Campaign - Catalytic Converter Inspection/Replacement: Overview

FILE:
SERVICE: GROUP 00 OF SERVICE INFORMATION BINDER
PARTS: GROUP I OF INFORMATION _ PARTS & ACCESSORIES BINDER

Campaign No. 2005110002, December 2005

TO: ALL MERCEDES-BENZ CENTERS

SUBJECT:
MODEL 220, MODEL YEAR 2004

INSPECT CATALYTIC CONVERTER, REPLACE IF NECESSARY

This Service Campaign has been initiated because DCAG has determined that on the affected vehicles (see VIN range below) the steel material used to manufacture the catalytic converter housing did not meet DIN specifications and could lead to a noise complaint.

Please review the Effective Serial Number chart located below and if necessary repair the subject vehicles during the vehicle's next service.

Prior to performing this Service Campaign:

^ Please check VMI to insure the vehicle is involved and to determine if the vehicle has been previously repaired.

^ Please review the entire Service Campaign bulletin.

Approximately 1,712 vehicles are affected.





Effective Serial Number Range

Procedure

A. INSPECT CATALYTIC CONVERTERS

WARNING!
Exhaust system will become hot within a short time after starting engine causing injury to body parts that may come in contact with hot exhaust components. Wear protective clothing as needed (e.g., gloves, long sleeve shirts).

1. Place vehicle on lift.





2. Read the date (arrow, Figure 1) stamped into each of the four catalytic converters.

Date Location on Front Catalytic Converters





^ Use a mirror to locate the stamped date (arrow, figure 2).

^ On the front right catalytic converter, the date stamp is located on the upper left of the converter directly under the lettering "ZEUNA STARKER".

^ On the front left catalytic converter, the date stamp is located on the upper right of the converter directly under the lettering "ZEUNA STARKER".

Note:
When determining the date on the front catalytic converters, rubbing on some rust penetrating oil on the date location is helpful.

WARNING!
Ensure catalytic converters are cool before applying rust penetrating oil.

Date Location on Rear Catalytic Converters





^ The stamped dates are viewable on the bottom of the rear catalytic converters (arrows, Figure 3).

^ The date stamp is located directly under the lettering "ZEUNA STARKER".

3. If any of the four converters have the following production dates stamped into them: XX.02.04, XX.03.04 or XX.04.04, replace that respective converter ONLY; Proceed to Subject B.

4. If the production date on all four catalytic converters does not fall into the above range; further work is not necessary, the campaign is complete.

Note:
^ The letters XX (left) represent the calendar day of production (ranging from 1-31) and can be disregarded when determining the production date.

^ The six digit date in dd.mm.yy (day. month.year) format is located directly under the marking "ZEUNA STARKER"

B. REPLACE CATALYTIC CONVERTERS

Note:
Replace only the respective (left, right, or both) catalytic converters that are in the affected production range.





1. Disconnect oxygen sensor connectors (G3/3x1 - G3/6x1, Figure 4) from the wire harness connectors. Refer to WIS: AR14.00-P-5303AA.

2. Remove bolts (11/5, figure 4) from the flange connection.

3. Remove head pipe flange connection bolts (11/1, Figure 4).

4. Remove nuts from the exhaust hanger bracket (11/2, Figure 4).





5. Loosen bolt and remove exhaust support (arrow, Figure 5).

6. Remove catalytic converter/front exhaust (158, Figure 4).

Note:
^ Ensure heat shields are not damaged when removing and reinstalling catalytic converter/front exhaust (158).

7. Remove oxygen sensors (G3/3-G3/6, Figure 4) from catalytic converter/front exhaust and install on new catalytic converter/front exhaust. Refer to WIS: AR14.00-P-5303AA.

8. Install new catalytic converter(s) in reverse order.

Note:
^ Replace exhaust hanger bracket nuts (11/2, Figure 4).

^ Replace rivet nuts in exhaust manifold and head pipe flange bolts (11/1, Figure 4) if bolts were difficult to remove or if the threads were damaged (during removal). Refer to WIS: AR49.10-P-5531-01DA.





Primary Parts Information








Warranty Information