Recall - Steering Coupler Pinch Bolt Torque: Overview
Campaign No. 2003080003August 2003
FILE:
SERVICE:
GROUP 00 OF SERVICE INFORMATION BINDER
PARTS:
GROUP I OF INFORMATION - PARTS & ACCESSORIES BINDER
TO: ALL MERCEDES-BENZ CENTERS
SUBJECT:
MODELS 203 AND 211 (MY 2003)
CHECKING TORQUE OF PINCH BOLT FOR STEERING COUPLING
This campaign has been initiated because DCAG has determined that the steering coupling pinch bolt nut (circle, Figure 1) of certain MY 2003 C-Class and E-Class vehicles may have insufficient torque to prevent loosening. Additionally, the clearance gap between the steering coupling and the plastic protective boot (Figure 2) must be checked and if necessary corrected to the proper specification. This recall campaign bulletin contains separate repair instructions for each model/engine version, thus please read this recall campaign bulletin in its entirety, prior to performing this recall.
Approximately 1344 vehicles are involved, for your reference, a Chassis End Number Range Chart is listed below.
Effective Serial Number Range
Prior to performing this Recall Campaign, please check VMI to insure the vehicle is involved and to determine if the vehicle has been previously repaired
A. Checking Clearance gap of Steering Coupling/Plastic Protective Boot and Torque of Steering Coupling Pinch Bolt Procedure
Model 203 with engine 271/112 and Model 211 with engine 112
1. Drive vehicle onto chassis lift (ensure steering is not locked), remove lower engine noise encapsulation panel.
Caution! Risk of bodily injury!
Ensure catalytic converter has cooled sufficiently to ensure prevention of bodily injury.
2. Visually check the steering coupling for correct seating on input shaft of steering gear.
Note:
If steering coupling pinch bolt is missing, replace bolt and please see:
B. Resetting Clearance Gap between Steering Coupling/Plastic Protective Boot and Retorque-ing Pinch Bolt for Steering Coupling
Note:
The clearance gap between the steering coupling and the plastic protective boot on the control head of the steering gear should be no more than 5 mm (Figure 2).
3. If the clearance gap is found to be correct, check if steering coupling pinch bolt lock nut is torqued correctly (25 Nm). See Installation Note under instruction B for torque-ing procedure. If the steering pinch bolt torque is found to be correct then no further repair is necessary, complete repair with Step 5.
4. If the torque for the steering coupling pinch bolt is found to be incorrect, then proceed to:
B. Resetting Clearance Gap between Steering Coupling/Plastic Protective Boot and Retorque-ing Pinch Bolt for Steering Coupling
Note:
It is very important to use the proper tools and procedure to torque (Figure 7) the steering coupling pinch bolt with lock nut.
Figure 3: Model 203 with engine 271
Figures 4 and 5: Model 203 and 211 with engine 112
5. Re-install the previously removed engine noise encapsulation panel.
B. Resetting Clearance Gap between Steering Coupling/Plastic Protective Boot and Retorque-ing Pinch Bolt for Steering Coupling
Model 203 with engine 271/112 and Model 211 with engine 112 (procedure shown on Model 211)
Caution! Risk of bodily injury!
Ensure catalytic converter has cooled sufficiently to ensure prevention of bodily injury.
1. If the clearance gap is found to be incorrect, and the pinch bolt is present please proceed with the following steps:
Using the appropriate tools, see:
Note: below,
loosen threaded connection and mount steering coupling correctly, ensure that the self-locking nut (PIN A140 990 09 58) is replaced as well. It may be necessary to rotate shaft to point the front wheels in a different direction in order to gain access to the steering coupling pinch bolt and lock nut (arrow, Figure 8):
^ Place a 13 mm socket wrench (arrow, Figures 7, 8) on bolt head to counter bolt: Route socket wrench through opening between steering rack and front subframe and place on bolt head
^ Hold newly installed lock nut using a 13 mm flexible socket, extension and ratchet (Figure 9) while assistant holds socket wrench (arrow, Figure 8) to counter-hold bolt
^ Tighten the steering coupling pinch bolt and lock nut (arrow, Figure 7) between steering coupling and steering gear to the specified torque (see below). Ensure clearance between coupling and rack is within specification (5 mm).
Note:
Use of the proper tools and procedure to torque the steering coupling pinch bolt with lock nut (Figure 7) is required, see:
Figure 3: Model 203 with engine 271
Figures 4 and 5: Model 203 and 211 with engine 112
Observe tightening torque of: Nm 25
Installation Note:
After installing (missing) pinch bolt into steering coupling, place pressure on bolt by prying steering coupling and steering shaft apart using a screw driver (this prevents bolt from turning in the coupling while threading the new lock nut onto the bolt). Ensure clearance between coupling and rack is within specification.
1. Tighten the steering coupling pinch bolt and lock nut (Figure 9) between steering coupling and steering gear to the specified torque (see below).
Note:
Ensure clearance between steering coupling ana plastic protective boot remains within specification while tightening the lock nut.
Observe tightening torque of: Nm 25
Note:
Use of the proper tools and procedure to torque the steering coupling pinch bolt with lock nut (Figure 7) is required, see:
Figure 3: Model 203 with engine 271
Figures 4 and 5: Model 203 and 211 with engine 112
2. Re-install the previously removed engine noise encapsulation panel.
Parts Information