Service Campaign 2005020003 - Inspect, If Necessary Replace Harmonic Balancer Pulley (2005020003)

Publication date: 2005-12-02
Reference number: 2005020003

SERVICE CAMPAIGN 2005020003 - INSPECT, IF NECESSARY REPLACE HARMONIC BALANCER PULLEY

SERVICE CAMPAIGN BULLETIN

Reference Number(s): 2005020003, Date of Issue: December 2, 2005

MERCEDES-BENZ:	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
GROUP:	00 OF SERVICE INFORMATION BINDER
GROUP:	I OF INFORMATION - PARTS & ACCESSORIES BINDER

Superceded Bulletin(s): 2005020003, Date of Issue: April 2005, 2005020003, Date of Issue: May 2005, 2005020003, Date of Issue: July 2005

NOTE: This revised Service Campaign bulletin 2005020003 supersedes 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.

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 driveability, 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.

Attached 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.

Order No. P-SC-2005020003

This bulletin has been created and maintained in accordance with MBUSA-SLP S423QH001, Document and Data Control, and MBUSA-SLP S424HH001, Control of Quality Records.

EFFECTIVE SERIAL NUMBER RANGE

Models	Chassis End Number
Models	From	To
129.068	F169044	F196751
170.465	F160121	F188963
202.029	A488715	A869700
202.029	F590751	F831106
202.033	F670541	F906121
208.365	F001037	F161911
208.370	F020368	F161908
208.465	T000142	T054450
208.470	T023042	T054464
210.065	A366330	A999987
210.065	B000013	B173052
210.070	A502461	A999921
210.070	B000052	B173025
210.082	X000423	X043576
210.083	X028837	X043567
210.265	A415666	A999957
210.265	B000061	B172971
210.282	X000451	X043582
215.375	A000652	A007949
220.170	A000669	A137742
220.175	A000671	A137729
163.154	A000011	A202488
163.172	A030358	A202485
463.206	7113127	7113248
463.206	X114583	X122824
463.240	X114559	X117434
463.241	7112081	7122967
463.241	X121984	X121984

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

Fig 1: Harmonic Balancer Pulley Part Number

Sample only shown. Refer to specific part numbers below in step 2.

A. CHECK PART NUMBER OF HARMONIC BALANCER PULLEY

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

Fig 2: Removing Harmonic Balancer (Engines 112 And 113 With Viscous Engine Fan)

Remove lower engine cover (only on model 163.172) refer to WIS: AR61.20-P-1105GH.
Remove front air filter cover or engine cover (as necessary).
Remove viscous fan (1, Fig 2), refer to WIS: AR20.40-P-5660C.
Remove clips (6), remove fan shroud (3)
NOTE: Models 163.154/172: Remove two 2 screws at bottom of fan shroud.
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.
Remove harmonic damper pulley bolt (4):
- Position harmonic damper pulley at 40° ATDC.
- Counter hold crankshaft with special tool: counter holder W112 589 00 40 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, Fig 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.
Remove harmonic balancer pulley (5, Fig 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.
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 bolt (4) in two stages: First torque bolt to: 200 Nm then turn bolt 95°.

C. ENGINES 112 AND 113 WITH ELECTRIC ENGINE FAN

Fig 3: Removing Harmonic Balancer (Engines 112 And 113 With Electric Engine Fan)

Remove front air filter cover or engine cover as necessary.
Remove electric fan (1, Fig 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.
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.
Remove harmonic damper pulley bolt (4):
- Position harmonic damper pulley at 40° ATDC.
- Counter hold crankshaft with special tool: counter holder W112 589 00 40 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 harmonic balancer pulley bolt (4, Fig 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.
Remove harmonic balance pulley (5, Fig 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.
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°.

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

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.
If damage is visible on the timing case cover and the oil pan, compare the damage to Fig 4.
If damage is less than what is shown in Fig 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.
If damage is of equal or greater extent, replace the timing case cover and the oil pan ONLY . Use the appropriate WIS instructions.

Fig 4: Timing Case Cover And Oil Pan Damage

Note (regarding special tool referred to in procedures): Please inspect your Special Tool 112 589 00 40 00 Counter Holding Tool for harmonic damper pulley (front of crankshaft) and assure that the three aluminum sleeves are in place and are in good condition. Note that replacement sleeves are available and can be ordered using the Special Tool Number: 112 589 00 40 01

SPECIAL TOOL

Fig 5: Special Tools

PARTS INFORMATION

Qty.

Part Name

Part Number

Harmonic balancer pulley

A112 035 13 00 05

Bolt (if required)

A006 990 70 04

Belt (if required)

A011 997 97 92⁽¹⁾

Timing case cover

*See Note

Oil pan, upper part

*See Note

⁽¹⁾	Parts are in critical supply and will be limited, please see the PAC weekly status report on parts availability status and delivery expectations. This report is located on the PAC website.

*NOTE:

Specify correct part by VIN using Electronic Parts Catalog (Engine group 01)
Specify correct necessary related parts and materials for oil pan and timing case cover replacement (ex. Engine oil, screws, sealant)

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.

NOTE: The following allowable labor operation should be used when submitting a warranty claim for this repair:

WARRANTY INFORMATION

Note Regarding Warranty Claims on Model 463:

If filing a claim on a Model 463, please refer to the following Model Indicator Chart below. Please not that these are the only affected 463 variants in this Service Campaign.

MODEL INDICATOR

Model Indicator	Model Designation
L4	463.206
L5	463.240
L6	463.241

Repair 1

Operation: Vibration damper - part number, Check (02-4567)

WARRANTY INFORMATION - REPAIR 1

Damage Code	Operation Number	Labor Time (hrs.)	Model Indicator(s)
03 900 22 8 Check only	02-4567	0.3 hrs.	98, C5, C6, E4, E6, E7, E8, E9, F2, G3, H1, H2, H3, H4, K1, K2, M1, M2, N1, L4, L5, L6

Repair 2

Operation: Vibration damper - part number, Check (02-4567) Vibration damper - (after check), Replace (02-4568) (Includes belt and bolt replacement if necessary)

WARRANTY INFORMATION - REPAIR 2

Damage Code	Operation Number	Labor Time (hrs.)	Model Indicator(s)
03 900 22 7 Check and Replace Harmonic Balancer Pulley	02-4567	0.3 hrs.	M1, M2, N1
	02-4568	1.1 hrs.	M1, M2, N1
	02-4567	0.3 hrs.	98, E4, E6, E7, E8, E9, F2, G3
	02-4568	1.2 hrs.	98, E4, E6, E7, E8, E9, F2, G3
	02-4567	0.3 hrs.	C5, C6, H1, H2, H3, H4
	02-4568	1.3 hrs.	C5, C6, H1, H2, H3, H4
	02-4567	0.3 hrs.	K1, K2
	02-4568	1.4 hrs.	K1, K2
	02-4567	0.3 hrs.	L4, L5, L6
	02-4568	1.5 hrs.	L4, L5, L6

Repair 3

Operation: Vibration damper - part number, Check (02-4567) Vibration damper - (after check), Replace (02-4568)

Engine main oil pan, repl. (01-7540)

Addition to oil pan, R & R - Vehicles with automatic trans. (01-7623)

NOTE:

(Includes harmonic balancer pulley, and oil pan replacement)
(Includes belt, bolt replacement if necessary)
(Includes other related parts for oil pan replacement if necessary (ex. Engine oil, screws, sealant))

WARRANTY INFORMATION - REPAIR 3

Damage Code	Operation Number	Labor Time (hrs.)	Model Indicator(s)
03 900 22 7 Check and Replace Harmonic Balancer Pulley Oil Pan	02-4567	0.3 hrs.	N1
	02-4568	1.1 hrs.
	01-7540	3.6 hrs.
	02-4567	0.3 hrs.	M1, M2
	02-4568	1.1 hrs.
	01-7540	5.6 hrs.
	02-4567	0.3 hrs.	G3
	02-4568	1.2 hrs.
	01-7540	3.6 hrs.
	01-7623	0.4 hrs.
	02-4567	0.3 hrs.	98
	02-4568	1.2 hrs.
	01-7540	6.2 hrs.
	02-4567	0.3 hrs.	E4, E6, E9
	02-4568	1.2 hrs.
	01-7540	6.8 hrs.
	02-4567	0.3 hrs.	E7, E8
	02-4568	1.2 hrs.
	01-7540	7.9 hrs.
	02-4567	0.3 hrs.	F2
	02-4568	1.2 hrs.
	01-7540	8.8 hrs.
	02-4567	0.3 hrs.	H1, H3
	02-4568	1.3 hrs.
	01-7540	6.1 hrs.
	02-4567	0.3 hrs.	C5
	02-4568	1.3 hrs.
	01-7540	6.2 hrs.
	01-7623	0.5 hrs.
	02-4567	0.3 hrs.	C6
	02-4568	1.3 hrs.
	01-7540	6.2 hrs.
	01-7623	0.6 hrs.
	02-4567	0.3 hrs.	H2, H4
	02-4568	1.3 hrs.
	01-7540	7.5 hrs.
	02-4567	0.3 hrs.	K1
	02-4568	1.4 hrs.
	01-7540	5.1 hrs.
	02-4567	0.3 hrs.	K2
	02-4568	1.4 hrs.
	01-7540	5.8 hrs.
	02-4567	0.3 hrs.	L4, L5, L6
	02-4568	1.5 hrs.
	01-7540	4.1 hrs.

Repair 4

Operation: Vibration damper - part number, Check (02-4567) Timing chain cover, Replace (01-8060)

Additional to timing case cover remove and install (01-8120) (Vehicles with oil cooler)

Addl. To oper. no. 8000/8060 - veh. with auto trans optional (01-8150)

NOTE:

(Includes harmonic balancer pulley, timing case cover, and oil pan replacement)
(Includes belt, bolt replacement if necessary)
(Includes other related parts for oil pan and timing case cover replacement if necessary (ex. Engine oil, screws, sealant)).

WARRANTY INFORMATION - REPAIR 4

Damage Code	Operation Number	Labor Time (hrs.)	Model Indicator(s)
03 900 22 7 Check and Replace Harmonic Balancer Pulley Timing Case Cover Oil Pan	02-4567	0.3 hrs.	M1, M2
	01-8060	15.0 hrs.	M1, M2
	02-4567	0.3 hrs.	N1
	01-8060	12.3 hrs.	N1
	02-4567	0.3 hrs.	E4, E6, E9
	01-8060	11.5 hrs.
	01-8120	0.6 hrs.
	02-4567	0.3 hrs.	98
	01-8060	13.1 hrs.	98
	02-4567	0.3 hrs.	E7, E8
	01-8060	16.6 hrs.
	01-8120	0.6 hrs.
	02-4567	0.3 hrs.	F2
	01-8060	17.2 hrs.
	01-8120	0.6 hrs.
	02-4567	0.3 hrs.	G3
	01-8060	11.2 hrs.
	01-8150	0.5 hrs.
	02-4567	0.3 hrs.	C5, C6
	01-8060	11.9 hrs.
	01-8120	0.3 hrs.
	02-4567	0.3 hrs.	H1, H3, K1, K2
	01-8060	12.1 hrs.	H1, H3, K1, K2
	02-4567	0.3 hrs.	L4, L5, L6
	01-8060	13.8 hrs.	L4, L5, L6
	02-4567	0.3 hrs.	H2, H4
	01-8060	14.1 hrs.	H2, H4

NOTE: Upon inspection of previously replaced oil pans and timing housing covers, it has been determined there have been very few instances where replacement was necessary. Unnecessary replacement of these components will be returned and debited.

Note - Vehicle Towing:

If it is necessary to have the vehicle towed, warranty claims for towing can be submitted as a "sublet" with sublet code of "SUB." It must be stated in the dealer text that the sublet is for towing.

CUSTOMER REIMBURSEMENT

SCENARIO I - VEHICLES THAT WERE PREVIOUSLY REPAIRED PRIOR TO THE ORIGINAL CAMPAIGN ANNOUNCEMENT ON APRIL 05, 2005

If the customer already paid to have this service 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 the harmonic balancer pulley, bolt, serpentine belt, timing case cover, oil pan, and related parts associated to these replacements (ex. Engine oil, screws, sealant), would have cost if completed by an authorized Mercedes-Benz dealer under this campaign.

Submit a warranty claim, utilizing Damage Code 03 900 22 8 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 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.

SCENARIO II - VEHICLES THAT WERE PREVIOUSLY REPAIRED (EITHER BY THE DEALER OR INDEPENDENT SERVICE PROVIDER) WHERE CONSEQUENTIAL DAMAGE WAS DENIED

Customer reimbursement for previously repaired vehicles, that did not reimburse oil pan and timing case covers, may now be eligible for reimbursement.

Submit a warranty claim, utilizing Damage Code 03 314 01 8 as a Sublet, utilizing the sublet code of "SUB." Supplemental reimbursement is limited to the replacement of the bolt, oil pan and timing case cover, related parts associated to these replacements (ex. Engine oil, screws, sealant), and the respective labor times. Sublet repairs require dealer text as stated in the Warranty Policies and Procedures Manual. Repair date should be the date that customer paid for the repair.

The use of Damage Code 03 314 01 8 may only be utilized if damage code 03 900 22 7 was previously claimed and consequential damage was denied. Please contact any customer who would be eligible for reimbursement and provide refund as soon as possible. Reimbursement for this circumstance will end on August 31, 2005.

CUSTOMER NOTIFICATION LETTER

Service Campaign #2005-020003

April, 2005

Dear Mercedes-Benz Owner,

Your vehicle is equipped with a harmonic balancer pulley on the front of the engine's crankshaft which drives a serpentine belt that powers the alternator, power steering pump, air conditioner and other vehicle accessories. 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 driveability, it will create several different types of driver warnings such as noticeable engine vibrations.

Our records indicate that your vehicle is included in the affected population of vehicles. Your authorized Mercedes-Benz dealer will inspect, and if required, replace the harmonic balancer pulley in your vehicle 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 Service Campaign #2005-020003

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 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 service. If your dealer is unable to remedy your situation please contact us at 1-(800) FOR-MERCedes (1-800-367-6372).

We apologize for any inconvenience this situation may cause you.

Sincerely,

Klaus Ulkann

Vice President, Customer Services