Recall Campaign 2004070010 - Installation Of Blower Motor Wiring Harness (2004070010)

Publication date: 2005-11-01
Reference number: 2004070010

RECALL CAMPAIGN 2004070010 - INSTALLATION OF BLOWER MOTOR WIRING HARNESS

SERVICE CAMPAIGN BULLETIN

Reference Number(s): 2004070010, Date of Issue: November 15, 2005

MERCEDES-BENZ:	MODELS 215/220, MODEL YEARS 2000 THROUGH 2001
GROUP:	00 OF SERVICE INFORMATION BINDER
GROUP:	I OF INFORMATION - PARTS & ACCESSORIES BINDER

Superceded Bulletin(s): 2004070010, Date of Issue: October 12, 2004

SUBJECT

MODELS 215/220, MODEL YEARS 2000 THROUGH 2001

INSTALLATION OF BLOWER MOTOR WIRING HARNESS

This revised Recall Campaign bulletin 2004070010 supersedes previously issued Recall Campaign bulletin 2004070010 released in October 2004. It contains new and updated Special Tools information. Please destroy all previous Recall Campaign bulletin versions.

This Recall Campaign has been initiated because DCAG has determined that on the affected vehicles (see VIN range below), due to a production deficiency occurring during the production process of the blower motor fuse holder, the size of the electric conductor on the blower motor fuse holder may be below appropriate tolerances. Consequently, the electric conductor of the blower motor fuse holder may dissipate more heat than the plastic fuse holder was designed to withstand, which could result in overheating of the blower motor fuse holder and disabling of the blower motor and the ability to defrost or defog the windshield in cold or hot and humid weather conditions. Depending on the occurrence and weather situation, driver visibility could be reduced, which could result in a crash.

Please review the Effective Serial Number Chart located below.

Attached 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 insure the vehicle is involved and to determine if the vehicle has been previously repaired.
Please review the entire Recall Campaign bulletin.

Approximately 54,438 vehicles are affected.

EFFECTIVE SERIAL NUMBER RANGE

Models	Chassis End Number
Models	From	To
215	A000652	A011473
220	A000671	A167371

NOTE: Every vehicle in the VIN range may not be included in the campaign. VMI must always be checked before performing campaigns to verify that the campaign is required on a specific vehicle. VMI always overrides the bulletin in reference to a specific vehicle's inclusion in a particular campaign. Please also note that Recalls and Service Campaigns do not expire and may also be performed on a vehicle with a vehicle status indicator.

PROCEDURE

Fig 1: Terminal Block And Fuse Box

A. PRELIMINARY WORK

Disconnect battery ground cable WIS: AR54.10-P-0003I.
CAUTION: Do not install quiescent current retention unit.
Remove right front floor covering WIS: AR68.20-P-2070M.
NOTE: Only remove as far as necessary until the foot support is accessible.
Remove right front foot support.
Lift up right front SAM (WIS: AR54.21-P-1261I) to gain access to harness opening in bulkhead.
NOTE:
- Do not completely remove right front SAM.
- If necessary, disconnect wire harness connectors from ME-SFI control module.

B. INSTALLATION OF BLOWER MOTOR WIRING HARNESS

Route new interior blower motor wiring harness (1, Fig 2) with ring connector from the right fuse box (F1/1, Fig 3) into the right front footwell.
NOTE: A wire puller/"snake" (shop made tool: e.g., mechanic's wire etc.) may be used to aid in routing the new harness into footwell area through the bulkhead.

Fig 2: Interior Blower Motor Wiring Harness
Route new interior blower motor wiring harness (1, Fig 2) along existing cables to the cable connector and fuse box terminal 30 (X4/10) and secure with cable ties.
Connect ring connector to designated M8 screw connection and torque M8 nut (arrow, Fig 2) to 9 Nm. (+ / - 1 Nm).

Fig 3: Interior Blower Motor Wiring Harness Routing To Fuse Box
Remove brown fuse holder (fuse 35, Fig 4) with 40A fuse from the right fuse box (F1/1, Fig 3).
Unpin wire connector (with r/y wire, Fig 4) from brown fuse holder (35):
- Remove fuse from fuse holder (35).
- Unclip two outer locking tabs (A, Fig 4) furthest from the hinge (B) then partially pry open cover.
- Unclip two outer locking tabs (C, Fig 4) closest to the hinge (B) then fully open cover to expose wire connectors.
- Push the wire connector (with r/y wire) out from fuse side of fuse holder using special tools: Blade Handle W220 589 01 99 50 with blade W220 589 01 99 61 (Also, see the "note" below concerning additional Special Tool information).
NOTE:
- The fuse holder (35) and fuse can be discarded.
- r/y designates red/yellow wire.
  
  Fig 4: Brown Fuse Holder (Fuse 35)
Install unpinned wire connector (with r/y wire, Fig 5) into new harness connector (A):
- Insert the unpinned wire connector (with r/y wire, Fig 5) into position 1 of the new harness connector (A).
- Secure wire connector (with r/y wire) into position by locking closed the harness connector cover (arrow).
  
  Fig 5: Unpinned Wire Connector (With R/Y Wire)
Connect the new harness connector (arrow, Fig 6) to the harness connector on the new blower motor harness wire (1) and place coupled connector (X64/1) below right front SAM in the right fuse box (F1/1).

Fig 6: Connecting Harness Connector

Fig 7: Installing Maxi Fuse Holder
Install new maxi fuse holder (5, Fig 7) into grommet breakthrough (arrow) in right fuse box (F1/1).
Route interior blower motor harness below right front SAM in right fuse box (F1/1).
Reinstall right front SAM, reconnect wire harnesses to ME-SFI control module (if removed in step 4,, subject A) and reassemble interior of vehicle in reverse order.
Reconnect battery ground cable WIS: AR54.10-P-0003I.
Read fault memory and erase using Star Diagnosis.
Check operation of interior blower motor.
Affix fuse/relay label over area of fuse chart identifying location of fuse/relays in right front fuse and relay box (fuses 28-49).
NOTE: Fuse and relay chart is located in trunk under lug wrench (in tool kit).
Reinstall remaining parts in reverse order.

SPECIAL TOOLS

Fig 8: Special Tools

NOTE: ¹⁾ Both tools are contained within kit W220 589 01 99 00 and W220 589 02 99 00, previously released automatically to all MB dealers.

²⁾ For new purchase, Special Tool Number: W220 589 01 99 61 has been superseded to a newer version blade, Special Tool Number: W000 589 10 99 30. This newer version blade can be used to perform the same function as W220 589 01 99 61 described in this bulletin.

PRIMARY PARTS INFORMATION

Qty.

Part Name

Part Number

Estimated Replacement Rate

Interior blower motor harness/Fuse holder

A 220 540 95 07 05

100%

Wire harness connector

A 032 545 88 28 05

100%

Fuse/relay label (packs of 10) ⁽¹⁾

BQ 454 0025

100%

⁽¹⁾	Part cannot be claimed for reimbursement

NOTE: There are no secondary parts for this campaign.

NOTE: The following allowable Labor Operations should be used when submitting a warranty claim for this repair.

WARRANTY INFORMATION

Operation: Wiring harness - Interior Blower, Install (02-4340)

WARRANTY INFORMATION

Damage Code	Operation Number	Labor Time (hrs.)	Model Indicator(s)
83 900 32	02-4340	1.5 hrs.	M1, M2, M4, M5, N1, N2,

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.

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.

CUSTOMER NOTIFICATION LETTER

Safety Recall #2004- 070010

October, 2004

Dear Mercedes-Benz Owner,

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. WE SENT YOU THIS NOTICE BECAUSE WE ARE CONCERNED ABOUT YOUR SAFETY.

DaimlerChrysler AG (DCAG), the manufacturer of Mercedes-Benz vehicles, has decided that a defect which relates to motor vehicle safety exists in certain Model Year 2000 - 2001 S-Class and CL-Class vehicles. Mercedes-Benz USA, LLC (MBUSA) therefore has initiated a recall of these vehicles. Our records indicate that your vehicle is included in this group.

DCAG has determined that, due to a production deficiency occurring during the production process of the blower motor fuse holder, the size of the electric conductor on the blower motor fuse holder may be below appropriate tolerances. Consequently, the electric conductor of the blower motor fuse holder may dissipate more heat than the plastic fuse holder was designed to withstand, which could result in overheating of the blower motor fuse holder and disabling of the blower motor and the ability to defrost or defog the windshield in cold or hot and humid weather conditions. Depending on the occurrence and weather situation, driver visibility could be reduced, which could result in a crash.

Your authorized Mercedes-Benz dealer is available to provide this service, free of charge. The working time required is approximately two hours. Please contact your authorized Mercedes-Benz dealer to schedule an appointment at your earliest convenience. Please mention Recall Campaign #2004-070010

If you are no longer the vehicle owner, or have a change of address, please complete the reverse side of this letter and return the complete letter in the enclosed envelope. If this is a leased vehicle and the lessor and registered owner receive this notice, please forward this information by first class mail to the lessee. If you have paid to have this recall condition corrected prior to this notice you may be eligible to receive reimbursement. Please see the reverse side of this notice for details.

Please contact your authorized Mercedes-Benz dealer should you have any questions or encounter any difficulty regarding this recall. If your dealer is unable to remedy your situation please contact us at 1-(800) FOR-MERCedes. (1-800-367-6372).

If an authorized Mercedes-Benz dealer or Mercedes-Benz USA, LLC, fails or is unable to perform this service without charge within 60 days, pursuant to law 49 U.S.C. Chapter 301, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call the toll-free Auto Safety Hotline at 888-327-4236.

Again, we apologize for any inconvenience this situation may cause you.

Sincerely

Klaus Ulkann

Vice President, Customer Services