Mercedes Benz C 43 AMG Technical Service Bulletin # 2005020003 Date: 051201

Mercedes Benz C 43 AMG Technical Service Bulletin # 2005020003 Date: 051201

Campaign - Harmonic Balancer Inspection/Replacement

FILE:

SERVICE: GROUP 00 OF SERVICE INFORMATION BINDER

PARTS: GROUP I OF INFORMATION _ PARTS & ACCESSORIES BINDER

Campaign No. 2005020003 April 2005

Revised May 2005

Revised July 2005

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Revised December 2005

This revised Service Campaign bulletin 2005020003 supercedes previously issued Service Campaign bulletin 2005020003 released in July 2005.

This campaign has been updated to include model 463.

Please destroy all previous Service Campaign bulletin versions.

TO: ALL MERCEDES-BENZ CENTERS

SUBJECT:

MODELS 163, 202, 208, 210 WITH ENGINES 112,

MODELS 129, 163, 202, 208, 210 215, 220, 463 WITH ENGINES 113,

MODEL YEARS 1998-2000;

MODEL 170 WITH ENGINE 112, MODEL YEAR 2001

INSPECT, IF NECESSARY REPLACE HARMONIC BALANCER PULLEY

This Service Campaign has been initiated because DCAG has determined that due to a supplier quality problem the harmonic balancer pulley in

certain model year 1998-2001 vehicles may, depending upon vehicle use characteristics, be subject to high under-hood temperatures that can, over a

long period of time, cause it to deteriorate. Prior to a harmonic balancer pulley deteriorating to a point of affecting vehicle performance and

drivability, it will create several different types of driver warnings such as noticeable engine vibrations. Affected vehicles will be checked and the

harmonic balancer replaced, as required.

Shown in this bulletin is a sample copy of a letter which owners of the affected vehicles will receive.

Prior to performing this Service Campaign:

^ Please check VMI to insure the vehicle has not been previously repaired for this condition and does not have other open campaigns.

^ Please review the entire Service Campaign bulletin.

^ Please verify the customer has presented a letter or has a complaint related to the harmonic balancer (explained above).

Approximately 363,487 vehicles are affected.

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Effective Serial Number Range

Special Tools

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Parts Information

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Warranty Information

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Customer Reimbursement

Procedure

A. CHECK PART NUMBER OF HARMONIC BALANCER PULLEY

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1. Turn crankshaft in direction of normal rotation until the part number (arrow, Figure 1) of the harmonic balancer pulley is visible.

2. If the harmonic balancer pulley has one of the part numbers listed below, it must be replaced (for replacement procedure refer to next step):

Note:

ONLY these 2 part numbers (below) require replacement.

^ A112 035 00 00

^ A112 035 06 00

3. Replacement procedures for harmonic balancer pulley:

^ Engines 112 and 113 with viscous engine fan (non AMG models) refer to subject B.

^ Engines 112 and 113 with electric engine fan (non AMG models) refer to subject C.

B. ENGINES 112 AND 113 WITH VISCOUS ENGINE FAN

1. Remove lower engine cover (only on model 163.172) refer to WIS: AR61.20-P-1105GH.

2. Remove front air filter cover or engine cover (as necessary).

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3. Remove viscous fan (1 Figure 2), refer to WIS: AR20.40-P-5660C.

4. Remove clips (6), remove fan shroud (3).

Note:

Models 163.154/172: Remove two 2 screws at bottom of fan shroud.

5. Remove engine belt (2) refer to WIS: AR13.22-P-1202B (special tool: external torx set W001 589 76 09 00).

Note:

Replace engine belt only if belt is damaged due to a deteriorated harmonic balancer pulley. Replacement of belt due to normal wear may

not be claimed under this campaign.

6. Remove harmonic damper pulley bolt (4):

^ Position harmonic damper pulley at 40锟斤拷 ATDC.

^ Counter hold crankshaft with special tool: counter holder W112 589 0040 00 and extension (refer to WIS: WF58.50-P-0330-02A)

CAUTION!

For vehicles with automatic transmissions:

Do not counter hold crankshaft at ring gear to remove central bolt (4, Figure 2). Counter hold crankshaft only at spokes of the harmonic

damper pulley due to high (harmonic balancer pulley) bolt (4) torque.

^ Remove harmonic damper pulley bolt (4).

Note:

Undamaged harmonic damper pulley bolt may be reused.

7. Remove harmonic balancer pulley (5, Figure 2).

Note:

If there is evidence of related damage to the timing case cover and oil pan due to the harmonic balancer pulley grinding against them, refer

to subject D for proper evaluation and repair procedures.

8. Installation is in reverse order.

Note:

^ The (fixed) installation position of the harmonic balancer pulley (5) on the crankshaft is specified by the parallel (woodruff type) key

installed on the crankshaft (refer to WIS: GF03.30-P-1600-01C).

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^ Lubricate the harmonic balancer pulley bolt head (4) contact surface (where bolt head contacts pulley) with clean engine oil.

^ Torque harmonic balancer bolt (4) in two stages:

First torque bolt to: 200 Nm then turn bolt 95锟斤拷.

C. ENGINES 112 AND 113 WITH ELECTRIC ENGINE FAN

1. Remove front air filter cover or engine cover as necessary.

2. Remove electric fan (1 Figure 3) and fan shroud (3):

^ Model 163: refer to WIS: AR20.40-P-5000GH

^ Models 208: remove clips securing fan to radiator, disconnect fan harness connector, remove fan (1) and shroud (3) as an assembly.

^ Model 170: refer to WIS: AR20.40-P-5000SV.

3. Remove engine belt (2):

^ Model 163 refer to WIS: AR13.22-P-1202BA

^ Models 208, 210, 215, 220 refer to WIS: AR13.22-P-1202BA

^ Model 170.465 refer to WIS: AR13.22-P-1202SV.

^ Special tool: external torx set W001 589 76 09 00

Note:

Replace engine belt only if belt is damaged due to a deteriorated harmonic balancer pulley. Replacement of belt due to normal wear may

not be claimed under this campaign.

4. Remove harmonic damper pulley bolt (4):

^ Position harmonic damper pulley at 40锟斤拷 ATDC.

^ Counter hold crankshaft with special tool: counter holder W112 589 0040 00 and extension (refer to WIS: WF58.50-P-0330-02A).

CAUTION!

For vehicles with automatic transmissions:

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Do not counter hold crankshaft at ring gear to remove harmonic balancer pulley bolt (4, Figure 3). Counter hold crankshaft only at spokes

of the harmonic damper pulley due to high bolt (4) torque.

^ Remove harmonic damper pulley bolt (4)

Note:

Undamaged harmonic balancer pulley bolt may be reused.

5. Remove harmonic balance pulley (5, Figure 3).

Note:

If there is evidence of related damage to the timing case cover and oil pan due to the harmonic balancer pulley grinding against them, refer

to subject D for proper evaluation and repair procedures.

6. Installation is in reverse order.

Note:

^ The (fixed) installation position of the harmonic balancer pulley (5) on the crankshaft is specified by the parallel (woodruff type) key

installed on the crankshaft (refer to WIS: GF03.30-P-1600-01C).

^ Lubricate the harmonic balancer pulley bolt head (4) contact surface (where bolt head contacts pulley) with clean engine oil.

^ Torque harmonic balancer pulley bolt (4) in two stages:

First torque bolt to: 200 Nm then turn bolt 95锟斤拷.

D. EVALUATION OF RELATED DAMAGE TO TIMING CASE COVER AND OIL PAN

1. If damage is only visible on the oil pan, check to see if oil is leaking. If oil is leaking between timing case cover and oil plan, replace oil pan

only. Use the appropriate WIS instructions.

2. If damage is visible on the timing case cover and the oil pan, compare the damage to Figure 4.

3. If damage is less than what is shown in Figure 4, check to see if oil is leaking. If oil is leaking between timing case cover and oil plan, replace

oil pan only. No additional repairs are required.

4. If damage is of equal or greater extent, replace the timing case cover and the oil pan ONLY. Use the appropriate WIS instructions.