Campaign - ESP Module Ground Connection Inspection

Campaign No. 2001100003
March 2002

FILE:
SERVICE:
GROUP 00 OF SERVICE INFORMATION BINDER

PARTS:
GROUP I OF INFORMATION - PARTS & ACCESSORIES BINDER

TO: ALL MERCEDES-BENZ DEALERS

SUBJECT:
MODEL 203.061/064/065/264
INSPECTION OF GROUND CONNECTION (W16/3) FOR ESP CONTROL
MODULE (N47-5)





In some cases, on subject vehicles within the effective serial number range chart noted below, it may be possible that the ESP ground cable connector (W16/3, located just forward of the left hand shock tower) (Figure 1) for the ESP control Module (N47-5), was not assembled properly. In addition, the ESP control module harness plug must be checked for moisture intrusion (Figure 4). Please inspect the subject vehicles on the next scheduled service visit, to determine if the ESP ground cable connector has been assembled properly, and to remove any moisture accumulation in the ESP control module harness connector.





Effective Serial Number Range

Checking Ground Connector Assembly and Moisture removal from ESP Harness Plug

Procedure:

1. 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.

2. Loosen ground nut at W16/3 (Figure 1) and remove ESP Control Module ground wire (thick wire), as well as all other wires.





3. Remove heat shrink from cable lug completely, using a suitable tool (Figure 2).

NOTE:
take care not to damage the wire insulation when removing heat shrink.





4. Once the heat shrink has been removed from the cable lug, remove the balance (A, Figure 3) of the heat shrink from the ground wire itself.

5. Unplug the ESP harness plug from the ESP Control Module (N47-5), see WIS document AR42.45-P-0820P.





6. Carefully tap the unplugged harness plug against your hand to remove any moisture, additionally, blow out the ESP harness plug with dry compressed air while elevated above the ground cable, for 3 minutes, at the ground pins (arrows, Figure 4), to ensure complete removal of any moisture.

7. Next blow out, with dry compressed air, the multi-pin connector directly at the ESP Control Module, then carefully reconnect the ESP harness plug to the ESP Control Module connector.

8. Install new heat shrink tubing onto ESP Control Module ground wire (thick wire), ensure that the heat shrink tubing stops where removed (A, Figure 2), and does not cover crimped end.

9. Place the 6 x 1.2 mm washer onto the ground stud at W16/3 (1 Figure 1).

10. Install thin ground wires first, then reinstall the ESP ground wire (thick wire) and secure with the previously removed ground nut, observing tightening torque of 10 Nm for the nut.





Parts Information





In Case of Warranty