Recall - Power Steering Hose Replacement
Campaign No. 2003040005, October 2008FILE:
SERVICE:
GROUP 00 OF SERVICE INFORMATION BINDER
PARTS:
GROUP I OF INFORMATION - PARTS & ACCESSORIES BINDER
Revision History
TO: ALL MERCEDES-BENZ CENTERS
SUBJECT: Models 163.154/157/172/174/175, Model Years 1998 - 2004 Replace Power Steering Hose and Hose Clamp
Revision d of this Recall Campaign involves replacement of the low pressure power steering hose and clamp (1 and 2, Figure 1) on certain vehicles that were previously repaired without the latest repair kit. MBUSA has determined that, on certain vehicles, the repairs previously conducted under this recall may have been performed with a method that makes it susceptible to future power steering fluid leaks or disconnection of the low pressure power steering hose. Vehicles repaired without the latest repair method will be repaired again. These vehicles will be repaired with the latest service instructions and with a parts kit that was designed to eliminate the potential for future leakage. This action involves approximately 111,382 vehicles that were part of the earlier recall of approximately 225,901 vehicles. MBUSA will also be mailing a version of this notice to the approximately 9,521 owners who have not responded to the 2003 owner notification. In addition, based on our latest review of warranty data and current vehicle registrations, MBUSA will be mailing notifications to 4,323 MY 2003 - 2004 owners who were not included in the initial 2003 campaign. Dealers will replace the lower power steering hose and clamp in all affected subject vehicles.
Attached are sample copies of a letters 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 125,228 vehicles are involved in this relaunch.
Replacement Procedure
1. Drive vehicle onto a lift, shut-off engine and remove ignition key from ignition lock.
2. Open engine hood.
3. Remove engine cover and set aside.
Warning:
- Risk of Bodily injury if skin or eyes are exposed to high pressure hydraulic fluid release.
- Risk of poisoning if hydraulic fluid is ingested.
Please refer to WIS: AS00.00-Z-0013-01A for all applicable safety precautions and information
NOTE: Before opening the hydraulic system, clean areas surrounding low pressure power steering hose connections (radiator, steering rack etc.). Any contamination entering the hydraulic component may cause component failure or total loss of the hydraulic system operation.
4. Remove fluid from power steering reservoir using hand pump (Special Tool 210 589 00 71 00).
5. Raise vehicle on lift.
NOTE: Before removing hose, observe orientation of low pressure power steering hose at steering rack to ensure proper positioning of replacement hose.
6. Detach low pressure power steering hose mounting grommets (7, Figure 2) from 4 holders (attached to frame rail on the left front of vehicle).
7. Loosen hose clamp (6, Figure 2) and disconnect low pressure power steering hose (2) from radiator fitting.
8. Remove banjo bolt (9, Figure 2) securing low pressure power steering hose (2) to power steering rack (10) and remove low pressure power steering hose by routing out towards rear of vehicle.
NOTE:
- Carefully clean low pressure power steering hose connection (8, Figure 2) at the radiator, using a lint-free shop towel to ensure that no power steering fluid residue is present on the hose connection. Install the low pressure power steering hose DRY onto the hose connection (8, Figure 2) at the radiator (12, Figure 2)
- Do not use any cleaning agents.
9. Install new low pressure power steering hose (2, Figure 1) in reverse order (use new hose clamp, as provided in the repair kit).
NOTE: Install new sealing rings (11, Figure 2) or rubber O-rings as applicable when installing new low pressure power steering hose (2).
10. As equipped: torque banjo bolt to 30 Nm or flare fitting with O-ring to 30 Nm, see WIS document: AR46.20-P-0600GH.
Note (regarding above WIS instructions):
Illustration in WIS instructions shows low pressure power steering hose with flare fitting and O-ring.
11. Slide the installed new hose clamp toward the radiator and locate in the proper position on the low pressure power steering hose (1, Figure 1) as shown and tighten hose clamp screw (6, Figure 2).
NOTE:
- Observe tightening torque of: Nm 2.0 + 0.5 / - 0.0 and proper orientation of the anti-rotation tabs (5, Figure 1).
- Ensure that only the low pressure power steering hose clamp, as supplied in the repair kit, is used during the reinstallation of the low pressure power steering hose.
- Do not exceed the specified torque value, even if the low pressure power steering hose can still be rotated on the fitting.
12. Lower vehicle.
13. Refill power steering fluid reservoir with Mercedes-Benz approved power steering fluid, refer to WIS: AR46.30-P-0010B.
14. Start up engine and check function of the power steering system, check all connections for fluid leaks.
15. Lower vehicle, check power steering fluid for proper level. Replenish power steering fluid as necessary, bring fluid level to the correct level.
16. Reinstall remaining components in reverse order.
Special Tools
Tool Information
Parts Information
Warranty Information
NOTE REGARDING CUSTOMER REIMBURSEMENT
Reimbursement to customers for repairs performed prior to this recall:
If the customer already paid to have this recall 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 may be limited to the amount the repair would have cost if completed by an authorized Mercedes-Benz dealer. See "Reimbursement to customer for repairs performed prior to recall" in MBUSA's Warranty Policy and Procedures Manual.
Reimbursement will only be made with adequate documentation for repairs performed between March 26, 2002 and June 30, 2003
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 recall in the usual manner.
When performing the recall as indicated, the proper hose and hose clamp must be used.
Reimbursement to Customers for Repairs Performed Prior to Recall
If you have already paid to have this recall condition corrected you may be eligible to receive reimbursement.
Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized Mercedes-Benz dealer. The following documentation must be presented to your dealer for reimbursement.
Original or clear copy of all receipts, invoices and/or repair orders that show:
- The name and address of the person who paid for the repair.
- The Vehicle Identification Number (VIN) of the vehicle that was repaired.
- What problem occurred, what repair was done, when it was done and who repaired it.
- The total cost of the repair expense that is being claimed.
- Proof of payment of repair (copy of front and back of cancelled check, or copy of credit card receipt).
- Reimbursement will be made by check from your dealer. If your claim is denied you will receive a letter from MBUSA within 60 days of receipt with the reason(s) for the denial.
Please speak with your dealer concerning this matter.
Reimbursement to Customers for Repairs Performed Prior to Recall
If you have already paid to have this recall condition corrected you may be eligible to receive reimbursement.
Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized Mercedes-Benz dealer. The following documentation must be presented to your dealer for reimbursement.
Original or clear copy of all receipts, invoices and/or repair orders that show:
- The name and address of the person who paid for the repair.
- The Vehicle Identification Number (VIN) of the vehicle that was repaired.
- What problem occurred, what repair was done, when it was done and who repaired it.
- The total cost of the repair expense that is being claimed.
- Proof of payment of repair (copy of front and back of cancelled check, or copy of credit card receipt).
- Reimbursement will be made by check from your dealer. If your claim is denied you will receive a letter from MBUSA within 60 days of receipt with the reason (s) for the denial.
Please speak with your dealer concerning this matter.
Reimbursement to Customers for Repairs Performed Prior to Recall
If you have already paid to have this recall condition corrected you may be eligible to receive reimbursement.
Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized Mercedes-Benz dealer. The following documentation must be presented to your dealer for reimbursement.
Original or clear copy of all receipts, invoices and/or repair orders that show:
- The name and address of the person who paid for the repair.
- The Vehicle Identification Number (VIN) of the vehicle that was repaired.
- What problem occurred, what repair was done, when it was done and who repaired it.
- The total cost of the repair expense that is being claimed.
- Proof of payment of repair (copy of front and back of cancelled check, or copy of credit card receipt).
- Reimbursement will be made by check from your dealer. If your claim is denied you will receive a letter from MBUSA within 60 days of receipt with the reason (s) for the denial.
Please speak with your dealer concerning this matter.