FILE: SERVICE: GROUP 00 OF SERVICE INFORMATION BINDER

PARTS: GROUP I OF INFORMATION _ PARTS & ACCESSORIES BINDER

Campaign No. 2005070017, April 2006

Revision History
Revision Date Purpose
D 04/06/06 Update of model 163 in VIN list and warranty information; change of affected
model years
C 04/05/06 Addition of new affected models—163, 208, 209, 215, 219, 220, and 463—and
part number
B 02/08/06 Update of VIN list and change of regulator part number
A 08/29/05 Breakdown of parts information into primary and secondary parts; addition of
estimated replacement rates
- 08/01/05 Initial issue

TO: ALL MERCEDES-BENZ CENTERS

SUBJECT: MODELS 163/ 208/ 209/ 211/ 215/ 219/ 220/ 230/ 463
MODEL YEARS 2001-2006
ENGINES 112 AND 113
INSPECT ALTERNATOR, REPLACE REGULATOR IF NECESSARY

This Service Campaign has been initiated because DCAG has determined that on the affected vehicles
(see VIN range below) the alternator regulator may fail to prevent voltage values ranging beyond the
specified tolerance limits. As a result, the battery may be insufficiently recharged and the convenience
systems may be shut off due to a resulting under voltage condition. The voltage drop is accompanied by
a corresponding message display at the instrument cluster. This campaign includes checking the
alternator and replacing the regulator if necessary.

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 279,948 vehicles are affected.

Order No. P-SC-2005070017

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.
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Effective Serial Number Range

Models Chassis End Number
From To
163.174 A318687 A440701
163.175 A318687 A569678
208.370 F192569 F201799
T093068 T128471
208.374 F192579 F198331
T093560 T120625
208.470 T093056 T144410
208.474 T093122 T129637
209.375 F000313 F151415
209.376 F019833 F151253
209.475 F111256 F151424
T000115 T047048
209.476 T009165 T046986
211.065 A014562 A734487
X097696 X116123
211.070 A042945 A773521
211.076 A136286 A773571
211.082 X108074 X178595
211.083 X108399 X178599
211.265 A307691 A732056
211.276 A715663 A772339
211.282 X108182 X178465
211.283 X108624 X178584
215.373 A019008 A031309
215.374 A030004 A046181
215.375 A019005 A046183
219.375 A000205 A010499
220.067 A374774 A458342
220.170 A227053 A459236
220.173 A227313 A301296
220.174 A306185 A459218
220.175 A227057 A459237
220.183 A310904 A459235
220.184 A308819 A459238
230.474 F009458 F098828
230.475 F001175 F098841
463.246 X134785 X147514
463.249 X126770 X159330
463.271 X146910 X159323

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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. Only
procedures below are applicable to an individual VIN. Not all vehicles require all repair
procedures.

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A. INSPECT ALTERNATOR

Procedure

Figure 1

1. Vehicles with engine 112: Check the manufacturer of the alternator using a mirror (arrow, Figure 1).
• If the alternator is manufactured by Valeo:
This campaign is completed, no further action needs to be taken.
• If the installed alternator is made by Bosch (A) replace regulator:
For models 211 4Matic/ 220: Proceed to Subject B.
For model 211: Proceed to Subject C.

2. Vehicles with engine 113: Replace regulator:

• For models 163/ 211 4Matic/ 215/ 220/ 463: Proceed to Subject B.
• For models 209/ 211/ 219/ 230: Proceed to Subject C.

Note:
• IT IS NOT NECESSARY TO CHECK THE MANUFACTURER OF THE ALTERNATOR ON VEHICLES
EQUIPPED WITH ENGINE 113.
• ALL 113 ENGINES ARE EQUIPPED WITH BOSCH ALTERNATORS AND REQUIRE REGULATOR
REPLACEMENT.

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B. REMOVE REGULATOR WITH ALTERNATOR IN ENGINE COMPARTMENT

MODELS 163/ 211 4MATIC/ 215/ 220/ 463

Note:
• Model 163: Proceed to step 1.
• Model 463: Proceed to step 2.
• Models 211 4Matic/ 215/ 220: Proceed to
step 3

1. Model 163: Remove alternator from vehicle

(refer to WIS: AR15.40-P-5032GH) then
proceed to Subject D, Replace Regulator.
2. Model 463:
• Disconnect battery ground cable from battery
terminal.

Figure 2
• Remove right air intake duct (arrow,
Figure 2).
• Remove front section of upper engine cover
(A, Figure 2).
• Remove engine fan refer to WIS:
AR20.40-P-5660C.
• Remove engine belt from alternator pulley
(do not remove belt from vehicle) refer to
WIS: AR13.22-P-1202B
Note (regarding above WIS instructions):
When removing engine belt from alternator
pulley, do not remove fan shroud.
• Remove upper alternator mounting bolt
(B, Figure 3).
Figure 3 (Shown on model 211)
• Loosen lower alternator mounting bolt (A,
Figure 3) from mounting bracket (arrow).

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• Disconnect circuit 61 harness connector

(arrow, Figure 4) from regulator.
• Remove circuit 30 terminal cover (A)

Figure 4 (shown on model 208)

• Remove nut (arrow, Figure 5) then remove

circuit 30 harness connector (A) from
terminal stud.
• Remove lower alternator bolt (A, Figure 3)
from mounting bracket.
• Remove alternator (B, Figure 5) from
mounting brackets.
Note:
Do not remove alternator (B) from engine
compartment.

Figure 5 (shown on model 208)

• Position alternator (A, Figure 6) with

regulator facing up and pulley facing down.
Regulator will be replaced with alternator
in engine compartment (proceed to
Subject D).

Note:
Replacement of engine belt is not included in this
campaign.

Figure 6

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Figure 7 (Shown on model S55 AMG) Figure 8 (Shown on model S55 AMG)
3. Models 211 4Matic/ 215/ 220:
• Disconnect battery ground cable from battery
terminal.
• Remove right air intake duct (arrow,
Figure 7).
• Remove front section of upper engine cover
(A, Figure 7).
• Models 215/ 220 AMG only:
♦ Remove supercharger belt from vehicle
refer to WIS: AR13.21-P-1202RVK.
♦ Remove cap (arrow, Figure 8) on idler
pulley (A).
♦ Remove idler pulley bolt (arrow, Figure 9)
and idler pulley (A). Figure 9
Installation Note:
When reinstalling, torque bolt (A) to 68
Nm.
• Remove engine belt from alternator pulley
(do not remove belt from vehicle) refer to
WIS: Group 13.22
• Model 211 4Matic only: Unclip heater hose
(A, Figure 10) from mounting clip (arrow).

Note:
Replacement of engine belt and/or supercharger
belt are not included in this campaign.

Figure 10

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Figure 11 (shown on model 208) Figure 12 (shown on model 208)

• Disconnect circuit 61 harness connector (arrow, Figure 11) from regulator.

• Raise vehicle on vehicle lift then remove lower (center) engine cover.
• Remove circuit 30 terminal cover (A, Figure 12).
• Remove nut (arrow, Figure 12) then remove circuit 30 harness connector (A) from terminal stud on alternator
(B).

Figure 13 (Shown on model 211) Figure 14 (Shown on model S55 AMG)

• Loosen upper alternator mounting bolt (B, Figure 13).

• Remove lower alternator mounting bolt (A), then remove upper alternator mounting bolt (B).
• Remove alternator from mounting brackets.
Note:
Do not remove alternator from engine compartment.
• Position alternator (A, Figure 14) with regulator facing up and pulley facing down. REGULATOR WILL BE
REPLACED WITH ALTERNATOR IN ENGINE COMPARTMENT (proceed to Subject D).

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C. REMOVE REGULATOR WITH ALTERNATOR BOLTED TO ENGINE

MODELS 208/ 209/ 211/ 219/ 230

Note:
Subject C does not apply to 4Matic models.

1. Disconnect battery ground cable from battery

terminal.

2. Raise vehicle.

3. Remove lower engine cover:

• Models 211/ 219/ 230: Remove lower middle
engine cover.
• Models 208/ 209: Remove (single) lower
engine cover.

4. Disconnect circuit 61 connector (arrow,

Figure 15) from regulator.
Figure 15 (shown on model 208)
5. Remove circuit 30 cover (A, Figure 15) from
terminal.

6. Remove nut (arrow, Figure 16) then remove

circuit 30 harness connector (A) from
terminal stud on alternator (B).

7. Replace regulator with alternator bolted to

engine (proceed to Subject D).

Figure 16

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D. REPLACE REGULATOR

Figure 17 Figure 18

1. Remove the two nuts (1, Figure 17) from studs and one Philips head screw (2); remove the plastic cover
from the rear of the generator.
Note:
Observe which nut is removed from either stud.

2. Remove three Philips head screws

(2, 3, Figure 18); remove regulator (1) from the generator.

3. Install new regulator (1) with original Philips head screws and torque screws to:
• (2) = 2.0-2.4 Nm
• (3) = 1.0-1.4 Nm

Note:
Ensure the carbon brushes (arrows, Figure 19)
are not damaged during the installation
procedure.

4. Install the plastic cover on the back of the

generator and torque the Philips head screw
(2, Figure 17) to: 2.2 - 2.6 Nm and the two
nuts (1) as follows:
• On long stud: 29.0 - 32.0 Nm
• On short stud:11.0 - 13.0 Nm

5. Reinstall the alternator in reverse order

Figure 19

6. Reinstall components in reverse order.

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7. Reconnect battery cable to negative battery terminal, reinitialize vehicle systems (e.g., steering angle
sensor, power windows etc.); refer to WIS: AR00.19-P-0200P

8. Connect SDS and erase any faults that may have been stored.

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Primary Parts Information

Qty. Part Name Part Number Estimated Replacement
Rate
1 Regulator (Models 208/ 211/ 215/ A 003 154 51 06 Engine 113: 100%
219/ 220/ 230/ 463) Engine 112: See note below
Regulator (Models 163/ 209) A 003 154 52 06

Note: 100% replacement rate on vehicles with 112 Engines only applies to those equipped with
Bosch Alternators. Vehicles with 112 Engines equipped with Valero alternator do not require
replacement as part of the campaign.

NOTE:
THE FOLLOWING SECONDARY PART(S) IS/ARE NOT TO BE ORDERED IN EQUAL QUANTITIES
AS THE PRIMARY PART(S). THEREFORE DO NOT PACKAGE OR KIT CAMPAIGN PARTS
TOGETHER SINCE NOT ALL VEHICLES WILL REQUIRE THESE PARTS.

Secondary Parts Information

Qty. Part Name Part Number Estimated Replacement
Rate
As Required Screw (regulator to alternator) A 001 990 61 21 25%
(Maximum of 3)

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. Accordingly, warranty claims
submitted with reference to an improper part number(s) will be denied.
• The following allowable labor operation should be used when submitting a warranty claim
for this repair:

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Warranty Information

Repair 1 (Engine 112- Check Alternator Only)

Operation: Voltage Regulator- Alternator M112, Check (02-4827)

Damage Code Operation Number Labor Time (hrs.) Model Indicator(s)

54 930 01 8 02-4827 0.1 hrs. J2, T1, T4, U1, U4

Repair 2 (Engine 112- Check Alternator and Replace Regulator)

Operation: Voltage Regulator- Alternator M112, Check (02-4827)
Voltage Regulator- Alternator (DAS Connected), Replace (02-4828)
Diagnosis Assistance System (DAS), Connect & Disconnect (02-4762)

Damage Code Operation Number Labor Time (hrs.) Model Indicator(s)

54 930 01 7 02-4827 0.1 hrs. J2, T1, T4, U1, U4
02-4828 0.6 hrs. T1, T4, U1, U4
02-4828 0.7 hrs. J2
02-4762 0.2 hrs. J2, T1, T4, U1, U4

Repair 3 (Engine 113- Replace Regulator Only)

Operation: Voltage Regulator- Alternator (DAS Connected), Replace (02-4828)
Diagnosis Assistance System (DAS), Connect & Disconnect (02-4762)

Damage Code Operation Number Labor Time (hrs.) Model Indicator(s)

54 930 01 7 02-4828 0.6 hrs. L1, L2, L3, T2, T3, T5,
U3, U5, Y1
02-4828 0.7 hrs. M1, M2, M5, N1, R1,
R2, S2, S3, S5, S6
02-4828 0.8 hrs. K3, K4, M6, M7, M9,
N3, N5
02-4828 1.1 hrs. H2, H4, H5, H6
02-4762 0.2 hrs. H2, H4, H5, H6, K3,
K4, L1, L2, L3, M1,
M2, M5, M6, M7, M9,
N1, N3, N5, R1, R2,
S2, S3, S5, S6, T2, T3,
T5, U3, U5, Y1

P-SC-2005070017