right camshaft exhaust solenoid) to component N3/10 (ME-SFI [ME] control unit)
End of test
Component Y49/6 (Left camshaft exhaust solenoid) has an open circuit in the wiring. (P0013)
4
Possible cause:
- Y49/6 (Left camshaft exhaust solenoid)

- N10/1kI (Circuit 87 relay, engine)
- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 1: Check power supply of component N3/10 (ME-SFI [ME] control unit).
Test 2: Arrangement of fuses
Test 4: Check component Y49/6 (Left camshaft exhaust solenoid).
1. Check power supply of component N3/10 (ME-SFI [ME] control unit).
Test 1.1: Test voltage supply of circuit 87. ( Check using actual value )
Test 1.2: Test voltage supply of circuit 30.
Test 1.4: Test current consumption of component N10/1kR (Circuit 87 relay, engine).
1.1. Test voltage supply of circuit 87. ( Check using actual value )
Test prerequisite
- The voltage test at component G1 (Battery) is o.k.

- Ignition ON
- Battery voltage:Warning! Communication with ECU required.
Specified value
- Battery voltage[11.0 ... 15.0] V

Question:Is the actual value o.k.?
YES
The actual value is okay.End of test
NO
The actual value is not o.k.Possible cause and remedy
- Test voltage supply of circuit 30.

1.2. Test voltage supply of circuit 30.

Connect socket box to component N3/10 (ME-SFI [ME] control unit).
Figure legend

- 108 -Test cable 266 589 01 63 00
5
Warning!
-
Test voltage supply of circuit 30.
Test sequence
- Measure direct voltage with multimeter between sockets [ F.2 ] 98 and [ F.16 ] 112 of the 35-pole socket box tester.
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
6

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
- Measure direct voltage with multimeter between sockets [ F.2 ] 98 and [F.3] 99 of the 126-pole socket box tester.
Specified value
7
- Voltage[11.0...15.0] V
Question
- Are the measurement values OK?
YES
The measurement values are OK.Further possible causes of fault
NO
The measurement values are not OK.Possible cause and remedy
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
- N10/1 (Driver-side SAM control unit with fuse and relay module)
End of test
1.4. Test current consumption of component N10/1kR (Circuit 87 relay, engine).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
8
Test current consumption of component N10/1kR (Circuit 87 relay, engine).
Test sequence
- Measure direct current with multimeter between sockets [F.4] 100 and [F.27] 123 of the 126-pole socket box tester.
Specified value
- Amperage[0.1...0.3] A
Question
YES
The test was okay.End of test
NO
- Lines to component N10/1kR (Circuit 87 relay, engine)

- N10/1kR (Circuit 87 relay, engine)
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
9
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
2. Arrangement of fuses
Figure legend/figure
10
Fuses
- FuseF43-F67
Relays
- I =N10/1kI (Circuit 87 relay, engine)

- K =N10/1kK (Circuit 87 relay, chassis)
- L =N10/1kL (Starter relay)
- M =N10/1kM (SEQ [ASG] pump control relay)
- N =N10/1kN (Circuit 15 relay)
- O =N10/1kO (FAN relay module)
- P =N10/1kP (Circuit 15R relay)
- R =N10/1kR (Air pump or oil cooler fan relay)
3. Power supply
4. Check component Y49/6 (Left camshaft exhaust solenoid).
Test 4.1: Test actuation of component Y49/6 (Left camshaft exhaust solenoid).
Test 4.2: Test current consumption of component Y49/6 (Left camshaft exhaust solenoid).
4.1. Test actuation of component Y49/6 (Left camshaft exhaust solenoid).

Test prerequisite
- Engine at idle
Note

4.2. Test current consumption of component Y49/6 (Left camshaft exhaust solenoid).
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
11
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

- Line from component Y49/6 (Left camshaft exhaust solenoid) to component N3/10 (ME-SFI [ME] control unit)
End of test
P1832
The output stage in control module N15/5 (Electronic selector lever module control unit) has Short circuit.
Possible cause:
- N15/5 (Electronic selector lever module control unit)

Affected functions:
- Drive position selection
-------------------------------------------------
Test 1: Remedial action if control unit is faulty 'N15/5 (Electronic selector lever module (ESM [EWM]))'
12
1. Remedial action if control unit is faulty 'N15/5 (Electronic selector lever module (ESM [EWM]))'
Operation number of operation texts and work units or standard texts and flat rates:27-0641Possible cause and remedy
- Internal fault in control unit

- Replace component Floor-mounted shift.
WARNING
- No adaptations are required to bring control unit ESM into service.

End of test
P1833
The output stage in control module N15/5 (Electronic selector lever module control unit) has Open circuit.
Possible cause:

Affected functions:
-------------------------------------------------

WARNING

End of test
P1856
Selector lever position detection has failed.
Possible cause:

Affected functions:
- Engine start
-------------------------------------------------

WARNING

End of test
P1875
CAN communication with other control units installed in this vehicle is not possible.
Possible cause:
13
- Engine compartment CAN databus

Affected functions:
- CAN Communication
-------------------------------------------------
Test 1: Remedial action if no CAN communication is possible with other control units installed in this vehicle
1. Remedial action if no CAN communication is possible with other control units installed in this vehicle
Operation number of operation texts and work units or standard texts and flat rates:27-0641Start test sequence.1. Erase fault memory.2. Perform a
road test and switch the ignition off and on several times with the vehicle stationary.Continue check procedure.1. Once again read fault
memory.NOTE
- The fault memory is erased by pressing button "F2".

Continue with button "F2"
P1910
The supply voltage of the control unit is too high (overvoltage).
Possible cause:
- Local overvoltage of component N15/5 (Electronic selector lever module control unit)
Affected functions:
- Battery / On-board electrical system
-------------------------------------------------
Test 1: Check power supply at control unit N15/5 (Electronic selector lever module control unit).
1. Check power supply at control unit N15/5 (Electronic selector lever module control unit).
Operation number of operation texts and work units or standard texts and flat rates:27-0641Test sequence
- Switch off ignition.

- Disconnect connector at component N15/5 (Electronic selector lever module control unit).
- [A.2] Measure direct voltage with multimeter between 2 and 1 [A.1]
Specified value
- Voltage[7.0...16.0] V
Question
YES
The measurement value is OK.Possible cause and remedy

End of test
NO
- Check fuse f55 (voltage supply from control unit ESM) in component N10/1 (Front SAM control unit with fuse and relay module).
- Check all affected plugs, connectors and electrical components for damage, loose contact, corrosion etc. and repair if necessary.
End of test
P2002
The tip switch in the floor-mounted shift has a short circuit to ground.
14
Possible cause:

Affected functions:
- Transmission mode selection
-------------------------------------------------

WARNING

End of test
P2123
Check potentiometer of component B37 (Accelerator pedal sensor). Hall sensor 1 : Short circuit to positive (P2123)
Possible cause:
- B37 (Accelerator pedal sensor)

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 1: Check component B37 (Accelerator pedal sensor).
1. Check component B37 (Accelerator pedal sensor).
Test 1.1: Check component B37 (Accelerator pedal sensor) using actual value.
Test 1.2: Check power supply of component B37 (Accelerator pedal sensor).
1.1. Check component B37 (Accelerator pedal sensor) using actual value.
Test sequence
Status of the relevant actual values:
- B37 (Pedal value sensor) Voltage 1:Warning! Communication with ECU required.
Specified values
- Accelerator pedal position:Idle speed

- B37 (Accelerator pedal sensor)Signal1 : [0.2...0.5] V
- Accelerator pedal position:Kickdown

Question
- Are the actual values o.k.?
YES
The actual values are okay.End of test
15
NO
The actual values are not okay.Possible cause and remedy
- Check power supply of component B37 (Accelerator pedal sensor).

- Check lines from component N3/10 (ME-SFI [ME] control unit) to component B37 (Accelerator pedal sensor).
1.2. Check power supply of component B37 (Accelerator pedal sensor).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite
- The actual value is not o.k.

- The power supply of component N3/10 (ME-SFI [ME] control unit) is OK.
Test sequence

- Connect socket box (126-pin) to component N3/10 (ME-SFI [ME] control unit).
- Measure direct voltage with multimeter between sockets [F.11] 107 and [F.23] 119 of the 126-pole socket box tester.
Specified value
- Voltage[4.75...5.25] V
Question
16
YES
- Signal lines
End of test
NO
- Cable for voltage supply

End of test
P2122
Check potentiometer of component B37 (Accelerator pedal sensor). Hall sensor 1 : Short circuit to ground or open circuit (P2122)
Test 2: Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
Test sequence
Specified values


Question
YES
NO


Figure legend
17

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO
18
End of test
2. No further information available.
P2128
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test sequence
Specified values


Question
YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
19
Warning!
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
P2127
20
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test sequence
Specified values


Question
YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
21
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
B37 (Accelerator pedal sensor) : Voltage of Hall sensor 1 does not agree with voltage of Hall sensor
2. (P2138)
B37 (Accelerator pedal sensor) : Voltage of Hall sensor 1 does not agree with voltage of Hall sensor 2. (P2138)
Possible cause:

Affected functions:
22
- Engine diagnosis
- Engine output
-------------------------------------------------
Test sequence
Specified values


Question
YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
23
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
The values from the position sensors of the accelerator pedal are implausible in relation to each
other. (P2138)
The values from the position sensors of the accelerator pedal are implausible in relation to each other. (P2138)
Possible cause:

Affected functions:
24
- Engine diagnosis
-------------------------------------------------
Test sequence
Specified values


Question
YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
25
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
P0651
B37 (Accelerator pedal sensor) : Power supply (P0651)
Possible cause:

Affected functions:
- Engine diagnosis
26
- Engine output
-------------------------------------------------
Test sequence
Specified values


Question
YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
27
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
P0599
Component Y110 (Three-disk thermostat valve) has a short circuit to positive. (P0599)
Possible cause:
- Y110 (Three-disk thermostat valve)

Affected functions:
- Heating
28
- Engine cooling
-------------------------------------------------
Test 1: Check component Y110 (Three-disk thermostat valve).
1. Check component Y110 (Three-disk thermostat valve).
Test 1.1: Component Y110 (Three-disk thermostat valve) is mechanically damaged or it sticks.
Test 1.2: Test current consumption of component Y110 (Three-disk thermostat valve).
1.1. Component Y110 (Three-disk thermostat valve) is mechanically damaged or it sticks.
Test 1.1.1: Y110 (Three-disk thermostat valve) : Coolant temperature is not reached.
Test 1.1.2: Y110 (Three-disk thermostat valve) : Coolant temperature is too high.
1.1.1. Y110 (Three-disk thermostat valve) : Coolant temperature is not reached.

1.1.2. Y110 (Three-disk thermostat valve) : Coolant temperature is too high.

1.2. Test current consumption of component Y110 (Three-disk thermostat valve).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
29
Test sequence
Specified value
- Amperage[0.6...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)

- Check lines from component N3/10 (ME-SFI [ME] control unit) to component Y110 (Three-disk thermostat valve).
End of test
P0598
Component Y110 (Three-disk thermostat valve) has a short circuit to ground. (P0598)
Possible cause:

Affected functions:
- Heating
- Engine cooling
-------------------------------------------------



Figure legend

30
- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
Specified value
- Amperage[0.6...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test
P0597
Component Y110 (Three-disk thermostat valve) has an open circuit in the wiring. (P0597)
Possible cause:
31

- N10/1f57 (Fuse 57)
- Voltage supply via component Z7/36 (Circuit 87 M2e connector sleeve)
Affected functions:
- Heating
- Engine cooling
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
32
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
33
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
34
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
35
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
36
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

37
3. Power supply
Voltage supply via component Z7/36 (Circuit 87 M2e connector sleeve)



Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
38
Test sequence
Specified value
- Amperage[0.6...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test
M16/6 (Throttle valve actuator) : Actual value potentiometer 1 or 2 has failed. (P2135)
Possible cause:
- M16/6 (Throttle valve actuator)

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 1: Check component M16/6 (Throttle valve actuator).
1. Check component M16/6 (Throttle valve actuator).
39
Test 1.1: Check component M16/6 (Throttle valve actuator) using actual value.
Test 1.2: Test voltage supply of the potentiometers of component M16/6 (Throttle valve actuator).
1.1. Check component M16/6 (Throttle valve actuator) using actual value.
1.2. Test voltage supply of the potentiometers of component M16/6 (Throttle valve actuator).
Test prerequisite
- At least one of the relevant actual values is not okay.

Test sequence

- Measure direct voltage with multimeter between sockets (M.39) 39 and (M.43) 43 of the 35-pole socket box tester.
Specified value
- Voltage[4.75...5.25] V
Question
YES
- Check lines from component M16/6 (Throttle valve actuator) to component N3/10 (ME-SFI [ME] control unit).
End of test
NO

End of test
M16/6 (Throttle valve actuator) : There is a comparison error between actual value potentiometers
1 and 2. (P2135)
M16/6 (Throttle valve actuator) : There is a comparison error between actual value potentiometers 1 and 2. (P2135)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
40
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
M16/6 (Throttle valve actuator) : There is a comparison error between actual value potentiometers
2 and 1. (P2135)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence
41
Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
M16/6 (Throttle valve actuator) : Output stage (P2101)

Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
Test 1.1: Check component M16/6m1 (Actuator motor) by means of actuation.
Test 1.2: Check internal resistance of component M16/6m1 (Actuator motor).
1.1. Check component M16/6m1 (Actuator motor) by means of actuation.

Test prerequisite
- Operate engine at idling speed.

Note
- If the throttle valve angle is< 1,1°, unmetered air may be present.
- Throttle valve angle:Warning! Communication with ECU required.
Move on to actuation with button F2
1.2. Check internal resistance of component M16/6m1 (Actuator motor).

Figure legend

- 108 -Test cable 266 589 01 63 00
42
Warning!
Test sequence

- Disconnect coupling M at component N3/10 (ME-SFI [ME] control unit).
- Measure resistance with multimeter between sockets (M.75) 75 and (M.74) 74 of the 126-pole socket box tester.
Specified value
- Resistor[1...10]ohms
Question
YES
NO
- Lines between N3/10 (ME-SFI [ME] control unit) and M16/6m1 (Actuator motor)
- M16/6m1 (Actuator motor)
End of test
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
43
Question
YES
End of test
NO

End of test
M16/6 (Throttle valve actuator) : Position Throttle valve (P2101)

Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
Test 1.4: Perform mechanical inspection of component M16/6 (Throttle valve actuator).

Test prerequisite

Note

Figure legend

- 108 -Test cable 266 589 01 63 00
44
Warning!
Test sequence

Specified value
Question
YES
NO
End of test
1.4. Perform mechanical inspection of component M16/6 (Throttle valve actuator).

Test sequence

- Expose component M16/6 (Throttle valve actuator).
- Slowly operate throttle flap by hand up to full load.
Specified value
- The throttle valve must not stick and must close by internal spring force.
Question
- Is the test o.k?
45
YES
The test is o.k..Possible cause and remedy

End of test
NO
The test is not o.k..Possible cause and remedy
- Check intake tract for residue and clean if necessary.If no residue is present, replace component M16/6 (Throttle valve actuator).
M16/6 (Throttle valve actuator) : Throttle valve adaptation is faulty. (P2101)

Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
Test 1: Learning of the throttle valve stop
1. Learning of the throttle valve stop

P2111
M16/6 (Throttle valve actuator) : Mechanical fault (P2111)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Test sequence

Specified value
Question
- Is the test o.k?
46
YES
The test is o.k..End of test
NO
P2112

Affected functions:
- Engine diagnosis
- Engine running

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
The safety fuel shutoff is active. (P2176)

Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
47
Test 1.1: Check component B37 (Accelerator pedal sensor).
Test 1.2: Check component M16/6 (Throttle valve actuator).
1.1. Check component B37 (Accelerator pedal sensor).
Test 1.1.1: Check component B37 (Accelerator pedal sensor) using actual value.
Test 1.1.2: Check power supply of component B37 (Accelerator pedal sensor).
1.1.1. Check component B37 (Accelerator pedal sensor) using actual value.
Test sequence
Specified values


Question
YES
NO

1.1.2. Check power supply of component B37 (Accelerator pedal sensor).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
48
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
1.2. Check component M16/6 (Throttle valve actuator).
Test 1.2.1: Check component M16/6 (Throttle valve actuator) using actual value.
Test 1.2.2: Check component M16/6m1 (Actuator motor) by means of actuation.
1.2.1. Check component M16/6 (Throttle valve actuator) using actual value.
1.2.2. Check component M16/6m1 (Actuator motor) by means of actuation.
49
Test prerequisite

Note

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
M16/6 (Throttle valve actuator) : The throttle valve is jamming or is stiff. (P2176)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
Test 1.4: Note : Control unit programming must be performed on control unit variants VC6 to VC8.

Test prerequisite
50
Note

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
1.4. Note : Control unit programming must be performed on control unit variants VC6 to VC8.
1.4. No further information available.
M16/6 (Throttle valve actuator) : Perform throttle valve adaptation. (P2176)

Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

P0011
Continuous camshaft adjustment ( RIGHT ): Incorrect position of the intake camshaft (P0011)
Test 1: Intake camshaft of right cylinder bank
- Intake camshaft of right cylinder bank

Affected functions:
- Engine diagnosis
51
- Engine output
1. Intake camshaft of right cylinder bank

P0012
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

P0021
Continuous camshaft adjustment ( LEFT ): Incorrect position of the intake camshaft (P0021)
Possible cause:
- Intake camshaft of left cylinder bank

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 1: Intake camshaft of left cylinder bank
1. Intake camshaft of left cylinder bank

P0022
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
52

Component Y49/5 (Right camshaft intake solenoid) has an open circuit in the wiring. (P0010)
Possible cause:
- Y49/5 (Right camshaft intake solenoid)

- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 4: Check component Y49/5 (Right camshaft intake solenoid).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
53
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test
54

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
55
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
56
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
57
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
58
Fuses
- FuseF43-F67
Relays

3. Power supply
4. Check component Y49/5 (Right camshaft intake solenoid).
Test 4.1: Test actuation of component Y49/5 (Right camshaft intake solenoid).
Test 4.2: Test current consumption of component Y49/5 (Right camshaft intake solenoid).
4.1. Test actuation of component Y49/5 (Right camshaft intake solenoid).

Test prerequisite
- Engine at idle
Note

4.2. Test current consumption of component Y49/5 (Right camshaft intake solenoid).
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
59
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

- Line from component Y49/5 (Right camshaft intake solenoid) to component N3/10 (ME-SFI [ME] control unit)
End of test
Possible cause:
- Stepless adjustment of intake camshaft of right cylinder bank

Affected functions:
- Engine output
-------------------------------------------------
60

Component Y49/4 (Left camshaft intake solenoid) has an open circuit in the wiring. (P0020)
Possible cause:
- Y49/4 (Left camshaft intake solenoid)

- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 4: Check component Y49/4 (Left camshaft intake solenoid).
Test prerequisite

- Ignition ON
Specified value

YES
NO


61
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
62

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
63
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
64
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
65
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
66
Fuses
- FuseF43-F67
Relays

3. Power supply
4. Check component Y49/4 (Left camshaft intake solenoid).
Test 4.1: Test actuation of component Y49/4 (Left camshaft intake solenoid).
Test 4.2: Test current consumption of component Y49/4 (Left camshaft intake solenoid).
4.1. Test actuation of component Y49/4 (Left camshaft intake solenoid).

Test prerequisite
- Engine at idle
Note

4.2. Test current consumption of component Y49/4 (Left camshaft intake solenoid).
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
67
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

- Line from component Y49/4 (Left camshaft intake solenoid) to component N3/10 (ME-SFI [ME] control unit)
End of test
Possible cause:
- Stepless adjustment of intake camshaft of left cylinder bank

Affected functions:
- Engine output
-------------------------------------------------
68

P0277
The injection valve output stage of cylinder 6 detects a short circuit to positive. (P0277)
Possible cause:
- Y62y6 (Fuel injector cylinder 6)

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
Test 1: Check component Y62y6 (Fuel injector cylinder 6).
1. Check component Y62y6 (Fuel injector cylinder 6).
Test 1.1: Check component Y62y6 (Fuel injector cylinder 6).
1.1. Check component Y62y6 (Fuel injector cylinder 6).

Safety note
Warning!Risk of explosion, poisoning and injury!Fuels are highly inflammable and toxic if inhaled. Fuels may cause skin damage. fuel vapors are
explosive, invisible and spread out at floor level, they are toxic if inhaled and produce giddiness and an anaesthetizing effect.Rules of conduct and
protective measures
- Wear suitable protective clothing.

- Pay attention to national safety precautions and regulations.
- No fire, sparks, naked flames and smoking.
- Ensure the work place is adequately ventilated.
- Never drain or pour in fuels over assembly pits.
- Store drained fuel in a suitable and sealed vessel.
- Immediately eliminate any fuel which has flowed out.
First-aid measures
- Clean moistened skin with water and soap.

- Change moistened clothing as quickly as possible.
- If fuel gets into your eyes, rinse out your eyes immediately with water and contact a doctor if necessary.
Test 1.1.1: Test actuation of component Y62y6 (Fuel injector cylinder 6).
Test 1.1.2: Test signal voltage of component Y62y6 (Fuel injector cylinder 6).
Test 1.1.3: Inspect component Y62y6 (Fuel injector cylinder 6) for leaks.
Test 1.1.4: Inspect operation and spray pattern of component Y62y6 (Fuel injector cylinder 6).
Test 1.1.5: Check internal resistance of component Y62y6 (Fuel injector cylinder 6).
1.1.1. Test actuation of component Y62y6 (Fuel injector cylinder 6).

Test prerequisite

- Engine RUNNING
1.1.2. Test signal voltage of component Y62y6 (Fuel injector cylinder 6).
69
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

- ConnectionMeasuring system
- Observe oscilloscope pattern between sockets [M.3] 3 and [F.3] 99 of the 126-pole socket box tester.
- Run engine.
Note
- Measuring system:Communication with ECU required
1.1.3. Inspect component Y62y6 (Fuel injector cylinder 6) for leaks.

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
70
Figure legend
- 055Measuring beakerY62 (Fuel injectors)

Test sequence

- Remove fuel rail together with component Y62y6 (Fuel injector cylinder 6).
- Bridge between sockets (F.4) 100 and (F.17) 113 of the 126-pole socket box tester.
Specified value
- Component Y62y6 (Fuel injector cylinder 6) must not drip.

Question
- Was the test o.k.?
71
YES
The test was okay.Further possible causes of fault
- Inspect operation and spray pattern of component Y62y6 (Fuel injector cylinder 6).
NO
The test was not okay.Possible cause and remedy
1.1.4. Inspect operation and spray pattern of component Y62y6 (Fuel injector cylinder 6).
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend(Shop-made tool)
- 1xClutch 140 545 35 28

- 2xContact spring 004 545 56 26
- 1xRed banana connector
- 1xBlack banana connector
- 2,2 mRed cable with diameter 1,5 mm(Pin 1)
- 2,2 mBrown cable with diameter 1,5 mm(Pin 2)
- 2 mInsulation sheathing with diameter 6 mm
72
Test sequence

- Component M3 (Fuel pump) runs.
- Hold component Y62y6 (Fuel injector cylinder 6) in a vessel and briefly operate manually with shop-made test cable set at sockets 98 and 99
of the 126-pin socket box.
Specified value
- Fuel injectors should eject fuel uniformly.

Question
YES
The test was okay. End of test
NO

End of test
1.1.5. Check internal resistance of component Y62y6 (Fuel injector cylinder 6).
Figure legend
73

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

- Measure resistance with multimeter between sockets [M.3] 3 and [F.3] 99 of the 126-pole socket box tester.
Specified value
Question
YES
The measurement value is OK.Note
- In the event of stored faults with a high fault frequency count or in the event of customer complaints, check lines and connectors for loose
contact and corrosion..
NO
The measurement value is not OK.Test sequence

- Connect shop-made test cable set to component Y62y6 (Fuel injector cylinder 6).
- Measure resistance with multimeter between pins (Y62) 1 and (Y62) 2
Specified value
74
Question
YES
- Lines to component Y62y6 (Fuel injector cylinder 6)
NO
P0276
The injection valve output stage of cylinder 6 detects a short circuit to ground. (P0276)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

First-aid measures

75
Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

- Run engine.
Note
Figure legend

76
- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
NO

Specified value
Question
77
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
78
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
79
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
80
YES
NO

End of test
P0274
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

81
First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
82
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
83
NO

Specified value
Question
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
84
Figure legend

Test sequence

Specified value

Question
85
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
- 1xClutch 140 545 35 28

86
Test sequence

Specified value

Question
YES
NO

End of test
P0273
87
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
88
Warning!
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
89
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
90

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
91
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
92
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
93
YES
NO

End of test
Self-adaptation of mixture formation for enrichment at partial load for the left cylinder bank is
above the permissible limit.
Self-adaptation of mixture formation for enrichment at partial load for the left cylinder bank is above the permissible limit. (P0174)
Possible cause:
- Selfadaptation of mixture formation

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 1: Check self-adaptation of mixture formation. Left bank of cylinders
1. Check self-adaptation of mixture formation. Left bank of cylinders

Test sequence
- Check actual value Selfadaptation of mixture formation.

- Carry out the following tests.
Continue with button F2
Self-adaptation of mixture formation for enrichment at idle for the left cylinder bank is above the
permissible limit. (P0174)
Self-adaptation of mixture formation for enrichment at idle for the left cylinder bank is above the permissible limit. (P0174)
94
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence

Lambda control, before TWC left : Lambda control is at lean stop. (P0174)
Possible cause:
- Lambda control
Affected functions:
- Engine output
-------------------------------------------------
Test 1: In connection with warranty and goodwill work, supplemental information on this symptom is available in TIPS.
Test 2: Check self-adaptation.
1. In connection with warranty and goodwill work, supplemental information on this symptom is available in TIPS.
2. Check self-adaptation.
Test 2.1: Check lambda control.
2.1. Check lambda control.
Test 2.1.1: Inspect air cleaner housing.
Test 2.1.2: Check component G3/3 (Left O2 sensor, before TWC [KAT]).
Test 2.1.3: Check component Y62 (Fuel injectors).
Test 2.1.4: Check exhaust system for leaks.
Test 2.1.5: Check component Y58/1 (Purge control valve).
Test 2.1.6: Check signal from component B2/5 (Hot film mass air flow sensor) via actual value.
Test 2.1.7: Check seal of component B2/5 (Hot film mass air flow sensor) with air filter for cracks.
2.1.1. Inspect air cleaner housing.
95
- Inspect air cleaner housing for correct installation.

Note
- Proper sealing between the air filter housing and the housing of the HFM mass air flow sensor must be guaranteed (the gasket surface must
not be cracked).
End of test
2.1.2. Check component G3/3 (Left O2 sensor, before TWC [KAT]).

2.1.3. Check component Y62 (Fuel injectors).

Safety note
protective measures

First-aid measures

Test 2.1.3.1: Inspect component Injectors for leaks.
Test 2.1.3.2: Inspect operation and spray pattern of component Injectors.
2.1.3.1. Inspect component Injectors for leaks.

Figure legend

Test sequence
96
- Remove fuel rail together with component Y62 (Fuel injectors).
- Bridge between socket (F.4) 100 of the 35-pole socket box tester and socket (F.17) 113 of the 126-pole socket box tester.
Specified value
- Component Y62 (Fuel injectors) must not drip.

Question
YES
- Inspect operation and spray pattern of component Y62 (Fuel injectors).
NO
- Y62 (Fuel injectors)
2.1.3.2. Inspect operation and spray pattern of component Injectors.

- 1xClutch 140 545 35 28

97
Test sequence

- Insert bridge.:
- Hold component Y62 (Fuel injectors) in a vessel and briefly operate manually with shop-made test cable set at sockets 5 and 9 of the 35-pin
socket box.
Specified value

Question
YES
NO

End of test
98
2.1.4. Check exhaust system for leaks.

Possible cause of fault
- Leaks
Possible remedy
- Check entire exhaust system for leaks.
2.1.5. Check component Y58/1 (Purge control valve).
Test 2.1.5.1: Actuate component Y58/1 (Purge control valve).
Test 2.1.5.2: Test current consumption of component Y58/1 (Purge control valve).
Test 2.1.5.3: Perform mechanical inspection of component Y58/1 (Purge control valve).
2.1.5.1. Actuate component Y58/1 (Purge control valve).

Test sequence
- Actuate component Y58/1 (Purge control valve).(Operate pushbutton F2.)
2.1.5.2. Test current consumption of component Y58/1 (Purge control valve).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
99
Test prerequisite
- The actual values are not okay.

Test sequence
- Measure direct current with multimeter between socket [F.4] 100 of the 126-pole socket box tester and socket [F.45] 15 of the 35-pole socket
box tester.
Specified value
- Amperage[0.4...0.9] A
Question
YES
NO
- N10/1f57 (Fuse 57)

- Line from component N3/10 (ME-SFI [ME] control unit) to component Y58/1 (Purge control valve)
- Line from component N10/1 (Driver-side SAM control unit with fuse and relay module) to component Y58/1 (Purge control valve)
- Y58/1 (Purge control valve)
End of test
2.1.5.3. Perform mechanical inspection of component Y58/1 (Purge control valve).

Figure legend
- 019Vacuum tester
Test prerequisite
- Actuation is OK.
Test sequence

- Connect the vacuum tester to the input of component Y58/1 (Purge control valve) with the 3 x distributor.
- Engine at operating temperature
- Actuate component Y58/1 (Purge control valve), then with key F2.
100
2.1.6. Check signal from component B2/5 (Hot film mass air flow sensor) via actual value.
Test 2.1.6.1: Check signal of component B2/5 (Hot film mass air flow sensor) via actual value with engine OFF.
Test 2.1.6.2: Check signal of component B2/5 (Hot film mass air flow sensor) via actual value with engine speed greater than 3500 rpm.
Test 2.1.6.3: Check reference signal of component B2/5 (Hot film mass air flow sensor).
2.1.6.1. Check signal of component B2/5 (Hot film mass air flow sensor) via actual value with engine OFF.
2.1.6.2. Check signal of component B2/5 (Hot film mass air flow sensor) via actual value with engine speed greater than 3500 rpm.
2.1.6.3. Check reference signal of component B2/5 (Hot film mass air flow sensor).
Test sequence
- HFM-SFI ( Reference signal ):Warning! Communication with ECU required.
Specified value
- Reference signal[46...59] ms
Question
YES
NO
- Check lines from component N3/10 (ME-SFI [ME] control unit) to component B2/5 (Hot film mass air flow sensor).
101
- B2/5 (Hot film mass air flow sensor)
2.1.7. Check seal of component B2/5 (Hot film mass air flow sensor) with air filter for cracks.
- Check seal of component B2/5 (Hot film mass air flow sensor) with air filter for cracks.
Note
- Proper sealing between the air cleaner housing and the housing of the HFM mass air flow sensor must be assured.
End of test
Self-adaptation of mixture formation for enleanment at partial load for the left cylinder bank is
below the permissible limit.
Self-adaptation of mixture formation for enleanment at partial load for the left cylinder bank is below the permissible limit. (P0175)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence

Self-adaptation of mixture formation for enleanment at idle for the left cylinder bank is below the
102
Self-adaptation of mixture formation for enleanment at idle for the left cylinder bank is below the permissible limit. (P0175)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence

Lambda control, before TWC left : Lambda control is at rich stop. (P0175)
Possible cause:
- Lambda control is at rich stop.

Affected functions:
- Engine output
-------------------------------------------------
Test 1.1: Lambda control is at rich stop.
1.1. Lambda control is at rich stop.
Test 1.1.3: Test fuel pressure and delivery of component M3 (Fuel pump).
Test 1.1.4: Test gasoline fuel for water and diesel portions.
Test 1.1.5: Inspect the intake system of the engine for leaks.
103
Test sequence
Specified value
Question
YES
NO
Note
End of test
1.1.3. Test fuel pressure and delivery of component M3 (Fuel pump).
104
Safety note
protective measures

First-aid measures

Test 1.1.3.1: Test fuel pressure and internal leaks of fuel system.
Test 1.1.3.2: Test delivery of component M3 (Fuel pump).
Test 1.1.3.3: Test current consumption of component M3 (Fuel pump).
Test 1.1.3.4: Test current consumption of component N10/2kA (Fuel pump relay).
1.1.3.1. Test fuel pressure and internal leaks of fuel system.

Question
- Can the vehicle engine be operated at idle speed?
YES
Figure legend
- 043Pressure gage(103 589 00 21 00)

- 055Measuring beaker
- 069Pressure hose(119 589 04 63 00)
Warning!On USA vehicles with code 917 ( PZEV ), the sealing ring of the service valve for the protective cap must be replaced.Test sequence

- Connect test pressure gauge.
- Engine at idle
Specified value
- Pressure[3.7...4.2] bar
Question
105
YES
The measurement value is OK.Test prerequisite
- Test pressure gage is connected.

Test sequence
- Run the engine for a short time and switch off again.
Specified value
- Pressure after 30 minutes:[> 2.5] bar

Question
YES
The measurement value is OK.Further possible causes of fault
- Test delivery of component M3 (Fuel pump).
NO
- In the event of slow pressure drop:Check component Y62 (Fuel injectors).

- In the event of rapid pressure drop:Check valve in component M3 (Fuel pump)
NO
- Test current consumption of component M3 (Fuel pump).

- Fuel filter with integrated pressure regulator
NO
Figure legend

106
- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend
- 043Pressure gage
- 069Pressure hose(119 589 04 63 00)

- Insert bridge.:
- Bridge between sockets [F.4] 100 and [F.17] 113 of the 126-pole socket box tester.
- Warning! Insert bridge only for a short time.
Specified value
Question
107
YES

Test sequence

- Insert bridge.:
- Remove bridge.
Specified value

Question
YES
NO

NO
- N10/2f4 (Fuse 4)
- N10/2kA (Fuel pump relay)
108
1.1.3.2. Test delivery of component M3 (Fuel pump).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend
Test sequence

- Separate fuel feed hose at the fuel line and hold in a suitable measuring beaker.
- Insert bridge.:
- Bridge between sockets [F.4] 100 and [F17] 113 of the 126-pole socket box tester.
- Switch on ignition.<->Component M3 (Fuel pump) runs.
Specified value
- 1 liters of fuel should flow in a maximum of 20 seconds.

Question
109
YES
NO
- Inspect fuel lines for restriction points (in particular pinching).

- Fuel filter
1.1.3.3. Test current consumption of component M3 (Fuel pump).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
110
Figure legend
- 003Multimeter
- N10/2f3 (Fuse 3)
Test prerequisite
- Carry out test only if complaint exists.

Test sequence

- Insert bridge.:
- Unplug component N10/2f3 (Fuse 3) from component N10/2 (Rear SAM control unit with fuse and relay module).
- Measurement is performed at the contact slot of component N10/2f3 (Fuse 3).
- Measure direct current with multimeter between sockets [F10f3] -.- and [F10f3] -.-
Specified value
- Amperage[4...9] A
Question
111
YES
- M3 (Fuel pump)
End of test
NO
- N10/2f4 (Fuse 4)
- Test cables
- M3 (Fuel pump)
End of test
1.1.3.4. Test current consumption of component N10/2kA (Fuel pump relay).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
112
Test sequence

Specified value
- Amperage[0,1...0,3] A
- Component M3 (Fuel pump assembly) is switched on and is heard to run.
Question
YES
NO
- Lines to component N10/2kA (Fuel pump relay)

End of test
1.1.4. Test gasoline fuel for water and diesel portions.

Safety note
protective measures

First-aid measures

113
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Check proportion of water in gasoline fuel.
Figure legend
- 043Pressure gage
- 069Pressure hose(119 589 04 63 00)
Test sequence

- Hold the open fuel line in measuring beaker (055).
- Insert bridge.:
- Drain off about 0.5 l fuel.
- Remove bridge.
Specified value
- Testing If water is present in the fuel, the fuel is cloudy.After being left for a few hours, the water settles on the bottom of the measuring
beaker.
- In cases of doubt, compare the fuel drained with proper fuel.
Question
114
YES
Check proportion of diesel in gasoline fuel.
Test sequence
- Allow a few drops of the drain fuel to drip onto a sheet of paper.
Specified value
- Testing The fuel should evaporate within a few minutes practically free of stains.If diesel portions are present in the fuel, a clearly visible oil
stain remains after the gasoline has evaporated.
Question
YES
NO
- Diesel is present in the gasoline fuel.Replace the fuel.

End of test
NO
- Water is present in the fuel.Replace the fuel.
1.1.5. Inspect the intake system of the engine for leaks.

- Unmetered air
Possible remedy
- Check entire air intake system for unmetered air.

End of test
115
- Leaks
Possible remedy
P0038
Heating of component G3/5 (Left O2 sensor, after TWC [KAT]) : Heating capacity is too low. (P0038)
Possible cause:
- G3/5 (Left O2 sensor, after TWC [KAT])

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test 1: Check component G3/5 (Left O2 sensor, after TWC [KAT]).
1. Check component G3/5 (Left O2 sensor, after TWC [KAT]).

P0037
Heating of component G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit to ground (P0037)
Possible cause:
- G3/6 (Right O2 sensor, after TWC [KAT])

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test 1: Check component G3/6 (Right O2 sensor, after TWC [KAT]).
1. Check component G3/6 (Right O2 sensor, after TWC [KAT]).

P0036
Heating of component G3/6 (Right O2 sensor, after TWC [KAT]) : Open circuit (P0036)
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
116
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
117
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
118

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
119
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
120
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
121
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
122

P0058
Heating of component G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit to positive (P0058)

Affected functions:
- Engine diagnosis
- Exhaust system

P0057
Heating of component G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit to ground (P0057)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P0056
Heating of component G3/5 (Left O2 sensor, after TWC [KAT]) : Open circuit (P0056)
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Engine diagnosis
- Exhaust system
123
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
124
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
125

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
126
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
127
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
128
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
129

The electronic analysis system for the O2 sensor in the engine control unit is defective. (P0607)
Possible cause:
- Test control unit.

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test 1: Test control unit.
1. Test control unit.

Test control unit.
- Erase fault memory and start engine.

- Reread fault memory of control unit N3/10 (ME-SFI [ME] control unit).If fault reoccurs, replace component N3/10 (ME-SFI [ME] control
unit).
Read coding and transfer to the new control unit.End of test
Voltage supply of component Motor electronics / Battery voltage too low for ADC (P0607)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisite

- Ignition ON
130
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
131
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
132
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
133
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Control module has an internal error. (P0607)

134
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test control unit.

unit).
P0032
Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Short circuit to positive (P0032)
Possible cause:
- G3/4 (Right O2 sensor, before TWC [KAT])

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test 1: Check component G3/4 (Right O2 sensor, before TWC [KAT]).
1. Check component G3/4 (Right O2 sensor, before TWC [KAT]).

P0031
Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Short circuit to ground (P0031)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P0030
135
Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Open circuit (P0030)

Affected functions:
- Engine diagnosis
- Exhaust system
1. Power supply


P0052
Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Short circuit to positive (P0052)
Possible cause:
- G3/3 (Left O2 sensor, before TWC [KAT])

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test 1: Check component G3/3 (Left O2 sensor, before TWC [KAT]).
1. Check component G3/3 (Left O2 sensor, before TWC [KAT]).

P0051
Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Short circuit to ground (P0051)
Possible cause:

Affected functions:
136
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P0050
Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Open circuit (P0050)
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO
137


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
138
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
139
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
140
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
141
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
142
Fuses
- FuseF43-F67
Relays

3. Power supply


P0328
Component A16/1 (knock sensor 1, right) has a short circuit to positive. (P0328)
Possible cause:
- A16/1 (knock sensor 1, right)

Affected functions:
- Engine running
-------------------------------------------------
Test 1: Check component A16/1 (knock sensor 1, right).
1. Check component A16/1 (knock sensor 1, right).

Test prerequisite
- Engine running
Test sequence
143
- Briefly blip throttle.

- Coolant temperature:Warning! Communication with ECU required.
- Knock control enable:Warning!
Specified value
- Knock control enable:YES

Question
- Is the actual value o.k.?
YES
NO
- Lines to component A16/1 (knock sensor 1, right)

- Component A16/1 (knock sensor 1, right)
End of test
P0333
Component A16/2 (knock sensor 2, left) has a short circuit to positive. (P0333)
Possible cause:
- A16/2 (knock sensor 2, left)

Affected functions:
- Engine running
-------------------------------------------------
Test 1: Check component A16/2 (knock sensor 2, left).
1. Check component A16/2 (knock sensor 2, left).

Test prerequisite
- Engine running
Test sequence

Specified value

Question
YES
NO
- Lines to component A16/2 (knock sensor 2, left)

- Component A16/2 (knock sensor 2, left)
End of test
P0332
144
Component A16/2 (knock sensor 2, left) has a short circuit to ground. (P0332)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test prerequisite
- Engine running
Test sequence

Specified value

Question
YES
NO

End of test
P2270
G3/6 (Right O2 sensor, after TWC [KAT]) : Aging (P2270)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P2271
145
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P0139
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P2272
G3/5 (Left O2 sensor, after TWC [KAT]) : Aging (P2272)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P2273
Possible cause:
146
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P0159
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P0158
G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit to positive / Resistance of sensor heater too low (P0158)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P2626
G3/4 (Right O2 sensor, before TWC [KAT]) : Open circuit (P2626)
Possible cause:

Affected functions:
- Engine diagnosis
147
- Exhaust system
-------------------------------------------------

P2629
G3/3 (Left O2 sensor, before TWC [KAT]) : Open circuit (P2629)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

G3/4 (Right O2 sensor, before TWC [KAT]) : Voltage is too high. (P2237)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------


Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
148

G3/4 (Right O2 sensor, before TWC [KAT]) : Signal voltage is implausible. (P2237)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

G3/3 (Left O2 sensor, before TWC [KAT]) : Voltage is too high. (P2240)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------


Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
149

G3/3 (Left O2 sensor, before TWC [KAT]) : Signal voltage is implausible. (P2240)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P2243
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P2247
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

150
P2251
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P2254
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P0040
O2 sensors upstream TWC : Plug connections of the O2 sensors are wrongly connected. (P0040)
Possible cause:
- Check assignment of plug connections to O2 sensors.

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test 1: Plug connections of the O2 sensors are wrongly connected.
1. Plug connections of the O2 sensors are wrongly connected.

- The connectors of the O2 sensors upstream of the catalytic converter are swapped.
End of test
151
P2279
Check intake tract for unmetered air. (P2279)
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
Test 1: Check self-adaptation of mixture formation.
1. Check self-adaptation of mixture formation.

Test sequence

P0339
B70 (Crankshaft Hall sensor) : Check wiring of signal line and voltage. (P0339)
Possible cause:
- B70 (Crankshaft Hall sensor)

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test 1: Check component B70 (Crankshaft Hall sensor).
1. Check component B70 (Crankshaft Hall sensor).
Test 1.1: Test signal voltage of component B70 (Crankshaft Hall sensor).
Test 1.2: Check power supply of component B70 (Crankshaft Hall sensor).
1.1. Test signal voltage of component B70 (Crankshaft Hall sensor).
Test 1.1.1: The engine does not start.
Test 1.1.2: Engine running
1.1.1. The engine does not start.

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
152
Settings
- Trigger level: 50 %
- Time range: 5 ms
Test sequence

- Observe oscilloscope pattern between sockets (M.80) 80(A7) and (M.81) 81(A4) of the 126-pole socket box tester.
- Start engine.
Specified value
- Measuring system
Warning!The rising signal edge in the gap (see arrow) may vary.Note
153
1.1.2. Engine running

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
154
Settings
- Time range: 5 ms
Test sequence

Specified value
- Measuring system
- Signal (4,7 - 5,3) V
1.2. Check power supply of component B70 (Crankshaft Hall sensor).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
155
Test sequence
Specified value
- Voltage[4.8...5.3] V
Question
YES
- Signal wire
End of test
NO
- Lines to component B70 (Crankshaft Hall sensor)

End of test
P0343
B6/5 (Right intake camshaft Hall sensor) : Short circuit to positive or open circuit (P0343)
Possible cause:
- B6/5 (Right intake camshaft Hall sensor)

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 1: Check component B6/5 (Right intake camshaft Hall sensor).
156
1. Check component B6/5 (Right intake camshaft Hall sensor).
Test 1.1: Check component B6/5 (Right intake camshaft Hall sensor) using actual value.
Test 1.2: Check power supply of component B6/5 (Right intake camshaft Hall sensor).
Test 1.3: Check assignment of signals from Hall sensors 'Camshafts' and 'Crankshaft'.
1.1. Check component B6/5 (Right intake camshaft Hall sensor) using actual value.
1.2. Check power supply of component B6/5 (Right intake camshaft Hall sensor).
Test prerequisite

Test sequence

- Detach coupling at component B6/5 (Right intake camshaft Hall sensor).
- [ B6/5 ]Measure direct voltage with multimeter between sockets 1 and 3[ B6/5 ]
Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

- Lines to component B6/5 (Right intake camshaft Hall sensor)
End of test
1.3. Check assignment of signals from Hall sensors 'Camshafts' and 'Crankshaft'.
Check assignment of signals from Hall sensors 'Camshafts' and 'Crankshaft'.
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
157
Figure legend
- 1Signal from component B6/5 (Right intake camshaft Hall sensor)

- 2Signal from component B6/7 (Right exhaust camshaft Hall sensor)
- 3Signal from component B6/4 (Left intake camshaft Hall sensor)
- 4Signal from component B6/6 (Left exhaust camshaft Hall sensor)
- 5Signal from component B70 (Crankshaft Hall sensor)
Test prerequisite
- Voltage supply is o.k.

Test sequence

- Component B6/5 (Right intake camshaft Hall sensor):(A7) Observe oscilloscope pattern between sockets [M16] 16 and [M.57] 57 of the
126-pole socket box tester. (A.1)
- Component B6/7 (Right exhaust camshaft Hall sensor):(A7) Observe oscilloscope pattern between sockets [M16] 16 and [M.10] 10 of the
- Component B6/4 (Left intake camshaft Hall sensor):(A7) Observe oscilloscope pattern between sockets [M16] 16 and [M.56] 56 of the
- Component B6/6 (Left exhaust camshaft Hall sensor):(A7) Observe oscilloscope pattern between sockets [M16] 16 and [M.34] 34 of the
- Component B70 (Crankshaft Hall sensor):(A7) Observe oscilloscope pattern between sockets [M16] 16 and [M.81] 81 of the 126-pole socket
box tester. (A5)
- Start engine.
- Enter the settings as shown in the right-hand diagram.
Specified value
- Measuring system
Note
158
P0342
B6/5 (Right intake camshaft Hall sensor) : Short circuit to ground (P0342)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
159
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
160
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
161
P0348
B6/4 (Left intake camshaft Hall sensor) : Short circuit to positive or open circuit (P0348)
Possible cause:
- B6/4 (Left intake camshaft Hall sensor)

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 1: Check component B6/4 (Left intake camshaft Hall sensor).
162
1. Check component B6/4 (Left intake camshaft Hall sensor).
Test 1.1: Check component B6/4 (Left intake camshaft Hall sensor) using actual value.
Test 1.2: Check power supply of component B6/4 (Left intake camshaft Hall sensor).
1.1. Check component B6/4 (Left intake camshaft Hall sensor) using actual value.
1.2. Check power supply of component B6/4 (Left intake camshaft Hall sensor).
Test prerequisite

Test sequence

- Detach coupling at component B6/4 (Left intake camshaft Hall sensor).
Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

- Lines to component B6/4 (Left intake camshaft Hall sensor)
End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
163
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
164
P0347
B6/4 (Left intake camshaft Hall sensor) : Short circuit to ground (P0347)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
165
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
166
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
167
P0368
B6/7 (Right exhaust camshaft Hall sensor) : Short circuit to positive or open circuit (P0368)
Possible cause:
- B6/7 (Right exhaust camshaft Hall sensor)

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 1: Check component B6/7 (Right exhaust camshaft Hall sensor).
168
1. Check component B6/7 (Right exhaust camshaft Hall sensor).
Test 1.1: Check component B6/7 (Right exhaust camshaft Hall sensor) using actual value.
Test 1.2: Check power supply of component B6/7 (Right exhaust camshaft Hall sensor).
1.1. Check component B6/7 (Right exhaust camshaft Hall sensor) using actual value.
1.2. Check power supply of component B6/7 (Right exhaust camshaft Hall sensor).
Test prerequisite

Test sequence

- Detach coupling at component B6/7 (Right exhaust camshaft Hall sensor).
Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

- Lines to component B6/7 (Right exhaust camshaft Hall sensor)
End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
169
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
170
P0367
B6/7 (Right exhaust camshaft Hall sensor) : Short circuit to ground (P0367)

Affected functions:
- Engine diagnosis
- Engine output
171
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
172
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
173
P0393
B6/6 (Left exhaust camshaft Hall sensor) : Short circuit to positive or open circuit (P0393)
Possible cause:
- B6/6 (Left exhaust camshaft Hall sensor)

Affected functions:
- Engine diagnosis
- Engine output
174
-------------------------------------------------
Test 1: Check component B6/6 (Left exhaust camshaft Hall sensor).
1. Check component B6/6 (Left exhaust camshaft Hall sensor).
Test 1.1: Check component B6/6 (Left exhaust camshaft Hall sensor) using actual value.
Test 1.2: Check power supply of component B6/6 (Left exhaust camshaft Hall sensor).
1.1. Check component B6/6 (Left exhaust camshaft Hall sensor) using actual value.
1.2. Check power supply of component B6/6 (Left exhaust camshaft Hall sensor).
Test prerequisite

Test sequence

- Detach coupling at component B6/6 (Left exhaust camshaft Hall sensor).
Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

- Lines to component B6/6 (Left exhaust camshaft Hall sensor)
End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
175
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
176
P0392
B6/6 (Left exhaust camshaft Hall sensor) : Short circuit to ground (P0392)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
177
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
178
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
179
B6/6 (Left exhaust camshaft Hall sensor) : The alternation frequency of the signal value is
implausible. (P0391)
B6/6 (Left exhaust camshaft Hall sensor) : The alternation frequency of the signal value is implausible. (P0391)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
180
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
181
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
182
B6/6 (Left exhaust camshaft Hall sensor) : The time of the signal value change is implausible.
(P0391)
B6/6 (Left exhaust camshaft Hall sensor) : The time of the signal value change is implausible. (P0391)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
183
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
184
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
185
P2195
The signal of the oxygen sensor upstream of the catalytic converter of the right cylinder bank is shifted towards 'Lean'. (P2195)
Possible cause:
- Check exhaust system for leaks.

Affected functions:
- Power generation
-------------------------------------------------
Test 1: Check exhaust system for leaks.
186
1. Check exhaust system for leaks.

P2196
The signal of the oxygen sensor upstream of the catalytic converter of the right cylinder bank is shifted towards 'Rich'. (P2196)
Possible cause:

Affected functions:
- Power generation
-------------------------------------------------

P2197
The signal of the oxygen sensor upstream of the catalytic converter of the left cylinder bank is shifted towards 'Lean'. (P2197)
Possible cause:

Affected functions:
- Power generation
-------------------------------------------------

P2198
The signal of the oxygen sensor upstream of the catalytic converter of the left cylinder bank is shifted towards 'Rich'. (P2198)
Possible cause:

Affected functions:
- Power generation
-------------------------------------------------

187
P2440
The secondary air valve (cylinder bank 1) is jammed open. (P2440)
Possible cause:
- Y32 (Air pump switchover valve)

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test 1: Check component Y32 (Air pump switchover valve).
1. Check component Y32 (Air pump switchover valve).
Test 1.1: Test actuation of component Y32 (Air pump switchover valve).
Test 1.2: Test current consumption of component Y32 (Air pump switchover valve).
1.1. Test actuation of component Y32 (Air pump switchover valve).

Test sequence
- Actuate component Y32 (Air pump switchover valve).(Proceed to 'Actuation' with F2)
1.2. Test current consumption of component Y32 (Air pump switchover valve).
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
188
Test prerequisite
- The actuation was not okay.

Test sequence

- Measure direct current with multimeter between sockets (F.4) 100 and [M.53] 53 of the 126-pole socket box tester.
Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

- Line between component N3/10 (ME-SFI [ME] control unit) and component Y32 (Air pump switchover valve)
- Line between component N10/1 (Driver-side SAM control unit with fuse and relay module) and component Y32 (Air pump switchover
valve)
End of test
P2442
Possible cause:

Affected functions:
- Engine diagnosis
189
-------------------------------------------------

Test sequence
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence
190

Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
End of test
P0459
Y58/1 (Purge control valve) : Short circuit to positive / Switchover valve permanently closed (P0459)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test 1: Check component Y58/1 (Purge control valve).
1. Check component Y58/1 (Purge control valve).
Test 1.1: Actuate component Y58/1 (Purge control valve).
Test 1.2: Test current consumption of component Y58/1 (Purge control valve).
Test 1.3: Perform mechanical inspection of component Y58/1 (Purge control valve).
1.1. Actuate component Y58/1 (Purge control valve).

Test sequence
1.2. Test current consumption of component Y58/1 (Purge control valve).

Figure legend

191
- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence
box tester.
Specified value
- Amperage[0.4...0.9] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test
1.3. Perform mechanical inspection of component Y58/1 (Purge control valve).

Figure legend
- 019Vacuum tester
192
Test prerequisite
- Actuation is OK.
Test sequence

P0458
Y58/1 (Purge control valve) : Short circuit to ground / Switchover valve permanently open (P0458)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test sequence
193

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence
box tester.
Specified value
- Amperage[0.4...0.9] A
Question
YES
194
NO
- N10/1f57 (Fuse 57)

End of test

Figure legend
- 019Vacuum tester
Test prerequisite
- Actuation is OK.
Test sequence

P0726
The input signal of the engine speed has a malfunction. (P0726)
Possible cause:

- Smooth engine running
Affected functions:
195
- Engine diagnosis
-------------------------------------------------
Test 1: Check smooth engine running.
1. Check smooth engine running.
Test 1.1: Check self-adaptation of mixture formation. ( Check by means of actual values )
Test 1.2: Check water and diesel content in gasoline fuel. (Fuel quality)
Test 1.3: Test fuel pressure and delivery of component M3 (Fuel pump).
Test 1.4: Compression test
1.1. Check self-adaptation of mixture formation. ( Check by means of actual values )

1.2. Check water and diesel content in gasoline fuel. (Fuel quality)
Safety note
protective measures

First-aid measures

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
196
Figure legend
- 043Pressure gage
- 069Pressure hose(119 589 04 63 00)
Test sequence

- Insert bridge.:
- Remove bridge.
Specified value
beaker.
Question
197
YES
Test sequence
Specified value
Question
YES
NO

End of test
NO
1.3. Test fuel pressure and delivery of component M3 (Fuel pump).

Safety note
protective measures

198
First-aid measures

Test 1.3.1: Test fuel pressure and internal leaks of fuel system.
Test 1.3.2: Test delivery of component M3 (Fuel pump).
Test 1.3.3: Test current consumption of component M3 (Fuel pump).
Test 1.3.4: Test current consumption of component N10/2kA (Fuel pump relay).
1.3.1. Test fuel pressure and internal leaks of fuel system.

Question
YES
Figure legend
- 043Pressure gage(103 589 00 21 00)

- 069Pressure hose(119 589 04 63 00)

- Engine at idle
Specified value
Question
YES
199

Test sequence
Specified value

Question
YES
NO

NO

NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
200
Figure legend
- 043Pressure gage
- 069Pressure hose(119 589 04 63 00)

- Insert bridge.:
Specified value
Question
201
YES

Test sequence

- Insert bridge.:
- Remove bridge.
Specified value

Question
YES
NO

NO
- N10/2f4 (Fuse 4)
202
1.3.2. Test delivery of component M3 (Fuel pump).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend
Test sequence

- Insert bridge.:
Specified value

Question
203
YES
NO

- Fuel filter
1.3.3. Test current consumption of component M3 (Fuel pump).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
204
Figure legend
- 003Multimeter
- N10/2f3 (Fuse 3)
Test prerequisite

Test sequence

- Insert bridge.:
Specified value
- Amperage[4...9] A
Question
205
YES
- M3 (Fuel pump)
End of test
NO
- N10/2f4 (Fuse 4)
- Test cables
- M3 (Fuel pump)
End of test
1.3.4. Test current consumption of component N10/2kA (Fuel pump relay).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
206
Test sequence

Specified value
- Amperage[0,1...0,3] A
Question
YES
NO

End of test
1.4. Compression test

Test prerequisite
- Connect battery charger.

- Ignition ON
- Engine not running
- Coolant temperature between 70° C and 90° C
Actual values:
Note
- If the rpm difference is greater than 28 1/min, a cylinder leak test must be performed on all cylinders as per the repair instructions to pinpoint
the fault.
207

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Settings
- Time range: 5 ms
Test sequence

- Start engine.
Specified value
- Measuring system
208

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
209
Settings
- Time range: 5 ms
Test sequence

Specified value
- Measuring system
- Signal (4,7 - 5,3) V

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
210
Test sequence
Specified value
- Voltage[4.8...5.3] V
Question
YES
- Signal wire
End of test
NO

End of test
P2414
G3/4 (Right O2 sensor, before TWC [KAT]) : Signal implausible (P2414)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
211

P2415
G3/3 (Left O2 sensor, before TWC [KAT]) : Signal implausible (P2415)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P2422
Mechanical defect or component Y58/4 (Activated charcoal canister shut-off valve) permanently closed (P2422)
Possible cause:
- Mechanical fault of component Y58/4 (Activated charcoal canister shut-off valve)

Affected functions:
- Engine diagnosis
-------------------------------------------------
Ignition coil primary current of cylinder 6 is too high. (P0356)

Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------
Test 1: Check component T1/x (ignition coil(s)).
1. Check component T1/x (ignition coil(s)).
Test 1.1: Check component T1/6 (ignition coil cylinder 6).
1.1. Check component T1/6 (ignition coil cylinder 6).

Warning!Hazard as a result of high voltage at the ignition system!
- Electronic ignition systems operate within a hazardous power range both at the low voltage side (primary circuit) as well as on the high
voltage side (secondary circuit).
- Contacts with such parts can result in burns, heart flutter or cardiac arrest.
Rules of conduct and protective measures
212
- Persons with heart pacemakers must not perform any work on the ignition system.
- Switch off the ignition when performing work on the ignition system.
- Do not touch any parts of the ignition system when starting the engine or when the engine is running.
- Wear protective shoes with rubber soles.
- Do not install any uninsulated adapters into the ignition cables.
Ignition coil primary current of cylinder 6 is too low. (P0356)

Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

Signal fault of ignition coil diagnosis of cylinder 6 (P0356)

Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------
213

Ignition coil primary current of cylinder 6 alternates between too high and too low. (P0356)
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

The control line to the ignition coil of cylinder 6 has an open circuit. (P0356)
Possible cause:
- Line from ignition coil to control unit

Affected functions:
- Engine running
214
-------------------------------------------------

The output stage to ignition coil of cylinder 6 detects an electrical fault. (P0356)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------


215
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------


Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

216

Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

217
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

218
P2301
The control line to the ignition coil of cylinder 1 has a short circuit to positive. (P2301)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

P2300
The control line to the ignition coil of cylinder 1 has a short circuit to ground. (P2300)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------
219

P2310
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

P2309
Possible cause:
220
Affected functions:
- Engine running
-------------------------------------------------

P2307
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

P2306
221
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

P2316
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

222
P2315
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

P2304
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

223
P2303
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

P2313
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------
224

P2312
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

P2258
Relay for air pump : Short circuit to positive (P2258)
Possible cause:
- N10/1kP (Secondary air injection relay)

- N10/1kR (Air pump or oil cooler fan relay)
- N10/1f61 (Fuse 61)
225
Affected functions:
- Engine diagnosis
-------------------------------------------------
Test 2: Check component N10/1kR (Air pump or oil cooler fan relay).
Fuses
- FuseF43-F67
Relays

2. Check component N10/1kR (Air pump or oil cooler fan relay).
Test 2.1: Test current consumption of component N10/1kR (Air pump or oil cooler fan relay).
2.1. Test current consumption of component N10/1kR (Air pump or oil cooler fan relay).
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
226
Test sequence

Warning!Perform the measurement only for a short time so that component M33 (electric air pump) does not overheat.Specified value
- Amperage[0.1...0.3] A
- Component M33 (electric air pump) is switched on and is heard to run.
Question
YES
NO
- N10/1f61 (Fuse 61)

- Lines to component N10/1kR (Air pump or oil cooler fan relay)
End of test
P2257
Relay for air pump : Short circuit to ground (P2257)
Possible cause:

- N10/1f61 (Fuse 61)
Affected functions:
- Engine diagnosis
-------------------------------------------------
227
Fuses
- FuseF43-F67
Relays

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
228
Test sequence

- Amperage[0.1...0.3] A
Question
YES
NO
- N10/1f61 (Fuse 61)

End of test
P2421
Mechanical defect or component Y58/1 (Purge control valve) is permanently open (P2421)
Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
229

Test sequence

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence
box tester.
230
Specified value
- Amperage[0.4...0.9] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test

Figure legend
- 019Vacuum tester
Test prerequisite
- Actuation is OK.
Test sequence

The voltage at relay 'Circuit 87' is too high. (P2505)

231
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
232
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

233
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
234
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
235
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
236
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

The voltage at relay 'Circuit 87' is too low. (P2505)
237
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
238
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
239

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
240
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
241
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
242
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

Constant adjustment of exhaust camshaft of right cylinder bank in direction 'Advanced' (P0017)
243
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Constant adjustment of exhaust camshaft of right cylinder bank in direction 'Retarded' (P0017)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Constant adjustment of exhaust camshaft of left cylinder bank in direction 'Advanced' (P0019)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Constant adjustment of exhaust camshaft of left cylinder bank in direction 'Retarded' (P0019)
Possible cause:

Affected functions:
244
- Engine diagnosis
-------------------------------------------------

Constant adjustment of intake camshaft of right cylinder bank in direction 'Advanced' (P0016)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Constant adjustment of intake camshaft of right cylinder bank in direction 'Retarded' (P0016)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Constant adjustment of intake camshaft of left cylinder bank in direction 'Advanced' (P0018)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
245

Constant adjustment of intake camshaft of left cylinder bank in direction 'Retarded' (P0018)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

P0068
The measured air mass is implausible compared to the position of the throttle valve. (P0068)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 1: Check component B2/5 (Hot film mass air flow sensor).
1. Check component B2/5 (Hot film mass air flow sensor).
Test 1.1: Check signal of component B2/5 (Hot film mass air flow sensor) via actual value with engine OFF.
Test 1.2: Check signal of component B2/5 (Hot film mass air flow sensor) via actual value with engine speed greater than 3500 rpm.
Test 1.3: Check reference signal of component B2/5 (Hot film mass air flow sensor).
Test 1.4: Check power supply of component B2/5 (Hot film mass air flow sensor).
1.1. Check signal of component B2/5 (Hot film mass air flow sensor) via actual value with engine OFF.
1.2. Check signal of component B2/5 (Hot film mass air flow sensor) via actual value with engine speed greater than 3500 rpm.
1.3. Check reference signal of component B2/5 (Hot film mass air flow sensor).
Test sequence
246
Specified value
Question
YES
NO
1.4. Check power supply of component B2/5 (Hot film mass air flow sensor).
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

- Detach coupling at component B2/5 (Hot film mass air flow sensor).
- Measure direct voltage with multimeter between sockets (B2/5) 2 and (B2/5) 1
Specified value
- Voltage[11.0...15.0] V
Question
247
YES
The actual value is okay.Further possible causes of fault
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Test 2.4: Check internal resistance of component M16/6 (Throttle valve actuator).

Test prerequisite

Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
248
Test sequence

Specified value
Question
YES
NO
End of test
2.4. Check internal resistance of component M16/6 (Throttle valve actuator).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
249
Test prerequisites
- The throttle flap of component M16/6 (Throttle valve actuator) should operate freely and must not stick or rub.
Test sequence

- Remove component B2/5 (Hot film mass air flow sensor).
M16/6r3 (Actual value potentiometer (sliding contact 1))
Specified values
- Throttle valve not actuated[ca. 1380]ohms

- Throttle valve fully actuated[ca. 480]ohms
Specified values

Question
YES
- Test voltage supply of the potentiometers of component M16/6 (Throttle valve actuator).
NO
- Lines to component M16/6 (Throttle valve actuator)

End of test
250
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
251
Test sequence
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
252
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test

Test prerequisite

Note
253

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
NO
End of test

Figure legend
254

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisites
Test sequence

Specified values

Specified values

Question
255
YES
NO

End of test
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
The air mass measured by hot film MAF sensor is too low. / The cycle duration of the HFM signal is
too long. (P0101)
The air mass measured by hot film MAF sensor is too low. / The cycle duration of the HFM signal is too long. (P0101)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
256
Test sequence
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
257
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
The air mass measured by the hot film MAF sensor is too high. / The cycle duration of the HFM
signal is too short. (P0101)
The air mass measured by the hot film MAF sensor is too high. / The cycle duration of the HFM signal is too short. (P0101)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
258
Test sequence
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
259
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
P0102
B2/5 (Hot film mass air flow sensor) : Open circuit / Short circuit to ground or to positive (P0102)

Affected functions:
- Engine diagnosis
- Engine output
260
Test sequence
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
261
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
B2/5 (Hot film mass air flow sensor) : Loose contact with low frequency (P0104)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
262
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Unmetered air
- Signal wire
End of test
263
NO
- N10/1f43 (Fuse 43)

End of test
Test sequence
Specified value
Question
YES
NO
B2/5 (Hot film mass air flow sensor) : Loose contact with high frequency (P0104)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
264
Test sequence
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
265
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
P0041
O2 sensors downstream TWC : Plug connections of the O2 sensors are wrongly connected. (P0041)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

- Test plug connections.

End of test
P2229
Sensor 'Ambient pressure' in control module Motor electronics (P2229)
266
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
P2228
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
P2227
Sensor 'Ambient pressure' in control module Motor electronics : Implausible value (P2227)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.
267

unit).
P0071
Plausibility error between signal of temperature sensor in intake pipe and signal of outside temperature sensor (P0071)
Possible cause:
- Ambient temperature values are implausible.

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test 1: Ambient temperature
1. Ambient temperature
Test 1.1: Check component B14 (Ambient temperature display temperature sensor).
Test 1.2: Check component B2/5b1 (Intake air temperature sensor).
1.1. Check component B14 (Ambient temperature display temperature sensor).

Test prerequisites
- The power supply of component N10/1 (Driver-side SAM control unit with fuse and relay module) is OK.
- Fault code 9063 is current, and (or) at least one of the relevant actual values is not OK.
Test sequence
- Detach coupling at component B14 (Ambient temperature display temperature sensor).

- Connect resistance simulator to the connector of component B14 (Ambient temperature display temperature sensor).
- Connect resistance substitution unit between sockets (B14)1 and (B14) 2
- Adjust resistance values one after another and compare them with the actual value.
- B14 (Ambient temperature display temperature sensor):Warning! Communication with ECU required.
Specified value
- Resistor9.6 kohms:Temperature: [0° C]

YES
The actual value is okay.Possible cause and remedy
- Component B14 (Ambient temperature display temperature sensor) is defective.

End of test
268
NO
- Check lines from B14 (Ambient temperature display temperature sensor) to N10/1 (Driver-side SAM control unit with fuse and relay
module) for Short circuit or open circuit.
- Component N10/1 (Driver-side SAM control unit with fuse and relay module) is defective.
End of test
1.2. Check component B2/5b1 (Intake air temperature sensor).
Test 1.2.1: Check component B2/5b1 (Intake air temperature sensor) using actual value.
Test 1.2.2: Check plausibility of actual value B2/5b1 (Intake air temperature sensor) in control module ME 9.7.
Test 1.2.3: Check internal resistance of component B2/5b1 (Intake air temperature sensor).
1.2.1. Check component B2/5b1 (Intake air temperature sensor) using actual value.
Test prerequisites

- Leave vehicle with engine hood open for > 12 h.
Note
- The test prerequisites must be fulfilled for the test result to be meaningful.
Test sequence
269
- Intake air temperature:Warning! Communication with ECU required.
- Ambient temperature:Warning! Communication with ECU required.
Specified value
- The intake air temperature may be max. 5° C below the ambient temperature or 15° C above the ambient temperature.
Question
- Is the actual value for intake air temperature OK?
YES
The actual value is okay.Further procedure
- If only fault codes 1599 and 1600 occur in control unit ME-SFI, erase the fault memory.
- The component may not be replaced.
End of test
NO
- Check plausibility of actual value B2/5b1 (Intake air temperature sensor) in control module N3/10 (ME-SFI [ME] control unit).
- Check internal resistance of component B2/5b1 (Intake air temperature sensor).
1.2.2. Check plausibility of actual value B2/5b1 (Intake air temperature sensor) in control module ME 9.7.
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
- If the connector is unplugged at component B2/5b1 (Intake air temperature sensor), value [ -40° C ] is displayed.
- Bridge pin 2 in pin 3 at the unplugged connection of component B2/5b1 (Intake air temperature sensor).The value is approx. [ 150 ° C ] for a
short period of time and drops back down to the substitute value of approx. [ -40° C ].
Question
270
YES
NO
- Signal wire
End of test
1.2.3. Check internal resistance of component B2/5b1 (Intake air temperature sensor).
Test sequence

271
- Measure resistance with multimeter between pins (B2/5) 2 and (B2/5) 3
Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
YES
The measurement values are OK.End of test
NO
- B2/5b1 (Intake air temperature sensor)

End of test
P0106
B28 (Pressure sensor) : Implausible value (P0106)
Possible cause:
- B28 (Pressure sensor)

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
272
Test 1: Check component B28 (Pressure sensor).
1. Check component B28 (Pressure sensor).
Test 1.1: Check component B28 (Pressure sensor) using actual value.
Test 1.2: Check power supply of component B28 (Pressure sensor).
Test 1.3: Test signal voltage of component B28 (Pressure sensor).
1.1. Check component B28 (Pressure sensor) using actual value.

Test sequence
- Intake manifold pressure (ADC):Warning! Communication with ECU required.

Specified values

- Intake manifold pressure,Ignition ON: > 3.5 V
- Intake manifold pressure,Operate engine at idling speed.:< 2 V
Question
YES
NO
- Check power supply of component B28 (Pressure sensor).

- Test signal voltage of component B28 (Pressure sensor).
Further possible causes of fault
- Vacuum line
1.2. Check power supply of component B28 (Pressure sensor).

Figure legend

- 126/1 -'Secondary air injection left bank of cylinders' shutoff valve
Test prerequisite

Test sequence

- Detach coupling at component B28 (Pressure sensor).
- Measure direct voltage with multimeter between sockets (B28) 1 and (B28) 3
Specified value
- Voltage[4.75...5.25] V
Question
273
YES
NO
- Lines to component N3/10 (ME-SFI [ME] control unit)

End of test
1.3. Test signal voltage of component B28 (Pressure sensor).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
274
Figure legend

Test prerequisite
- The power supply of component B28 (Pressure sensor) is OK.

Test sequence

- Connect the vacuum tester to the input of component B28 (Pressure sensor) with the 3 x distributor.
- Measure direct voltage with multimeter between sockets [ M.15 ] 15 and [ M.86 ] 86 of the 126-pole socket box tester.
Specified values
- Ignition ON: >3.5 V

- Operate engine at idling speed.(Vacuum> 500 mbar):< 2 V
Question
275
YES
NO
- Lines to component B28 (Pressure sensor)

- Vacuum line
End of test
P0107
B28 (Pressure sensor) : Short circuit to ground (P0107)
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

Test sequence
276

Specified values

Question
YES
NO

- Vacuum line

Figure legend

Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
277
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test prerequisite

Test sequence

278
Specified values

Question
YES
NO

- Vacuum line
End of test
P0108
B28 (Pressure sensor) : Short circuit to positive or open circuit (P0108)
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
279

Test sequence

Specified values

Question
YES
NO

- Vacuum line

Figure legend

Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
280
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
281
Figure legend

Test prerequisite

Test sequence

Specified values

Question
282
YES
NO

- Vacuum line
End of test
The value of component B2/5b1 (Intake air temperature sensor) is implausible. (P0111)
Possible cause:
- B11/4 (Coolant temperature sensor)

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test 1: Check component B2/5b1 (Intake air temperature sensor).
Test 2: Check component B11/4 (Coolant temperature sensor).
1. Check component B2/5b1 (Intake air temperature sensor).
Test 1.1: Check component B2/5b1 (Intake air temperature sensor) using actual value.
Test 1.2: Check plausibility of actual value B2/5b1 (Intake air temperature sensor) in control module ME 9.7.
Test 1.3: Check internal resistance of component B2/5b1 (Intake air temperature sensor).
1.1. Check component B2/5b1 (Intake air temperature sensor) using actual value.
Test prerequisites
283
Note
Test sequence
Specified value
Question
YES
End of test
NO
1.2. Check plausibility of actual value B2/5b1 (Intake air temperature sensor) in control module ME 9.7.
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
284
YES
NO
- Signal wire
End of test
1.3. Check internal resistance of component B2/5b1 (Intake air temperature sensor).
Test sequence

285
Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
YES
NO

End of test
2. Check component B11/4 (Coolant temperature sensor).
Test 2.1: Check component B11/4 (Coolant temperature sensor) using actual value.
Test 2.2: Check signal lines on component B11/4 (Coolant temperature sensor).
Test 2.3: Check internal resistance of component B11/4 (Coolant temperature sensor).
2.1. Check component B11/4 (Coolant temperature sensor) using actual value.
Test prerequisite

Test sequence
286
- Coolant temperature sensor ( Signal voltage ):Warning! Communication with ECU required.
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
- Line from component B11/4 (Coolant temperature sensor) to component N3/10 (ME-SFI [ME] control unit)
End of test
2.2. Check signal lines on component B11/4 (Coolant temperature sensor).

Test sequence
Specified value
- If the connection is unplugged at component B11/4 (Coolant temperature sensor), the value is approx. 5 V.
- Bridge pin 1 in pin 2 at the unplugged connection of component B11/4 (Coolant temperature sensor).The value is< 0.5 V.
Question
YES
- Check internal resistance of component B11/4 (Coolant temperature sensor).
NO
- Check lines from component B11/4 (Coolant temperature sensor) to component N3/10 (ME-SFI [ME] control unit).
End of test
2.3. Check internal resistance of component B11/4 (Coolant temperature sensor).

Test prerequisite

Test sequence

- Disconnect connector at component B11/4 (Coolant temperature sensor).
- Measure resistance with multimeter between pins ( B11/4 ) 1 and ( B11/4 ) 2
Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
287
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
The value of component B2/5b1 (Intake air temperature sensor) does not change. (P0111)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisites

Note
Test sequence
Specified value
Question
288
YES
End of test
NO
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
289
YES
NO
- Signal wire
End of test
Test sequence

290
Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
YES
NO

End of test
Test prerequisite

Test sequence
291
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test

Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
292
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
P0112
Component B2/5b1 (Intake air temperature sensor) has a short circuit to ground. (P0112)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisites

Note
Test sequence
Specified value
Question
293
YES
End of test
NO
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
294
YES
NO
- Signal wire
End of test
Test sequence

Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
295
YES
NO

End of test
P0113
Component B2/5b1 (Intake air temperature sensor) has a short circuit to positive or an open circuit. (P0113)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisites

Note
296
Test sequence
Specified value
Question
YES
End of test
NO
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
297
YES
NO
- Signal wire
End of test
Test sequence

298
Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
YES
NO

End of test
Component Y16/2 (Heating system shutoff valve) has a short circuit to positive. (P0115)
Possible cause:
- Y16/2 (Heating system shutoff valve)

Affected functions:
- Heating
-------------------------------------------------
Test 1: Check component Y16/2 (Heating system shutoff valve).
299
1. Check component Y16/2 (Heating system shutoff valve).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test current consumption of component Y16/2 (Heating system shutoff valve).
Test sequence

Specified value
- Amperage[0.7...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)

- Line between component N10/1 (Driver-side SAM control unit with fuse and relay module) and component Y16/2 (Heating system shutoff
valve)
300
- Line between component N10/1 (Driver-side SAM control unit with fuse and relay module) and component N3/10 (ME-SFI [ME] control
unit)
End of test
Component Y16/2 (Heating system shutoff valve) has a short circuit to ground. (P0115)
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Heating
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

301
- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
302

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
303
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
304
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
305
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
306
Fuses
- FuseF43-F67
Relays


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
307
Test sequence

Specified value
- Amperage[0.7...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
unit)
End of test
Component Y16/2 (Heating system shutoff valve) has an open circuit in the wiring. (P0115)
Possible cause:

- N10/1f57 (Fuse 57)
308
Affected functions:
- Heating
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
309
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
310

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
311
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
312
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
313
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
314

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
- Amperage[0.7...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)
315
valve)
unit)
End of test
B11/4 (Coolant temperature sensor) : Shunt fault / Sensor characteristic curve (P0116)
Possible cause:

Affected functions:
- Engine cooling
-------------------------------------------------
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test
316

Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
B11/4 (Coolant temperature sensor) : Coolant temperature is too high. (P0116)

Possible cause:
317

- The cooling performance of the engine cooling system is poor.
Affected functions:
- Engine diagnosis
- Engine cooling
-------------------------------------------------
Test 1: The cooling performance of the engine cooling system is poor.
1. The cooling performance of the engine cooling system is poor.

The cooling performance of the engine cooling system is poor.
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test

Test sequence
318
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
319


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
Specified value
- Amperage[0.6...1.2] A
Question
YES
NO
320
- N10/1f57 (Fuse 57)

End of test
B11/4 (Coolant temperature sensor) : Coolant temperature is too low. (P0116)

Possible cause:

Affected functions:
- Engine diagnosis
- Engine cooling
-------------------------------------------------
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test
321

Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
The engine temperature from the engine control module is implausible. Signal voltage is
The engine temperature from the engine control module is implausible. Signal voltage is implausible. (P0116)
322
Possible cause:

Affected functions:
- Engine diagnosis
- Engine cooling
-------------------------------------------------
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test

Test sequence
Specified value
Question
323
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
The engine temperature from the engine control module is implausible. Shunt fault / Sensor
characteristic curve (P0116)
The engine temperature from the engine control module is implausible. Shunt fault / Sensor characteristic curve (P0116)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine cooling
-------------------------------------------------
324
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test

Test sequence
Specified value
Question
YES
NO
End of test
325

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
B11/4 (Coolant temperature sensor) : Short circuit to positive / Open circuit (P0117)
Possible cause:

Affected functions:
- Engine cooling
-------------------------------------------------
Test prerequisite

Test sequence
326
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test

Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
327
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
B11/4 (Coolant temperature sensor) (P0117)

Possible cause:

Affected functions:
- Engine cooling
-------------------------------------------------
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
328
YES
NO
End of test

Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO
329

End of test
B11/4 (Coolant temperature sensor) : Short circuit to ground (P0118)

Possible cause:

Affected functions:
- Engine cooling
-------------------------------------------------


Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence
330

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test
331



Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
Specified value
- Amperage[0.6...1.2] A
Question
332
YES
NO
- N10/1f57 (Fuse 57)

End of test
Component B11/4 (Coolant temperature sensor) has a short circuit to positive or an open circuit.
(P0118)
Component B11/4 (Coolant temperature sensor) has a short circuit to positive or an open circuit. (P0118)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
333
NO
End of test

Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
334
P0122
M16/6 (Throttle valve actuator) : Actual value potentiometer 1 : Short circuit to ground (P0122)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
P0123
M16/6 (Throttle valve actuator) : Actual value potentiometer 1 : Short circuit to positive or open circuit (P0123)
Possible cause:

Affected functions:
335
- Engine diagnosis
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
P0128
Component Y110 (Three-disk thermostat valve) jams in opened position. : Coolant temperature rises too slowly. (P0128)
Possible cause:
- Mechanical fault of component Y110 (Three-disk thermostat valve)

Affected functions:
- Engine diagnosis
-------------------------------------------------
336



Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
Specified value
- Amperage[0.6...1.2] A
Question
337
YES
NO
- N10/1f57 (Fuse 57)

End of test
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

G3/4 (Right O2 sensor, before TWC [KAT]) : Voltage is too low. (P0130)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Short circuit to positive /
Resistance of sensor heater too low
Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Short circuit to positive / Resistance of sensor heater too low (P0135)
Possible cause:
338

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------


Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Heating capacity is too low.
(P0135)
Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Heating capacity is too low. (P0135)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------


G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit to ground (P0136)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
339

G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit between signal line and line to sensor
heater (P0136)
G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit between signal line and line to sensor heater (P0136)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P0138
G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit to positive / Resistance of sensor heater too low (P0138)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P0140
G3/6 (Right O2 sensor, after TWC [KAT]) : Discontinuity of signal line (P0140)
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
340
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
341
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
342

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
343
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
344
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
345
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
346

Heating of component G3/6 (Right O2 sensor, after TWC [KAT]) : Heating capacity is too low.
(P0141)
Heating of component G3/6 (Right O2 sensor, after TWC [KAT]) : Heating capacity is too low. (P0141)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------


Heating of component G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit to positive (P0141)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

Possible cause:
347

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

G3/3 (Left O2 sensor, before TWC [KAT]) : Voltage is too low. (P0150)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Short circuit to positive /
Resistance of sensor heater too low
Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Short circuit to positive / Resistance of sensor heater too low (P0155)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Heating capacity is too low.
(P0155)
Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Heating capacity is too low. (P0155)
Possible cause:
348

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit to ground (P0156)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit between signal line and line to sensor
heater (P0156)
G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit between signal line and line to sensor heater (P0156)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

P0160
G3/5 (Left O2 sensor, after TWC [KAT]) : Discontinuity of signal line (P0160)
Possible cause:
349

- N10/1f57 (Fuse 57)
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
350
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
351
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
352
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
353
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
354
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

355
3. Power supply

Lambda control, before TWC right : Control implausible (P0170)

Possible cause:
- Lambda control
Affected functions:
- Engine output
-------------------------------------------------
Test 1.1.4: Check component G3/4 (Right O2 sensor, before TWC [KAT]).
Test sequence
356
Specified value
Question
YES
NO
Note
End of test


Note
not be cracked).
End of test
357
1.1.4. Check component G3/4 (Right O2 sensor, before TWC [KAT]).


Safety note
protective measures

First-aid measures


Figure legend

Test sequence

Specified value

Question
358
YES
NO

- 1xClutch 140 545 35 28

359
Test sequence

- Insert bridge.:
socket box.
Specified value

Question
YES
NO

End of test

- Leaks
Possible remedy
Lambda control, before TWC right (P0170)

360
Possible cause:
- Lambda control
Affected functions:
- Engine output
-------------------------------------------------
Test sequence
Specified value
Question
YES
NO
361
Note
End of test


Note
not be cracked).
End of test
362


Safety note
protective measures

First-aid measures


Figure legend

Test sequence

Specified value

Question
363
YES
NO

- 1xClutch 140 545 35 28

Test sequence
364

- Insert bridge.:
socket box.
Specified value

Question
YES
NO

End of test

- Leaks
Possible remedy
Self-adaptation of mixture formation for enrichment at partial load for the right cylinder bank is
above the permissible limit.
Self-adaptation of mixture formation for enrichment at partial load for the right cylinder bank is above the permissible limit. (P0171)
Possible cause:
365

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test 1: Check self-adaptation of mixture formation. Right cylinder bank
1. Check self-adaptation of mixture formation. Right cylinder bank

Test sequence

Self-adaptation of mixture formation for enrichment at idle for the right cylinder bank is above the
Self-adaptation of mixture formation for enrichment at idle for the right cylinder bank is above the permissible limit. (P0171)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence

Lambda control, before TWC right : Lambda control is at rich stop. (P0171)
Possible cause:
- Lambda control
Affected functions:
- Engine output
-------------------------------------------------
366

Test sequence

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
367
Test prerequisite

Test sequence
box tester.
Specified value
- Amperage[0.4...0.9] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test

Figure legend
- 019Vacuum tester
Test prerequisite
- Actuation is OK.
Test sequence

368
Test sequence
Specified value
Question
YES
NO
369
Note
End of test


Note
not be cracked).
End of test
370


Safety note
protective measures

First-aid measures


Figure legend

Test sequence

Specified value

Question
371
YES
NO

- 1xClutch 140 545 35 28

372
Test sequence

- Insert bridge.:
socket box.
Specified value

Question
YES
NO

End of test

- Leaks
Possible remedy
Self-adaptation of mixture formation for enleanment at partial load for the right cylinder bank is
below the permissible limit.
Self-adaptation of mixture formation for enleanment at partial load for the right cylinder bank is below the permissible limit. (P0172)
373
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence

Self-adaptation of mixture formation for enleanment at idle for the right cylinder bank is below the
Self-adaptation of mixture formation for enleanment at idle for the right cylinder bank is below the permissible limit. (P0172)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence

Lambda control, before TWC right : Lambda control is at lean stop. (P0172)
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
374
Test sequence
Specified value
Question
YES
NO
Note
End of test
375

Safety note
protective measures

First-aid measures


Question
YES
Figure legend
- 043Pressure gage(103 589 00 21 00)

- 069Pressure hose(119 589 04 63 00)

376
- Engine at idle
Specified value
Question
YES

Test sequence
Specified value

Question
YES
NO

NO

377
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend
- 043Pressure gage
- 069Pressure hose(119 589 04 63 00)

- Insert bridge.:
Specified value
Question
378
YES

Test sequence

- Insert bridge.:
- Remove bridge.
Specified value

Question
YES
NO

NO
- N10/2f4 (Fuse 4)
379

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend
Test sequence

- Insert bridge.:
Specified value

Question
380
YES
NO

- Fuel filter

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
381
Figure legend
- 003Multimeter
- N10/2f3 (Fuse 3)
Test prerequisite

Test sequence

- Insert bridge.:
Specified value
- Amperage[4...9] A
Question
382
YES
- M3 (Fuel pump)
End of test
NO
- N10/2f4 (Fuse 4)
- Test cables
- M3 (Fuel pump)
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
383
Test sequence

Specified value
- Amperage[0,1...0,3] A
Question
YES
NO

End of test

Safety note
protective measures

First-aid measures

384
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend
- 043Pressure gage
- 069Pressure hose(119 589 04 63 00)
Test sequence

- Insert bridge.:
- Remove bridge.
Specified value
beaker.
Question
385
YES
Test sequence
Specified value
Question
YES
NO

End of test
NO

- Unmetered air
Possible remedy

End of test
386
- Leaks
Possible remedy
Lambda control, before TWC left : Control implausible (P0173)

- Lambda control
Affected functions:
- Engine output
Test sequence
Specified value
Question
387
YES
NO
Note
End of test


Note
not be cracked).
End of test
388


Safety note
protective measures

First-aid measures


Figure legend

Test sequence

Specified value

Question
389
YES
NO

- 1xClutch 140 545 35 28

390
Test sequence

- Insert bridge.:
socket box.
Specified value

Question
YES
NO

End of test

- Leaks
Possible remedy
Lambda control, before TWC left (P0173)
391
Possible cause:
- Lambda control
Affected functions:
- Engine output
-------------------------------------------------
Note
End of test

392

Note
not be cracked).
End of test


Safety note
protective measures

First-aid measures


Figure legend

Test sequence

393
Specified value

Question
YES
NO

- 1xClutch 140 545 35 28

394
Test sequence

- Insert bridge.:
socket box.
Specified value

Question
YES
NO

End of test
395

- Leaks
Possible remedy
Test sequence
Specified value
Question
YES
NO
P0201
The injection valve output stage of cylinder 1 detects a line discontinuity. (P0201)
Possible cause:

- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
396
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
397
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
398

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
399
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
400
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
401
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
402

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
403
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
404
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
405

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
406
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
407
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
408
YES
NO

End of test
P0202
Possible cause:

- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
409
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
410
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
411

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
412
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
413
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
414
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
415

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
416
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
417
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
418

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
419
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
420
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
421
YES
NO

End of test
P0203

- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine running

Safety note
protective measures
422
First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
423
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
424
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
425

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
426
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
427
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
428
YES
NO

End of test
Test prerequisite

- Ignition ON
Specified value

YES
NO

429

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
430
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
431
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
432
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
433
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
434
Fuses
- FuseF43-F67
Relays

5. Power supply
P0204
Possible cause:

- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
435
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
436
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
437

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
438
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
439
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
440
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
441

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
442
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
443
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
444

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
445
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
446
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
447
YES
NO

End of test
P0205
Possible cause:

- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
448
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
449
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
450

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
451
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
452
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
453
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
454

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
455
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
456
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
457

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
458
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
459
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
460
YES
NO

End of test
P0206
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
1. Power supply

Safety note
461
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
462
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
463
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
464

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
465
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
466
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
467
YES
NO

End of test
P0222
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence
468

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
P0223
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
469
YES
End of test
NO

End of test
P0261
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

First-aid measures


Test prerequisite
470

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

- Run engine.
Note
Figure legend

471
- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
NO

Specified value
Question
472
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
473
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
474
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
475
YES
NO

End of test
P0262
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

476
First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
477
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
478
NO

Specified value
Question
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
479
Figure legend

Test sequence

Specified value

Question
480
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
- 1xClutch 140 545 35 28

481
Test sequence

Specified value

Question
YES
NO

End of test
P0264
482
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
483
Warning!
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
484
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
485

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
486
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
487
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
488
YES
NO

End of test
P0265
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

489
First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
490
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
491
NO

Specified value
Question
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
492
Figure legend

Test sequence

Specified value

Question
493
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
- 1xClutch 140 545 35 28

494
Test sequence

Specified value

Question
YES
NO

End of test
P0267
495

Affected functions:
- Engine diagnosis
- Engine running

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
496
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
497
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
498

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
499
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
500
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
501
YES
NO

End of test
P0268
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

502
First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
503
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
504
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
505

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
506
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
507
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
508
YES
NO

End of test
P0270
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

509
First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
510
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
511
NO

Specified value
Question
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
512
Figure legend

Test sequence

Specified value

Question
513
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
- 1xClutch 140 545 35 28

514
Test sequence

Specified value

Question
YES
NO

End of test
P0271
515
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
516
Warning!
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
517
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
518

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
519
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
520
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
521
YES
NO

End of test
P0300
Misfiring (P0300)
Possible cause:
- Combustion misfirings
Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
Test 1: Combustion misfirings
1. Combustion misfirings
Misfiring of cylinder 1 : Damages TWC (P0301)

Possible cause:
Affected functions:
- Engine diagnosis
522
-------------------------------------------------
Misfiring of cylinder 1 : Worsening of exhaust emission values (P0301)

Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
Misfiring of cylinder 1 : Worsening of exhaust emission values after engine start (P0301)
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------

Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
523

Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------

Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
524
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------

Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------

Possible cause:
525
Affected functions:
- Engine diagnosis
-------------------------------------------------
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------

Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------

Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
526
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------

Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------

Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
527
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
P0324
The knock control has a malfunction. (P0324)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test control unit.

unit).
P0325
Component A16/1 (knock sensor 1, right) has an electrical fault. (P0325)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test prerequisite
- Engine running
528
Test sequence

Specified value

Question
YES
NO

End of test
P0327
Component A16/1 (knock sensor 1, right) has a short circuit to ground. (P0327)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test prerequisite
- Engine running
Test sequence

Specified value

Question
YES
NO

End of test
P0330
529
Component A16/2 (knock sensor 2, left) has an electrical fault. (P0330)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test prerequisite
- Engine running
Test sequence

Specified value

Question
YES
NO

End of test
P0335
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
530

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Settings
- Time range: 5 ms
Test sequence

- Start engine.
Specified value
- Measuring system
531

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
532
Settings
- Time range: 5 ms
Test sequence

Specified value
- Measuring system
- Signal (4,7 - 5,3) V

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
533
Test sequence
Specified value
- Voltage[4.8...5.3] V
Question
YES
- Signal wire
End of test
NO

End of test
Number of teeth on sensor rotor too high or too low or wiring error (P0336)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
534

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Settings
- Time range: 5 ms
Test sequence

- Start engine.
Specified value
- Measuring system
535

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
536
Settings
- Time range: 5 ms
Test sequence

Specified value
- Measuring system
- Signal (4,7 - 5,3) V

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
537
Test sequence
Specified value
- Voltage[4.8...5.3] V
Question
YES
- Signal wire
End of test
NO

End of test
No tooth space on sensor rotor detected or wiring error (P0336)

Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
538

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Settings
- Time range: 5 ms
Test sequence

- Start engine.
Specified value
- Measuring system
539

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
540
Settings
- Time range: 5 ms
Test sequence

Specified value
- Measuring system
- Signal (4,7 - 5,3) V

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
541
Test sequence
Specified value
- Voltage[4.8...5.3] V
Question
YES
- Signal wire
End of test
NO

End of test
Tooth space on sensor rotor temporarily not detected or wiring error (P0336)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
542

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Settings
- Time range: 5 ms
Test sequence

- Start engine.
Specified value
- Measuring system
543

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
544
Settings
- Time range: 5 ms
Test sequence

Specified value
- Measuring system
- Signal (4,7 - 5,3) V

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
545
Test sequence
Specified value
- Voltage[4.8...5.3] V
Question
YES
- Signal wire
End of test
NO

End of test
B6/5 (Right intake camshaft Hall sensor) : The alternation frequency of the signal value is
B6/5 (Right intake camshaft Hall sensor) : The alternation frequency of the signal value is implausible. (P0341)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
546
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
547
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
548
B6/5 (Right intake camshaft Hall sensor) : The time of the signal value change is implausible.
(P0341)
B6/5 (Right intake camshaft Hall sensor) : The time of the signal value change is implausible. (P0341)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
549
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
550
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
551

Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------
552


Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------


Possible cause:
- Primary current
553
Affected functions:
- Engine running
-------------------------------------------------

Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

554
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

555

Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------


Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

556

Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------
557

Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Possible cause:

Affected functions:
558
- Engine running
-------------------------------------------------


Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

559
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------


Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

560
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

561
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------


Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------
562


Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------


Possible cause:
- Primary current
Affected functions:
- Engine running
563
-------------------------------------------------

Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

564
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

565
B6/7 (Right exhaust camshaft Hall sensor) : The alternation frequency of the signal value is
B6/7 (Right exhaust camshaft Hall sensor) : The alternation frequency of the signal value is implausible. (P0366)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
566
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
567
- Measuring system
Note
B6/7 (Right exhaust camshaft Hall sensor) : The time of the signal value change is implausible.
(P0366)
B6/7 (Right exhaust camshaft Hall sensor) : The time of the signal value change is implausible. (P0366)
Possible cause:

Affected functions:
568
- Engine diagnosis
- Engine output
-------------------------------------------------
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test prerequisite
569

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
570
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
B6/4 (Left intake camshaft Hall sensor) : The alternation frequency of the signal value is
B6/4 (Left intake camshaft Hall sensor) : The alternation frequency of the signal value is implausible. (P0346)
571
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
572
Warning!
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
573
B6/4 (Left intake camshaft Hall sensor) : The time of the signal value change is implausible. (P0346)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
574
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
575
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
576
Malfunction of secondary air injection at right bank of cylinders (function chain) (P0410)
Possible cause:

- M33 (electric air pump)
Affected functions:
- Engine diagnosis
-------------------------------------------------
577
Test 1: Test secondary air injection (function chain).
Test 2: Check component M33 (electric air pump).
1. Test secondary air injection (function chain).

Test sequence
- Test secondary air injection (function chain).(Move on to actuation with button F2)
2. Check component M33 (electric air pump).
Test 2.1: Check component M33 (electric air pump) by means of actuation.
Test 2.2: Check power supply of component M33 (electric air pump).
Test 2.3: Check component N10/1kR (Air pump or oil cooler fan relay).
2.1. Check component M33 (electric air pump) by means of actuation.

Test prerequisite
- Actuate component M33 (electric air pump).(Move on to actuation with button F2)
2.2. Check power supply of component M33 (electric air pump).

Test prerequisite
- Actuation is not OK.

Test sequence

- (M33) Measure direct voltage with multimeter between 2 and 1 (M33)
- Proceed to 'Actuation' with F2
Specified value
- Voltage[11.0...15.0] V
578
2.3. Check component N10/1kR (Air pump or oil cooler fan relay).
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
579
Test prerequisites
- Actuation of component M33 (electric air pump) is not OK.

Test sequence

- Amperage[0.1...0.3] A
Question
YES
The measurement value is OK.Question
- Does component M33 (electric air pump) run during the current measurement?
YES
NO
Test actuation of component M33 (electric air pump).
Figure legend:1

Figure legend:2

Test sequence

- Detach coupling at component M33 (electric air pump).
- Insert bridge for actuating component N10/1kR (Air pump or oil cooler fan relay).:
580
Specified value
- Voltage[11.0...15.0] V
Question
YES

End of test
NO
- Voltage supply of component N10/1kR (Air pump or oil cooler fan relay)
- Lines to component M33 (electric air pump)
End of test
NO

End of test

Test sequence
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
581
Test prerequisite

Test sequence

Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
End of test
Malfunction of secondary air injection at left bank of cylinders (function chain) (P0410)
Possible cause:

Affected functions:
582
- Engine diagnosis
-------------------------------------------------

Test sequence

Test prerequisite

Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
583
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
584
Test prerequisites

Test sequence

- Amperage[0.1...0.3] A
Question
YES
YES
NO
Figure legend:1

Figure legend:2

Test sequence

585
Specified value
- Voltage[11.0...15.0] V
Question
YES

End of test
NO
End of test
NO

End of test

Test sequence
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
586
Test prerequisite

Test sequence

Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
End of test
P0412
Y32 (Air pump switchover valve) : Open circuit (P0412)
Possible cause:

- N10/1f57 (Fuse 57)
587
Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
588
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
589

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
590
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
591
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
592
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
593

Test sequence
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence
594
Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
End of test
P0413
Y32 (Air pump switchover valve) : Short circuit to positive (P0413)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test sequence
Figure legend

- 108 -Test cable 266 589 01 63 00
595
Warning!
Test prerequisite

Test sequence

Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
End of test
P0414
Y32 (Air pump switchover valve) : Short circuit to ground (P0414)
Possible cause:
596

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test sequence
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
597
Test prerequisite

Test sequence

Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
End of test
The efficiency of the right catalytic converter is insufficient. (function chain) (P0422)
Possible cause:
- Catalytic converter of right cylinder bank

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test 1: Effect of the catalytic converter for the right cylinder bank
1. Effect of the catalytic converter for the right cylinder bank
Test 1.1: Check component G3/4 (Right O2 sensor, before TWC [KAT]).
Test 1.2: Check component G3/6 (Right O2 sensor, after TWC [KAT]).
1.1. Check component G3/4 (Right O2 sensor, before TWC [KAT]).

1.2. Check component G3/6 (Right O2 sensor, after TWC [KAT]).

The efficiency of the left catalytic converter is insufficient. (function chain) (P0422)
598
Possible cause:
- Catalytic converter of left cylinder bank

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test 1: Effect of the catalytic converter for the left cylinder bank
1. Effect of the catalytic converter for the left cylinder bank
Test 1.1: Check component G3/3 (Left O2 sensor, before TWC [KAT]).
Test 1.2: Check component G3/5 (Left O2 sensor, after TWC [KAT]).
1.1. Check component G3/3 (Left O2 sensor, before TWC [KAT]).

1.2. Check component G3/5 (Left O2 sensor, after TWC [KAT]).

P0442
Purge control system has slight leak / Leak in hose connection or shutoff valve of activated charcoal canister (P0442)
Possible cause:
- Purge control system has leak (function chain)

Affected functions:
- Fuel system
-------------------------------------------------
P0444
Y58/1 (Purge control valve) : Open circuit / Switchover valve permanently closed (P0444)
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Engine diagnosis
-------------------------------------------------
599
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
600
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
601

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
602
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
603
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
604
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

605

Test sequence

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence
box tester.
Specified value
- Amperage[0.4...0.9] A
606
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test

Figure legend
- 019Vacuum tester
Test prerequisite
- Actuation is OK.
Test sequence

Component Y58/4 (Activated charcoal canister shut-off valve) has an open circuit in the wiring.
(P0446)
Component Y58/4 (Activated charcoal canister shut-off valve) has an open circuit in the wiring. (P0446)
607
Possible cause:
- Y58/4 (Activated charcoal canister shut-off valve)

Affected functions:
- Engine diagnosis
-------------------------------------------------
Mechanical defect or component Y58/4 (Activated charcoal canister shut-off valve) is permanently
open (P0446)
Mechanical defect or component Y58/4 (Activated charcoal canister shut-off valve) is permanently open (P0446)
Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
P0447
Component Y58/4 (Activated charcoal canister shut-off valve) has a short circuit to positive. (P0447)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
P0448
Component Y58/4 (Activated charcoal canister shut-off valve) has a short circuit to ground. (P0448)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
B4/3 (Fuel tank pressure sensor) : Short circuit to positive (P0451)

Possible cause:
- B4/3 (Fuel tank pressure sensor)

Affected functions:
- Fuel system
-------------------------------------------------
608
B4/3 (Fuel tank pressure sensor) : Short circuit to ground (P0451)

Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
B4/3 (Fuel tank pressure sensor) : Open circuit (P0451)

Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
B4/3 (Fuel tank pressure sensor) : Signal implausible (P0451)

Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
P0452
Tank pressure sensor diagnosis : Short circuit to ground (P0452)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
P0453
Tank pressure sensor diagnosis : Short circuit to positive (P0453)
Possible cause:

Affected functions:
- Engine diagnosis
609
-------------------------------------------------
P0455
Major leak in purge system / Hose in system not connected or filler cap open (P0455)
Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
P0456
Purge control system has a slight leak (minor leak) (P0456)
Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
P0073
Component B14 (Ambient temperature display temperature sensor) has a short circuit to positive. (P0073)
Possible cause:
- B14 (Ambient temperature display temperature sensor)

Affected functions:
- Power generation
-------------------------------------------------
Test 2: Check component B14 (Ambient temperature display temperature sensor).

Test prerequisites
Test sequence
610

Specified value

YES

End of test
NO
End of test
611
Test prerequisites

Note
Test sequence
Specified value
Question
YES
End of test
NO
612
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
613
YES
NO
- Signal wire
End of test
Test sequence

Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
614
YES
NO

End of test
2. Check component B14 (Ambient temperature display temperature sensor).

Test prerequisites
Test sequence

Specified value

615
YES

End of test
NO
End of test
616
P0072
Component B14 (Ambient temperature display temperature sensor) has a short circuit to ground. (P0072)
Possible cause:

Affected functions:
- Power generation
-------------------------------------------------

Test prerequisites
Test sequence

Specified value

YES

End of test
617
NO
End of test
Test prerequisites

Note
Test sequence
618
Specified value
Question
YES
End of test
NO
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
619
YES
NO
- Signal wire
End of test
Test sequence

620
Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
YES
NO

End of test

Test prerequisites
Test sequence

621
Specified value

YES

End of test
NO
End of test
622
P2539
Component B4/7 (Fuel pressure sensor) has an electrical fault. (P2539)
Possible cause:
- This fault can be ignored and erased.

Affected functions:
- Power generation
-------------------------------------------------
Test 1: This fault can be ignored and erased.
1. This fault can be ignored and erased.

Note:This fault can be ignored and erased.
P2542
Component B4/7 (Fuel pressure sensor) has a short circuit to positive. (P2542)
Possible cause:

Affected functions:
- Power generation
-------------------------------------------------

P2541
Component B4/7 (Fuel pressure sensor) has a short circuit to ground. (P2541)
623
Possible cause:

Affected functions:
- Power generation
-------------------------------------------------

P0506
The idle speed is too low during catalytic converter warm-up. (P0506)
Possible cause:

- Inspect the intake system of the engine for leaks.
Affected functions:
- Engine output
-------------------------------------------------
Test 2: Check air filter and intake tract for blockage.

Test prerequisite

Note

Figure legend

624
- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
NO
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
625
Warning!
Test prerequisites
Test sequence

Specified values

Specified values

Question
YES
NO
626

End of test
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
2. Check air filter and intake tract for blockage.

- Intake system clogged

Possible remedy

End of test
P2158
CAN signal 'Vehicle speed at front axle' from control unit Traction systems is implausible. (P2158)
Possible cause:
- N47-5 (ESP control unit)

Affected functions:
- Electronic stability program ESP
-------------------------------------------------
Test 1: Test wheel speed signals.
Test 2: Check component N47-5 (ESP control unit).
1. Test wheel speed signals.

- Read out fault memory of control unit ESP.

End of test
627
2. Check component N47-5 (ESP control unit).

- Read out fault memory of control unit N47-5 (ESP control unit).
End of test
P0460
B4 (Fuel level sensor) (P0460)
Possible cause:
- N10/2 (Rear SAM control unit with fuse and relay module)
Affected functions:
- Fuel system
-------------------------------------------------
Test 1: Check component N10 (SAM control unit).
1. Check component N10 (SAM control unit).

- Read out fault memory of control unit N10/2 (Rear SAM control unit with fuse and relay module).
End of test
P0507
The idle speed is too high during catalytic converter warm-up. (P0507)
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
Test 1: Inspect the intake system of the engine for leaks.
1. Inspect the intake system of the engine for leaks.

- Unmetered air
Possible remedy

End of test
Voltage supply of component Motor electronics / Battery voltage too low (P0562)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
628
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
629
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
630

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend
631

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
632
Fault present in control module Transmission : Battery voltage too low (P0562)
Fault present in control module Transmission : Battery voltage too low (P0562)
Possible cause:
- Fault present in control module Transmission

Affected functions:
- Engine diagnosis
- Automatic transmission Function
-------------------------------------------------
Test 1: Check component N15/3 (ETC [EGS] control unit).
1. Check component N15/3 (ETC [EGS] control unit).

Read out fault memory of transmission control unit and process stored fault codes.
- Read out fault memory of transmission control unit and process stored fault codes.
End of test
Voltage supply of component Motor electronics / Battery voltage too high (P0563)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisite
633
- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
634
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
635
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
636
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fault present in control module Transmission : Battery voltage too high (P0563)
Fault present in control module Transmission : Battery voltage too high (P0563)
637
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P0604
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
P0605
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.
638

unit).
P0606
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).

Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test sequence

Specified value
Question
- Is the test o.k?
YES
639
NO
M16/6 (Throttle valve actuator) : The component was replaced without performing throttle valve
adaptation. (P0638)
M16/6 (Throttle valve actuator) : The component was replaced without performing throttle valve adaptation. (P0638)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

M16/6 (Throttle valve actuator) : Throttle valve jamming (iced up) (P0638)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

P0513
Start enable of DAS not sent : See fault codes in control unit EZS (P0513)
Possible cause:
- N73 (EIS [EZS] control unit)

Affected functions:
- Engine start
-------------------------------------------------
Test 1: Check component N73 (EIS [EZS] control unit).
1. Check component N73 (EIS [EZS] control unit).
640
- Read out fault memory of control unit N73 (EIS [EZS] control unit).
End of test
Part 1
The engine off time has an implausible value. (P2610)
Possible cause:
- A1 (Instrument cluster)
Affected functions:
- CAN Communication
-------------------------------------------------
Test 1: Engine compartment CAN test
Test 2: Check component A1 (Instrument cluster).
1. Engine compartment CAN test
Test 1.1: Engine compartment CAN test
1.1. Engine compartment CAN test
Test 1.1.1: Procedure in case of CAN faults
Test 1.1.2: Read current CAN configuration and CAN fault codes
Test 1.1.3: Further CAN test options
1.1.1. Procedure in case of CAN faults
Test 1.1.1.1: How do I quickly reach my goal?
Test 1.1.1.2: General test information
Test 1.1.1.3: General CAN fundamentals
Test 1.1.1.4: Possible aids and their usage
1.1.1.1. How do I quickly reach my goal?

How do I quickly reach my goal?First call up menu item 'Evaluation of CAN fault codes' in case of CAN timeout fault codes and communication
errors.The resulting tests must be performed.Menu item 'Further CAN test options' should only be called up if the above-specified tests do not
produce the desired result.Note:Menu item 'General test information' can be called up for an explanation of the different CAN fault types.
1.1.1.2. General test information

Notes on CAN fault codes:CAN timeout fault
- A CAN timeout fault code is set due to the absence of a CAN input signal.The cause of this may be not only the transmitter control unit, but
also the CAN networking.
- For example:No CAN message was received from control unit A.
Bus OFF fault
- A Bus OFF fault code is set, when the control unit cannot send a certain amount of messages to the CAN bus or the messages are
incomplete.The control unit then switches off for a short time from CAN bus.
- For example:CAN controller: CAN bus OFF
Functional CAN fault
- A functional CAN fault code is set because of an implausible CAN input signal.The cause of this is not the CAN networking, but the
transmitter control unit or its sensors.
- For example:CAN signal 'A' from control unit B is implausible.
Notes on CAN faults that cannot be read out as fault codes.Bus wake-up event
- An event that wakes up the bus without reason is designated a bus wake-up event.
641
- The cause of this is not the CAN networking, but the transmitter control unit or its sensors.
- Further possible causes of fault:
- Magnetic fields caused by nearby high-voltage installations, railroad installations or power plants.
- Magnetic fields can radiate on to lines and control units in rare cases and cause undefined behavior in the control units.
- The special tool 'Star Diagnosis CANtool' can be used to log bus wake-up events, bus keepawake events and other signals.
Bus keepawake event
- When a control unit keeps communication on the bus awake without reason, this is designated a bus keepawake event.
1.1.1.2. No further information available.
1.1.1.3. General CAN fundamentals
Test 1.1.1.3.1: Low-Speed CAN (83,3 kBit/s)
Test 1.1.1.3.2: High-Speed CAN (125 kBit/s , 500 kBit/s)
1.1.1.3.1. Low-Speed CAN (83,3 kBit/s)

General CAN fundamentals
Low-Speed CAN (83,3 kBit/s)
- 83,3 kBit/s : For example:Interior CAN busSeries 211
- This CAN bus enables single-wire mode.

- 'Single-wire mode' means that fault-free communication between the control units is still possible even if one of the two CAN lines fails.
- This CAN bus does not require external terminating resistors.
Legend and description for figure 1CAN-H: CAN bus HighCAN-L: CAN bus LowECU 1 ... n: Control unit 1 ... nLegend and description for figure
2U 1: Specification approx. 3,6 voltsU 2: Specification approx. 0 voltsU 3: Specification approx. 2,5 voltsU 4: Specification approx. 1,4 voltsU 5:
Specification approx. 5 voltsContinue with button F2
642
1.1.1.3.1. No further information available.
1.1.1.3.2. High-Speed CAN (125 kBit/s , 500 kBit/s)

High-Speed CAN (125 kBit/s , 500 kBit/s)
- 125 kBit/s : Interior CAN busSeries 221

- 125 kBit/s : Telematic CAN busSeries 221
- 500 kBit/s : For example:Drive train CAN bus
- 500 kBit/s : For example:Diagnostic CAN-Bus
- This CAN bus does not permit single-wire mode.

- This means that both CAN lines are always required for fault-free communication between the control units.
- This CAN bus requires external terminating resistors.
- The terminating resistors can be located in control units or voltage distributors depending on the CAN bus.
Legend and description for figure 1CAN-H: CAN bus HighCAN-L: CAN bus LowECU 1 ... n: Control unit 1 ... nCAN terminating resistor (
Example: 120ohms)Legend and description for figure 2U 1: Specification approx. 3,6 voltsU 2: Specification approx. 2,5 voltsU 3: Specification
approx. 1,4 voltsContinue with button F2
643
1.1.1.4. Possible aids and their usage

Evaluation of CAN fault codes
- The control units present in the vehicle (actual configuration) are compared with the coding in control unit CGW (specified configuration).
- Filtering and evaluation of all CAN timeout fault codes present in the vehicleThe result of the evaluation leads to the required test steps.
Multimeter
- Aids for voltage and resistance measurement in menu item 'Measurements with multimeter on CAN network'
Measuring system
- Aid for graphic representation of CAN signal and voltage levels

- The specified characteristics shown in Measurement Technology are used to recognize changed CAN voltage levels, which can be caused by
faulty CAN components.
- Possible procedure: Disconnect and then reconnect the CAN bus subscribers at the voltage distributor one at a time.Compare the pass image
with the actual image from the oscilloscope.
Star Diagnosis CANtool
- Aids for representation of actual values and identification of bus wake-up events and bus keepawake events
1.1.2. Read current CAN configuration and CAN fault codes

1.1.3. Further CAN test options
Test 1.1.3.1: Information to engine compartment CAN network
Test 1.1.3.2: Measurements with multimeter on CAN network
Test 1.1.3.3: Test with the aid of the measuring system
Test 1.1.3.4: Display CAN signals with the aid of the special tool 'Star Diagnosis CANtool'.
1.1.3.1. Information to engine compartment CAN network
Test 1.1.3.1.1: Arrangement diagramNOTESome of the control units listed are special equipment and not installed in every vehicle.
Test 1.1.3.1.2: Wiring diagram of CAN bus
1.1.3.1.1. Arrangement diagramNOTESome of the control units listed are special equipment and not installed in every vehicle.
Location diagram (with special equipment)
644
Figure legend
- A89 (DTR controller unit)
- N3/9 (CDI control unit)
- N15/3 (ETC [EGS] control unit)
- N47-5 (ESP, SPS [PML] and BAS control unit)
- N51 (AIRmatic with ADS control module)
- N63/1 (DTR control module)
- N71 (Headlamp range adjustment control module)
- N80 (Steering column module)
- N93 (Central gateway control unit)
- N97 (Rear axle level control system control module)
- X11/4 (Diagnosis test connector)
- X30/5 (Left voltage distributor (CAN) connector)
- Installation point of plug connection X30/5 (Left voltage distributor (CAN) connector)
- Communication with ECU required
1.1.3.1.2. Wiring diagram of CAN bus

Note
- WIS is not available on this system.

- It is not possible to display the requested WIS document [ pe0019p2200da ].
- You can start WIS on another system and display the WIS document by entering the document number [ pe0019p2200da ] in the 'Contents'
field.
1.1.3.2. Measurements with multimeter on CAN network
645
Test 1.1.3.2.1: Voltage supply of engine compartment CAN control modules
Test 1.1.3.2.2: Resistance test of engine compartment CAN
1.1.3.2.1. Voltage supply of engine compartment CAN control modules
Test 1.1.3.2.1.1: Check power supply at control unit A1 (Instrument cluster).
Test 1.1.3.2.1.2: Check power supply at control unit A89 (DTR controller unit).
Test 1.1.3.2.1.3: Check power supply at control unit N3/10 (ME-SFI [ME] control unit).
Test 1.1.3.2.1.4: Check power supply at control unit N15/3 (ETC [EGS] control unit).
Test 1.1.3.2.1.5: Check power supply at control unit N15/5 (Electronic selector lever module control unit).
Test 1.1.3.2.1.6: Check power supply at control unit N15/6 (Sprintshift control module).
Test 1.1.3.2.1.7: Check power supply at control unit N47-5 (ESP, SPS [PML] and BAS control unit).
Test 1.1.3.2.1.8: Check power supply at control unit N51 (AIRmatic with ADS control module).
Test 1.1.3.2.1.9: Check power supply at control unit N63/1 (DTR control module).
Test 1.1.3.2.1.10: Check power supply at control unit N71 (Headlamp range adjustment control module).
Test 1.1.3.2.1.11: Check power supply at control unit N73 (EIS [EZS] control unit).
Test 1.1.3.2.1.12: Check power supply at control unit N80 (Steering column module).
Test 1.1.3.2.1.13: Check power supply at control unit Y3/8n4 (Fully integrated transmission control (VGS) control unit).
1.1.3.2.1.1. Check power supply at control unit A1 (Instrument cluster).

Test prerequisites
- The fuses are OK.

- The power supply of the control unit N10/1 (Front SAM control unit with fuse and relay module) is OK.
Test sequence

- Detach the socket at component A1 (Instrument cluster).
- Measure direct voltage with multimeter between sockets (A1) 1 and (A1) 6
Specified value
- Voltage [11.0...14.5] V
Question:Is the measurement value OK?
YES
- Perform inspection of connector and of socket for bent pins and enlarged contacts.
- Control unit A1 (Instrument cluster)
End of test
NO
- Line between component A1 (Instrument cluster) and component N10/1 (Front SAM control unit with fuse and relay module)
- Lines between A1 (Instrument cluster) and W28/1 (Ground, left inner door sill)
End of test
1.1.3.2.1.2. Check power supply at control unit A89 (DTR controller unit).
Check power supply at control unit A89 (DTR controller unit).
Figure legend
646

Test prerequisite

- Fuse 45 in component N10/1 (Driver-side SAM control unit with fuse and relay module) is o.k.
Test sequence

- Detach coupling at component A89 (DTR controller unit).
- 1.Measure direct voltage with multimeter between sockets 1 and 1.6
Specified value
- [11.0 ... 14.5] V

Question
- Is the value o.k.?
YES
Note
End of test
NO
The measured value is not within the specified value range.Possible cause and remedy
- Cables between component N10/1 (Driver-side SAM control unit with fuse and relay module) and control module A89 (DTR controller unit)
- Plug connection X11/36
647
1.1.3.2.1.3. Check power supply at control unit N3/10 (ME-SFI [ME] control unit).
Test 1.1.3.2.1.3.1: Test voltage supply of circuit 87. ( Check using actual value )
Test 1.1.3.2.1.3.2: Test voltage supply of circuit 30.
Test 1.1.3.2.1.3.3: Test current consumption of component N10/1kR (Circuit 87 relay, engine).
1.1.3.2.1.3.1. Test voltage supply of circuit 87. ( Check using actual value )
Test prerequisite

- Ignition ON
Specified value

YES
NO

1.1.3.2.1.3.2. Test voltage supply of circuit 30.

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
648
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
1.1.3.2.1.3.3. Test current consumption of component N10/1kR (Circuit 87 relay, engine).

Figure legend
649

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend
650

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
651
1.1.3.2.1.4. Check power supply at control unit N15/3 (ETC [EGS] control unit).
Test 1.1.3.2.1.4.1: Guided test
1.1.3.2.1.4.1. Guided test

Operation number of operation texts and work units or standard texts and flat rates:27-0641Possible cause
- Battery has incorrect charge state or is faulty.

- Local undervoltage of component N15/3 (ETC [EGS] control unit)
Test sequence
- Erase fault memory.

1.1.3.2.1.5. Check power supply at control unit N15/5 (Electronic selector lever module control unit).

- Supply voltage (tml. 15):Warning! Communication with ECU required.
Specified value
- Voltage[7.0...16.0] V
Question
YES

End of test
NO
End of test
1.1.3.2.1.6. Check power supply at control unit N15/6 (Sprintshift control module).

- Connect socket box to component N15/6 (Sprintshift control module).
- Measure direct voltage with multimeter between sockets (B.36) 36 and (B.38) 38 of the 126-pole socket box tester.
652
Specified value
- Voltage[11.0...14.5] V
Question
YES

- Measure direct voltage with multimeter between sockets (A.30) 30 and (A.29) 29 of the 126-pole socket box tester.
Specified value
- Voltage[11.0...14.5] V
Question
653
YES
NO
- Line from component N10/1 (Front SAM control unit with fuse and relay module) to component N15/6 (Sprintshift control module)
End of test
NO
- Check fuse "f63" (voltage supply from control unit ASG) in component N10/1 (Front SAM control unit with fuse and relay module).
- Test cables
End of test
654
1.1.3.2.1.7. Check power supply at control unit N47-5 (ESP, SPS [PML] and BAS control unit).
Test 1.1.3.2.1.7.1: Test voltage of terminal 87 at control unit N47-5 (ESP, SPS [PML] and BAS control unit).
Test 1.1.3.2.1.7.2: Test of cable for voltage supply
Test 1.1.3.2.1.7.3: Test procedure ground cable
1.1.3.2.1.7.1. Test voltage of terminal 87 at control unit N47-5 (ESP, SPS [PML] and BAS control unit).
Test prerequisite
- Battery voltage is OK.

Test sequence

- Connect socket box.
- Measure direct voltage with multimeter between sockets (2.23) 57 and (2.14) 48 of the 126-pole socket box tester.
Specified value
- [11...14 V]
Question
YES
End of test
NO
- Lines to component N47-5 (ESP, SPS [PML] and BAS control unit)
- N10/1f47 (Fuse 47)
End of test
1.1.3.2.1.7.2. Test of cable for voltage supply

Test prerequisite

Test sequence

- Measure direct voltage with multimeter between ground and socket (2.14) 48 of the 126-pole socket box tester.
Specified value
- [11...14 V]
Question
YES
End of test
NO
655
- N10/1f47 (Fuse 47)
End of test
1.1.3.2.1.7.3. Test procedure ground cable

Test prerequisite

Test sequence

- WMeasure resistance with multimeter between 9 and (2.23) 57 of the 35-pole socket box tester.
Specified value
- [<1ohms]
Question
YES
End of test
NO
- Ground cable
- W9 (Ground (at front left headlamp unit))
End of test
Part 2
The engine off time has an implausible value. (P2610)
1.1.3.2.1.8. Check power supply at control unit N51 (AIRmatic with ADS control module).
Test 1.1.3.2.1.8.1.1: Test voltage of terminal 30 at control unit N51 (AIRmatic with ADS control module).
Test 1.1.3.2.1.8.1.2: Test of cable for voltage supply
Test 1.1.3.2.1.8.1.3: Test procedure ground cable
1.1.3.2.1.8.1.1. Test voltage of terminal 30 at control unit N51 (AIRmatic with ADS control module).
Test prerequisite

- Terminal 30:Warning! Communication with ECU required.
Test sequence

656
Specified value
- [11...14 V]
Question
YES
End of test
NO
The actual value is not o.k.Note
- This test did not produce any clear result.

- Select further tests.
1.1.3.2.1.8.1.2. Test of cable for voltage supply

Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO
- Lines to component N51 (AIRmatic with ADS control module)

- F34f37 (Fuse 37)
End of test
1.1.3.2.1.8.1.3. Test procedure ground cable

Test prerequisite

Test sequence

- W15/Measure resistance with multimeter between 1 and (2.21) 55 of the 35-pole socket box tester.
Specified value
- [<1ohms]
657
Question
YES
End of test
NO
- Ground cable
- W15/1 (Ground (right footwell))
End of test
Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO


Test prerequisite

Test sequence

658
Specified value
- [11...14 V]
Question
YES
End of test
NO

- N10/1f45 (Fuse 45)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
YES
End of test
NO
- Ground cable
End of test
1.1.3.2.1.9. Check power supply at control unit N63/1 (DTR control module).
Check power supply at control unit N63/1 (DTR control module).
Test sequence

- Disconnect coupling 2 at component N63/1 (DTR control module).
- Measure direct voltage with multimeter between sockets (N63/1) 2.8 and (N63/1) 2.4
Specified value
- [11.0 ... 14.5] V

Question
659
YES
Note
End of test
NO
- Cables between component N10/1 (Driver-side SAM control unit with fuse and relay module) and control module N63/1 (DTR control
module)5A
1.1.3.2.1.10. Check power supply at control unit N71 (Headlamp range adjustment control module).
If the fault code is not current, it may be deleted. In this case, the battery voltage was too low over an extended period.Charge the battery, if
necessary.Question:Is there a current undervoltage fault is several control modules?Note:This fault could result in consequential faults. You should
therefore process this fault first and then erase the fault memory.
660
YES
- Battery voltage too low.Test battery.Charge battery, replace if necessary.

- If fault occurs again:Check alternator.Communication with ECU required
- The quiescent current is too high.Test quiescent current.
NO
Figure legend 1:N71 (Headlamp range adjustment control module)Figure legend 2:N10/1 (Driver-side SAM control unit with fuse and relay
module)Test prerequisite
- The relevant actual value is not okay.

- Fuse N10/1f52 (Fuse 52) is OK.
Test sequence

- Disconnect connector at component N71 (Headlamp range adjustment control module).
- Measure direct voltage with multimeter between sockets (N71) 20 and (N71) 19
Specified value:Voltage = [11.0...14.5] VQuestion
661
YES
The measurement value is OK.Figure legend 1:N71 (Headlamp range adjustment control module)Figure legend 2:N10/1 (Driver-side SAM control
unit with fuse and relay module)Possible cause or remedy in case of malfunction
- Inspect plug connections N71x1 and (N10/1) I10 for damage, loose contact and corrosion, and repair if necessary.
End of test
662
NO
The measurement value is not OK.Figure legend 1:N71 (Headlamp range adjustment control module)Figure legend 2:N10/1 (Driver-side SAM
control unit with fuse and relay module)Possible cause and remedy
- Cable (N10/1) I10.3 - (N71) 19 is faulty .

- Cable (N71) 20 - W15/1 (Ground (right footwell)) is faulty .
End of test
663
1.1.3.2.1.11. Check power supply at control unit N73 (EIS [EZS] control unit).
Test prerequisite

- Fuse F34f29 (Fuse 29) is OK.
- Power supply:Warning! Communication with ECU required.
Specified value
- Power supply [11.0...14.5] V

Question
YES
- Check alternator.
End of test
NO
The actual value is not o.k.Test sequence

- Detach sockets A and C at component N73 (EIS [EZS] control unit).
- Measure direct voltage with multimeter between sockets (N73) B.2 and (N73) C.1
Specified value
- Voltage [11.0...14.5] V
Question
YES
The measurement values are OK.Possible cause and remedy
- Inspect connector B,C at control unit N73 (EIS [EZS] control unit) for damage, correct connection, loose contact and corrosion and repair, if
necessary.
664
End of test
NO
- Check lines between components N73 (EIS [EZS] control unit) and N10/1 (Driver-side SAM control unit with fuse and relay module) and
repair or replace if necessary.
- Fuse and component F34 (Interior fuse box)
- Check component N10/1 (Driver-side SAM control unit with fuse and relay module).
Question
- Continue troubleshooting in control unit N10/1 (Driver-side SAM control unit with fuse and relay module)?
1.1.3.2.1.11. No further information available.
1.1.3.2.1.12. Check power supply at control unit N80 (Steering column module).
Manual check of supply voltage
Test prerequisite
- The fuses are OK.

- One of the fault codes 9010/9011 is present, or the associated actual value is not OK.
Test sequence
- Remove component N80 (Steering column module).

- Disconnect connector A at component N80 (Steering column module).
- Measure direct voltage with multimeter between sockets [N80] A.8 and [N80] A.9
Specified value
- Voltage [11.0...14.5] V
Question
YES
- Inspect connector A at control unit N80 (Steering column module) for damage, correct connection, loose contact and corrosion and repair, if
necessary.
- Otherwise select further tests.
End of test
NO
- Line between component N80 (Steering column module) and component N10/1 (Driver-side SAM control unit with fuse and relay module)
- Z7/58 (Circuit 30 connector sleeve)
- Line between component N80 (Steering column module) and component W15/1 (Ground (right footwell))
- Z6 (Ground connector sleeve)
End of test
1.1.3.2.1.13. Check power supply at control unit Y3/8n4 (Fully integrated transmission control (VGS) control unit).
Operation number of operation texts and work units or standard texts and flat rates:27-0641Test prerequisite

- Fuse N10/1f46 (Fuse 46) in component N10/1 (Driver-side SAM control unit with fuse and relay module) is o.k.
Test sequence

- Separate plug connection at transmission.
- Measure voltage in transmission wiring harness using a multimeter.
665
Measure direct voltage with multimeter between 5 and 4Specified value
- Voltage [8,5...16,4] V
Question
YES
The measurement value is OK.Further causes
- The diagnosis line is not OK

- Perform test on diagnosis line.
Press button "F2" for further tests
Test K cable to control unit Y3/8n4 (Fully integrated transmission control (VGS) control unit).
- The power supply of component Y3/8n4 (Fully integrated transmission control (VGS) control unit) is OK.
Test sequence
- Test voltage at component X11/4 (Diagnosis test connector).
- If several control modules are connected to a K-wire, the voltage can be measured even if an open circuit exists.
Measure direct voltage with multimeter between (X11/4) 11 and (-) ground.Specified value
- Voltage [8,5...16,4] V
Question
666
YES
Test sequence

- Measure resistance with multimeter between ground and 3

Specified value
- Resistance measured: [OL] ohms

Question
YES
667
Further image can be displayed with key F7.X11/4 (Diagnosis test connector)Test sequence

- Measure resistance with multimeter between 3 and 11 (X11/4)

Specified value
- Resistance measured: [< 0,6] ohms

Question
YES
The measurement value is OK.Cause
- Control module has an internal error.
668
REMEDY
- Disassemble and assemble automatic transmission using the repair instructions.

- Exchange electrohydraulic control unit.
IMPORTANT NOTEFollowing the repair measures, the following checks MUST be carried out using the Diagnosis Assistance System, menu
'Control unit adaptations'
- Flash programming of control unit Y3/8n4 (Fully integrated transmission control (VGS) control unit)
- SCN coding
End of test
NO
- Diagnostic cable has open circuit.

- Inspect wiring and connectors at connection points for loose contacts, damage and corrosion. Repair or replace as required.
End of test
NO
- Diagnostic cable has short to ground.

End of test
NO


Specified value

Question
669
YES
Test sequence


Specified value

Question
YES
670

REMEDY

- SCN coding
End of test
NO

End of test
NO

End of test
NO
The measurement value is not OK.Further causes
- Voltage supply line is not OK.

1.1.3.2.2. Resistance test of engine compartment CAN
Test 1.1.3.2.2.1: Test total resistance of engine compartment CAN.
Test 1.1.3.2.2.2: Test terminating resistor of component X30/5 (Left voltage distributor (CAN) connector).
Test 1.1.3.2.2.3: Test terminating resistor of CAN element in control module N3/10 (ME-SFI [ME] control unit).
1.1.3.2.2.1. Test total resistance of engine compartment CAN.
Test 1.1.3.2.2.1.1: Perform measurement at component X30/5 (Left voltage distributor (CAN) connector).
Test 1.1.3.2.2.1.2: Perform measurement at component N3/10 (ME-SFI [ME] control unit).
1.1.3.2.2.1.1. Perform measurement at component X30/5 (Left voltage distributor (CAN) connector).
Test total resistance of engine compartment CAN.
Figure legend

Test sequence

- Measurement with multimeter
- (X30/5) 2.Measure resistance with multimeter between pins 2 and 2.1 (X30/5)
Adapter cable no. W220 589 00 99 36 may be used.Specified value
- [55...65]ohms
Question:
- Is the measured value within the specified value range?
671
YES
NO
- Line from component N3/10 (ME-SFI [ME] control unit) to component X30/5 (Left voltage distributor (CAN) connector)
- Test terminating resistor of component X30/5 (Left voltage distributor (CAN) connector).
- Test terminating resistor of CAN element in control module N3/10 (ME-SFI [ME] control unit).
End of test
1.1.3.2.2.1.2. Perform measurement at component N3/10 (ME-SFI [ME] control unit).

Test total resistance of the CAN engine.
Test sequence

- Connect socket box to component N3/10 (ME-SFI [ME] control unit).
- Measure resistance with multimeter between sockets (F.41) 11 and (F.54) 24 of the 35-pole socket box tester.
Specified value
Question
YES
NO
672
End of test
1.1.3.2.2.2. Test terminating resistor of component X30/5 (Left voltage distributor (CAN) connector).
Test terminating resistor of component X30/5 (Left voltage distributor (CAN) connector).
Test sequence

- Disconnect coupling F at component N3/10 (ME-SFI [ME] control unit).
Specified value
Question
YES
NO
- Line from component X30/5 (Left voltage distributor (CAN) connector) to component N3/10 (ME-SFI [ME] control unit)
- Component X30/5 (Left voltage distributor (CAN) connector)
End of test
1.1.3.2.2.3. Test terminating resistor of CAN element in control module N3/10 (ME-SFI [ME] control unit).
Test terminating resistor of component N3/10 (ME-SFI [ME] control unit).
Test sequence

- Connector F is plugged in at control unit.
- Unplug the socket F from the wiring harness at the socket box.
Specified value
Question
YES
NO
- Control unit N3/10 (ME-SFI [ME] control unit)

End of test
1.1.3.3. Test with the aid of the measuring system

Test sequence
- Measurement of level voltage of engine CAN buses CAN bus High and CAN bus Low with the universal oscilloscope
- Separating one user from the connector strip X30/5 (Left voltage distributor (CAN) connector)
- Observe level voltage.
- Plug in connector again at connector strip X30/5 (Left voltage distributor (CAN) connector).
- Repeat this procedure for all CAN users.
Specified value
- As soon as the faulty branch was disconnected, the current image of the level voltage changes.
Possible cause of fault in the faulty branch
673

- Test connectors and wiring for CAN of engine compartment CAN control modules.
- Control unit
Communication with ECU required ( Measuring system )
1.1.3.4. Display CAN signals with the aid of the special tool 'Star Diagnosis CANtool'.
Important notes
- When CAN diagnosis is finished, the 8-pin CAN cable must be replaced with the diagnostic cable.
- Before values are read out from a control unit, the control unit must be reinitialized.
Test 1.1.3.4.1: Actual values via CAN ( Engine CAN bus )
1.1.3.4.1. Actual values via CAN ( Engine CAN bus )

Note
- The actual values shown on the following screens are only displayed and updated as long as the CAN bus is active.
Test 1.1.3.4.1.1: Function-specific actual values :
Test 1.1.3.4.1.2: Cruise control
Test 1.1.3.4.1.3: Drive authorization
Test 1.1.3.4.1.4: Control unit-specific actual values :
Test 1.1.3.4.1.5: Electronic selector module
Test 1.1.3.4.1.6: Transmission control
Test 1.1.3.4.1.7: Motor electronics
Test 1.1.3.4.1.8: Steering column module
1.1.3.4.1.1. Function-specific actual values :
1.1.3.4.1.2. Cruise control

1.1.3.4.1.3. Drive authorization

1.1.3.4.1.4. Control unit-specific actual values :
1.1.3.4.1.5. Electronic selector module

1.1.3.4.1.6. Transmission control

1.1.3.4.1.7. Motor electronics

674
1.1.3.4.1.8. Steering column module

2. Check component A1 (Instrument cluster).

Read and process fault code from control module A1 (Instrument cluster).
- Read and process fault code from control module A1 (Instrument cluster).
End of test
P0702
Fault present in control module Transmission (P0702)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P0798
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P2716
675
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P2725
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P2734
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

676
End of test
P2810
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P2759
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P0642
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
677

End of test
P0643
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P0706
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P0722
Possible cause:
678
Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P2767
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P0717
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P0730
679
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P0748
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P0620
Operational fault of component G2 (generator) (P0620)
Possible cause:
- Poly-V-belt
Affected functions:
-------------------------------------------------
Test 1: Poly-V-belt
1. Poly-V-belt
Possible cause
- Poly V-belt thrown or broken

Question
680
- Is the poly-V belt OK?
YES
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisites
- Check plug connection and screw connection B+ to battery, prefuse box and alternator for correct seating.
Test sequence

- Detach sockets F and M at component N3/10 (ME-SFI [ME] control unit).
- Measure direct voltage with multimeter between sockets [ F.2 ] 98 and [ M.45 ] 45 of the 126-pole socket box tester.
Specified value
- Voltage [ > 11 V ]
Question
YES
Test sequence

- Reconnect detached couplings.
- Disconnect 2-pin plug from component Generator.
- Connect adapter cable no. 220 589 00 99 35 at component Generator.
681
- Connect multimeter to red socket of adapter and socket box.
- Measure direct voltage with multimeter between pin [G2] 2 and socket [ M.45 ] 45 of the 126-pole socket box tester.
Specified value
- Voltage [approx.0 mV ]
Question
YES
The measurement value is OK.Other possible cause of fault
- The alternator regulator is defective

End of test
NO
- Check lines and connectors for proper connection and locking, loose contact, damage, contamination and corrosion.
- Check engine wiring harness for correct routing, chafe marks and proper contact at the control unit.
For cleaning, the connector may only be blown out with compressed air! Cleaning agents must not be used.
NO
- Check LIN lines between control unit N3/10 (ME-SFI [ME] control unit) and component Generator.
Test sequence

Specified value
Question
YES

End of test
NO
NO
Remedy
- Repair component Poly-V-belt.

End of test
P0778
682
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P1750
The supply voltage of the control unit is too low (undervoltage).
Possible cause:
- Local undervoltage of component N15/5 (Electronic selector lever module control unit)
Affected functions:
-------------------------------------------------
Test 1: Check power supply at control unit N15/5 (Electronic selector lever module control unit).
1. Check power supply at control unit N15/5 (Electronic selector lever module control unit).

Specified value
- Voltage[7.0...16.0] V
Question
YES

End of test
NO
End of test
The idle speed with warm engine is above the permissible range limit. (P1999)
The idle speed with warm engine is above the permissible range limit. (P1999)
683
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
Test 1: Inspect the intake system of the engine for leaks.
1. Inspect the intake system of the engine for leaks.

- Unmetered air
Possible remedy

End of test
The idle speed with warm engine is below the permissible range limit. (P1999)
The idle speed with warm engine is below the permissible range limit. (P1999)
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
Test 2: Check air filter and intake tract for blockage.

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
684
Test prerequisites
Test sequence

Specified values

Specified values

Question
YES
NO

End of test
685
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test

Test prerequisite

Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
686
Test sequence

Specified value
Question
YES
NO
End of test
2. Check air filter and intake tract for blockage.

- Intake system clogged

Possible remedy

End of test
P2003
The tip switch in the floor-mounted shift has an open circuit.
Possible cause:

Affected functions:
687
-------------------------------------------------

WARNING

End of test
ESL Version 203

The tip switch in the floor-mounted shift has a short circuit to positive.
Possible cause:

Affected functions:
-------------------------------------------------

WARNING

End of test
ME9.7
Diagnosis of tumble flap 'Intake manifold' : Short circuit to ground of sensor lines / Tumble flap shafts stick in the actuated position.
(P2004)
Possible cause:
- Tumble flap shafts stick in the actuated position.

Affected functions:
- Engine output
-------------------------------------------------
Test 1: Diagnosis of tumble flap 'Intake manifold' : Short circuit to ground of sensor lines / Tumble flap shafts stick in the actuated position.
1. Diagnosis of tumble flap 'Intake manifold' : Short circuit to ground of sensor lines / Tumble flap shafts stick in the actuated position.
ESL Version 203

The voltage value of the touch pushbutton is implausible.
688
Possible cause:

Affected functions:
-------------------------------------------------

WARNING

End of test
ME9.7
Diagnosis of tumble flap 'Intake manifold' : Short or open circuit in sensor lines / Mechanical fault of one actuating lever / Sensor faulty,
replace sensor. (P2005)
Possible cause:
- Diagnosis of tumble flap 'Intake manifold'

Affected functions:
- Engine output
-------------------------------------------------
Test 1: Diagnosis of tumble flap 'Intake manifold' : Short or open circuit in sensor lines / Mechanical fault of one actuating lever Sensor faulty,
replace sensor.
1. Diagnosis of tumble flap 'Intake manifold' : Short or open circuit in sensor lines / Mechanical fault of one actuating lever Sensor faulty,
replace sensor.
ESL Version 203

The voltage value of the touch pushbutton is implausible.
Possible cause:

Affected functions:
-------------------------------------------------

WARNING
689

End of test
ME9.7
Diagnosis of tumble flap 'Intake manifold' : Open circuit of sensor lines / Tumble flap shafts stick in the nonactuated position. (P2006)
Possible cause:
- Vacuum supply of component Y22/9 (Intake manifold tumble flap switchover valve) or the aneroid capsule for the tumble flap
Affected functions:
- Engine output
-------------------------------------------------
Test 1: Diagnosis of tumble flap 'Intake manifold' : Open circuit of sensor lines / Tumble flap shafts stick in the nonactuated position.
1. Diagnosis of tumble flap 'Intake manifold' : Open circuit of sensor lines / Tumble flap shafts stick in the nonactuated position.
P2007
Control unit N15/5 (Electronic selector lever module control unit) is defective.
Possible cause:

Affected functions:

-------------------------------------------------

WARNING

End of test
ESL Version 203

Possible cause:

Affected functions:

-------------------------------------------------
690

WARNING

End of test
Y22/6 (variable intake manifold switchover valve) : Open circuit (P2008)

Possible cause:
- Y22/6 (variable intake manifold switchover valve)

- N10/1f57 (Fuse 57)
Affected functions:
- Engine output
-------------------------------------------------
Test 4: Check component Y22/6 (variable intake manifold switchover valve).
Test prerequisite

- Ignition ON
Specified value

YES
NO

691

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
692

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
693
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
694
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
695
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
696
Fuses
- FuseF43-F67
Relays

3. Power supply
4. Check component Y22/6 (variable intake manifold switchover valve).
Test 4.1: Test actuation of component Y22/6 (variable intake manifold switchover valve).
Test 4.2: Test current consumption of component Y22/6 (variable intake manifold switchover valve).
4.1. Test actuation of component Y22/6 (variable intake manifold switchover valve).
Test prerequisite
- The vacuum system is leaktight.

Test sequence
- Actuate component Y22/6 (variable intake manifold switchover valve).(Actuate with key F2.)
Specified value
- Testing The rod of the vacuum unit can be seen to operate.(See arrow)
697
4.2. Test current consumption of component Y22/6 (variable intake manifold switchover valve).
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
698
Test prerequisites

Test sequence
- Measure direct current with multimeter between sockets (F.4) 100 and (M.21) 21 of the 126-pole socket box tester.
Specified value
- Amperage[0.2...0.6] A
Question
YES
- Vacuum unit for variable intake manifold

End of test
NO
- Voltage supply of component Y22/6 (variable intake manifold switchover valve)(N10/1f57 (Fuse 57))
- Wiring from control unit N3/10 (ME-SFI [ME] control unit) to component Y22/6 (variable intake manifold switchover valve)
Y22/9 (Intake manifold tumble flap switchover valve) : Open circuit (P2008)
Possible cause:
- Y22/9 (Intake manifold tumble flap switchover valve)

- N10/1f57 (Fuse 57)
Affected functions:
699
- Engine output
-------------------------------------------------
Test 4: Check component Y22/9 (Intake manifold tumble flap switchover valve).
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
700
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
701

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
702
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
703
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
704
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
705
4. Check component Y22/9 (Intake manifold tumble flap switchover valve).
Test 4.1: Test actuation of component Y22/9 (Intake manifold tumble flap switchover valve).
Test 4.2: Test current consumption of component Y22/9 (Intake manifold tumble flap switchover valve).
4.1. Test actuation of component Y22/9 (Intake manifold tumble flap switchover valve).
Test prerequisite

Test sequence

- Actuate component Y22/9 (Intake manifold tumble flap switchover valve).(Actuate with key F2.)
Specified value
- Testing The rod of the vacuum unit can be seen to operate.The linkage of the swirl flap can be seen to move.(See arrow)
4.2. Test current consumption of component Y22/9 (Intake manifold tumble flap switchover valve).
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
706
Test prerequisites

Test sequence
Specified value
- Amperage[0.2...0.6] A
Question
YES

End of test
NO
- Voltage supply of component Y22/9 (Intake manifold tumble flap switchover valve)(N10/1f57 (Fuse 57))
- Wiring from control unit N3/10 (ME-SFI [ME] control unit) to component Y22/9 (Intake manifold tumble flap switchover valve)
ESL Version 203

Possible cause:

Affected functions:

707
-------------------------------------------------

WARNING

End of test
Y22/6 (variable intake manifold switchover valve) : Short circuit to ground (P2009)
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence
Specified value
708
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
709
Test prerequisites

Test sequence
Specified value
- Amperage[0.2...0.6] A
Question
YES

End of test
NO
Y22/9 (Intake manifold tumble flap switchover valve) : Short circuit to ground (P2009)
710

- N10/1f57 (Fuse 57)
Affected functions:
- Engine output
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
711
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
712

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
713
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
714
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
715
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
716
Test prerequisite

Test sequence

Specified value
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
717
Test prerequisites

Test sequence
Specified value
- Amperage[0.2...0.6] A
Question
YES

End of test
NO
Y22/6 (variable intake manifold switchover valve) : Short circuit to positive (P2010)
Possible cause:

Affected functions:
718
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence
Specified value
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
719
Test prerequisites

Test sequence
Specified value
- Amperage[0.2...0.6] A
Question
YES

End of test
NO
Y22/9 (Intake manifold tumble flap switchover valve) : Short circuit to positive (P2010)
Possible cause:

Affected functions:
720
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence

Specified value
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
721
Test prerequisites

Test sequence
Specified value
- Amperage[0.2...0.6] A
Question
YES

End of test
NO
P2072
Throttle valve jamming (iced up) (P2072)
Possible cause:

Affected functions:
- Engine output
722
-------------------------------------------------
Test 1.1: Throttle valve jamming (iced up)
1.1. Throttle valve jamming (iced up)

Fault freeze frame data
Intake air temperature [°C] ( Limit value : 1 °C )
Test 1.1.2: Check internal resistance of component M16/6 (Throttle valve actuator).
Test 1.1.3: Perform mechanical inspection of component M16/6 (Throttle valve actuator).
1.1.2. Check internal resistance of component M16/6 (Throttle valve actuator).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisites
723
Test sequence

Specified values

Specified values

Question
YES
NO

End of test
1.1.3. Perform mechanical inspection of component M16/6 (Throttle valve actuator).

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
P2088
Component Y49/5 (Right camshaft intake solenoid) has a short circuit to ground. (P2088)
724
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
725
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
P2089
Component Y49/5 (Right camshaft intake solenoid) has a short circuit to positive. (P2089)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
726

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
- Amperage[1.0...1.8] A
Question
727
YES
NO
- N10/1f43 (Fuse 43)

End of test
Component Y49/7 (Right camshaft exhaust solenoid) has a short circuit to ground. (P2090)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
728
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
Component Y49/6 (Left camshaft exhaust solenoid) has a short circuit to ground. (P2090)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
729

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
- Amperage[1.0...1.8] A
Question
730
YES
NO
- N10/1f43 (Fuse 43)

End of test
Component Y49/7 (Right camshaft exhaust solenoid) has a short circuit to positive. (P2091)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
731
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
Component Y49/6 (Left camshaft exhaust solenoid) has a short circuit to positive. (P2091)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
732

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
- Amperage[1.0...1.8] A
Question
733
YES
NO
- N10/1f43 (Fuse 43)

End of test
P2092
Component Y49/4 (Left camshaft intake solenoid) has a short circuit to ground. (P2092)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
734
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
P2093
Component Y49/4 (Left camshaft intake solenoid) has a short circuit to positive. (P2093)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
735

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
- Amperage[1.0...1.8] A
Question
736
YES
NO
- N10/1f43 (Fuse 43)

End of test
P0723
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P2768
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P2766
737
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P0718
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P0716
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

738
End of test
P0219
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
P2757
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

End of test
1
A L L Diagnostic Trouble Codes ( DTC ): Manufacturer Code Charts
EP1860
The right rear wheel rpm signal sent from the traction system via the CAN bus is implausible.
Possible cause:
- N47-5 (ESP and BAS control module)

Affected functions:
- CAN Communication
-------------------------------------------------
Test 1: Interrupted or missing CAN signals from control unit N47-5 (ESP and BAS control module)
1. Interrupted or missing CAN signals from control unit N47-5 (ESP and BAS control module)
Operation number of operation texts and work units or standard texts and flat rates:27-0641WARNING
- This is not a function error of control module N15/5 (Electronic selector lever module control unit) and does not justify replacement.
Possible cause for the entry of this event code
- Operational fault of component N47-5 (ESP and BAS control module)

Possible measures
- Read out fault memory of control unit N47-5 (ESP and BAS control module).
- Process displayed fault codes in control module N47-5 (ESP and BAS control module).
End of test
EP1861
The left rear wheel rpm signal sent from the traction system via the CAN bus is implausible.
Possible cause:

Affected functions:
- CAN Communication
-------------------------------------------------

Possible measures
End of test
EP1876
The signals sent by control unit N47-5 (ESP and BAS control module) for the wheel speeds and the braking torque are not available on the
CAN bus.
Possible cause:
2

Affected functions:
-------------------------------------------------

EP2000
The braking torque value sent from the traction system via the CAN bus is implausible.
Possible cause:

Affected functions:
-------------------------------------------------

Possible measures
End of test
EP2001
The signal sent by control unit N73 (EIS [EZS] control unit) for the stop lamp status is not available on the CAN bus.
Possible cause:

Affected functions:
- CAN Communication
-------------------------------------------------

Part 1
CAN controller: CAN bus OFF
3
Possible cause:
- CAN controller: CAN bus OFF

Affected functions:
- CAN Communication
-------------------------------------------------
Test 1.1: Procedure in case of CAN faults
Test 1.2: Evaluation of CAN fault codes
Test 1.3: Further CAN test options
1.1. Procedure in case of CAN faults
Test 1.1.1: How do I quickly reach my goal?
Test 1.1.2: General test information
Test 1.1.3: General CAN fundamentals
Test 1.1.4: Possible aids and their usage
1.1.1. How do I quickly reach my goal?

1.1.2. General test information

Bus OFF fault
Bus keepawake event
4
1.1.2. No further information available.
1.1.3. General CAN fundamentals
Test 1.1.3.1: Low-Speed CAN (83,3 kBit/s)
Test 1.1.3.2: High-Speed CAN (125 kBit/s , 500 kBit/s)
1.1.3.1. Low-Speed CAN (83,3 kBit/s)


1.1.3.2. High-Speed CAN (125 kBit/s , 500 kBit/s)


5

1.1.4. Possible aids and their usage

Multimeter
Measuring system

6
1.2. Evaluation of CAN fault codes

1.3. Further CAN test options
Test 1.3.1: Information to engine compartment CAN network
Test 1.3.2: Measurements with multimeter on CAN network
Test 1.3.3: Test with the aid of the measuring system
1.3.1. Information to engine compartment CAN network
Test 1.3.1.1: Arrangement diagram
Test 1.3.1.2: Wiring diagram of CAN bus
1.3.1.1. Arrangement diagram

Figure legend
- N15/6 (Sprintshift control module)
- X63/4 (CAN databus adapter connector, 2-pin)
- Installation point of plug connection X63/4 (CAN databus adapter connector, 2-pin)
7
1.3.1.2. Wiring diagram of CAN bus

Note

- It is not possible to display the requested WIS document [ PE0019P2200TA ].
- You can start WIS on another system and display the WIS document by entering the document number [ PE0019P2200TA ] in the 'Contents'
field.
1.3.2. Measurements with multimeter on CAN network
Test 1.3.2.1: Voltage supply of engine compartment CAN control modules
Test 1.3.2.2: Resistance test of engine compartment CAN
1.3.2.1. Voltage supply of engine compartment CAN control modules
Test 1.3.2.1.1: Check power supply at control unit ME-SFI.
Test 1.3.2.1.2: Check power supply at control unit ESP.
Test 1.3.2.1.3: Check power supply at control unit ETC.
Test 1.3.2.1.4: Check power supply at control unit ESM.
Test 1.3.2.1.5: Check power supply at control unit EZS.
Test 1.3.2.1.6: Check power supply at control unit A1 (Instrument cluster).
Test 1.3.2.1.7: Check power supply at control unit N80 (Steering column module).
Test 1.3.2.1.8: Check power supply at control unit N71 (Headlamp range adjustment control module).
8
Test 1.3.2.1.9: Check power supply at control unit N93 (Central gateway control unit).
Test 1.3.2.1.10: Check power supply at control unit Y3/8n4 (Fully integrated transmission control (VGS) control unit).
1.3.2.1.1. Check power supply at control unit ME-SFI.
Test 1.3.2.1.1.1: Test voltage supply of circuit 30.
Test 1.3.2.1.1.2: Test current consumption of component N10/1kR (Circuit 87 relay, engine).
1.3.2.1.1.1. Test voltage supply of circuit 30.

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
9
YES
NO
- N10/1f57 (Fuse 57)

- Lines
End of test
1.3.2.1.1.2. Test current consumption of component N10/1kR (Circuit 87 relay, engine).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
10
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
11
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1kP (Circuit 15 relay)

- Lines
End of test
1.3.2.1.2. Check power supply at control unit ESP.
Test 1.3.2.1.2.1: Test voltage of terminal 87 at control unit N47-5 (ESP, SPS [PML] and BAS control unit).
12
Test 1.3.2.1.2.2: Test of cable for voltage supply
Test 1.3.2.1.2.3: Test procedure ground cable
1.3.2.1.2.1. Test voltage of terminal 87 at control unit N47-5 (ESP, SPS [PML] and BAS control unit).
1.3.2.1.2.2. Test of cable for voltage supply

Test prerequisite

Test sequence

Specified value
- Voltage[11.0...14.5] V
Question
YES
NO
- Lines
- F1f34 (Fuse 34)
End of test
1.3.2.1.2.3. Test procedure ground cable

Test prerequisite

Test sequence

Specified value
- Resistor< 1ohms
Question
YES
The measurement values are OK.Note
End of test
NO
13
At least one of the measured values is not o.k.Possible cause and remedy
- Ground cable
- W16/3 (Ground (left of component compartment, power ground))
End of test
1.3.2.1.3. Check power supply at control unit ETC.


- Measure direct voltage with multimeter between sockets [2.30] 30 and [2.29] 29 of the 126-pole socket box tester.
Specified value
- Voltage[11.0...14.0] V
Question
YES
- Replace component N15/3 (ETC [EGS] control unit).

End of test
NO
- Inspect connector 2 at control unit N15/3 (ETC [EGS] control unit) for damage, correct connection, loose contact and corrosion and repair, if
necessary.
End of test
1.3.2.1.4. Check power supply at control unit ESM.


Specified value
- Voltage[7.0...16.0] V
Question
YES

End of test
NO
End of test
Part 2
CAN controller: CAN bus OFF
1.3.2.1.5. Check power supply at control unit EZS.

Test prerequisite
14

- Fuse F34.f36 is OK.
Specified value

Question
YES
- Check alternator.
End of test
NO

Specified value
- Voltage [11.0...14.5] V
Question
YES
necessary.
End of test
NO
1.3.2.1.6. Check power supply at control unit A1 (Instrument cluster).
1.3.2.1.7. Check power supply at control unit N80 (Steering column module).
Test 1.3.2.1.7.1: Inspect control unit N80 (Steering column module) for undervoltage fault.
Test 1.3.2.1.7.2: Test voltage supply of circuit 30 by means of actual value.
Test 1.3.2.1.7.3: Test voltage supply of circuit 30 by means of measured value.
15
Test 1.3.2.1.7.4: CAN controller: CAN bus OFF
1.3.2.1.7.1. Inspect control unit N80 (Steering column module) for undervoltage fault.
necessary.Question:Is the fault current in several control modules?Note:This fault could result in consequential faults. You should therefore process
this fault first and then erase the fault memory.
YES

NO
Test prerequisite
- Fuse F34f33 (Fuse 33) in component F34 (Interior fuse box) is o.k.
- Actual value is not okay or there is a complaint.
- Voltage at terminal 30:Warning! Communication with ECU required.
Test sequence

- Remove component Airbag.
- Please refer to WIS document AR91.60-P-0660.
- Remove component Multifunction steering wheel.
- Remove component A45 (Clock spring contact).
- This information can be shown using the help function (F6 button) in menu item 'Testing and repair work'.
- Measure direct voltage with multimeter between sockets [N80] 1.8 and [N80] 1.9
Specified value
- Voltage [11.0...14.5] V
Question
16
YES
- Inspect connector 1 at control unit N80 (Steering column module) for damage, correct connection, loose contact and corrosion and repair, if
necessary.
End of test
NO
- Plug connection at control unit N80 (Steering column module)

- Line between component N80 (Steering column module) and component W12 (Ground, center console)
- Line between component N80 (Steering column module) and component F34f33 (Fuse 33)
End of test
1.3.2.1.7.2. Test voltage supply of circuit 30 by means of actual value.

Test prerequisites
- Relevant fault codes exist or a complaint has been received.

Specified value
- Voltage [11.0 ... 14.5] V

Question:
YES
- If fault code 9010/9011 occurs without complaints or function faults, erase fault memory and perform a function check.
- Check alternator.
End of test
NO
17
- Test voltage supply of component N80 (Steering column module) by means of measured value.
End of test
1.3.2.1.7.3. Test voltage supply of circuit 30 by means of measured value.

Test prerequisite
Test sequence

Specified value
- Voltage [11.0...14.5] V
Question
18
YES
necessary.
End of test
NO

End of test
1.3.2.1.7.4. CAN controller: CAN bus OFF

Test prerequisite
- Fault code 9349 or 9350 is present.

Status of relevant fault code:Test sequence
- Check CAN line between control units N80 (SCM [MRM] control unit) and N93 (Central gateway control unit).
- If there is no malfunction, ignore the fault code.
End of test
1.3.2.1.8. Check power supply at control unit N71 (Headlamp range adjustment control module).
YES

NO
Figure legend 1:N71 (Headlamp range adjustment control module)Figure legend 2:N10/1 (Front SAM control unit with fuse and relay module)Test
prerequisite
19

Test sequence

YES
The measurement value is OK.Figure legend 1:N71 (Headlamp range adjustment control module)Figure legend 2:N10/1 (Front SAM control unit
with fuse and relay module)Possible cause or remedy in case of malfunction
- Inspect plug connections N71x1 and (N10/1) 24 for damage, loose contact and corrosion, and repair if necessary.
End of test
20
NO
The measurement value is not OK.Figure legend 1:N71 (Headlamp range adjustment control module)Figure legend 2:N10/1 (Front SAM control
unit with fuse and relay module)Possible cause and remedy
- Cable (N10/1) 24.1 - (N71) 19 is faulty .

- Cable (N71) 20 - W16/3 (Ground (left of component compartment, power ground)) is faulty .
- N10/1 (Front SAM control unit with fuse and relay module)
End of test
21
1.3.2.1.9. Check power supply at control unit N93 (Central gateway control unit).
necessary.Note:This fault could result in consequential faults. You should therefore process this fault first and then erase the fault
memory.Question:Is the fault current in several control modules?
YES

NO
Test prerequisite
- Fuse o.k.
- Fuse o.k.
Test sequence
- Ignition: OFF
- Measurement at component
- Measure direct voltage with multimeter between ground socket and socket
Specified value
- Voltage[11.0...14.5] V
Question

( Picture : Example )
22
YES
Test sequence
- Unplug connector 8 at control unit N93 (Central gateway control unit).

- Measurement at connector 8
- Measure direct voltage with multimeter between sockets (N93) 8.1 and (N93) 8.6
Specified value
- Voltage[11.0...14.5] V
Question
YES
The measurement value is OK.Restore original status.
- Plug in the connector 8 at component N93 (Central gateway control unit).

End of test
NO
The measurement value is not OK.Possible cause and remedy in the case of undervoltage
- Lines between N93 (Central gateway control unit) and

End of test
NO
23
- Lines between and

- G1 (Battery)
- G2 (generator)
End of test
1.3.2.1.10. Check power supply at control unit Y3/8n4 (Fully integrated transmission control (VGS) control unit).

Measure direct voltage with multimeter between 5 and 4Specified value:
- Voltage[8,5...16,4] V
Question
YES
The measurement value is OK.Possible cause of fault
- The conductors in the electrohydraulic control unit are interrupted.

- Component Y3/8n4 (Fully integrated transmission control (VGS) control unit) is defective.
Possible remedy
- Replace component Y3/8 (Electric control unit (VGS)).

Following the repair measures, the following checks MUST be carried out using the Diagnosis Assistance System, menu 'Initial startup'
- Initial startup with manual settings input for new control unit
End of test
24
NO
Test 1.3.2.1.10.1: The measurement value is not OK.
Test 1.3.2.1.10.2: Possible cause and remedy
Test 1.3.2.1.10.3: Test regulator and generator.
1.3.2.1.10.1. The measurement value is not OK.
1.3.2.1.10.2. Possible cause and remedy
1.3.2.1.10.3. Test regulator and generator.

Note on alternator testDepending on the engine variant, different alternators are installed.
- Alternators without networking

- Alternators networked with engine control unit
Networked alternators can be diagnosed via the engine control unit.Detailed information on alternator testing can be found in WIS.Press button F2
to go to WIS documents
1.3.2.2. Resistance test of engine compartment CAN
Test 1.3.2.2.1: Test total resistance of engine compartment CAN.
Test 1.3.2.2.2: Test terminating resistor of component X63/4 (CAN databus adapter connector, 2-pin).
Test 1.3.2.2.3: Test terminating resistor of CAN element in control module N3/10 (ME-SFI [ME] control unit).
1.3.2.2.1. Test total resistance of engine compartment CAN.
Test 1.3.2.2.1.1: Perform measurement at component X63/4 (CAN databus adapter connector, 2-pin).
Test 1.3.2.2.1.2: Perform measurement at component N3/10 (ME-SFI [ME] control unit).
1.3.2.2.1.1. Perform measurement at component X63/4 (CAN databus adapter connector, 2-pin).
Figure legend
25

Test sequence

- [55...65]ohms
Question:
YES
NO
- Line from component N3/10 (ME-SFI [ME] control unit) to component X63/4 (CAN databus adapter connector, 2-pin)
- Test terminating resistor of component X63/4 (CAN databus adapter connector, 2-pin).
End of test
1.3.2.2.1.2. Perform measurement at component N3/10 (ME-SFI [ME] control unit).

Test sequence

Specified value
26
Question
YES
NO
End of test
1.3.2.2.2. Test terminating resistor of component X63/4 (CAN databus adapter connector, 2-pin).
Test terminating resistor of component X63/4 (CAN databus adapter connector, 2-pin).
Test sequence

Specified value
Question
YES
NO
- Line from component X63/4 (CAN databus adapter connector, 2-pin) to component N3/10 (ME-SFI [ME] control unit)
- Component X63/4 (CAN databus adapter connector, 2-pin)
End of test
1.3.2.2.3. Test terminating resistor of CAN element in control module N3/10 (ME-SFI [ME] control unit).
Test sequence

Specified value
Question
YES
NO
27
End of test
1.3.3. Test with the aid of the measuring system

Test sequence
- Separating one user from the connector strip X63/4 (CAN databus adapter connector, 2-pin)
- Plug in connector again at connector strip X63/4 (CAN databus adapter connector, 2-pin).
Specified value

- Control unit
C300
Component Y3/8n4 (Fully integrated transmission control (VGS) control unit) is defective.
Possible cause:
- Y3/8n4 (Fully integrated transmission control (VGS) control unit)

Affected functions:
-------------------------------------------------
Test 1: Remedial action if component 'Y3/8n4 (Fully integrated transmission control (VGS) control unit)' is faulty
1. Remedial action if component 'Y3/8n4 (Fully integrated transmission control (VGS) control unit)' is faulty
Test prerequisites
- First of all process all other current fault codes.

POSSIBLE CAUSES
Preconditions
- Print out the initial quick test log before processing the fault code C300.
- Create control unit log.
Important notes before commencing repair measures
- Always use the same diagnostic unit after the repair measure.
Part 1
One or more messages from control unit N80 (Steering column module) are not available on the CAN bus.
Possible cause:

Affected functions:
- CAN Communication
-------------------------------------------------
28


Bus OFF fault
Bus keepawake event

29




30

Multimeter
Measuring system


31

Figure legend

Note

field.
32

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
33
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f57 (Fuse 57)

- Lines
End of test

Figure legend
34

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend
35

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO

- Lines
End of test
36

Test prerequisite

Test sequence

Specified value
- Voltage[11.0...14.5] V
Question
YES
NO
- Lines
- F1f34 (Fuse 34)
End of test

Test prerequisite

Test sequence

37
Specified value
- Resistor< 1ohms
Question
YES
End of test
NO
- Ground cable
End of test


Specified value
- Voltage[11.0...14.0] V
Question
YES

End of test
NO
necessary.
End of test


Specified value
- Voltage[7.0...16.0] V
Question
YES
38

End of test
NO
End of test
Part 2
One or more messages from control unit N80 (Steering column module) are not available on the CAN bus.

Test prerequisite

Specified value

Question
YES
- Check alternator.
End of test
NO

Specified value
- Voltage [11.0...14.5] V
Question
YES
necessary.
End of test
NO
39
Test 1.3.2.1.7.4: Engine compartment CAN test
YES

NO
Test prerequisite
Test sequence

Specified value
- Voltage [11.0...14.5] V
Question
40
YES
necessary.
End of test
NO

End of test

Test prerequisites

Specified value
41
- Voltage [11.0 ... 14.5] V

Question:
YES
- Check alternator.
End of test
NO
End of test

Test prerequisite
Test sequence

Specified value
- Voltage [11.0...14.5] V
Question
42
YES
necessary.
End of test
NO

End of test
1.3.2.1.7.4. Engine compartment CAN test
YES

NO
prerequisite

Test sequence
43

YES
End of test
44
NO

End of test
45
YES

NO
Test prerequisite
- Fuse o.k.
- Fuse o.k.
Test sequence
- Ignition: OFF
Specified value
- Voltage[11.0...14.5] V
Question

46
YES
Test sequence

Specified value
- Voltage[11.0...14.5] V
Question
YES

End of test
NO

End of test
NO
47
- Lines between and

- G1 (Battery)
- G2 (generator)
End of test

- Voltage[8,5...16,4] V
Question
YES

Possible remedy

End of test
48
NO


Figure legend
49

Test sequence

- [55...65]ohms
Question:
YES
NO
End of test

Test sequence

Specified value
50
Question
YES
NO
End of test
Test sequence

Specified value
Question
YES
NO
End of test
Test sequence

Specified value
Question
YES
NO
51
End of test

Test sequence
Specified value

- Control unit
Part 1
No CAN message was received from control unit N73 (EIS [EZS] control unit) or N93 (Central gateway control unit).
Possible cause:
- Check the CAN communication with control unit N93 (Central gateway control unit).
- Interior CAN bus
Affected functions:
- CAN Communication
-------------------------------------------------
Test 2: Check the CAN communication with control unit N93 (Central gateway control unit).
Test 3: Interior CAN check


52
Bus OFF fault
Bus keepawake event


53



54

Multimeter
Measuring system



Figure legend
55

Note

field.
56

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
57
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f57 (Fuse 57)

- Lines
End of test

Figure legend
58

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend
59

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO

- Lines
End of test
60

Test prerequisite

Test sequence

Specified value
- Voltage[11.0...14.5] V
Question
YES
NO
- Lines
- F1f34 (Fuse 34)
End of test

Test prerequisite

Test sequence

61
Specified value
- Resistor< 1ohms
Question
YES
End of test
NO
- Ground cable
End of test


Specified value
- Voltage[11.0...14.0] V
Question
YES

End of test
NO
necessary.
End of test


Specified value
- Voltage[7.0...16.0] V
Question
YES
62

End of test
NO
End of test
Part 2
No CAN message was received from control unit N73 (EIS [EZS] control unit) or N93 (Central gateway control unit).

Test prerequisite

Specified value

Question
YES
- Check alternator.
End of test
NO

Specified value
- Voltage [11.0...14.5] V
Question
YES
necessary.
End of test
NO
63
Test 1.3.2.1.7.4: Interior CAN check
Test 1.3.2.1.7.5: Check the CAN communication with control unit CGW.
YES

NO
Test prerequisite
Test sequence

Specified value
- Voltage [11.0...14.5] V
Question
64
YES
necessary.
End of test
NO

End of test

Test prerequisites

Specified value
65
- Voltage [11.0 ... 14.5] V

Question:
YES
- Check alternator.
End of test
NO
End of test

Test prerequisite
Test sequence

Specified value
- Voltage [11.0...14.5] V
Question
66
YES
necessary.
End of test
NO

End of test
1.3.2.1.7.4. Interior CAN check

1.3.2.1.7.5. Check the CAN communication with control unit CGW.

Test prerequisite
- The current fault code 9344 is present.

- If a CAN fault regarding communication with control module CGW is present in this control module, then first of all test CAN lines between
the two control modules.
- Continue troubleshooting in control module CGW.
End of test
YES
67

NO
prerequisite

Test sequence

YES
End of test
68
NO

End of test
69
YES

NO
Test prerequisite
- Fuse o.k.
- Fuse o.k.
Test sequence
- Ignition: OFF
Specified value
- Voltage[11.0...14.5] V
Question

70
YES
Test sequence

Specified value
- Voltage[11.0...14.5] V
Question
YES

End of test
NO

End of test
NO
71
- Lines between and

- G1 (Battery)
- G2 (generator)
End of test

- Voltage[8,5...16,4] V
Question
YES

Possible remedy

End of test
72
NO


Figure legend
73

Test sequence

- [55...65]ohms
Question:
YES
NO
End of test

Test sequence

Specified value
74
Question
YES
NO
End of test
Test sequence

Specified value
Question
YES
NO
End of test
Test sequence

Specified value
Question
YES
NO
75
End of test

Test sequence
Specified value

- Control unit
2. Check the CAN communication with control unit N93 (Central gateway control unit).
3. Interior CAN check

ED50B
One or more of the signals transmitted by control unit N73 (EIS [EZS] control unit) or N93 (Central gateway control unit) via the CAN
bus are implausible.
Possible cause:

Affected functions:
- CAN Communication
-------------------------------------------------
Test 1: Fault in CAN communication with control unit N73 (EIS [EZS] control unit).
1. Fault in CAN communication with control unit N73 (EIS [EZS] control unit).
- This is not a function error of control module Y3/8n4 (Fully integrated transmission control (VGS) control unit) and does not justify
replacement.
- Operational fault of component N73 (EIS [EZS] control unit)

Possible measures
- Read out fault memory of control unit N73 (EIS [EZS] control unit).
- Process displayed fault codes in control module N73 (EIS [EZS] control unit).
End of test
ED504
One or more signals sent from control unit N80 (Steering column module) via the CAN bus is implausible.
Possible cause:

Affected functions:
76
- CAN Communication
-------------------------------------------------
Test 1: Fault in CAN communication with control unit N80 (Steering column module).
1. Fault in CAN communication with control unit N80 (Steering column module).
replacement.
- Operational fault of component N80 (Steering column module)

Possible measures
- Read out fault memory of control unit N80 (Steering column module).
- Process displayed fault codes in control module N80 (Steering column module).
End of test
Part 1
The CAN signal for start enable sent to the drive authorization system by transmission control is missing or invalid.
Possible cause:
- Check the CAN communication with control unit N93 (Central gateway control unit).
- Central CAN bus
Affected functions:
- DAS Function
- CAN Communication
-------------------------------------------------
Test 2: Check the CAN communication with control unit N93 (Central gateway control unit).
Test 3: Central CAN test


77
Bus OFF fault
Bus keepawake event


78



79

Multimeter
Measuring system



Figure legend
80

Note

field.
81

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
82
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f57 (Fuse 57)

- Lines
End of test

Figure legend
83

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend
84

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO

- Lines
End of test
85

Test prerequisite

Test sequence

Specified value
- Voltage[11.0...14.5] V
Question
YES
NO
- Lines
- F1f34 (Fuse 34)
End of test

Test prerequisite

Test sequence

86
Specified value
- Resistor< 1ohms
Question
YES
End of test
NO
- Ground cable
End of test


Specified value
- Voltage[11.0...14.0] V
Question
YES

End of test
NO
necessary.
End of test


Specified value
- Voltage[7.0...16.0] V
Question
YES
87

End of test
NO
End of test
Part 2
The CAN signal for start enable sent to the drive authorization system by transmission control is missing or invalid.

Test prerequisite

Specified value

Question
YES
- Check alternator.
End of test
NO

Specified value
- Voltage [11.0...14.5] V
Question
YES
necessary.
End of test
NO
88
Test 1.3.2.1.7.4: Interior CAN check
Test 1.3.2.1.7.5: Check the CAN communication with control unit CGW.
YES

NO
Test prerequisite
Test sequence

Specified value
- Voltage [11.0...14.5] V
Question
89
YES
necessary.
End of test
NO

End of test

Test prerequisites

Specified value
90
- Voltage [11.0 ... 14.5] V

Question:
YES
- Check alternator.
End of test
NO
End of test

Test prerequisite
Test sequence

Specified value
- Voltage [11.0...14.5] V
Question
91
YES
necessary.
End of test
NO

End of test
1.3.2.1.7.4. Interior CAN check

1.3.2.1.7.5. Check the CAN communication with control unit CGW.

Test prerequisite
- The current fault code 9344 is present.

- If a CAN fault regarding communication with control module CGW is present in this control module, then first of all test CAN lines between
the two control modules.
- Continue troubleshooting in control module CGW.
End of test
YES
92

NO
prerequisite

Test sequence

YES
End of test
93
NO

End of test
94
YES

NO
Test prerequisite
- Fuse o.k.
- Fuse o.k.
Test sequence
- Ignition: OFF
Specified value
- Voltage[11.0...14.5] V
Question

95
YES
Test sequence

Specified value
- Voltage[11.0...14.5] V
Question
YES

End of test
NO

End of test
NO
96
- Lines between and

- G1 (Battery)
- G2 (generator)
End of test

- Voltage[8,5...16,4] V
Question
YES

Possible remedy

End of test
97
NO


Figure legend
98

Test sequence

- [55...65]ohms
Question:
YES
NO
End of test

Test sequence

Specified value
99
Question
YES
NO
End of test
Test sequence

Specified value
Question
YES
NO
End of test
Test sequence

Specified value
Question
YES
NO
100
End of test

Test sequence
Specified value

- Control unit
2. Check the CAN communication with control unit N93 (Central gateway control unit).
3. Central CAN test

E1707
Function shutoff of system due to excessive temperature and overvoltage
Possible cause:
- Excess temperature
Affected functions:
-------------------------------------------------
Test 1: Remedial action after a shutdown of the transmission functions due to the occurrence of an overtemperature and (or) overvoltage
1. Remedial action after a shutdown of the transmission functions due to the occurrence of an overtemperature and (or) overvoltage
replacement.
- The vehicle was jump-started.
End of test
060C
Possible cause:

Affected functions:
-------------------------------------------------
101
Operation number of operation texts and work units or standard texts and flat rates:27-0641Warning!In the event of stored faults with high fault
frequency counter:The control module must not be replaced.Cause

REMEDY

Notes on submitting warranty or goodwill claimsSEAG damage code (7 digits): 54553 73IMPORTANT NOTEFollowing the repair measures, the
following checks MUST be carried out using the Diagnosis Assistance System, menu 'Initial startup'
061B
The internal engine torque computation performed in component Y3/8n4 (Fully integrated transmission control (VGS) control unit) is
faulty.
Possible cause:
- Transmission shift
Affected functions:
-------------------------------------------------
Test 1: Possible causes and remedial action when fault code P061B is displayed
1. Possible causes and remedial action when fault code P061B is displayed
Particulars of complaint
- After the engine control unit and (or) transmission control unit have been programmed, fault code 061B may be stored in the transmission
control unit.
Cause
-The torque interfaces of the engine control unit and transmission control unit are not optimally suited to each other.Torque control is not
possible or only partially possible.
REMEDY
102
- Program control unit N3/10 (ME-SFI [ME] control unit).

- Perform final quick test.
IMPORTANT NOTE
- Even if no new engine software is detected by STAR DIAGNOSIS, the SCN coding is still to be performed.
- If fault code 061B reoccurs, it can be ignored until a new engine control software version is available.
Notes on submitting warranty or goodwill claimsSEAG damage code (7 digits): 54 553 EDEnd of test
062F
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
- Print out the initial quick test log before processing the fault code 062F.
Sequence
- Data are being read from the old control unit.

Start process with button F2.
0059
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

103
0060
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

0063
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

0064
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

104
0065
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
105
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
0066
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
106

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
- Amperage[1.0...1.8] A
Question
107
YES
NO
- N10/1f43 (Fuse 43)

End of test
0067
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
1. Power supply

Test prerequisite
- Engine at idle
Note

Figure legend

108
- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
0069
Possible cause:

Affected functions:
109
- Engine diagnosis
- Engine output
-------------------------------------------------

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
110
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
0070
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
111
Warning!
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
0071
Possible cause:

- N10/1f43 (Fuse 43)
112
Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
113
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
114

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
115
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
116
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
117
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
118

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
119
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
0073
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test sequence
Specified values


Question
YES
NO
120


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
121
- Signal lines
End of test
NO

End of test
0077

Affected functions:
- Engine diagnosis
- Engine output
Test sequence
Specified values


Question
YES
NO


Figure legend

122
- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
123
0081
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test sequence
Specified values


Question
YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
124
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
0085
Possible cause:
125

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test sequence
Specified values


Question
YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
126
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
0089
B37 (Accelerator pedal sensor) : Voltage of Hall sensor 1 does not agree with voltage of Hall sensor 2. (P2138)
Possible cause:

Affected functions:
- Engine diagnosis
127
- Engine output
-------------------------------------------------
Test sequence
Specified values


Question
YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
128
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
0093
B37 (Accelerator pedal sensor) : Power supply (P0651)
Possible cause:

Affected functions:
- Engine diagnosis
129
- Engine output
-------------------------------------------------
Test sequence
Specified values


Question
YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
130
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
0117
Possible cause:

Affected functions:
- Engine diagnosis
131
-------------------------------------------------

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Settings
- Time range: 5 ms
Test sequence

- Start engine.
132
Specified value
- Measuring system

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
133
Settings
- Time range: 5 ms
Test sequence

Specified value
- Measuring system
- Signal (4,7 - 5,3) V
134

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
135
Test sequence
Specified value
- Voltage[4.8...5.3] V
Question
YES
- Signal wire
End of test
NO

End of test
0119
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
136
Settings
- Time range: 5 ms
Test sequence

- Start engine.
Specified value
- Measuring system
137

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
138
Settings
- Time range: 5 ms
Test sequence

Specified value
- Measuring system
- Signal (4,7 - 5,3) V

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
139
Test sequence
Specified value
- Voltage[4.8...5.3] V
Question
YES
- Signal wire
End of test
NO

End of test
0120
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
140

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Settings
- Time range: 5 ms
Test sequence

- Start engine.
Specified value
- Measuring system
141

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
142
Settings
- Time range: 5 ms
Test sequence

Specified value
- Measuring system
- Signal (4,7 - 5,3) V

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
143
Test sequence
Specified value
- Voltage[4.8...5.3] V
Question
YES
- Signal wire
End of test
NO

End of test
0153
Component Y110 (Three-disk thermostat valve) has a short circuit to positive. (P0599)
Possible cause:

Affected functions:
- Heating
- Engine cooling
-------------------------------------------------
144



Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
145
Specified value
- Amperage[0.6...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test
0154
Component Y110 (Three-disk thermostat valve) has a short circuit to ground. (P0598)
Possible cause:

Affected functions:
- Heating
- Engine cooling
-------------------------------------------------



Figure legend

- 108 -Test cable 266 589 01 63 00
146
Warning!
Test sequence
Specified value
- Amperage[0.6...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test
0155
Component Y110 (Three-disk thermostat valve) has an open circuit in the wiring. (P0597)
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
147
- Heating
- Engine cooling
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
148
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
149

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
150
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
151
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
152
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
153



Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
154
Specified value
- Amperage[0.6...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test
0160
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
155
YES
End of test
NO

End of test
0161
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO
156

End of test
0162
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
0164
Possible cause:
157

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
0165
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
158
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
0166
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
159
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
0168
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence
160
Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
0185
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Test prerequisite

Note

Figure legend

- 108 -Test cable 266 589 01 63 00
161
Warning!
Test sequence

Specified value
Question
YES
NO
End of test
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
162
Question
YES
End of test
NO

End of test
0186
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Test prerequisite

Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
163
Test sequence

Specified value
Question
YES
NO
End of test
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
164
YES
End of test
NO

End of test
0187
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Test prerequisite

Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
165
Test sequence

Specified value
Question
YES
NO
End of test
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
166
End of test
NO

End of test
0188
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Test prerequisite

Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
167
Test sequence

Specified value
Question
YES
NO
End of test
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
168
End of test
NO

End of test
0189
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
0190

Affected functions:
- Engine diagnosis
- Engine running
169

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
0193
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
170
0194
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
0200
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
171

Test prerequisite

Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

172
Specified value
Question
YES
NO
End of test

Test sequence

Specified value
Question
- Is the test o.k?
YES

End of test
NO
0204
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
Test 1.1: Check component B37 (Accelerator pedal sensor).
Test 1.2: Check component M16/6 (Throttle valve actuator).
173
1.1. Check component B37 (Accelerator pedal sensor).
Test 1.1.1: Check component B37 (Accelerator pedal sensor) using actual value.
Test 1.1.2: Check power supply of component B37 (Accelerator pedal sensor).
1.1.1. Check component B37 (Accelerator pedal sensor) using actual value.
Test sequence
Specified values


Question
YES
NO

1.1.2. Check power supply of component B37 (Accelerator pedal sensor).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
174
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
1.2. Check component M16/6 (Throttle valve actuator).
Test 1.2.2: Check component M16/6m1 (Actuator motor) by means of actuation.
1.2.2. Check component M16/6m1 (Actuator motor) by means of actuation.
175
Test prerequisite

Note

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
0205
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Test prerequisite
176
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
NO
177
End of test

Test sequence

Specified value
Question
- Is the test o.k?
YES

End of test
NO
0206
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Test prerequisite

Note

Figure legend
178

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
NO
End of test

Test sequence

179
Specified value
Question
- Is the test o.k?
YES

End of test
NO
0212
M16/6 (Throttle valve actuator) : The component was replaced without performing throttle valve adaptation. (P0638)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

0216
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

180
0217
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
Test 1.4: Note : Control unit programming must be performed on control unit variants VC6 to VC8.

Test prerequisite

Note

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
1.4. Note : Control unit programming must be performed on control unit variants VC6 to VC8.
181
722.9 (7-gear) ETC2 as of 2005

Temperature of gear oil is too high.
Possible cause:
- Temperature of gear oil is too high.

Affected functions:
-------------------------------------------------
Test 1: Remedial action if transmission oil temperature is too high
1. Remedial action if transmission oil temperature is too high

Operation number of operation texts and work units or standard texts and flat rates:27-0641 Error response:- Control unit Y3/8n4 (Fully integrated
transmission control (VGS) control unit) initiates a reduction of the engine torque in relation to the measured transmission oil temperature.- The
reduction of the engine torque necessarily produces a power loss in the engine.POSSIBLE CAUSES
- This fault code may have resulted from the transmission having previously gone into emergency mode, or from stored fault code 2759.
REMEDY
- If fault codes are present, process these.

- Check transmission oil cooling for proper operation and for leakage.
- Perform condition check of the transmission oil.(Continue with button "F6")
ME9.7
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Test prerequisite
182
Note

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
0224
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

0228
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------
183
0230
Due to a possible leak in the intake air system, an implausible signal was received from oxygen sensor 1 (cylinder bank 1).
Possible cause:
- Intake system
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0234
Due to a possible leak in the intake air system, an implausible signal was received from oxygen sensor 1 (cylinder bank 2).
Possible cause:
- Intake system
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0237
The request for fan output is implausible.
Possible cause:
- Heat management
Affected functions:
- Engine cooling
-------------------------------------------------
Test 1: Check component M4/7 (Engine and AC electric suction fan with integrated control).
1. Check component M4/7 (Engine and AC electric suction fan with integrated control).
Test 1.1: Check component M4/7 (Engine and AC electric suction fan with integrated control) by means of actuation.
Test 1.2: Test PWM signal for operating the suction fan.
1.1. Check component M4/7 (Engine and AC electric suction fan with integrated control) by means of actuation.
Check component M4/7 (Engine and AC electric suction fan with integrated control) by means of actuation.
184
Test prerequisite
- Coolant temperature< 80° C

- Charger connected(The battery voltage must be higher than 12.5 V.)
- Ignition ON
Actual value:
Specified value

1.2. Test PWM signal for operating the suction fan.

Check power supply of component M4/7 (Engine and AC electric suction fan with integrated control).
Test prerequisite
- The ignition must be switched on.

Test sequence
- Check power supply at connector of component M4/7 (Engine and AC electric suction fan with integrated control) (pin 2) against ground.
Specified value
- Voltage[11.0...15.0] V
Test PWM signal for operating the suction fan.
Figure legend

- 108 -Test cable 266 589 01 63 00
Test sequence

Warning!
185
Test prerequisite

- Ignition ON
- There is no fault code present for component B11/4 (Coolant temperature sensor).
- The fuses of component M4/7 (Engine and AC electric suction fan with integrated control) are OK.
Actual values:
0271

Affected functions:
- Engine diagnosis
- Engine output

0272
Possible cause:
186

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

0275
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

0276
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

0277
Component Y49/5 (Right camshaft intake solenoid) has a short circuit to positive. (P2089)
Possible cause:

Affected functions:
187
- Engine diagnosis
- Engine output
-------------------------------------------------

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
188
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
0278
Component Y49/5 (Right camshaft intake solenoid) has a short circuit to ground. (P2088)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
189
Warning!
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
0279
Possible cause:

- N10/1f43 (Fuse 43)
190
Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
191
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test
192

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
193
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
194
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
195
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
196
Fuses
- FuseF43-F67
Relays

3. Power supply

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
197
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
0281
Component Y49/4 (Left camshaft intake solenoid) has a short circuit to positive. (P2093)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
198

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
199
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
0282
Component Y49/4 (Left camshaft intake solenoid) has a short circuit to ground. (P2092)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
200
Test sequence
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
0283
Possible cause:

- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine output
201
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
202
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
203

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
204
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
205
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
206
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
207

Test prerequisite
- Engine at idle
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
208
- Amperage[1.0...1.8] A
Question
YES
NO
- N10/1f43 (Fuse 43)

End of test
0301
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

First-aid measures

209

Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

- Run engine.
Note
Figure legend
210

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
NO

Specified value
211
Question
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value
212

Question
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
213
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
214
YES
NO

End of test
0302
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

215
First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
216
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
217
NO

Specified value
Question
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
218
Figure legend

Test sequence

Specified value

Question
219
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
- 1xClutch 140 545 35 28

220
Test sequence

Specified value

Question
YES
NO

End of test
0303
221
Possible cause:

- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
222
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
223

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
224
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
225
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
226
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
227
Fuses
- FuseF43-F67
Relays

3. Power supply

Safety note
protective measures

First-aid measures

228

Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

- Run engine.
Note
Figure legend
229

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
NO

Specified value
230
Question
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value
231

Question
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
232
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
233
YES
NO

End of test
0305
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

234
First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
235
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
236
NO

Specified value
Question
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
237
Figure legend

Test sequence

Specified value

Question
238
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
- 1xClutch 140 545 35 28

239
Test sequence

Specified value

Question
YES
NO

End of test
0306
240
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
241
Warning!
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
242
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
243

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
244
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
245
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
246
YES
NO

End of test
0307
Possible cause:

- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
247
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
248
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
249

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
250
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
251
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
252
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
253

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
254
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
255
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
256

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
257
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
258
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
259
YES
NO

End of test
0309
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

260
First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
261
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
262
NO

Specified value
Question
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
263
Figure legend

Test sequence

Specified value

Question
264
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
- 1xClutch 140 545 35 28

265
Test sequence

Specified value

Question
YES
NO

End of test
0310
266

Affected functions:
- Engine diagnosis
- Engine running

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
267
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
268
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
269

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
270
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
271
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
272
YES
NO

End of test
0311

- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine running

Safety note
273
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
274
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
275
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
276

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
277
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
278
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
279
YES
NO

End of test
Test prerequisite

- Ignition ON
Specified value

YES
NO

280

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
281
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
282
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
283
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
284
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
285
Fuses
- FuseF43-F67
Relays

5. Power supply
0313
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

286
First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
287
Test sequence

- Run engine.
Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
288
Figure legend

Test sequence

Specified value

Question
289
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
- 1xClutch 140 545 35 28

290
Test sequence

Specified value

Question
YES
NO

End of test
Figure legend
291

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
NO

Specified value
292
Question
YES
NO
0314
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

First-aid measures

293
Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

- Run engine.
Note
Figure legend

294
- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
NO

Specified value
Question
295
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
296
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
297
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
298
YES
NO

End of test
0315
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
1. Power supply

Safety note
299
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
300
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
301
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
302

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
303
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
304
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
305
YES
NO

End of test
0317
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

306
First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
307
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
308
NO

Specified value
Question
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
309
Figure legend

Test sequence

Specified value

Question
310
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
- 1xClutch 140 545 35 28

311
Test sequence

Specified value

Question
YES
NO

End of test
0318
312
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
313
Warning!
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
314
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
315

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
316
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
317
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
318
YES
NO

End of test
0319
Possible cause:

- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
319
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
320
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
321

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
322
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
323
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
324
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
325

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
326
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
327
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
328

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
329
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
330
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
331
YES
NO

End of test
0321
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

332
First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
333
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
334
NO

Specified value
Question
YES
NO

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
335
Figure legend

Test sequence

Specified value

Question
336
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
- 1xClutch 140 545 35 28

337
Test sequence

Specified value

Question
YES
NO

End of test
0322
338
Possible cause:

Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
339
Warning!
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
340
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
341

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
342
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
343
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
344
YES
NO

End of test
0323
Possible cause:

- N10/1f43 (Fuse 43)
Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
345
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
346
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
347

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
348
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
349
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
350
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
351

Safety note
protective measures

First-aid measures


Test prerequisite

- Engine RUNNING
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
352
Test sequence

- Run engine.
Note
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
353
Test sequence

Specified value
Question
YES
NO

Specified value
Question
YES
NO
354

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test sequence

Specified value

Question
355
YES
NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
356
- 1xClutch 140 545 35 28

Test sequence

Specified value

Question
357
YES
NO

End of test
0337
Self-adaptation of mixture formation for enrichment at partial load for the right cylinder bank is above the permissible limit. (P0171)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence

0338
Self-adaptation of mixture formation for enleanment at partial load for the right cylinder bank is below the permissible limit. (P0172)
Possible cause:
358

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence

0339
This fault can be ignored and erased.
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

0340
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

0341
Self-adaptation of mixture formation for enrichment at partial load for the left cylinder bank is above the permissible limit. (P0174)
Possible cause:

Affected functions:
359
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence

0342
Self-adaptation of mixture formation for enleanment at partial load for the left cylinder bank is below the permissible limit. (P0175)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence

0343
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

0344
360
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

0353
Possible cause:
Affected functions:
- Fuel system
-------------------------------------------------

End of test
0354
Possible cause:
Affected functions:
- Fuel system
-------------------------------------------------

End of test
0355
Possible cause:
Affected functions:
361
- Fuel system
-------------------------------------------------

End of test
0356
Possible cause:
Affected functions:
- Fuel system
-------------------------------------------------

End of test
0365
Operational fault of component G2 (generator) (P0620)
Possible cause:
- Poly-V-belt
Affected functions:
-------------------------------------------------
Test 1: Poly-V-belt
1. Poly-V-belt
Possible cause
- Poly V-belt thrown or broken

Question
- Is the poly-V belt OK?
YES
Figure legend

- 108 -Test cable 266 589 01 63 00
362
Warning!
Test prerequisites
Test sequence

Specified value
Question
YES
Test sequence

Specified value
Question
YES
363

End of test
NO
NO
Test sequence

Specified value
Question
YES

End of test
NO
NO
Remedy
- Repair component Poly-V-belt.

End of test
0405
Possible cause:

Affected functions:
- Heating
-------------------------------------------------
364

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
- Amperage[0.7...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
365
unit)
End of test
0406
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Heating
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

366
- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
367

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
368
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
369
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
370
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
371
Fuses
- FuseF43-F67
Relays


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
372
Test sequence

Specified value
- Amperage[0.7...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
unit)
End of test
0407
Possible cause:

- N10/1f57 (Fuse 57)
373
Affected functions:
- Heating
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
374
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
375

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
376
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
377
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
378
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
379

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
- Amperage[0.7...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)
380
valve)
unit)
End of test
0420
Heating of component G3/6 (Right O2 sensor, after TWC [KAT]) : Heating capacity is too low. (P0141)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------


0424
Heating of component G3/5 (Left O2 sensor, after TWC [KAT]) : Heating capacity is too low. (P0038)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0425
Possible cause:

Affected functions:
381
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0426
Heating of component G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit to ground (P0037)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0427
Heating of component G3/6 (Right O2 sensor, after TWC [KAT]) : Open circuit (P0036)
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
382
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
383
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
384

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
385
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
386
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
387
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
388

0429
Heating of component G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit to positive (P0058)

Affected functions:
- Engine diagnosis
- Exhaust system

0430
Heating of component G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit to ground (P0057)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0431
Heating of component G3/5 (Left O2 sensor, after TWC [KAT]) : Open circuit (P0056)
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Engine diagnosis
- Exhaust system
389
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
390
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
391

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
392
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
393
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
394
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
395

0433
Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Short circuit to positive / Resistance of sensor heater too low (P0135)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------


0435
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

Test control unit.

unit).
0436
Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Heating capacity is too low. (P0135)
396
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------


0437
Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Short circuit to positive / Resistance of sensor heater too low (P0155)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0438
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

0439
397
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

Test control unit.

unit).
0440
Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Heating capacity is too low. (P0155)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0441
Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Short circuit to positive (P0032)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

398
0442
Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Short circuit to ground (P0031)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0443
Heating of component G3/4 (Right O2 sensor, before TWC [KAT]) : Open circuit (P0030)

Affected functions:
- Engine diagnosis
- Exhaust system
1. Power supply


0445
Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Short circuit to positive (P0052)
Possible cause:
399

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0446
Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Short circuit to ground (P0051)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0447
Heating of component G3/3 (Left O2 sensor, before TWC [KAT]) : Open circuit (P0050)
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
400
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
401
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
402

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
403
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
404
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
405
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
406


0449
The electronic analysis system for the O2 sensor in the engine control unit is defective. (P064D)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

Test control unit.

unit).
0450
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

Test control unit.

unit).
0451
407
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

Test control unit.

unit).
0452
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

Test control unit.

unit).
0453
The electronic analysis system for the O2 sensor in the engine control unit is defective. (P064E)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
408

Test control unit.

unit).
0454
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

Test control unit.

unit).
0455
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

Test control unit.

unit).
0456
409
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

Test control unit.

unit).
0477
Possible cause:

Affected functions:
- Engine cooling
-------------------------------------------------

0478
Possible cause:

Affected functions:
- Engine cooling
-------------------------------------------------

0479
Possible cause:
410

Affected functions:
- Engine cooling
-------------------------------------------------

0485
Power output limited because of excessively high temperature of coolant
Possible cause:
Affected functions:
- Engine output
-------------------------------------------------
Test 1: Power output limited because of excessively high temperature of coolant
1. Power output limited because of excessively high temperature of coolant

Power output limited because of excessively high temperature of coolant
- Inspect radiator for soiling and clean, if necessary.

- Test thermostat.
- Electric suction fan
- Ambient temperature
End of test
0489
Relay 'Fuel pump'
Possible cause:

Affected functions:
- Engine start
-------------------------------------------------
Test 1: Check component Relay 'Fuel pump'.
1. Check component Relay 'Fuel pump'.

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
411
Test sequence

Specified value
- Amperage[0,1...0,3] A
Question
YES
NO

End of test
0490
Relay 'Fuel pump'
Possible cause:

Affected functions:
- Engine start
-------------------------------------------------
412

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
- Amperage[0,1...0,3] A
Question
YES
NO

End of test
413
0491
Relay 'Fuel pump'
Possible cause:

Affected functions:
- Engine start
-------------------------------------------------

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
- Amperage[0,1...0,3] A
414
Question
YES
NO

End of test
0493
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test control unit.

unit).
0494
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test control unit.

unit).
0496
415
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test control unit.

unit).
0500
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test control unit.

unit).
0501
Component A16/1 (knock sensor 1, right) has a short circuit to positive. (P0328)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test prerequisite
416
- Engine running
Test sequence

Specified value

Question
YES
NO

End of test
0502
Component A16/1 (knock sensor 1, right) has a short circuit to ground. (P0327)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test prerequisite
- Engine running
Test sequence

Specified value

Question
YES
NO

End of test
417
0504
Component A16/1 (knock sensor 1, right) has an electrical fault. (P0325)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test prerequisite
- Engine running
Test sequence

Specified value

Question
YES
NO

End of test
0505
Component A16/2 (knock sensor 2, left) has a short circuit to positive. (P0333)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test prerequisite
- Engine running
Test sequence

418
Specified value

Question
YES
NO

End of test
0506
Component A16/2 (knock sensor 2, left) has a short circuit to ground. (P0332)
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test prerequisite
- Engine running
Test sequence

Specified value

Question
YES
NO

End of test
0508
Component A16/2 (knock sensor 2, left) has an electrical fault. (P0330)
419
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test prerequisite
- Engine running
Test sequence

Specified value

Question
YES
NO

End of test
0509
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0510
Possible cause:
420
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0511
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0513
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0514
Possible cause:

Affected functions:
- Engine diagnosis
421
- Exhaust system
-------------------------------------------------

0515
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0521
Diagnosis of tumble flap 'Intake manifold' : Short circuit to ground of sensor lines / Tumble flap shafts stick in the actuated position.
(P2004)
Possible cause:
- Tumble flap shafts stick in the actuated position.

Affected functions:
- Engine output
-------------------------------------------------
Test 1: Diagnosis of tumble flap 'Intake manifold' : Short circuit to ground of sensor lines / Tumble flap shafts stick in the actuated position.
1. Diagnosis of tumble flap 'Intake manifold' : Short circuit to ground of sensor lines / Tumble flap shafts stick in the actuated position.
0522
Diagnosis of tumble flap 'Intake manifold' : Open circuit of sensor lines / Tumble flap shafts stick in the nonactuated position. (P2006)
Possible cause:
- Vacuum supply of component Y22/9 (Intake manifold tumble flap switchover valve) or the aneroid capsule for the tumble flap
Affected functions:
- Engine output
-------------------------------------------------
422
Test 1: Diagnosis of tumble flap 'Intake manifold' : Open circuit of sensor lines / Tumble flap shafts stick in the nonactuated position.
1. Diagnosis of tumble flap 'Intake manifold' : Open circuit of sensor lines / Tumble flap shafts stick in the nonactuated position.
0524
Diagnosis of tumble flap 'Intake manifold' : Short or open circuit in sensor lines / Mechanical fault of one actuating lever / Sensor faulty,
replace sensor. (P2005)
Possible cause:
- Diagnosis of tumble flap 'Intake manifold'

Affected functions:
- Engine output
-------------------------------------------------
Test 1: Diagnosis of tumble flap 'Intake manifold' : Short or open circuit in sensor lines / Mechanical fault of one actuating lever Sensor faulty,
replace sensor.
1. Diagnosis of tumble flap 'Intake manifold' : Short or open circuit in sensor lines / Mechanical fault of one actuating lever Sensor faulty,
replace sensor.
0537
B2/5 (Hot film mass air flow sensor)
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
423
Test sequence
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
424
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
0549
G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit to positive / Resistance of sensor heater too low (P0138)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0550
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0551
G3/6 (Right O2 sensor, after TWC [KAT]) : Discontinuity of signal line (P0140)
Possible cause:
425

- N10/1f57 (Fuse 57)
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
426
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
427
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
428
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
429
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
430
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

431
3. Power supply

0552
G3/6 (Right O2 sensor, after TWC [KAT]) : Short circuit between signal line and line to sensor heater (P0136)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0553
G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit to positive / Resistance of sensor heater too low (P0158)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0554
Possible cause:

Affected functions:
- Engine diagnosis
432
- Exhaust system
-------------------------------------------------

0555
G3/5 (Left O2 sensor, after TWC [KAT]) : Discontinuity of signal line (P0160)
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO

433

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
434
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
435
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
436
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
437
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
438
Fuses
- FuseF43-F67
Relays

3. Power supply

0556
G3/5 (Left O2 sensor, after TWC [KAT]) : Short circuit between signal line and line to sensor heater (P0156)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0559
439
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0563
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0565
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0567
Possible cause:
440

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0568
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0569
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0571
Possible cause:

Affected functions:
441
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0572
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0573
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0574
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
442
-------------------------------------------------

0577
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0578
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0583
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
443

0587
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0591
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0595
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
444

0600
O2 sensors upstream TWC : Plug connections of the O2 sensors are wrongly connected. (P0040)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

- The connectors of the O2 sensors upstream of the catalytic converter are swapped.
End of test
0607
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
- Print out the initial quick test log before processing the fault code 0607.
Sequence

445
0620
Check intake tract for unmetered air. (P2279)
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

Test sequence

0629
Misfiring (P0300)
Possible cause:
Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
0630
Misfiring (P0300)
Possible cause:
Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
446
0632
Misfiring (P0300)
Possible cause:
Affected functions:
- Engine diagnosis
- Engine running
-------------------------------------------------
722.9 (7-gear) ETC2 as of 2005

Possible cause:

Affected functions:
- DAS Function
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
Sequence

ME9.7
447
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
0634
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
0636
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
0637
Possible cause:
Affected functions:
448
- Engine diagnosis
-------------------------------------------------
0638
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
0640
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
722.9 (7-gear) ETC2 as of 2005

Possible cause:

Affected functions:
-------------------------------------------------
449
Test prerequisites

POSSIBLE CAUSES
Preconditions
Sequence

ME9.7
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
ME9.7
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
722.9 (7-gear) ETC2 as of 2005
450
The voltage supply of the speed sensors is faulty. ( Undervoltage )
Possible cause:
- Local undervoltage of component Speed sensors

Affected functions:
-------------------------------------------------
Test 1: Remedial action if faulty voltage supply to rpm sensors ( Undervoltage )
1. Remedial action if faulty voltage supply to rpm sensors ( Undervoltage )

Operation number of operation texts and work units or standard texts and flat rates:27-0641Cause
- The voltage supply of the speed sensors is faulty.(Undervoltage)

REMEDY

0644
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
451
0645
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
0646
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
0648
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
452
0649
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
0650
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
0652
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
0653
453
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
0654
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
0656
Possible cause:
Affected functions:
- Engine diagnosis
-------------------------------------------------
0688
Possible cause:

Affected functions:
454
- Engine diagnosis
-------------------------------------------------

0693
M4/7 (Engine and AC electric suction fan with integrated control) : Output stage
- Heat management
Affected functions:
- Engine cooling
Test prerequisite

- Ignition ON
Actual value:
Specified value


Test prerequisite

Test sequence
Specified value
- Voltage[11.0...15.0] V
Figure legend

455
- 108 -Test cable 266 589 01 63 00
Test sequence

Warning!
Test prerequisite

- Ignition ON
Actual values:
0694
Possible cause:
- Heat management
Affected functions:
- Engine cooling
456
-------------------------------------------------
Test prerequisite

- Ignition ON
Actual value:
Specified value


Test prerequisite

Test sequence
Specified value
- Voltage[11.0...15.0] V
Figure legend

- 108 -Test cable 266 589 01 63 00
Test sequence

Warning!
457
Test prerequisite

- Ignition ON
Actual values:
0695
Possible cause:
- Heat management
Affected functions:
- Engine cooling
-------------------------------------------------
Test prerequisite

458
- Ignition ON
Actual value:
Specified value


Test prerequisite

Test sequence
Specified value
- Voltage[11.0...15.0] V
Figure legend

- 108 -Test cable 266 589 01 63 00
Test sequence

Warning!
459
Test prerequisite

- Ignition ON
Actual values:
0701
Possible cause:

Affected functions:
-------------------------------------------------

REMEDY

460
0703
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
461
Settings
- Time range: 5 ms
Test sequence

- Start engine.
Specified value
- Measuring system
462

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
463
Settings
- Time range: 5 ms
Test sequence

Specified value
- Measuring system
- Signal (4,7 - 5,3) V

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
464
Test sequence
Specified value
- Voltage[4.8...5.3] V
Question
YES
- Signal wire
End of test
NO

End of test
0704
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
465

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Settings
- Time range: 5 ms
Test sequence

- Start engine.
Specified value
- Measuring system
466

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
467
Settings
- Time range: 5 ms
Test sequence

Specified value
- Measuring system
- Signal (4,7 - 5,3) V

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
468
Test sequence
Specified value
- Voltage[4.8...5.3] V
Question
YES
- Signal wire
End of test
NO

End of test
0705
Component Y3/8s1 (Selection range sensor (VGS)) is defective.
Possible cause:
- Y3/8s1 (Selection range sensor (VGS))

Affected functions:
-------------------------------------------------
Test 1: Remedial action if component 'Y3/8s1 (Selection range sensor (VGS))' is faulty
1. Remedial action if component 'Y3/8s1 (Selection range sensor (VGS))' is faulty
469
Test prerequisites

POSSIBLE CAUSES
Preconditions
Sequence

0706
Check component Y3/8s1 (Selection range sensor (VGS)).
Possible cause:
- Y3/8s1 (Selection range sensor (VGS))

Affected functions:
-------------------------------------------------
Test 1: Remedial action for an implausible signal from component Y3/8s1 (Selection range sensor (VGS))
1. Remedial action for an implausible signal from component Y3/8s1 (Selection range sensor (VGS))
Operation number of operation texts and work units or standard texts and flat rates:27-0641 NOTEThe following criteria cause fault code 2215 to
be stored
- Control module Y3/8n4 (Fully integrated transmission control (VGS) control unit) is not correctly learned.
- Initial startup of the control unit was aborted.(Abortion by user)
REMEDY
- Perform teach-in process for component 'Y3/8s1 (Selection range sensor (VGS))'.
Test 1.1: Teach-in of selection range sensor
1.1. Teach-in of selection range sensor

0713
The signal from component Y3/8s2 (Transmission oil temperature sensor (VGS)) is implausible. ( Overvoltage )
Possible cause:
- Y3/8s2 (Transmission oil temperature sensor (VGS))

Affected functions:
470
-------------------------------------------------
Test 1: Remedial action for an implausible signal from component Y3/8s2 (Transmission oil temperature sensor (VGS))
1. Remedial action for an implausible signal from component Y3/8s2 (Transmission oil temperature sensor (VGS))
Operation number of operation texts and work units or standard texts and flat rates:27-0641POSSIBLE CAUSES
- Component Y3/8s2 (Transmission oil temperature sensor (VGS)) is defective.

REMEDY

0716
The transmission input shaft has rotated at excessive rpms.
Possible cause:
- Engine overspeed
Affected functions:
-------------------------------------------------
Test 1: Remedial action on overspeed of transmission input shaft
1. Remedial action on overspeed of transmission input shaft

- Erase fault memory in control unit Y3/8n4 (Fully integrated transmission control (VGS) control unit)
- Conduct a road test with the vehicle.During the road test, drive the engine from gear 1 to gear 3 in the engine speed cutoff range.
- Read out fault memory of control unit Y3/8n4 (Fully integrated transmission control (VGS) control unit).
Question
- Is control unit EGS electronic transmission control indicating the current fault code 0716?
471
YES
Preconditions
- Control unit Y3/8n4 (Fully integrated transmission control (VGS) control unit) is indicating the current fault code 0716.
Remedy
- Performance of SCN coding

END OF TEST
NO
Preconditions
- Control unit Y3/8n4 (Fully integrated transmission control (VGS) control unit) is not indicating any fault codes.
Remedy
- Read out fault memory of control unit Engine management.

- Process displayed fault codes in control module Engine management.
END OF TEST
0718
Component Y3/8n1 (Turbine speed sensor (VGS)) is defective.
Possible cause:
- Y3/8n1 (Turbine speed sensor (VGS))

Affected functions:
-------------------------------------------------
Test 1: Remedial action if component 'Y3/8n1 (Turbine speed sensor (VGS))' is faulty
1. Remedial action if component 'Y3/8n1 (Turbine speed sensor (VGS))' is faulty

0720
Mechanical fault of component Drive train
Possible cause:
- Transmission output speed

Affected functions:
-------------------------------------------------
Test 1: Remedial action for non-available signal from component Y3/8n3 (Output speed sensor (VGS))
1. Remedial action for non-available signal from component Y3/8n3 (Output speed sensor (VGS))
0721
The transmission output speed signal is implausible when compared to the wheel rpm signal.
Possible cause:
472
- Transmission output speed

Affected functions:
-------------------------------------------------
0722
The signal from component Y3/8n3 (Output speed sensor (VGS)) is not available.
Possible cause:
- Y3/8n3 (Output speed sensor (VGS))

Affected functions:
-------------------------------------------------
0723
Component Y3/8n3 (Output speed sensor (VGS)) is defective.
Possible cause:
- Y3/8n3 (Output speed sensor (VGS))

Affected functions:
-------------------------------------------------
Test 1: Remedial action if component 'Y3/8n3 (Output speed sensor (VGS))' is faulty
1. Remedial action if component 'Y3/8n3 (Output speed sensor (VGS))' is faulty

0732
Possible cause:
- Stepless adjustment of exhaust camshaft of right cylinder bank

Affected functions:
- Engine output
473
-------------------------------------------------

0736
Possible cause:
- Stepless adjustment of exhaust camshaft of left cylinder bank

Affected functions:
- Engine output
-------------------------------------------------

0740
Possible cause:
- Stepless adjustment of intake camshaft of right cylinder bank

Affected functions:
- Engine output
-------------------------------------------------

0744
Possible cause:
- Stepless adjustment of intake camshaft of left cylinder bank

Affected functions:
- Engine output
-------------------------------------------------

474
0745
Self-adaptation of mixture formation for enrichment at idle for the right cylinder bank is above the permissible limit. (P0171)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence

0746
Self-adaptation of mixture formation for enleanment at idle for the right cylinder bank is below the permissible limit. (P0172)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence

0747
Possible cause:

Affected functions:
475
- Engine output
-------------------------------------------------

ME9.7
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

722.9 (7-gear) ETC2 as of 2005

The internal electrical check of component Y3/8y2 (K1 clutch control solenoid valve (VGS)) has failed.
Possible cause:
- Y3/8y2 (K1 clutch control solenoid valve (VGS))

Affected functions:
-------------------------------------------------
Test 1: Remedial action if component 'Y3/8y2 (K1 clutch control solenoid valve (VGS))' is faulty
1. Remedial action if component 'Y3/8y2 (K1 clutch control solenoid valve (VGS))' is faulty
- Component Y3/8y2 (K1 clutch control solenoid valve (VGS)) is defective.

REMEDY

476
0749
Self-adaptation of mixture formation for enrichment at idle for the left cylinder bank is above the permissible limit. (P0174)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence

0750
Self-adaptation of mixture formation for enleanment at idle for the left cylinder bank is below the permissible limit. (P0175)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
477

Test sequence

0751
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

0752
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

0753
B6/5 (Right intake camshaft Hall sensor) : Short circuit to positive or open circuit (P0343)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
478
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
479
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
480
0754
B6/5 (Right intake camshaft Hall sensor) : Short circuit to ground (P0342)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
481
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
482
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
483
0755
B6/5 (Right intake camshaft Hall sensor) : The alternation frequency of the signal value is implausible. (P0341)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
484
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
485
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
486
0756
B6/5 (Right intake camshaft Hall sensor) : The time of the signal value change is implausible. (P0341)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
487
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
488
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
489
0757
B6/4 (Left intake camshaft Hall sensor) : Short circuit to positive or open circuit (P0348)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
490
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
491
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
492
0758
B6/4 (Left intake camshaft Hall sensor) : Short circuit to ground (P0347)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
493
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
494
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
495
0759
B6/4 (Left intake camshaft Hall sensor) : The alternation frequency of the signal value is implausible. (P0346)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
496
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
497
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
498
0760
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
499
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
500
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
501
0761
B6/7 (Right exhaust camshaft Hall sensor) : Short circuit to positive or open circuit (P0368)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
502
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
503
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
504
0762
B6/7 (Right exhaust camshaft Hall sensor) : Short circuit to ground (P0367)

Affected functions:
- Engine diagnosis
- Engine output
505
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
506
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
507
0763
B6/7 (Right exhaust camshaft Hall sensor) : The alternation frequency of the signal value is implausible. (P0366)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
508
-------------------------------------------------
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
509
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
510
0764
B6/7 (Right exhaust camshaft Hall sensor) : The time of the signal value change is implausible. (P0366)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
511
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test prerequisite

Test sequence

512
box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
513
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
0765
B6/6 (Left exhaust camshaft Hall sensor) : Short circuit to positive or open circuit (P0393)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
514
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
515
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
516
0766
B6/6 (Left exhaust camshaft Hall sensor) : Short circuit to ground (P0392)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
517
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
518
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
519
0767
B6/6 (Left exhaust camshaft Hall sensor) : The alternation frequency of the signal value is implausible. (P0391)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
520
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
521
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
522
0768
B6/6 (Left exhaust camshaft Hall sensor) : The time of the signal value change is implausible. (P0391)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
523
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
524
Figure legend

Test prerequisite

Test sequence

box tester. (A5)
- Start engine.
Specified value
- Measuring system
Note
525
0773
The signal of the oxygen sensor upstream of the catalytic converter of the right cylinder bank is shifted towards 'Lean'. (P2A00)
Possible cause:
- The signal of the oxygen sensor upstream of the catalytic converter of the right cylinder bank is shifted towards 'Lean'.
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
526



0774
The signal of the oxygen sensor upstream of the catalytic converter of the right cylinder bank is shifted towards 'Rich'. (P2A00)

Affected functions:
- Engine diagnosis
- Exhaust system

- Leakage on catalytic converter at flange connection to exhaust manifold and in area of O2 sensor
Possible remedy
- Check O2 sensor for correct seating, tightening torque and leaktightness.

- Check weld seams on catalytic converter for leaktightness.
End of test

Test sequence


0775
527
The signal of the oxygen sensor upstream of the catalytic converter of the right cylinder bank is shifted towards 'Lean'. (P2195)
Possible cause:

Affected functions:
- Power generation
-------------------------------------------------

0776
The signal of the oxygen sensor upstream of the catalytic converter of the right cylinder bank is shifted towards 'Rich'. (P2196)
Possible cause:

Affected functions:
- Power generation
-------------------------------------------------

0777
The signal of the oxygen sensor upstream of the catalytic converter of the left cylinder bank is shifted towards 'Lean'. (P2A03)
Possible cause:
- The signal of the oxygen sensor upstream of the catalytic converter of the left cylinder bank is shifted towards 'Lean'.
Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------


528

ME9.7
The signal of the oxygen sensor upstream of the catalytic converter of the left cylinder bank is shifted towards 'Rich'. (P2A03)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

- Leakage on catalytic converter at flange connection to exhaust manifold and in area of O2 sensor
Possible remedy
- Check O2 sensor for correct seating, tightening torque and leaktightness.

- Check weld seams on catalytic converter for leaktightness.
End of test

Test sequence


722.9 (7-gear) ETC2 as of 2005

The internal electrical check of component Y3/8y5 (B1 brake control solenoid valve (VGS)) has failed.
Possible cause:
- Y3/8y5 (B1 brake control solenoid valve (VGS))

Affected functions:
-------------------------------------------------
529
Test 1: Remedial action if component 'Y3/8y5 (B1 brake control solenoid valve (VGS))' is faulty
1. Remedial action if component 'Y3/8y5 (B1 brake control solenoid valve (VGS))' is faulty
- Component Y3/8y5 (B1 brake control solenoid valve (VGS)) is defective.

REMEDY

0779
The signal of the oxygen sensor upstream of the catalytic converter of the left cylinder bank is shifted towards 'Lean'. (P2197)
Possible cause:

Affected functions:
- Power generation
-------------------------------------------------

0780
The signal of the oxygen sensor upstream of the catalytic converter of the left cylinder bank is shifted towards 'Rich'. (P2198)
530
Possible cause:

Affected functions:
- Power generation
-------------------------------------------------

0789
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

0790
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

0793
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
531

0794
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

0798
The internal electrical check of component Y3/8y7 (B3 brake control solenoid valve (VGS)) has failed.
Possible cause:
- Y3/8y7 (B3 brake control solenoid valve (VGS))

Affected functions:
-------------------------------------------------
Test 1: Remedial action if component 'Y3/8y7 (B3 brake control solenoid valve (VGS))' is faulty
1. Remedial action if component 'Y3/8y7 (B3 brake control solenoid valve (VGS))' is faulty
- Component Y3/8y7 (B3 brake control solenoid valve (VGS)) is defective.

REMEDY

532
0810
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test sequence

Test prerequisite
533

Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
534
Test prerequisites

Test sequence

- Amperage[0.1...0.3] A
Question
YES
YES
NO
Figure legend:1

Figure legend:2

Test sequence

535
Specified value
- Voltage[11.0...15.0] V
Question
YES

End of test
NO
End of test
NO

End of test

Test sequence
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
536
Test prerequisite

Test sequence

Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
End of test
0814
Possible cause:

Affected functions:
537
- Engine diagnosis
-------------------------------------------------

Test sequence

Test prerequisite

Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
538
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
539
Test prerequisites

Test sequence

- Amperage[0.1...0.3] A
Question
YES
YES
NO
Figure legend:1

Figure legend:2

Test sequence

540
Specified value
- Voltage[11.0...15.0] V
Question
YES

End of test
NO
End of test
NO

End of test

Test sequence
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
541
Test prerequisite

Test sequence

Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
End of test
0817
Possible cause:

Affected functions:
- Engine diagnosis
542
-------------------------------------------------

Test sequence
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence
543

Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
End of test
0821
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test sequence
Figure legend

- 108 -Test cable 266 589 01 63 00
544
Warning!
Test prerequisite

Test sequence

Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
End of test
0849
Y58/1 (Purge control valve) : Short circuit to positive / Switchover valve permanently closed (P0459)
545
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test sequence

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
546
Test prerequisite

Test sequence
box tester.
Specified value
- Amperage[0.4...0.9] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test

Figure legend
- 019Vacuum tester
Test prerequisite
- Actuation is OK.
Test sequence

547
0850
Y58/1 (Purge control valve) : Short circuit to ground / Switchover valve permanently open (P0458)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test sequence
548
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence
box tester.
Specified value
- Amperage[0.4...0.9] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test
549

Figure legend
- 019Vacuum tester
Test prerequisite
- Actuation is OK.
Test sequence

0851
Y58/1 (Purge control valve) : Open circuit / Switchover valve permanently closed (P0444)
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Engine diagnosis
-------------------------------------------------
550
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
551
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
552

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
553
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
554
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
555
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

556

Test sequence

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence
box tester.
Specified value
- Amperage[0.4...0.9] A
557
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test

Figure legend
- 019Vacuum tester
Test prerequisite
- Actuation is OK.
Test sequence

0856
Component Y110 (Three-disk thermostat valve) jams in opened position. : Coolant temperature rises too slowly. (P0128)
558
Possible cause:
- Mechanical fault of component Y110 (Three-disk thermostat valve)

Affected functions:
- Engine diagnosis
-------------------------------------------------



Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
559
Test sequence
Specified value
- Amperage[0.6...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test
0857
Possible cause:

Affected functions:
- Engine cooling
-------------------------------------------------
560


Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
561
NO

End of test
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test



Figure legend
562

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
Specified value
- Amperage[0.6...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test
0858
563
Possible cause:

Affected functions:
- Engine cooling
-------------------------------------------------
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test

Test sequence
Specified value
Question
564
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
0859
Possible cause:

Affected functions:
- Engine cooling
-------------------------------------------------
565
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test

Test sequence
Specified value
Question
YES
NO
End of test
566

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
0860
Possible cause:

Affected functions:
- Engine cooling
-------------------------------------------------
Test prerequisite

Test sequence
567
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test

Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
568
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
0865
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO

569
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
570

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
571
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
572
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
0866
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
573
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
574
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
575
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
576
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
0868
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisite

- Ignition ON
577
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
578
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
579
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
580
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
0872
The torque calculation of the control unit has a malfunction. (P061B)
581
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test sequence
Specified values


Question
YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
582
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
583

Test prerequisite

Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
584
YES
NO
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisites
Test sequence

585
Specified values

Specified values

Question
YES
NO

End of test
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
0876
The input signal of the engine speed has a malfunction. (P0726)
Possible cause:
586
- Smooth engine running
Affected functions:
- Engine diagnosis
-------------------------------------------------
Test 1: Check smooth engine running.
1. Check smooth engine running.
Test 1.1: Check self-adaptation of mixture formation. ( Check by means of actual values )
Test 1.2: Check water and diesel content in gasoline fuel. (Fuel quality)
Test 1.3: Test fuel pressure and delivery of component M3 (Fuel pump).
Test 1.4: Compression test
1.1. Check self-adaptation of mixture formation. ( Check by means of actual values )

1.2. Check water and diesel content in gasoline fuel. (Fuel quality)
Safety note
protective measures

First-aid measures

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
587
Figure legend
- 043Pressure gage
- 069Pressure hose(119 589 04 63 00)
Test sequence

- Insert bridge.:
- Remove bridge.
Specified value
beaker.
Question
588
YES
Test sequence
Specified value
Question
YES
NO

End of test
NO
1.3. Test fuel pressure and delivery of component M3 (Fuel pump).

Safety note
protective measures

589
First-aid measures

Test 1.3.1: Test fuel pressure and internal leaks of fuel system.
Test 1.3.2: Test delivery of component M3 (Fuel pump).
Test 1.3.3: Test current consumption of component M3 (Fuel pump).
Test 1.3.4: Test current consumption of component N10/2kA (Fuel pump relay).
1.3.1. Test fuel pressure and internal leaks of fuel system.

Question
YES
Figure legend
- 043Pressure gage(103 589 00 21 00)

- 069Pressure hose(119 589 04 63 00)

- Engine at idle
Specified value
Question
YES
590

Test sequence
Specified value

Question
YES
NO

NO

NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
591
Figure legend
- 043Pressure gage
- 069Pressure hose(119 589 04 63 00)

- Insert bridge.:
Specified value
Question
592
YES

Test sequence

- Insert bridge.:
- Remove bridge.
Specified value

Question
YES
NO

NO
- N10/2f4 (Fuse 4)
593
1.3.2. Test delivery of component M3 (Fuel pump).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend
Test sequence

- Insert bridge.:
Specified value

Question
594
YES
NO

- Fuel filter
1.3.3. Test current consumption of component M3 (Fuel pump).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
595
Figure legend
- 003Multimeter
- N10/2f3 (Fuse 3)
Test prerequisite

Test sequence

- Insert bridge.:
Specified value
- Amperage[4...9] A
Question
596
YES
- M3 (Fuel pump)
End of test
NO
- N10/2f4 (Fuse 4)
- Test cables
- M3 (Fuel pump)
End of test
1.3.4. Test current consumption of component N10/2kA (Fuel pump relay).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
597
Test sequence

Specified value
- Amperage[0,1...0,3] A
Question
YES
NO

End of test
1.4. Compression test

Test prerequisite
- Connect battery charger.

- Ignition ON
- Coolant temperature between 70° C and 90° C
Actual values:
Note
- If the rpm difference is greater than 28 1/min, a cylinder leak test must be performed on all cylinders as per the repair instructions to pinpoint
the fault.
598

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Settings
- Time range: 5 ms
Test sequence

- Start engine.
Specified value
- Measuring system
599

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
600
Settings
- Time range: 5 ms
Test sequence

Specified value
- Measuring system
- Signal (4,7 - 5,3) V

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
601
Test sequence
Specified value
- Voltage[4.8...5.3] V
Question
YES
- Signal wire
End of test
NO

End of test
0889

Affected functions:
- Engine diagnosis

Test control unit.
602

unit).
0890
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
0891
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
722.9 (7-gear) ETC2 as of 2005

Hydraulic fault in transmission (disengaging shift element does not disengage).
Possible cause:
- Mechanical or hydraulic defect in the transmission
603
Affected functions:
-------------------------------------------------
Test 1: Remedial action if hydraulic clutch in automatic transmission fails to cut out
1. Remedial action if hydraulic clutch in automatic transmission fails to cut out

Operation number of operation texts and work units or standard texts and flat rates:27-0641Remedy
- Check and, if necessary, correct oil level of automatic transmission.

Notes on submitting warranty or goodwill claimsSEAG damage code (7 digits): 27401 B1 END OF TEST
ME9.7
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
722.9 (7-gear) ETC2 as of 2005

The gear is implausible or the transmission is slipping.
Possible cause:
- Mechanical or hydraulic defect in the transmission

Affected functions:
-------------------------------------------------
Test 1: Remedial action on implausible gear or slipping transmission
1. Remedial action on implausible gear or slipping transmission

Operation number of operation texts and work units or standard texts and flat rates:27-0641Remedy
- Check and, if necessary, correct oil level of automatic transmission.

Notes on submitting warranty or goodwill claimsSEAG damage code (7 digits): 27401 B2 If complaint persists:Please contact the relevant product
service department.END OF TEST
ME9.7
Possible cause:
604

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
0895
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
0897
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

605
unit).
0898
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
0900
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
0904
The values from the position sensors of the accelerator pedal are implausible in relation to each other. (P2138)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
606
Test sequence
Specified values


Question
YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
607
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
- Signal lines
End of test
NO

End of test
0908
G3/4 (Right O2 sensor, before TWC [KAT]) : Signal implausible (P2414)
Possible cause:

Affected functions:
- Engine diagnosis
608
- Exhaust system
-------------------------------------------------

0912
G3/3 (Left O2 sensor, before TWC [KAT]) : Signal implausible (P2415)
Possible cause:

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------

0916
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
0920
Possible cause:

Affected functions:
609
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
0922
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
0923
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
610
0924
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
0940
S9/1 (Stop lamp switch)
Possible cause:
- S9/1 (Stop lamp switch)

Affected functions:
- Stop lamp
-------------------------------------------------
Test 1: Check component S9/1 (Stop lamp switch).
1. Check component S9/1 (Stop lamp switch).

Test sequence
- Stop lamp switch:Warning!
Specified value
- Switch S9/1 (Stop lamp switch) operated:OPERATED

- Switch S9/1 (Stop lamp switch) not operated:NOT OPERATED
The actual value is supplied through CAN bus from component N47-5 (ESP, SPS [PML] and BAS control unit).Question
YES
NO
- Read fault memory from control unit ESP and rectify faults.
End of test
0942
611
Possible cause:
- Catalytic converter of right cylinder bank

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test 1: Effect of the catalytic converter for the right cylinder bank
1. Effect of the catalytic converter for the right cylinder bank
Test 1.1: Check component G3/4 (Right O2 sensor, before TWC [KAT]).
Test 1.2: Check component G3/6 (Right O2 sensor, after TWC [KAT]).
1.1. Check component G3/4 (Right O2 sensor, before TWC [KAT]).

1.2. Check component G3/6 (Right O2 sensor, after TWC [KAT]).

0946
Possible cause:
- Catalytic converter of left cylinder bank

Affected functions:
- Engine diagnosis
- Exhaust system
-------------------------------------------------
Test 1: Effect of the catalytic converter for the left cylinder bank
1. Effect of the catalytic converter for the left cylinder bank
Test 1.1: Check component G3/3 (Left O2 sensor, before TWC [KAT]).
Test 1.2: Check component G3/5 (Left O2 sensor, after TWC [KAT]).
1.1. Check component G3/3 (Left O2 sensor, before TWC [KAT]).

1.2. Check component G3/5 (Left O2 sensor, after TWC [KAT]).

0954
Mechanical defect or component Y58/4 (Activated charcoal canister shut-off valve) permanently closed (P2422)
612
Possible cause:
- Mechanical fault of component Y58/4 (Activated charcoal canister shut-off valve)

Affected functions:
- Engine diagnosis
-------------------------------------------------
0957
Component Y58/4 (Activated charcoal canister shut-off valve) has a short circuit to positive. (P0447)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
0958
Component Y58/4 (Activated charcoal canister shut-off valve) has a short circuit to ground. (P0448)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
0959
Component Y58/4 (Activated charcoal canister shut-off valve) has an open circuit in the wiring. (P0446)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
0969
Tank pressure sensor diagnosis : Short circuit to positive (P0453)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
0970
Tank pressure sensor diagnosis : Short circuit to ground (P0452)
613
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
0976
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

Test control unit.

unit).
0981
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

614
0982
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

0983
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

615
0984
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

0985
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------
616

0986
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

0987
Possible cause:
- Primary current
Affected functions:
617
- Engine running
-------------------------------------------------

0988
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

0989
618
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

0990
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

619
0991
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

0992
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

620
0993
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

0994
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------
621

0995
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

0996
Possible cause:
- Primary current
Affected functions:
- Engine running
622
-------------------------------------------------

0997
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

0998
623
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

0999
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

624
1000
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

1001
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

625
1002
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

1003
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

626
1004
Possible cause:
- Primary current
Affected functions:
- Engine running
-------------------------------------------------

1013
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------
627

1014
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

1015
Possible cause:
628
Affected functions:
- Engine running
-------------------------------------------------

1016
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

1017
629
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

1018
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

630
1019
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

1020
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

631
1021
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

1022
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------
632

1023
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

1024
Possible cause:

Affected functions:
633
- Engine running
-------------------------------------------------

1025
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

1026
634
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

1027
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

635
1028
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

1029
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

636
1030
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

1031
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------
637

1032
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

1033
Possible cause:

Affected functions:
- Engine running
638
-------------------------------------------------

1034
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

1035
639
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

1036
Possible cause:

Affected functions:
- Engine running
-------------------------------------------------

640
1045
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
Test sequence
Specified value
Question
YES
NO
641
Note
End of test

Safety note
protective measures

First-aid measures

642

Question
YES
Figure legend
- 043Pressure gage(103 589 00 21 00)

- 069Pressure hose(119 589 04 63 00)

- Engine at idle
Specified value
Question
YES

Test sequence
Specified value

Question
643
YES
NO

NO

NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend
- 043Pressure gage
- 069Pressure hose(119 589 04 63 00)
644

- Insert bridge.:
Specified value
Question
YES

Test sequence

- Insert bridge.:
- Remove bridge.
Specified value

Question
YES
645
NO

NO
- N10/2f4 (Fuse 4)

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend
Test sequence

- Insert bridge.:
646
Specified value

Question
YES
NO

- Fuel filter

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
647
Figure legend
- 003Multimeter
- N10/2f3 (Fuse 3)
Test prerequisite

Test sequence

- Insert bridge.:
Specified value
- Amperage[4...9] A
Question
648
YES
- M3 (Fuel pump)
End of test
NO
- N10/2f4 (Fuse 4)
- Test cables
- M3 (Fuel pump)
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
649
Test sequence

Specified value
- Amperage[0,1...0,3] A
Question
YES
NO

End of test

Safety note
protective measures

First-aid measures

650
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend
- 043Pressure gage
- 069Pressure hose(119 589 04 63 00)
Test sequence

- Insert bridge.:
- Remove bridge.
Specified value
beaker.
Question
651
YES
Test sequence
Specified value
Question
YES
NO

End of test
NO

- Unmetered air
Possible remedy

End of test
652
- Leaks
Possible remedy
1046
Possible cause:
- Lambda control
Affected functions:
- Engine output
-------------------------------------------------

Test sequence
653

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence
box tester.
Specified value
- Amperage[0.4...0.9] A
Question
YES
NO
- N10/1f57 (Fuse 57)

654
End of test

Figure legend
- 019Vacuum tester
Test prerequisite
- Actuation is OK.
Test sequence

Test sequence
655
Specified value
Question
YES
NO
Note
End of test


Note
not be cracked).
End of test
656


Safety note
protective measures

First-aid measures


Figure legend

Test sequence

Specified value

Question
657
YES
NO

- 1xClutch 140 545 35 28

658
Test sequence

- Insert bridge.:
socket box.
Specified value

Question
YES
NO

End of test

- Leaks
Possible remedy
1047
659
Possible cause:
- Lambda control
Affected functions:
- Engine output
-------------------------------------------------
Test sequence
Specified value
Question
YES
NO
660
Note
End of test


Note
not be cracked).
End of test
661


Safety note
protective measures

First-aid measures


Figure legend

Test sequence

Specified value

Question
662
YES
NO

- 1xClutch 140 545 35 28

Test sequence
663

- Insert bridge.:
socket box.
Specified value

Question
YES
NO

End of test

- Leaks
Possible remedy
1048
Possible cause:
- Lambda control
664
Affected functions:
- Engine output
-------------------------------------------------
Test sequence
Specified value
Question
YES
NO
665
Note
End of test


Note
not be cracked).
End of test

666

Safety note
protective measures

First-aid measures


Figure legend

Test sequence

Specified value

Question
667
YES
NO

- 1xClutch 140 545 35 28

Test sequence
668

- Insert bridge.:
socket box.
Specified value

Question
YES
NO

End of test

- Leaks
Possible remedy
1049
Possible cause:
669
Affected functions:
- Engine output
-------------------------------------------------
Test sequence
Specified value
Question
YES
NO
670
Note
End of test

Safety note
protective measures

First-aid measures


Question
YES
Figure legend
- 043Pressure gage(103 589 00 21 00)
671
- 069Pressure hose(119 589 04 63 00)

- Engine at idle
Specified value
Question
YES

Test sequence
Specified value

Question
YES
NO

672
NO

NO
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend
- 043Pressure gage
- 069Pressure hose(119 589 04 63 00)

- Insert bridge.:
Specified value
Question
673
YES

Test sequence

- Insert bridge.:
- Remove bridge.
Specified value

Question
YES
NO

NO
- N10/2f4 (Fuse 4)
674

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend
Test sequence

- Insert bridge.:
Specified value

Question
675
YES
NO

- Fuel filter

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
676
Figure legend
- 003Multimeter
- N10/2f3 (Fuse 3)
Test prerequisite

Test sequence

- Insert bridge.:
Specified value
- Amperage[4...9] A
Question
677
YES
- M3 (Fuel pump)
End of test
NO
- N10/2f4 (Fuse 4)
- Test cables
- M3 (Fuel pump)
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
678
Test sequence

Specified value
- Amperage[0,1...0,3] A
Question
YES
NO

End of test

Safety note
protective measures

First-aid measures

679
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend
- 043Pressure gage
- 069Pressure hose(119 589 04 63 00)
Test sequence

- Insert bridge.:
- Remove bridge.
Specified value
beaker.
Question
680
YES
Test sequence
Specified value
Question
YES
NO

End of test
NO

- Unmetered air
Possible remedy

End of test
681
- Leaks
Possible remedy
1050
Possible cause:
- Lambda control
Affected functions:
- Engine output
-------------------------------------------------


Note
not be cracked).
End of test
682


Safety note
protective measures

First-aid measures


Figure legend

Test sequence

Specified value

Question
683
YES
NO

- 1xClutch 140 545 35 28

684
Test sequence

- Insert bridge.:
socket box.
Specified value

Question
YES
NO

End of test

- Leaks
Possible remedy
685

Test sequence

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence
box tester.
Specified value
- Amperage[0.4...0.9] A
Question
686
YES
NO
- N10/1f57 (Fuse 57)

End of test

Figure legend
- 019Vacuum tester
Test prerequisite
- Actuation is OK.
Test sequence

687
Test sequence
Specified value
Question
YES
NO
Note
End of test
688
1051
- Lambda control
Affected functions:
- Engine output
Test sequence
Specified value
Question
YES
NO
689
Note
End of test


Note
not be cracked).
End of test
690


Safety note
protective measures

First-aid measures


Figure legend

Test sequence

Specified value

Question
691
YES
NO

- 1xClutch 140 545 35 28

692
Test sequence

- Insert bridge.:
socket box.
Specified value

Question
YES
NO

End of test

- Leaks
Possible remedy
1052
693
Possible cause:
- Lambda control
Affected functions:
- Engine output
-------------------------------------------------
Note
End of test

694

Note
not be cracked).
End of test


Safety note
protective measures

First-aid measures


Figure legend

Test sequence

695
Specified value

Question
YES
NO

- 1xClutch 140 545 35 28

696
Test sequence

- Insert bridge.:
socket box.
Specified value

Question
YES
NO

End of test
697

- Leaks
Possible remedy
Test sequence
Specified value
Question
YES
NO
1053
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
698
1057
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

1061
The load limit is active.

Affected functions:
- Engine output
Test prerequisites

Note
Test sequence
Specified value
699
Question
YES
End of test
NO
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
700
YES
NO
- Signal wire
End of test
Test sequence

701
Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
YES
NO

End of test
702

Test prerequisite

Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
703
NO
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisites
Test sequence

Specified values

704
Specified values

Question
YES
NO

End of test
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
705
Test sequence
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
706
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test

Test sequence

1065
Relay for air pump : Short circuit to positive (P2258)
Possible cause:

- N10/1f61 (Fuse 61)
Affected functions:
- Engine diagnosis
-------------------------------------------------
707
Fuses
- FuseF43-F67
Relays

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
708
Test sequence

- Amperage[0.1...0.3] A
Question
YES
NO
- N10/1f61 (Fuse 61)

End of test
1066
Relay for air pump : Short circuit to ground (P2257)
Possible cause:

- N10/1f61 (Fuse 61)
Affected functions:
- Engine diagnosis
-------------------------------------------------
709
Fuses
- FuseF43-F67
Relays

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
710
Test sequence

- Amperage[0.1...0.3] A
Question
YES
NO
- N10/1f61 (Fuse 61)

End of test
1069
Y32 (Air pump switchover valve) : Short circuit to positive (P0413)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
711

Test sequence
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence

712
Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
End of test
1070
Y32 (Air pump switchover valve) : Short circuit to ground (P0414)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test sequence
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
713
Test prerequisite

Test sequence

Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
End of test
1071
Y32 (Air pump switchover valve) : Open circuit (P0412)
Possible cause:

714
- N10/1f57 (Fuse 57)
Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
715
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
716

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
717
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
718
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
719
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
720

Test sequence
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence
721
Specified value
- Amperage[0.3...0.6] A
Question
YES
NO
- N10/1f57 (Fuse 57)

valve)
End of test
1073
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence
Specified value
722
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
723
Test prerequisites

Test sequence
Specified value
- Amperage[0.2...0.6] A
Question
YES

End of test
NO
1074
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
724
Test prerequisite

Test sequence
Specified value
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
725
Test prerequisites

Test sequence
Specified value
- Amperage[0.2...0.6] A
Question
YES

End of test
NO
1075
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
726
- Engine output
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
727
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
728

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
729
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
730
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
731
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
732
Test prerequisite

Test sequence
Specified value
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
733
Test prerequisites

Test sequence
Specified value
- Amperage[0.2...0.6] A
Question
YES

End of test
NO
1077
Possible cause:

Affected functions:
- Fuel system
734
-------------------------------------------------

Test sequence

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
735
Test prerequisite

Test sequence
box tester.
Specified value
- Amperage[0.4...0.9] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test

Figure legend
- 019Vacuum tester
Test prerequisite
- Actuation is OK.
Test sequence

736
1078
Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------

Test sequence
737
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisite

Test sequence
box tester.
Specified value
- Amperage[0.4...0.9] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test
738

Figure legend
- 019Vacuum tester
Test prerequisite
- Actuation is OK.
Test sequence

1081
Purge control system has slight leak / Leak in hose connection or shutoff valve of activated charcoal canister (P0442)
Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
1085
Major leak in purge system / Hose in system not connected or filler cap open (P0455)
Possible cause:
739

Affected functions:
- Fuel system
-------------------------------------------------
1089
Purge control system has a slight leak (minor leak) (P0456)
Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
1097
Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
1098
Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
1101
B14 (Ambient temperature display temperature sensor) : Short circuit to positive
Possible cause:

Affected functions:
740
- Engine output
-------------------------------------------------
Test prerequisites

Note
Test sequence
Specified value
Question
YES
End of test
NO
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
741
Specified value
Question
YES
742
NO
- Signal wire
End of test
Test sequence

Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
YES
NO

End of test
743

Test prerequisites
Test sequence

Specified value

YES

End of test
NO
End of test
744
1102
B14 (Ambient temperature display temperature sensor) : Short circuit to ground
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
Test prerequisites

Note
Test sequence
745
Specified value
Question
YES
End of test
NO
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
746
YES
NO
- Signal wire
End of test
Test sequence

747
Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
YES
NO

End of test

Test prerequisites
Test sequence

748
Specified value

YES

End of test
NO
End of test
749
1103
B14 (Ambient temperature display temperature sensor) : Open circuit in wiring
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
Test prerequisites

Note
Test sequence
750
Specified value
Question
YES
End of test
NO
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
751
YES
NO
- Signal wire
End of test
Test sequence

752
Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
YES
NO

End of test

Test prerequisites
Test sequence

753
Specified value

YES

End of test
NO
End of test
754
1104
B14 (Ambient temperature display temperature sensor) : Plausibility error
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

Test prerequisites
Test sequence

Specified value

755
YES

End of test
NO
End of test
756
Test prerequisites

Note
Test sequence
Specified value
Question
YES
End of test
NO
757
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
758
YES
NO
- Signal wire
End of test
Test sequence

Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
759
YES
NO

End of test
Test prerequisites

Note
Test sequence
Specified value
Question
YES
760
End of test
NO
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
761
YES
NO
- Signal wire
End of test
Test sequence

Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
762
YES
NO

End of test
1105
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisite
763

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
764
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
765
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test
766

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
767
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
768
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

1636
Possible cause:
769
Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
Sequence

0604
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
Sequence

770
0605
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
Sequence

0613
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
771
Sequence

0643
The voltage supply of the speed sensors is faulty. ( Overvoltage )
Possible cause:
- Local overvoltage of component Speed sensors

Affected functions:
-------------------------------------------------
Test 1: Remedial action if faulty voltage supply to rpm sensors ( Overvoltage )
1. Remedial action if faulty voltage supply to rpm sensors ( Overvoltage )

- The voltage supply of the speed sensors is faulty.(Overvoltage)

REMEDY

772
0712
The signal from component Y3/8s2 (Transmission oil temperature sensor (VGS)) is implausible. ( Undervoltage )
Possible cause:
- Y3/8s2 (Transmission oil temperature sensor (VGS))

Affected functions:
-------------------------------------------------
Test 1: Remedial action for an implausible signal from component Y3/8s2 (Transmission oil temperature sensor (VGS))
1. Remedial action for an implausible signal from component Y3/8s2 (Transmission oil temperature sensor (VGS))
Operation number of operation texts and work units or standard texts and flat rates:27-0641POSSIBLE CAUSES
- Component Y3/8s2 (Transmission oil temperature sensor (VGS)) is defective.

REMEDY

0717
The signal from component Y3/8n1 (Turbine speed sensor (VGS)) is not available.
Possible cause:
- Y3/8n1 (Turbine speed sensor (VGS))

Affected functions:
773
-------------------------------------------------
Test 1: Remedial action for non-available signal from component Y3/8n1 (Turbine speed sensor (VGS))
1. Remedial action for non-available signal from component Y3/8n1 (Turbine speed sensor (VGS))
0741
Actuation of torque converter lockup clutch is not possible.
Possible cause:
- Torque converter lockup clutch

Affected functions:
-------------------------------------------------
Test 1: Remedial action on impermissible closing or excessively high friction power of the torque converter lockup clutch
1. Remedial action on impermissible closing or excessively high friction power of the torque converter lockup clutch
Operation number of operation texts and work units or standard texts and flat rates:27-0641Question:Does a customer complaint exist?
YES
Requirement:A customer complaint exists.Possible cause
- The software version of control unit EGS electronic transmission control is too old.
Remedy
- Program control unit EGS electronic transmission control.

Notes on submitting warranty or goodwill claimsSEAG damage code (7 digits): 54553 90 Continue with button "F2"
NO
Requirement:No customer complaint exists.RemedyIgnore fault code and erase fault memory. End of test
0742
Engaging of torque converter lockup clutch not permitted.
Possible cause:
- Torque converter lockup clutch

Affected functions:
-------------------------------------------------
Test 1: Remedial action on impermissible closing or excessively high friction power of the torque converter lockup clutch
1. Remedial action on impermissible closing or excessively high friction power of the torque converter lockup clutch
Operation number of operation texts and work units or standard texts and flat rates:27-0641Question:Does a customer complaint exist?
YES
Requirement:A customer complaint exists.RemedyPlease contact the relevant product service department. End of test
774
NO
Requirement:No customer complaint exists.RemedyIgnore fault code and erase fault memory. End of test
1629
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
Sequence

1631
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
775
Sequence

1632
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
Sequence

1633
Possible cause:

Affected functions:
-------------------------------------------------
776

REMEDY

1634
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
777
Sequence

1638
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
Sequence

1639
Possible cause:

Affected functions:
-------------------------------------------------
778
Test prerequisites

POSSIBLE CAUSES
Preconditions
Sequence

1710
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
Sequence

1711
779
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
Sequence

1712
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisites

POSSIBLE CAUSES
Preconditions
780
Sequence

1106
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

781
- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
782

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
783
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
784
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
785
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
786
Fuses
- FuseF43-F67
Relays

1108
Possible cause:

Affected functions:
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value
787

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
788
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
789
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test
790

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
791
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
792
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

1117
Possible cause:
793
Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
1118
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
1119
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
794
1185
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
Test prerequisite

Test sequence

Specified value
Figure legend
795

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisites

Test sequence
Specified value
- Amperage[0.2...0.6] A
Question
YES

End of test
NO
796
1186

- N10/1f57 (Fuse 57)
Affected functions:
- Engine output
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
797
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
798

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
799
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
800
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
801
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
802
Fuses
- FuseF43-F67
Relays

3. Power supply
Test prerequisite

Test sequence

Specified value
803
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
804
Test prerequisites

Test sequence
Specified value
- Amperage[0.2...0.6] A
Question
YES

End of test
NO
1187
Possible cause:

- N10/1f57 (Fuse 57)
805
Affected functions:
- Engine output
-------------------------------------------------
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
806
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
807

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
808
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
809
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
810
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Fuses
- FuseF43-F67
Relays

3. Power supply
811
Test prerequisite

Test sequence

Specified value
Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
812
Test prerequisites

Test sequence
Specified value
- Amperage[0.2...0.6] A
Question
YES

End of test
NO
1197
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
813

1198
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

1199
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

1200
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

814
1201
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

1202
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

1203
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

1204
815
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

1205
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

1206

Affected functions:
- Engine diagnosis

1207
Possible cause:

Affected functions:
816
- Engine diagnosis
-------------------------------------------------

1208
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

1209
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

1210
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
817

1211
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

1212
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

1301
Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
1302
Possible cause:
818

Affected functions:
- Fuel system
-------------------------------------------------
1303
Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
1304
Possible cause:

Affected functions:
- Fuel system
-------------------------------------------------
1305
Component Y10/1 (Power steering pump pressure regulator valve) has a short circuit to positive.
Possible cause:
- Y10/1 (Power steering pump pressure regulator valve)

Affected functions:
- Steering Function
-------------------------------------------------
Test 1: Check component Y10/1 (Power steering pump pressure regulator valve).
1. Check component Y10/1 (Power steering pump pressure regulator valve).

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
819
Test sequence

Specified value
- Amperage [1.5...2.2] A
Question
YES
End of test
NO
- N10/1f54 (Fuse 54)

- Check line from control module N3/10 (ME-SFI [ME] control unit) to component Y10/1 (Power steering pump pressure regulator valve).
End of test
1306
Component Y10/1 (Power steering pump pressure regulator valve) has a short circuit to ground.
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Steering Function
820
-------------------------------------------------

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
821
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
822
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
823
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Test prerequisite
824

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
825
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test
Fuses
- FuseF43-F67
Relays


Figure legend
826

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
- Amperage [1.5...2.2] A
Question
YES
End of test
NO
- N10/1f54 (Fuse 54)

End of test
827
1307
Component Y10/1 (Power steering pump pressure regulator valve) has an open circuit in the wiring.
Possible cause:

- N10/1f57 (Fuse 57)
Affected functions:
- Steering Function
-------------------------------------------------

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
828
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
Test prerequisite
829
- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
830
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
831
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f43 (Fuse 43)

- N10/1f44 (Fuse 44)
- Lines
End of test
832

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
833
Question
YES
NO

End of test
Fuses
- FuseF43-F67
Relays


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
834
Test sequence

Specified value
- Amperage [1.5...2.2] A
Question
YES
End of test
NO
- N10/1f54 (Fuse 54)

End of test
1313
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
835


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisites
836
Test sequence

Specified values

Specified values

Question
YES
NO

End of test

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
1314
Possible cause:
837

Affected functions:
- Engine output
-------------------------------------------------


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
838
Test prerequisites
Test sequence

Specified values

Specified values

Question
YES
NO

End of test
839

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
1315
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------


Figure legend

- 108 -Test cable 266 589 01 63 00
840
Warning!
Test prerequisites
Test sequence

Specified values

Specified values

Question
YES
841
NO

End of test

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
1316
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------


Figure legend
842

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisites
Test sequence

Specified values

Specified values

Question
843
YES
NO

End of test

Test sequence

Specified value
Question
- Is the test o.k?
YES
NO
1337
Alternator serial interface
Possible cause:
- Alternator serial interface

Affected functions:
- CAN Communication
-------------------------------------------------
Test 1: Alternator serial interface
1. Alternator serial interface

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
844
Test prerequisites
Test sequence

Specified value
Question
YES
Test sequence

Specified value
Question
YES

End of test
NO
845
NO
Test sequence

Specified value
Question
YES

End of test
NO
1345
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
846
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)
847
End of test
Test sequence
Specified value
Question
YES
NO
1346
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test sequence
848
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
849
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
1347
B2/5 (Hot film mass air flow sensor) : Open circuit / Short circuit to ground or to positive (P0102)

Affected functions:
- Engine diagnosis
- Engine output
Test sequence
Specified value
Question
YES
NO
850
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
1349
851
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test sequence
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite
852

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test
853

Test prerequisite

Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
854
YES
NO
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisites
Test sequence

855
Specified values

Specified values

Question
YES
NO

End of test
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
1350
Possible cause:
856
Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
Test sequence
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

857
Specified value
- Voltage[11.0...15.0] V
Question
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test

Test prerequisite
858

Note

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
NO
859
End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisites
Test sequence

Specified values

Specified values
860

Question
YES
NO

End of test
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
1351
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
861
Test sequence
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
862
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test

Test prerequisite

Note
863

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
NO
End of test

Figure legend
864

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisites
Test sequence

Specified values

Specified values

Question
865
YES
NO

End of test
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
1352
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
866
Test sequence
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
867
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test

Test prerequisite

Note
868

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence

Specified value
Question
YES
NO
End of test

Figure legend
869

- 108 -Test cable 266 589 01 63 00
Warning!
Test prerequisites
Test sequence

Specified values

Specified values

Question
870
YES
NO

End of test
Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
End of test
NO

End of test
1360
O2 sensors downstream TWC : Plug connections of the O2 sensors are wrongly connected. (P0041)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

- Test plug connections.

End of test
1361
871
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
1362
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
1365
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.
872

unit).
1366
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
1367
Control module has an internal error.
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
1368
Possible cause:

Affected functions:
873
- Engine diagnosis
-------------------------------------------------

Test control unit.

unit).
1389
Air injection diagnosis
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

Test sequence
1390
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

Test sequence
874
1392
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

Test sequence
1425
Wheel speed signal is implausible.
Possible cause:
- The signal transmitted by the CAN databus for the wheel speeds is implausible.
Affected functions:
- Electronic stability program ESP
-------------------------------------------------
Test 1: Test wheel speed signals.
1. Test wheel speed signals.

The actual values are supplied through CAN bus from component N47-5 (ESP, SPS [PML] and BAS control unit).Test prerequisites
- CAN communication to control module N47-5 (ESP, SPS [PML] and BAS control unit) is o.k.
Test sequence
- Rotate relevant wheel.(n >60 1/min)
- Vehicle speed at rear axle:Warning! Communication with ECU required.
- Vehicle speed at front axle:Warning! Communication with ECU required.
Specified values
- Vehicle speed>3 km/h

Question
YES
NO
875
- Read fault memory from control unit ESP and rectify faults.
End of test
1461
Possible cause:

Affected functions:
- Engine diagnosis
- Engine cooling
-------------------------------------------------

Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
876
End of test

Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
877



Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Test sequence
Specified value
878
- Amperage[0.6...1.2] A
Question
YES
NO
- N10/1f57 (Fuse 57)

End of test
1462
Possible cause:

Affected functions:
- Engine diagnosis
- Engine cooling
-------------------------------------------------
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
879
YES
NO
End of test

Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO
880

End of test
1463
The engine temperature from the engine control module is implausible. Signal voltage is implausible. (P0116)
Possible cause:

Affected functions:
- Engine diagnosis
- Engine cooling
-------------------------------------------------
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test

Test sequence
881
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
1464
The engine temperature from the engine control module is implausible. Shunt fault / Sensor characteristic curve (P0116)
Possible cause:

Affected functions:
882
- Engine diagnosis
- Engine cooling
-------------------------------------------------
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test

Test sequence
Specified value
Question
YES
883
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
1599
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test prerequisites
884
Test sequence

Specified value

YES

End of test
NO
End of test
885
Test prerequisites

Note
Test sequence
Specified value
Question
YES
End of test
NO
886
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
887
YES
NO
- Signal wire
End of test
Test sequence

Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
888
YES
NO

End of test
1600
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test prerequisites
Test sequence

889
Specified value

YES

End of test
NO
End of test
890
Test prerequisites

Note
Test sequence
Specified value
Question
YES
End of test
NO
891
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
892
YES
NO
- Signal wire
End of test
Test sequence

Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
893
YES
NO

End of test
1857
Ratio of HFM signal to intake manifold pressure is too high.
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
894
Test sequence
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
895
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test

Test sequence

Specified values

Question
YES
896
NO

- Vacuum line

Figure legend

Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
NO

End of test
897

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test prerequisite

Test sequence

Specified values

Question
898
YES
NO

- Vacuum line
End of test
1858
Ratio of HFM signal to intake manifold pressure is too low.
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------
899
Test sequence
Specified value
Question
YES
NO
Image legends

- Connector (5-pin)
Test prerequisite

Test sequence

Specified value
- Voltage[11.0...15.0] V
Question
900
YES
- Unmetered air
- Signal wire
End of test
NO
- N10/1f43 (Fuse 43)

End of test

Test sequence

Specified values

Question
YES
901
NO

- Vacuum line

Figure legend

Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
YES
NO

End of test
902

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test prerequisite

Test sequence

Specified values

Question
903
YES
NO

- Vacuum line
End of test
1861
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

1909
B28 (Pressure sensor) : Short circuit to positive or open circuit (P0108)
Possible cause:

Affected functions:
- Engine output
904
-------------------------------------------------

Test sequence

Specified values

Question
YES
NO

- Vacuum line

Figure legend

Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
905
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
906
Figure legend

Test prerequisite

Test sequence

Specified values

Question
907
YES
NO

- Vacuum line
End of test
1910
B28 (Pressure sensor) : Short circuit to ground (P0107)
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

Test sequence
908

Specified values

Question
YES
NO

- Vacuum line

Figure legend

Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
909
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test prerequisite

Test sequence

910
Specified values

Question
YES
NO

- Vacuum line
End of test
1913
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
911

Test sequence

Specified values

Question
YES
NO

- Vacuum line

Figure legend

Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
912
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
913
Figure legend

Test prerequisite

Test sequence

Specified values

Question
914
YES
NO

- Vacuum line
End of test
1914
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence
915

Specified values

Question
YES
NO

- Vacuum line

Figure legend

Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
916
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test prerequisite

Test sequence

917
Specified values

Question
YES
NO

- Vacuum line
End of test
1915
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------
918

Test sequence

Specified values

Question
YES
NO

- Vacuum line

Figure legend

Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
919
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
920
Figure legend

Test prerequisite

Test sequence

Specified values

Question
921
YES
NO

- Vacuum line
End of test
1916
Possible cause:

Affected functions:
- Engine diagnosis
- Engine output
-------------------------------------------------

Test sequence
922

Specified values

Question
YES
NO

- Vacuum line

Figure legend

Test prerequisite

Test sequence

Specified value
- Voltage[4.75...5.25] V
Question
923
YES
NO

End of test

Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
Figure legend

Test prerequisite

Test sequence

924
Specified values

Question
YES
NO

- Vacuum line
End of test
1921
SBC : Undervoltage supply
Possible cause:

Affected functions:
-------------------------------------------------
Test 2: Check component A7/3n1 (SBC control unit).
925
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
926
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
927

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend
928

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
929
2. Check component A7/3n1 (SBC control unit).

Read and process fault code from control module A7/3n1 (SBC control unit).
- Read and process fault code from control module A7/3n1 (SBC control unit).
End of test
Part 1
CAN bus OFF : Short circuit Engine CAN bus
Possible cause:

Affected functions:
- CAN Communication
-------------------------------------------------
Test 1: A guided test is not available at present.
1. A guided test is not available at present.

Note:A guided test is not available at present.

930

Bus OFF fault
Bus keepawake event


931



932

Multimeter
Measuring system


933
Figure legend

Note

field.
934

Test prerequisites
- The fuses are OK.

Test sequence

Specified value
- Voltage [11.0...14.5] V
YES
End of test
NO
End of test
Figure legend
935

Test prerequisite

Test sequence

Specified value
- [11.0 ... 14.5] V

Question
YES
Note
End of test
NO
936
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
937
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
938

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend
939

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
940
2.1.3.2.1.4.1. Guided test


Test sequence


Specified value
- Voltage[7.0...16.0] V
Question
YES

End of test
NO
End of test

941
Specified value
- Voltage[11.0...14.5] V
Question
YES

Specified value
- Voltage[11.0...14.5] V
Question
942
YES
NO
End of test
NO
- Test cables
End of test
943
Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO
- N10/1f47 (Fuse 47)
End of test

Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO
944
- N10/1f47 (Fuse 47)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
YES
End of test
NO
- Ground cable
End of test
Part 2
Test prerequisite

Test sequence

945
Specified value
- [11...14 V]
Question
YES
End of test
NO


Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO

- F34f37 (Fuse 37)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
946
Question
YES
End of test
NO
- Ground cable
End of test
Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO


Test prerequisite

Test sequence

947
Specified value
- [11...14 V]
Question
YES
End of test
NO

- N10/1f45 (Fuse 45)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
YES
End of test
NO
- Ground cable
End of test
Test sequence

Specified value
- [11.0 ... 14.5] V

Question
948
YES
Note
End of test
NO
module)5A
949
YES

NO

Test sequence

950
YES
End of test
951
NO

End of test
952
Test prerequisite

Specified value

Question
YES
- Check alternator.
End of test
NO

Specified value
- Voltage [11.0...14.5] V
Question
YES
necessary.
953
End of test
NO
Question
Test prerequisite
- The fuses are OK.

Test sequence

Specified value
- Voltage [11.0...14.5] V
Question
YES
necessary.
End of test
NO
End of test

Test sequence

954
- Voltage [8,5...16,4] V
Question
YES

Test sequence
- Voltage [8,5...16,4] V
Question
955
YES
Test sequence


Specified value

Question
YES
956


Specified value

Question
YES
957
REMEDY

- SCN coding
End of test
NO

End of test
NO

End of test
NO


Specified value

Question
958
YES
Test sequence


Specified value

Question
YES
959

REMEDY

- SCN coding
End of test
NO

End of test
NO

End of test
NO

Figure legend

Test sequence

- [55...65]ohms
Question:
960
YES
NO
End of test

Test sequence

Specified value
Question
YES
NO
961
End of test
Test sequence

Specified value
Question
YES
NO
End of test
Test sequence

Specified value
Question
YES
NO

End of test

Test sequence
Specified value
962

- Control unit
Important notes
Important notes :For safety reasons, the vehicle must not be driven during diagnosis with special tool 'Star Diagnosis CANtool'.The diagnostic
cable must now be replaced with the 8-pin CAN cable in order to display the CAN signals.Continue with button F2
Display CAN signals with the aid of the special tool 'Star Diagnosis CANtool'.
Note
- The following CAN actual values are displayed with the aid of the special tool 'Star Diagnosis CANtool'.
Test prerequisites
- Special tool Star Diagnosis CANtool is required.

- The SDconnect CAN cable (8-pin) with MB object number 6511240099 is connected.
- The electrical connection kit with MB object number 220 589 00 99 00 is required.
- CAN highAdapter cable220 589 00 99 36
Further image can be displayed with key F7.Continue with button F2
963
Preparation for test

- Connect special tool 'Star Diagnosis CANtool' to interface '(W)LAN' of STAR DIAGNOSIS.
- Connect socket box to component N3/9 (CDI control unit).
- Connect special tool 'Star Diagnosis CANtool' to the indicated sockets of the socket box.
- Connect special tool 'Star Diagnosis CANtool' to vehicle battery or a suitable power supply unit with fuse.
Socket box connector
- Sockets (F.41) 11 and (F.54) 24 of the 35-pole socket box tester.

964
Preparation for test

- Connect special tool 'Star Diagnosis CANtool' to interface 'RS232' of STAR DIAGNOSIS.
- Connect socket box to component N3/9 (CDI control unit).
- Connect special tool 'Star Diagnosis CANtool' to the indicated sockets of the socket box.
- Connect special tool 'Star Diagnosis CANtool' to vehicle battery or a suitable power supply unit with fuse.
Socket box connector
- Sockets (F.41) 11 and (F.54) 24 of the 35-pole socket box tester.

965
Part 1
Possible cause:

Affected functions:
- CAN Communication
-------------------------------------------------
Test 1: A guided test is not available at present.
1. A guided test is not available at present.

Note:A guided test is not available at present.
966


Bus OFF fault
Bus keepawake event


967



968

Multimeter
Measuring system


969
Figure legend

Note
970

field.

Test prerequisites
- The fuses are OK.

Test sequence

Specified value
- Voltage [11.0...14.5] V
YES
End of test
NO
971
End of test
Figure legend

Test prerequisite

Test sequence

Specified value
- [11.0 ... 14.5] V

Question
YES
972
Note
End of test
NO
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
973
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
974

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend
975

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
976
2.1.3.2.1.4.1. Guided test


Test sequence


Specified value
- Voltage[7.0...16.0] V
Question
YES

End of test
NO
End of test

977
Specified value
- Voltage[11.0...14.5] V
Question
YES

Specified value
- Voltage[11.0...14.5] V
Question
978
YES
NO
End of test
NO
- Test cables
End of test
979
Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO
- N10/1f47 (Fuse 47)
End of test

Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO
980
- N10/1f47 (Fuse 47)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
YES
End of test
NO
- Ground cable
End of test
Part 2
Test prerequisite

Test sequence

981
Specified value
- [11...14 V]
Question
YES
End of test
NO


Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO

- F34f37 (Fuse 37)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
982
Question
YES
End of test
NO
- Ground cable
End of test
Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO


Test prerequisite

Test sequence

983
Specified value
- [11...14 V]
Question
YES
End of test
NO

- N10/1f45 (Fuse 45)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
YES
End of test
NO
- Ground cable
End of test
Test sequence

Specified value
- [11.0 ... 14.5] V

Question
984
YES
Note
End of test
NO
module)5A
985
YES

NO

Test sequence

986
YES
End of test
987
NO

End of test
988
Test prerequisite

Specified value

Question
YES
- Check alternator.
End of test
NO

Specified value
- Voltage [11.0...14.5] V
Question
YES
necessary.
989
End of test
NO
Question
Test prerequisite
- The fuses are OK.

Test sequence

Specified value
- Voltage [11.0...14.5] V
Question
YES
necessary.
End of test
NO
End of test

Test sequence

990
- Voltage [8,5...16,4] V
Question
YES

Test sequence
- Voltage [8,5...16,4] V
Question
991
YES
Test sequence


Specified value

Question
YES
992


Specified value

Question
YES
993
REMEDY

- SCN coding
End of test
NO

End of test
NO

End of test
NO


Specified value

Question
994
YES
Test sequence


Specified value

Question
YES
995

REMEDY

- SCN coding
End of test
NO

End of test
NO

End of test
NO

Figure legend

Test sequence

- [55...65]ohms
Question:
996
YES
NO
End of test

Test sequence

Specified value
Question
YES
NO
997
End of test
Test sequence

Specified value
Question
YES
NO
End of test
Test sequence

Specified value
Question
YES
NO

End of test

Test sequence
Specified value
998

- Control unit
Important notes

Note





999

2025
Component B2/5b1 (Intake air temperature sensor) has a short circuit to ground. (P0112)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisites

Note
Test sequence
Specified value
Question
YES
End of test
NO
1000
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
1001
YES
NO
- Signal wire
End of test
Test sequence

Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
1002
YES
NO

End of test
2026
Component B2/5b1 (Intake air temperature sensor) has a short circuit to positive or an open circuit. (P0113)
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisites

Note
1003
Test sequence
Specified value
Question
YES
End of test
NO
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
1004
YES
NO
- Signal wire
End of test
Test sequence

1005
Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
YES
NO

End of test
2029
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
1006
Test prerequisites

Note
Test sequence
Specified value
Question
YES
End of test
NO
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
1007
Question
YES
NO
1008
- Signal wire
End of test
Test sequence

Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
YES
NO

End of test
1009
Test prerequisite

Test sequence
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test

Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite
1010

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
2030
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisites

Note
1011
Test sequence
Specified value
Question
YES
End of test
NO
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
1012
YES
NO
- Signal wire
End of test
Test sequence

1013
Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
YES
NO

End of test
Test prerequisite

Test sequence
1014
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test

Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
1015
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
2032
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------
Test prerequisites

Note
Test sequence
Specified value
Question
1016
YES
End of test
NO
Image legends
- Picture1
- Connector (5-pin)
- Picture2
- Connector (4-pin)
Test prerequisite

Test sequence
Specified value
Question
1017
YES
NO
- Signal wire
End of test
Test sequence

1018
Specified value
- Resistor(0° C): [5100...5900]ohms

- Resistor(5° C): [4100...4800]ohms
- Resistor(10° C): [3300...3900]ohms
- Resistor(15° C): [2700...3200]ohms
- Resistor(20° C): [2350...2500]ohms
- Resistor(25° C): [1900...2100]ohms
- Resistor(30° C): [1600...1700]ohms
- Resistor(35° C): [1300...1500]ohms
- Resistor(40° C): [1100...1200]ohms
- Resistor(45° C): [920...1100]ohms
- Resistor(50° C): [800...900]ohms
Question
YES
NO

End of test
Test prerequisite

Test sequence
1019
Specified values
- Voltage[20° C]: [3.45...3.32] V

- Voltage[30° C]: [2.93...2.82] V
- Voltage[40° C]: [2.41...2.32] V
- Voltage[50° C]: [1.93...1.86] V
- Voltage[60° C]: [1.51...1.46] V
- Voltage[70° C]: [1.18...1.13] V
- Voltage[80° C]: [0.90...0.87] V
- Voltage[90° C]: [0.70...0.67] V
- Voltage[100° C]: [0.54...0.25] V
- Voltage[110° C]: [0.42...0.40] V
Question
YES
NO
End of test

Test sequence
Specified value
Question
YES
NO
End of test

Test prerequisite

Test sequence

Specified values
- Resistor(20° C): [3030...3130]ohms

- Resistor(30° C]: [1950...2050]ohms
1020
- Resistor(40° C): [1275...1375]ohms
- Resistor(50° C): [850...950]ohms
- Resistor(60° C): [600...650]ohms
- Resistor(70° C): [420...460]ohms
- Resistor(80° C): [305...335]ohms
- Resistor(90° C): [220...240]ohms
- Resistor(100° C): [160...180]ohms
- Resistor(110° C): [120...140]ohms
Question
YES
NO

End of test
2037
Fault during the mixture adaptation (multiplicative or additive) bank 1
Possible cause:

Affected functions:
- Engine diagnosis
-------------------------------------------------

Test sequence

2041
Fault during the mixture adaptation (multiplicative or additive) bank 2
Possible cause:

Affected functions:
- Engine output
-------------------------------------------------

Test sequence
1021
Part 1
Physical fill level fault: upper limit exceeded
Possible cause:
Affected functions:
- CAN Communication
-------------------------------------------------


Bus OFF fault
1022
Bus keepawake event


1023



1024

Multimeter
Measuring system


1025
Figure legend

Note

field.
1026

Test prerequisites
- The fuses are OK.

Test sequence

Specified value
- Voltage [11.0...14.5] V
YES
End of test
NO
End of test
Figure legend
1027

Test prerequisite

Test sequence

Specified value
- [11.0 ... 14.5] V

Question
YES
Note
End of test
NO
1028
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
1029
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
1030

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend
1031

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
1032
1.1.3.2.1.4.1. Guided test


Test sequence


Specified value
- Voltage[7.0...16.0] V
Question
YES

End of test
NO
End of test

1033
Specified value
- Voltage[11.0...14.5] V
Question
YES

Specified value
- Voltage[11.0...14.5] V
Question
1034
YES
NO
End of test
NO
- Test cables
End of test
1035
Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO
- N10/1f47 (Fuse 47)
End of test

Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO
1036
- N10/1f47 (Fuse 47)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
YES
End of test
NO
- Ground cable
End of test
Part 2
Physical fill level fault: upper limit exceeded
Test prerequisite

Test sequence

1037
Specified value
- [11...14 V]
Question
YES
End of test
NO


Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO

- F34f37 (Fuse 37)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
1038
YES
End of test
NO
- Ground cable
End of test
Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO


Test prerequisite

Test sequence

1039
Specified value
- [11...14 V]
Question
YES
End of test
NO

- N10/1f45 (Fuse 45)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
YES
End of test
NO
- Ground cable
End of test
Test sequence

Specified value
- [11.0 ... 14.5] V

Question
1040
YES
Note
End of test
NO
module)5A
YES
1041

NO

Test sequence

1042
YES
End of test
1043
NO

End of test
1044
Test prerequisite

Specified value

Question
YES
- Check alternator.
End of test
NO

Specified value
- Voltage [11.0...14.5] V
Question
YES
necessary.
1045
End of test
NO
Question
Test prerequisite
- The fuses are OK.

Test sequence

Specified value
- Voltage [11.0...14.5] V
Question
YES
necessary.
End of test
NO
End of test

Test sequence

1046
- Voltage [8,5...16,4] V
Question
YES

Test sequence
- Voltage [8,5...16,4] V
Question
1047
YES
Test sequence


Specified value

Question
YES
1048


Specified value

Question
YES
1049
REMEDY

- SCN coding
End of test
NO

End of test
NO

End of test
NO


Specified value

Question
1050
YES
Test sequence


Specified value

Question
YES
1051

REMEDY

- SCN coding
End of test
NO

End of test
NO

End of test
NO

Figure legend

Test sequence

- [55...65]ohms
Question:
1052
YES
NO
End of test

Test sequence

Specified value
Question
YES
NO
1053
End of test
Test sequence

Specified value
Question
YES
NO
End of test
Test sequence

Specified value
Question
YES
NO

End of test

Test sequence
Specified value
1054

- Control unit
Important notes

Note





1055


End of test
Part 1
Physical fill level fault: upper limit exceeded (tank 2)
Possible cause:
Affected functions:
- CAN Communication
-------------------------------------------------


Bus OFF fault
1056
Bus keepawake event


1057



1058

Multimeter
Measuring system


Important notes
1059

Note






1060
Figure legend

Note

field.
1061

Test prerequisites
- The fuses are OK.

Test sequence

Specified value
- Voltage [11.0...14.5] V
YES
End of test
NO
End of test
1062
Figure legend

Test prerequisite

Test sequence

Specified value
- [11.0 ... 14.5] V

Question
YES
Note
End of test
NO
1063
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
1064
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
1065

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend
1066

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
1067
1.1.3.3.1.4.1. Guided test


Test sequence


Specified value
- Voltage[7.0...16.0] V
Question
YES

End of test
NO
End of test

1068
Specified value
- Voltage[11.0...14.5] V
Question
YES

Specified value
- Voltage[11.0...14.5] V
Question
1069
YES
NO
End of test
NO
- Test cables
End of test
Part 2
1070
Physical fill level fault: upper limit exceeded (tank 2)
Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO
- N10/1f47 (Fuse 47)
End of test

Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
1071
End of test
NO
- N10/1f47 (Fuse 47)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
YES
End of test
NO
- Ground cable
End of test
Test prerequisite

Test sequence

Specified value
1072
- [11...14 V]
Question
YES
End of test
NO


Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO

- F34f37 (Fuse 37)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
1073
YES
End of test
NO
- Ground cable
End of test
Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO


Test prerequisite

Test sequence

Specified value
1074
- [11...14 V]
Question
YES
End of test
NO

- N10/1f45 (Fuse 45)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
YES
End of test
NO
- Ground cable
End of test
Test sequence

Specified value
- [11.0 ... 14.5] V

Question
1075
YES
Note
End of test
NO
module)5A
YES
1076

NO

Test sequence

1077
YES
End of test
1078
NO

End of test
1079
Test prerequisite

Specified value

Question
YES
- Check alternator.
End of test
NO

Specified value
- Voltage [11.0...14.5] V
Question
YES
necessary.
1080
End of test
NO
Question
Test prerequisite
- The fuses are OK.

Test sequence

Specified value
- Voltage [11.0...14.5] V
Question
YES
necessary.
End of test
NO
End of test

Test sequence

1081
- Voltage [8,5...16,4] V
Question
YES

Test sequence
- Voltage [8,5...16,4] V
Question
1082
YES
Test sequence


Specified value

Question
YES
1083


Specified value

Question
YES
1084
REMEDY

- SCN coding
End of test
NO

End of test
NO

End of test
NO


Specified value

Question
1085
YES
Test sequence


Specified value

Question
YES
1086

REMEDY

- SCN coding
End of test
NO

End of test
NO

End of test
NO

Test sequence

Specified value
Question
YES
NO
1087

End of test
Figure legend

Test sequence

- [55...65]ohms
Question:
YES
NO
1088
End of test

Test sequence

Specified value
Question
YES
NO
End of test
Test sequence

Specified value
Question
YES
NO
End of test

Test sequence
Specified value
1089

- Control unit

End of test
Part 1
Physical fill level fault: signal implausible
Possible cause:
Affected functions:
- CAN Communication
-------------------------------------------------


Bus OFF fault
1090
Bus keepawake event


1091



1092

Multimeter
Measuring system


1093
Figure legend

Note

field.
1094

Test prerequisites
- The fuses are OK.

Test sequence

Specified value
- Voltage [11.0...14.5] V
YES
End of test
NO
End of test
Figure legend
1095

Test prerequisite

Test sequence

Specified value
- [11.0 ... 14.5] V

Question
YES
Note
End of test
NO
1096
Test prerequisite

- Ignition ON
Specified value

YES
NO


Figure legend

- 108 -Test cable 266 589 01 63 00
Warning!
-
1097
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- F34f42 (Fuse 42)

- Lines
End of test

Figure legend
1098

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Amperage[0.1...0.3] A
Question
YES
NO

End of test

Figure legend
1099

- 108 -Test cable 266 589 01 63 00
Warning!
-
Test sequence
Specified value
- Voltage[11.0...15.0] V
Question
YES
NO
- N10/1f52 (Fuse 52)

- Lines
End of test
1100
1.1.3.2.1.4.1. Guided test


Test sequence


Specified value
- Voltage[7.0...16.0] V
Question
YES

End of test
NO
End of test

1101
Specified value
- Voltage[11.0...14.5] V
Question
YES

Specified value
- Voltage[11.0...14.5] V
Question
1102
YES
NO
End of test
NO
- Test cables
End of test
1103
Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO
- N10/1f47 (Fuse 47)
End of test

Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO
1104
- N10/1f47 (Fuse 47)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
YES
End of test
NO
- Ground cable
End of test
Part 2
Physical fill level fault: signal implausible
Test prerequisite

Test sequence

1105
Specified value
- [11...14 V]
Question
YES
End of test
NO


Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO

- F34f37 (Fuse 37)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
1106
YES
End of test
NO
- Ground cable
End of test
Test prerequisite

Test sequence

Specified value
- [11...14 V]
Question
YES
End of test
NO


Test prerequisite

Test sequence

1107
Specified value
- [11...14 V]
Question
YES
End of test
NO

- N10/1f45 (Fuse 45)
End of test

Test prerequisite

Test sequence

Specified value
- [<1ohms]
Question
YES
End of test
NO
- Ground cable
End of test
Test sequence

Specified value
- [11.0 ... 14.5] V

Question
1108
YES
Note
End of test
NO
module)5A
YES
1109

NO

Test sequence

1110
YES
End of test

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Mercedes Benz C230

W203 Chassis - V6 2.5L M272 Engine

AH00.00-U-1000-01Z Observe Safety Regulations When the Engine Is Running

Before performing jobs with engine running apply parking brake.

Important repair information

AS54.00-Z-0001-01A Risk Of Death When Touching Components On Vehicles With High-voltage

High-voltage on-board electrical system

Risk of death caused by electric shock

A highly explosive gas mixture is produced when charging lead-acid batteries.

Protective measures/rules of conduct

Inhaling battery electrolyte mist

Swallowing battery electrolyte

Fire protection measures

Suitable extinguishing agents

Safety precautions and rules of conduct

First aid measures

Swallowing battery gel

Fire protection measures

Suitable extinguishing agents

These notes are identified by the following symbols (logos):

First aid measures

First aid measures for burns

DANGER: Protect cans from direct sunlight and temperatures above 50 °C

DANGER: Do not touch voltage conducting parts in the 220 V system

Risk of death caused by electric shock

Risk of injury caused by burns

Do not touch any conductive parts of the 220 V system.

Before beginning any work always:

Observe country-specific regulations.

First aid measures

First attempt to turn off the power.

If any of these symptoms occur, consult a physician immediately.

First aid measures

When eyes or skin come in contact with melted shrink tubing

When vapor is inhaled:

Fire protection measures

Suitable extinguishing agents

AH00.00-N-0005-01A Measures For Preventing Damage to Vehicles or Components When

1. Have fire extinguishers at the ready.

These notes are identified by the following symbols (logos):

AP00.20-P-0053BA Check All Visible Parts For Leaks and Damage

AR00.10-P-1010A Check Gear Capacity

AH54.21-P-0001-03Y Notes on Programming Control Units

Program using STAR DIAGNOSIS (Xentry flash)

Further explanation of terms:

Deliveries and costs

Offline programming with Release CD

Offline programming with Special Release CD

Program using STAR DIAGNOSIS (Xentry flash)

Further explanation of terms:

Offline programming with Special Release CD

Offline programming with Special Release CD

AH54.21-P-0004-01X Notes on SCN Coding of Control Units

Precondition for SCN coding:

Entry into coding in the Diagnosis Assistance System (DAS)

7. Continue with "F2".

The SCN coding of the control unit is completed.

Precondition for offline SCN coding:

The offline SCN coding is broken down into 2 steps:

14. Continue with "F2".

Offline programming with Release CD

Offline programming with special release CD.

AR54.21-P-0014Y Programming Of Control Units