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5TARTUNED@
Information for the Independent Mercedes-Benz Service ProfeSsional
March/April2011        u.s. $6.00   € 9.00   Volume II     Number 2




                                                IN THIS ISSUE:

                                                3   STOPPING ON A DIME
                                                    SBC Brake Systems

                                                6 ANATOMY OF A COLLISION REPAIR
                                                    Cost-effective restoration plan

                                                10 PICKING PARTS PERFECTLY
                                                    Streamline your work with EPC

                                                14THE NET
                                                    Tech info for you
TO OUR READERS:
Welcome to StarTuned, the magazine for independent service
technicians working on Mercedes-Benz vehicles. Your
Mercedes-Benz dealer sponsors StarTuned and provides the
information coming your way in each issue.
Mercedes-Benz wants to present the information you need to
know to diagnose and repair Mercedes-Benz vehicles accurately,
quickly and the first time; text, graphics, on-line and other                              Contributing Editor
technical sources combine to make this possible.                                           Chip Keen
Feature articles, derived from approved company sources,                                   ckeen@automotivedatamedia.com
focus on being useful and interesting.
Our digest of tech nical information can help you solve                                    Contributing Editor
                                                                                           Kerry Jonsson
unanticipated problems quickly and expertly.                                               kjonnson@automotivedatamedia.com
We wa nt StarTuned to be both helpful and informative, so
please let us know just what kinds of features and other
diagnostic services you'd like to see in it. We'll continue to
bring you selected service bulletins from Mercedes-Benz and
articles covering the different systems on these vehicles.
Send your suggestions, questions or comments to us at:
StarTuned                                                                                     and all past issues of StarTuned, along w1th a wealtll
One Mercedes Drive                                                                               information on Genuine Mercedes-Benz Parts.
Montva le, New Jersey 07645
Phone: 1 800 225 6262, ext. 7112
                                                                                                      To locate a Mercedes-Benz dealer near you,
e-mail: andrew.webb@mbusa.com
                                                                                                              go to www.mbusa.com.

StarTuned is a publi cation of Mercedes-Benz USA, LLC ("MBUSA"). No part of thi s magazine may be reproduced without the express written permission of MBUSA. Editorial
and Circulation Offices : 48 6 Pinecrest Rd., Springfield, PA 19064. Caution: Vehicle servicing performed by untrained persons CQuid result in serious injury to those persons or
others. Information conta ined in this magazine is intended for use by trained, professional auto repair technicians ONLY. This information is provided to inform these technicians
of cond itions which may occur in some vehicles or to provide information which cou ld assist them in proper servicing of these vehicles. Properly trained technicians have the
equipment, tools. safety instructions, and know-how to perform repairs correctly and safely. If a condition is described, DO NOT assume that a topic covered in these pages
automatically applies to your vehicle or that your vehicle has that condition. StarTuned is a registered trademark of MBUSA.




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STOPPING
                                                                             n a Dime
                                                                  One of Mercedes-Benz's main focal points is safety.
                                                                  SBe brake systems reduce stopping distances and
                                                                    allow the driver more control over the vehicle.

                                                                          Let us maintain this system to keep
                                                                             it at its optimal performance.




                                                            -      Mercedes-Benz has always believed that cutting-
                                                                edge technology can be used to make vehicles
                                                                safer, not just more efficient and luxurious.
                                                                Nowhere is this more evident than in the company's
                                                                braking systems. In the past, it was possible to
                                                                lock up the wheels during a panic stop, causing a
                                                                loss of directional stability - at that point the driver
                                                                is no longer in control of the vehicle. Anti-lock
                                                                brake systems have pretty much eliminated this
                                                                dangerous situation since 1984. These computer-
                                                                controlled systems have evolved throughout the
                                                                years into ASR, ETS, ESP, BAS, and, finally, the
                                                                Sensotronic Brake Control system (SBC). With
                                                                conventional brakes, when the driver applies the
                                                                pedal, muscle force levers a master cylinder piston
                                                                forward providing pressurized fluid to the calipers .
                                                                With Sensotronic, on the other hand, the brake
                                                                pedal serves as more of a sensor, signaling the SBC
                                                                unit to send braking pressure to the wheels. This
                                                                improves response time and provides more precise
                                                                control of braking pressure.

                                                            -      With computer-controlled braking, additional
                                                                features can easily be programmed into the system.
                                                                To bring the vehicle's speed down smoothly,
The heart of the Sensotronic braking is the SBC hydraulic       hydraulic pressure is reduced as the vehic le comes
unit. You can see the high-pressure hydraulic pump
                                                                to a stop. When the wiper input is put on th e CAN,
on the left and a pressure reservoir below it. This unit
                                                                light brake pressure is applied to keep friction
actually produces the fluid psi that stops the vehicle.
                                                                                   Mercedes-Benz    March/April 2011    3
STOPPING ON A DIME

                                                                                                                                 --
                                                                                                                                      --~ViN wBuFaiJixjool89~i2Tv~lIraEJ
surfaces wiped dry. Inputs that predict          Ct' 0:"_,UI(.')"t' IJII I Po"] d tl
                                                  ----~----~
                                                                                       11 (l 71)Q Ij 76jiOO79)
                                                                                                                 ----   ~-
                                                                                                                             ~   ~-------               -~
                                                                                                                                                              -

rap id brake application are looked at.            Vehicle                 /211.056                                                    Control unit   /sec
                                                  ISensotronic Brake Control
With sudden release of the gas pedal,
                                                   Control unit version
the SBC contro l unit precharges the               Fault codes
                                                   Diagnostic trouble code memory log (Shadow-Memory)
brakes to remove play in the system. Thi s         EEPROM
                                                   Event memory
helps reduce braking distances when the            Actual va lues
                                                   Deactivate system 'ssC'.
brakes are actua lly applied. SBC is part                                      ,                                                                                     J
of the overa ll dynamic chassis control            General servicing
                                                   Initial startup after maintenance
system, which includes ASR (Automatic              Initial startup after repair
                                                   Complete list of guided tests
Slip Reduction), ESP (Electron ic Stability        Control unit adaptations
                                                   Full list of fault codes and events
Program), ABS (Anti-lock Braking                   Customer complaints (without fault codes)
                                                   r Service information and up-ta-date trouble diagnosis
                                                    .&'"
System), and BAS (Braking Assist                   ~ Control unit log

System). Wheel speed sensors, the ASR              Development data


hydra ul ic unit, and a brake operating unit
make up the SBC system. The system
wakes up when a door is opened, the
                                                                 ~                              ~                            1J                              !J
                                                                                                                                                             F11


                                                  The SOS is needed to de-activate and re-activate the SBC system
remote Smart Key is operated, the key
                                                 before any broke Job or other service work can be performed. This
is turned on, the brakes are app li ed, or       reduces SBC pressure, and fluid lines can be opened.
when the parking brake is released .

- A self-check is performed when the
 system wakes up. Pressure is app li ed
 to the calipers while the system cycles
 solenoids and checks for leaks. This
 feature coupled with high brake pressures
 means we need to be extra carefu l while
 repairing these systems. SBC needs to be
 deactivated while servicing the system,
 even if only the brake pads and rotors are
 being replaced. Thi s way the technician
 wil l not in advertently activate the system
 whil e components are apart, which would
 cause damage and be a safety threat.
 This is done with a Mercedes-Benz SDS
 tool available for purchase from the
 company. Once work is comp leted, SBC           While picking up SBC components at your Mercedes-Benz dealer; you
 must be reactivated. Also, if the hydrau li c   should purchase at least two liters of approved broke fluid to completely
 system is opened for service, a specific        bleed the system. Since broke fluid is hydroscopic, it is recommended
 bleed procedure using the SDS must be           that it be replaced every two years as normal maintenance.
 followed . You will need somewhat less
 than two liters of approved brake fluid,
 which you may want to add to your orde r
 from your Mercedes-Benz dealer.
                                                                Keep it Genuine, and
- When the driver steps on the brake
 pedal, he or she is really engaging Pedal
                                                              you'll keep the customer.
                                                         USE MERCEDES-BENZ PARTS: UNSURPASSED QUALITY I FACTORY BUILT & TESTED I
 Value sensors. These two hall-effect                     COMPETITIVE PRICE I PROVEN RELIABILITY I PRECISION FIT I LIMITED WARRANTY


 4   St arTu ned
sensors tell how much pressure is applied
                                                                                      how quickly to the brake pedal. This
                                                                                      information is sent to the software in the
                                                                                      SBe hydraulic unit, which determines how
                                                                                      much pressure is appl ied to each whee l.
                                                                                      A pedal simulator gives the driver the
                                                                                      feel of a conve ntional brake pedal. Th ere
                                                                                      is sti ll a rod that applies pressure to the
                                                                                      piston in the tandem master cyl ind er, so
                                                                                      in the event of SBe power loss this brake
                                                                                      pressure is app lied mechanica lly to the
                                                                                      two front wheels through valves in the
                                                                                      hydraulic unit.

                                                                                      - You can eva lu ate sensor inputs by
                                                                                       look in g at data in the SBe system, and
When the 5BC is deactivated, or there is a failure in the system, you will
                                                                                       you can read the Pedal Value sensor
see a warning message in the instrument cluster. Pull codes and look at
                                                                                       signa l and individual whee l brake
pressure in the system before disconnecting any broke lines.
                                                                                       pressures. Thi s information can lead to
                                                                                       quicker and more accurate diagnosis .

 Vehicle        1211.070                                        Control unit   Isec   - Bleeding the system and checking for
 IGeneral servicing                                                                    air after replacing any components is
 Check operating time of component A7t3 (SBC hydraulic unit).
   eplace hydraulic brake system fluid t Bleed brake system
                                                                                       criti ca l to prope r performance and wi ll
 Inspect brake system for air.
 Pressure reservoir: check pretension pressure.
                                                                                       elimin ate any possib le fault codes after
                                                                                       work is comp leted. All of the steps are
                                                                                       in the SDS when you select to bleed
                                                                                       the system. You wi ll need other specia l
                                                                                       tools to complete the job, however. A
                                                                                       Mercedes-Benz-approved power bleeder
                                                                                       wi ll have to be attached to the brake
                                                                                       fluid reservoir to insure that the hydraulic
                                                                                       circuits do not run dry whi le bleed ing.
                                                                                       The sequence starts at the right front
                                                                                       whee l, followed by the right rear, left rear
Follow the steps outlined in the bleed procedure in your 5DS unit. Make                and left front whee ls. You will need to
sure to secure your broke bleeder lines to the screws since high pressure              secure a hose to the bleeder screw since
broke fluid comes out when opened.                                                     high pressure fluid comes out when it is
                                                                                       opened. After the process is comp lete,
                                                                                       clear the codes and verify that you have
                                                                                       no codes left in the SBe system. A test
                                                                                       drive should be performed before the
                                                                                       vehicle is delivered . A complete job wi ll
                                                                                       provide your customer with al l of the
                                                                                       benefits SBe has to offer in safety and
                                                                                       car control, and that's a job wel l done .


                                                                                              Mercedes-Benz     Marchi April 2011      5
• •                        Corne




- From the moment a vehicle comes into your                  damage. The front and rear crumple zones are
 shop for repair, the clock is ticking. The insurance        co ll apsib le structures. They are meant to absorb
 company has its agenda, the customer wants his              the energy of an impact and not pass it on to
 or her car back, and you have to make them both             the occupants. Even if the impact appears light
 happy. With new insurance and EPA regulations, it           enough and one or two corners are written off,
 seems you don't have a moment's rest from running           you must get this vehic le on a lift. Mercedes-Benz
 you r business, keeping your people employed, and           insists on the use of a chassis alignment jig when
 turning a profit. You must return the car with the          frame straightening to assure accuracy. Traditional
 same crash-worthiness and finish it had before the          measurement methods, such as those taken off the
 accident. This is certainly possible, but nothing           centerline of the chassis to various pick-up points,
 can reduce profits more than having to go back
 and do something over, or realizing that there is               Vehicle Body Information
 more damage than you'd seen before. To prevent
                                                                 216
 th is from happening, you need to come up with a
 plan the moment the vehicle comes in for repairs.
 This is not always easy depending on the damage.
 Mercedes-Benz veh icles have higher monetary va lue
 than ordinary cars, and as a consequence are more
 li ke ly to be repaired instead of tota led, so it's very
 important that you get it right the first time .
                                                                                             Mgd$leel "'300 N/rnm'ttn~511t11cth
                                                                                             HI&h·~ ' ttl.lh.lecl"'S5n ~ /mnllensllclluent1h
                                                                                             Modem hfJ/>-Rll'1!ithsteel -> l000 H/mm' l.ef$iIe.sDmtth
                                                                                             Ulluhl&fHlren~h   $tCd, hot ~~ -> ISao N/fIW!I' IffUIk.uenath


Step One                                                                                     "''''''''m
- Of course, every accident is different, but
                                                             The first step before performing any repair work is a visit
 yo u should focus on what is similar about every            to www.mbcollisioncenters.com for a look at the vehicle's
 one. There are accidents where on ly the body is            construction materials.This is an essential safety step and
 contacted, others that include suspension pieces.           will let you know when magnesium or ultro-high-strength
 Either way, you need to check for structural                steel is used. Repair procedures will be different as a result.
6   StarTuned
Opposite Page: Here we have a front-end hit on a 2002                    and repair processes . This information wil l allow
    208 chassis eLK. There is the obvious damage to the                      you to give the adjuster a tru ly accurate account of
    hood, center support, and front crash box, but what about                the time involved. EPC (Electronic Parts Catalog) is
    underlying damage ?The headlight frame mounting was                      also an essentia l tool for doing estimates. You can
    damaged on the passenger's side and may not have been
                                                                             look at the repair parts that Mercedes-Benz makes
    put on the estimate.
                                                                             available to ma ke sure you're ordering exactly the
    are simply too crude for "the best engineered cars                       right things .
    in the world." In fact , the company doesn't even
    publish these dimensions.                                                - Also, be prepared to remove fenders so the
                                                                              adjuster can look at possible damage under the
                                                                              surface paneling. Your goal is to put as much
    Crash Analysis                                                            needed work on the origina l estimate and reduce
- The use of jig sets prevents any surprises when                             the cost of any supplements. WIS gives detailed
 the bodywork is complete, such as finding that                               repair instructions for the job so you can give
 wheel alignment can't be accomplished because                                the adjuster a truly accurate account of the time
 there isn't enough range of adjustment to make up                            involved . EPC is also an essential tool for doing
 for dimensional discrepanc ies. This is especial ly                          estimates. You can look at the repair parts that
 true if a wheel, upright spindle, or suspension arm                          Mercedes-Benz makes avai lable.
 has been bent. Also, be prepared to remove fenders
 so the adjuster can look at possible damage under
 the surface paneling.                                                           Using Your Tools
                                                                             - Our example here is a 2002 208 chassis ClK
- This prevents any surprises when th e bod ywork                             that has been in a front-end collision. It appears on
 is complete, but wheel alignment cannot be                                   the surface that it wil l need a hood, upper radiator
 accomplished because there is not enough range of                            support, center support, and a front bumper cover.
 adjustment. This is especially true if a wheel, upright                      A deeper inspection, however, showed that the
 spindle, or suspension arm has been bent.                                    crossmember support, lower radiator support,


-     Your goal is to not miss any
    needed work on the original
    estimate and reduce the cost
    of any supplements. Use
    WIS (Workshop Information
    System, availab le with
    a paid subscription to
    www.startekinfo.com )


                                                           ~~
    to identify any repairs and
    procedures not included
    in the estimating guides
    (and, of course, to fi x the               12~         :~'if~j '~:;J
                                                   ~
                                                          " 4                    D   rJ '
    car right) . It gives detailed
                                               ~ .                                   ~.
    repair instructions for                   '5   it-e         '.
                                                                     r!F,3   .
                                                                                 ~5
    the job, and tells you the                            4             •
                                                                             H
                                                                                          .

    materials involved in the
    vehicle's construction that         Before you start to take the damaged section apart, look at the repair
    may necessitate the use of          instructions at www.startekinfo.com. and the parts information on EPCnet
    special tools, equipment,           (http://epc.startekinfo.com).This will help you generate an accurate estimate.
                                        Also, by quickly removing panels, you con look for further damage to the structure.
                                                                                                Mercedes-Benz   Marchi April 2011     7
ANATOMY O F A COLLISION RE P IR
                            A


and passenger side headlight stiffening support                                                                  for work in struction s, you know the materials
were all damaged. After reviewing the cost of the                                                                you may cut and reform, and you can now begin
components and the cost in labor of straighten ing                                                               tearing down the crash damage. Following the
them, it was agreed with the adjuster that each                                                                  steps out lined in Startekinfo, you can begin with the
damaged component shou ld be replaced in stead                                                                   front crash box. If there had been frame damage,
of being repaired . This saved a sign ificant amo unt                                                            you may need to put the veh icle on a CarBench or
of labor time and ended up being cost-effective for                                                              Celette bench and reposition it.
everyone involved .
                                                                                                               - We rea lize you probably don't get paid for the
- If you are a Mercedes-Benz co llision shop, yo ur                                                             time spent coming up with an efficient repair plan .
 next step should be to visit the Mercedes-Benz                                                                 While in negotiations with the in surance adjuster,
 Co llision website, www.mbcolissioncenters.com .                                                               you shou ld not let him or her dictate how this
 Here you wil l find specific information, especia lly                                                          particular veh icle will be repaired. By investing some
 about tools and body construction materials. This                                                              time and resea rching Mercedes-Benz Startekinfo,
 is an important safety step. Mercedes-Benz uses                                                                EPC and th e co llision website, yo u have armed
 hybrid construction in many models. This means                                                                 yourse lf with the specifi c information about what
 panels may be made of severa l different materia ls.                                                           the manufacturer requires to restore this vehicle to
                                                                                                                its previous cras hworthin ess, fit, and finish. With
                                                                                                                an accurate assessment of time and money, jobs
Hybrid Construction
                                                                                                                remain profitable and customers are happy. I
- Checki ng what
 materia ls are used is                                                                            31
                                 ftotJmo6e"     I.e. "         2'lJ836SClK320:0J:320JAl'~:cu:.320 U .,. "    2:05.365   ...    62 FRONT PANEl. ..   OOOWtfilHOUSE,FJl.ONT5U!fRA/'E '"
 critica l before starting any
                                                                                                            ~ ~. * '1 - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - L-1
 repa ir. Mercedes-Benz          ,     nnn."   Plllt n.rrb:f
                                                                                                                    -
                                  r    ,
 uses ultra-high-strength,
                                                                         WHU LHOUSE
                                                                         lEFT



 high-strength, and               r    ,                                                                                                     ~
                                                                                                                                             ~                              IGO
                                                                                                    "

                                                                                                                                              ~IOI!~
                                                                                               .
 mi ld steels, aluminum,          r    "
                                  r            A 208620 2261            . WllfiLHOUSE
 magnesium, and plastics               "                                    Rt'"'
                                  r    17      A 1296Z600 II            •• PlATE

 to bu ild a vehicle. If you      r    20      A 208626 01 16
                                                                             FRONTI'UaA TOWHEfI.HOlJ5f
                                                                                                                                           104~
 decided to cut an inner          r    20      A20862602 16             •• REJNfORaMfHT
                                                                             ENGlt.£HOOOHlNGf,RIGHT
                                                                                                                        00 1



 door panel on a 215              r
                                       "       A2:05620OSn              . . STIFfENJHG

                                                                             ,....,.,...,
                                                                             FRONT FEtaA TO lEfT FRONT


 chassis CL-C lass, for           r
                                       "       A 208620 06     n        "    STlffEl'llNG
                                                                             FRONT f EMJER T RIGHTFRONT
                                                                                            O


 instance, you need to            r    J2      A2!l26268B 14
                                                                             """""""
                                                                        •• DRAnEr
                                                                             HVllRAU.ICLMTBRAO:!:TT Ol EFT
                                                                             ~A8S/ETSJASA

 know th at it is made of         r    3S      AOCIl99CJI ZIO           " SCIlfW


 magnesium . This material       Looking at EPC, you con see the many stiffening support brackets in the front crash box that con
 burns a bright hot white        be replaced instead of worked straight. It may be cheaper and foster to replace components
 and may ignite whi le           instead of straightening them, and you get o.E. crashworthiness, too.
 being cut. The panel is
 also on ly available as a
 whole pi ece, so it does
 not make any sense to
 work it. In the case of
 the 208 chassis CLK320,
 th e body is constructed
 of mild steel. If you have
 looked at EPC for parts         Even with light hits, using OEM ports like this ML rear bumper cover will reduce labor time.
 ordering and Startekinfo        You will not have to modify the port to make it fit. It comes already primed so all you have
                                 to do is prep it for pointing.
 8   StarTuned
Picking Parts
                   Perfectly

                                                                         @ Mercedes-Benz




                            EPC is a great tool fo r streamlining your
                            work and avoiding errors. And it's free.


- A common element of most repa irs is t he need             - You probab ly know t hat your loca l Me rcedes-Benz
 for rep lacement parts. Sin ce t here are so many            dea ler has access to a comp rehensive Electronic
 differe nt pa rts , each one has its own number.             Parts Cata log, known as EPCnet, which lists th e
 Find ing the rig ht number - qui ck ly and acc urate ly -    pa rts for eve ry Me rcedes-Benz vehic le since about
 is of the utmost import ance if you wan t to provid e        1946. Bu t did yo u know t hat you can also acce ss
 qua lity repairs quick ly. Of co urse, we always             thi s pa rts ca t alog - for f ree?
 recommend (a nd use) Genu ine Mercedes-Benz
 replacement parts for every j ob sin ce t hey always        - To regu lar reade rs of StarTun ed, the STAR
 fit and perform perfect ly, not to me nti on having a        Tek lnfo web site (www.startekinfo.com ) -
 superb warranty to set your custo mers at ease. But          wh ich inc ludes EP Cnet access - isn't anything
 findin g exactly t he right part ca n sometim es present     new. But t here is a sister site, epc.sta rtekinfo.
 a challenge.                                                 com, t hat offe rs free access to EPCnet to an yo ne

 10   StarTuned
• ••




              . . . on all eight with www.startekinfo.coffi.

Mercedes-Benz USA Dealer Workshop Services is the source for all the technical
information needed to support, service, and maintain Mercedes-Benz vehicles.
Mercedes-Benz workshops rely on DWS products and services for getting jobs
done quickly and more efficiently. Our products include:
• STAR TekInfo with WIS-net (Workshop   •   Maintenance Manuals and Sheets
  Information System)                   •   STAR Service Manual Library CDs
• Electrical Troubleshooting Manuals    •   WIS and DAS software updates
• Installation Instructions             •   Star Diagnosis System (SDS)
• Technical Bulletins                   •   Operator's Manuals and COMAND Manuals
• Campaigns                             •   Mercedes-Benz Equipment
• Mercedes-Benz Special Tools           •   Inventory of technical publications


STAR TekInfo
Dealer Workshop Services
Engineering Services,
Mercedes-Benz USA, LLC.
                                                 @ Mercedes-Benz
P ICKIN G PARTS P ERFECTLY




in the United Sta tes, courtesy of Mercedees-Be nz
USA. Although you do have to prov ide a major                                                                                                                                             EPCnet Online
                                                                                                                                                                                          _ _ Gellltl StanId              AboutSlul      Account
credit card numbe r, th is is used on ly to verify that                                                                                                                                                                                You .... !tOt tlilftntly l ogg.d    Inf I.£II..!n
                                                                                                                                                    Mercedes·Benz
your mai ling address is within Mercedes-Benz                                                                                                     ... Welcom e
                                                                                                                                                      login
USA's assigned territo ry, not to assess charges.                                                                                                     Subscribe
                                                                                                                                                      STAR reklnfo
                                                                                                                                                      Me Classic Cenle'
If you live in another country, contact your sa les                                                                                                   Site Map


organization to ask about EPCnet access.
                                                                                                                                                                                          Welcome to EPCnet Online
                                                                                                                                                                                          EPCnet Online is the official Mertedes-8enz USA, LlC sIIe for
                                                                                                                                                                                          hoslJng spare parts documentallon for Mercedes-8enz cars and
- For most of us, it's often easier to have the                                                                                                                                           light trucks sold In the USA,

                                                                                                                                                                                          EPCnet Is a bfowser-based Electronic Parts catalog Which allows
 dealer look up whatever parts we need. Thi s                                                                                                                                             the user to specify virtually every spare part for the models coversd.
                                                                                                                                                                                          Art intuitive graphical user Interface pennlts easy navigation through
 usua lly works fine for common parts, like oil                                                                                                                                           the extensrve parts catalog. Tutorials are avaIlable at no charge to
                                                                                                                                                                                          help familiarize both new and experienced users with !he
                                                                                                                                                                                          Mel'Cedes-Senz :spare part.6 groJp system and the selErCtlon or the
 fi lters and shock absorbers. But have you ever                                                                                                                                          appropriate part for your particular vehicle,

                                                                                                                                                                                          A subscription is necessary to USB thls application. Before
 had the fr ustration of trying to exp lain some                                                                                                                                          sUbscribing, we fjlrongtv recommend thaI yoo review aUof Itse
                                                                                                                                                                                          Informa tion under the Getting Started and About Site tabs.

 arcane or unusua l part you need to someone on                                                                                                                                           Please be advIsed that you need 1 Install the necessary plug-Ins to
                                                                                                                                                                                                                             0
                                                                                                                                                                                          view the site content, as explaIned on the About Slie I Tech
                                                                                                                                                                                          RequIrements pages,
 th e phone? Spending time trying to get it right is                                                                                                                                      A dBtaffed IIsU of models covered by this Information can be
                                                                                                                                                                                                         ng
                                                                                                                                                                                          found on the About SIt. I Coverage page.
 t ime better spent ma king money.
                                                                                                                                                EPCnet Online is a free ports catalog available to
- Instead of faxin g images bac k and fo rth, or                                                                                                anyone within MBUSA's sales territory.Just go to STAR
 risking delivery of the wrong part, j ust have your                                                                                            Teklnfo's sister site -- http://epc.startekinfo .com -- to
 Merced es-Benz parts person te ll you which EPC                                                                                                sign up. This is the some catalog used by Authorized
 image he or she is looking at. With your free EPCnet                                                                                           Mercedes-Benz dealers.

 Identifkotion nunber     fWOB3 11210321C137181                                          ::::J IWll6EA32EtSCI3746t                                                                & I ~' I ~ ~ I f3i I ' u. ~ ~
  MDmode        ~   1. Car'"     121032 300 E USA;                        E 320 USA:32O E / E 32O:E 320 JAPAN     ~   121.032    ~
                                                                                                                                        16 STEERING     ~      015 STEERING GEAR            ~


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   -/     j Item ... j Parl number             j Des91alion/desaiptJon                                j Quantity         j verslon                                                                 ~     !     2 3 1 5 6 7 8 9 10                  ~I       I    11         816015000015

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                                                                                  ~~
                                                                                              )
                                                                                             '1...1 ~    :                                                     ~ i1iJ                                  I !4 IShopping list t..nsfer file                        ~         ....)
  Write protection       I ShoppinQ 1st                               IDate/Time ·            I               No.            l oam .. ·lltemno.      I Port number                   IESI IES2         I Des9lotion/description                          I Quont~y            I Qty 0...



                                                                                                                                                                                                                                                                                           J
                                                                                                              3                           11          A 11646601 60                                      SEAL RING                                               I



                                                                                                    J
   of                      .. T_ory shopplng 1st ..

   ill                     December 2010                                 12/20/10 12:05 PM

   ill                     left mirror cover                            07/12/10 07:31 AM                     2                        38            A 003 990 39 10                                    WASHER                                                        I

   ill                     WOB2 100s51.ll31                             01/05/10 10:11 AM
                                                                                                    ~         (I                                                                                                                                     I                                     ~
           Market: North America                              C.tolo9: ISV ·As 01 09/69

 EPCnet illustrations can be useful in reminding you how certain assemblies fit bock together While the illustrations are not
 meant to be exact reproductions of the port, they are close enough to provide the details you need.


 12       StarTuned
subscription, you and your dea ler can litera lly "be                                              Transmissions each have their own parts groups, as
on the same page" as you work your way through                                                     do some older steering boxes and rear differentials.
your parts list.                                                                                   There are several tutorials, including a listing of
                                                                                                   parts groups and what's in them, under the "Getting
- Got some customers who are more technica lly-                                                    Started" tab, which is visib le at epc.startekinfo.com
 incl ined than average? Let them know about the                                                   before logging in.
 free EPC subscription, and they'l l thank you for it.
 Information like this he lps bu ild customer loya lty                                           - The third step is to find the illustration that
 and demonstrates that your shop is linked in to                                                  shows your part. Most parts groups have several
 official Mercedes-Benz resources.                                                                subgroups, which will help you narrow your search.
                                                                                                  Just remember that the drawings in EPCnet aren't
- In many cases, the EPC illustrations can help                                                   meant to be photo-rea listic images of the parts in
 remind you how certa in assemblies fit back                                                      the car. Instead, they are meant to be a genera lized
 together. Even t hough the ill ustrations are not                                                representation of the part.
 intended to be exact reproductions of the part, they
 are general ly very close, as are exp loded views.                                              - The last step is to pick the part and determine the
                                                                                                  correct part number. Often, on ly one part number
- And, of course, sometimes you may just want                                                     is shown when you click on the illustration, but in
 to look up your own parts. With the latest version                                               cases where more t han one number is shown, read
 of EPCnet avai lab le to you on line, it's easier than                                           the footnotes and codes carefu lly, since these will
 ever before. The first step, once you've logged                                                  tel l you whether the part applies to the car you're
 in and started EPCnet, is to type in the Vehicle                                                 working on, or not.
 Identification Number (V IN) at the top. By do ing this,
 you are harnessing the powerful fi lters in EPCnet,                                              - One nice feature of EPCnet is the ability to build
 which remove from view parts that don't app ly to                                                 a "shopp ing list." After you've found the right part
 the car in question.                                                                              number, just click the checkbox to add it to the
                                                                                                   shopping list. Later, you can edit, save and print
- The second step is to pick the Parts Group where                                                 the list, making order placement that much easier.
 you think you' ll find the desired item. Engines and                                              You can fax or e-mai l the parts list directly to your
                                                          • SHOPPING LIST·
                                                                                                                                  dealer, not only saving
                                                                                                                                  time, but reducing any
                                                                                                                                  chances for mistakes.
                                Shopping list:   - Temporary shopping lisl- Dale/time:       01112111 10:54 AM
                                Customer name:                              Created by:
                                                                                                                                                  - EPCnet is a valuab le
                                Contact                                     Changed by: angelo
                                Order no.:                                  Wor1<shop 1 ::
                                                                                      0                                                            resource you can use to
                                Note:                                                                                                              repa ir your customers'
                                                                                                                                                   veh icles faster and
 DDmagecode   Item no.   Port no.          ES1   ES2   DeslgnDtion/descriptlon    Quanmy        Qty on hDnd      Price   Warranty/goodwill code    more efficiently -
                                                       SPRING
              17         A 124 993 46 01
                                                       CONTROlVflJ...VE
                                                                                  001                                                              and best of all, it's
              T7         A 000 990 40 50               NUT                        001                                                              free! Check into it at
              44
              35
                         A 201 461 00 60
                         A201 4500186
                                                       SE/lJ...RJNG
                                                       THREADED INSERT
                                                                                  001
                                                                                  001
                                                                                                                                                  hlli>.:JLwc.startekinfo.com.
                                                                                                                                                      _                          I
              41         A 116466 0160                 SE/lJ...RJNG               001
              38         A 003990 3940                 WASHER                     001


  If you specify your own ports, you can build a Shopping List like this one. Print it, e-mail it or
 fox it to your dealer to save time and reduce any chances for errors.


                                                                                                                                  Mercedes-Benz        Marchi April 2011         13
· What's New : Accessories tab added for
                                                                                                                                                                                            direct access to the item s that enhance your
                                                                                                                                                                                            Mercedes-Benz vehicle .
Sourcing Mercedes-Benz
Repair and Parts Information                                                                                                                                                              · Page with helpful parts information .
...
             ~                                                                                                                                                                            · Links to other informative site s like the
      Mercedes-Benz Service and Parts
      -----------------------------------
                    -                                                             ---                                  _. -    ~-~~-~                                       --



       SERVICING
       YOUR VEHICLE




      ......   -.       Keep It Genuine with Mercedes-Benz Service and Parts
                        ~orP9lfot .... IR'.ex~.oty'_• ....:Icutt~ild9f:t~ ..... luotyoU~. PKlfrom~_Befu. 'O •• I""""
                        drt.otyO'.lr~, ou'«>mrnitlncnt to ,.,..conIlnuol .. M"ooor1d_da.. Men:edcl·Bo>. "noIcoI,p,orU..,.,_ric"
                                                                                                                                                                           ..........
                                                                                                                                                                                          · Direct link to the El ectronic Parts Catalog (EPC)
                        c..,.I0!,...   "~   .. Icn. T..."ftiN... ~ .• ",~" ,," l~ """oC',,,"'.' .,.. O"<;,,'~ :,~'m~o.        "v'   ~ ~." t~ .. y "   ..... '1 . ,Iv   ' ... '-' ,1.'C'
                                                                                                                                                                                            to look up parts.
                        .r,      ".     , ..... t.,     ~.   ~~   .;,-.... , '.   p."'   Y'   "   '"   Y, · , ....   ,,-s



                                                                                                                                                                                          · Downloadable Remanufactured Parts Catalog
Superior performance, exquisite style, and cutting-                                                                                                                                         and Reman Parts policies.
edge technology are what you expect from
Mercedes-Benz.                                                                                                                                                                            · User friendly links to tools such as STAR Tekinfo
                                                                                                                                                                                            and WIS.
Certified Mercedes-Benz Technicians are required
to participate in ongoing training, assuri ng that they                                                                                                                                   · WebParts online ordering information and how-to
master the use of state-of-the-art diagnostics, tools,                                                                                                                                      video tutorial.
and equ ipment to properly repair Mercedes-Benz
veh icles.                                                                                                                                                                                . Search feature to find archived StarTuned Magazine
                                                                                                                                                                                            articles & information.
Genuine Mercedes-Benz replacement parts and                                                                                                                                                Please visit us at www.mbwholesaleparts .com
accessories insta ll ed by certified technicians
preserve the performance and integrity of your
vehicle. As well, keeping it genuine with
Mercedes-Benz parts wil l help maintain your
vehicle ' s residua l value.
                                                                                                                                                                                                       Accessories Detai Is
Show your customer why you recommend
Mercedes-Benz OE Parts.                                                                                                                                                                                &   link 10 MBU S A ACClllotlts
                                                                                                                                                                                                                                 ---
                                                      Please visit us at
www.mbusa.com / mercedes / service and pa rts / genu ine parts
R
   E                             •
   M ·                                                                        •       ••   -
   A                   =                       • •                                •
   N

Remanufacturing Process                        --=":'-0. __ -
                                                          "



1. Dismantle core               2. Rep lace key                 3. Test all                4. Replace
  and clean all                      components 100%              other critical               components that
  components.                        with new OE part.            components.                  do not meet



Rebuilt Process (Typical
                                   ~~~~======~
1. Identify damaged
   part or parts.




 Available through your local Mercedes :   -   .  --   -
COMPLIMENTS OF R B M OF ATLANTA, INC.
                                             770-390-0601




    Keep it Genuine, and you'll
    Your Mercedes-Benz customers expect the best without excuses or
    that's at stake when you use inferior pieces in place of Genuine Merc:e(lles...HelB2
    trusts you enough to give you their Mercedes-Benz to work on, there's
    a Mercedes-Benz when you give it back: Use Genuine Mercedes-Benz Parts.
    your local Mercedes-Benz Wholesale Parts Dealer or visit us at        WWW.11I11... 1I11I1. . . . .



    UNSURPASSED QUALITY I FACTORY BUILT & TESTED I COMPETITIVE PRICE I PROVEN RELIABILITY I ?~¢J$i'oN~




© 20 10 Mercedes-Benz USA. LLC.

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StarTuned Magazine March/April 2011

  • 1. 5TARTUNED@ Information for the Independent Mercedes-Benz Service ProfeSsional March/April2011 u.s. $6.00 € 9.00 Volume II Number 2 IN THIS ISSUE: 3 STOPPING ON A DIME SBC Brake Systems 6 ANATOMY OF A COLLISION REPAIR Cost-effective restoration plan 10 PICKING PARTS PERFECTLY Streamline your work with EPC 14THE NET Tech info for you
  • 2. TO OUR READERS: Welcome to StarTuned, the magazine for independent service technicians working on Mercedes-Benz vehicles. Your Mercedes-Benz dealer sponsors StarTuned and provides the information coming your way in each issue. Mercedes-Benz wants to present the information you need to know to diagnose and repair Mercedes-Benz vehicles accurately, quickly and the first time; text, graphics, on-line and other Contributing Editor technical sources combine to make this possible. Chip Keen Feature articles, derived from approved company sources, ckeen@automotivedatamedia.com focus on being useful and interesting. Our digest of tech nical information can help you solve Contributing Editor Kerry Jonsson unanticipated problems quickly and expertly. kjonnson@automotivedatamedia.com We wa nt StarTuned to be both helpful and informative, so please let us know just what kinds of features and other diagnostic services you'd like to see in it. We'll continue to bring you selected service bulletins from Mercedes-Benz and articles covering the different systems on these vehicles. Send your suggestions, questions or comments to us at: StarTuned and all past issues of StarTuned, along w1th a wealtll One Mercedes Drive information on Genuine Mercedes-Benz Parts. Montva le, New Jersey 07645 Phone: 1 800 225 6262, ext. 7112 To locate a Mercedes-Benz dealer near you, e-mail: andrew.webb@mbusa.com go to www.mbusa.com. StarTuned is a publi cation of Mercedes-Benz USA, LLC ("MBUSA"). No part of thi s magazine may be reproduced without the express written permission of MBUSA. Editorial and Circulation Offices : 48 6 Pinecrest Rd., Springfield, PA 19064. Caution: Vehicle servicing performed by untrained persons CQuid result in serious injury to those persons or others. Information conta ined in this magazine is intended for use by trained, professional auto repair technicians ONLY. This information is provided to inform these technicians of cond itions which may occur in some vehicles or to provide information which cou ld assist them in proper servicing of these vehicles. Properly trained technicians have the equipment, tools. safety instructions, and know-how to perform repairs correctly and safely. If a condition is described, DO NOT assume that a topic covered in these pages automatically applies to your vehicle or that your vehicle has that condition. StarTuned is a registered trademark of MBUSA. Broadway Car Wash Equipment Company Some of Our Nationwide Mercedes-Benz Partners: Partners with the Autohaus Concept! New Country Motors Hartford, CT ../ SPACE EFFICIENT Different models to fit almost any space Scholfield Motors Wi chita, KS ../ QUALITY WASHING Thirty years of proven histolY Mercedes-Benz of Smithtown ../ QUICKER RESULTS Saint James, NY Complete wash in 2 minutes or less w.I. Simonson Mercedes ../ EASY TO USE OPERATION Santa Monica, CA Simple operation increases efficiency ../ LASTING DURABILITY Mercedes-Benz of San Antonio Aluminum frame provides durability San Antonio, TX ~~ &~ e~ · 1-800-976-WASH • www.broadwayequipment.com
  • 3. STOPPING n a Dime One of Mercedes-Benz's main focal points is safety. SBe brake systems reduce stopping distances and allow the driver more control over the vehicle. Let us maintain this system to keep it at its optimal performance. - Mercedes-Benz has always believed that cutting- edge technology can be used to make vehicles safer, not just more efficient and luxurious. Nowhere is this more evident than in the company's braking systems. In the past, it was possible to lock up the wheels during a panic stop, causing a loss of directional stability - at that point the driver is no longer in control of the vehicle. Anti-lock brake systems have pretty much eliminated this dangerous situation since 1984. These computer- controlled systems have evolved throughout the years into ASR, ETS, ESP, BAS, and, finally, the Sensotronic Brake Control system (SBC). With conventional brakes, when the driver applies the pedal, muscle force levers a master cylinder piston forward providing pressurized fluid to the calipers . With Sensotronic, on the other hand, the brake pedal serves as more of a sensor, signaling the SBC unit to send braking pressure to the wheels. This improves response time and provides more precise control of braking pressure. - With computer-controlled braking, additional features can easily be programmed into the system. To bring the vehicle's speed down smoothly, The heart of the Sensotronic braking is the SBC hydraulic hydraulic pressure is reduced as the vehic le comes unit. You can see the high-pressure hydraulic pump to a stop. When the wiper input is put on th e CAN, on the left and a pressure reservoir below it. This unit light brake pressure is applied to keep friction actually produces the fluid psi that stops the vehicle. Mercedes-Benz March/April 2011 3
  • 4. STOPPING ON A DIME -- --~ViN wBuFaiJixjool89~i2Tv~lIraEJ surfaces wiped dry. Inputs that predict Ct' 0:"_,UI(.')"t' IJII I Po"] d tl ----~----~ 11 (l 71)Q Ij 76jiOO79) ---- ~- ~ ~------- -~ - rap id brake application are looked at. Vehicle /211.056 Control unit /sec ISensotronic Brake Control With sudden release of the gas pedal, Control unit version the SBC contro l unit precharges the Fault codes Diagnostic trouble code memory log (Shadow-Memory) brakes to remove play in the system. Thi s EEPROM Event memory helps reduce braking distances when the Actual va lues Deactivate system 'ssC'. brakes are actua lly applied. SBC is part , J of the overa ll dynamic chassis control General servicing Initial startup after maintenance system, which includes ASR (Automatic Initial startup after repair Complete list of guided tests Slip Reduction), ESP (Electron ic Stability Control unit adaptations Full list of fault codes and events Program), ABS (Anti-lock Braking Customer complaints (without fault codes) r Service information and up-ta-date trouble diagnosis .&'" System), and BAS (Braking Assist ~ Control unit log System). Wheel speed sensors, the ASR Development data hydra ul ic unit, and a brake operating unit make up the SBC system. The system wakes up when a door is opened, the ~ ~ 1J !J F11 The SOS is needed to de-activate and re-activate the SBC system remote Smart Key is operated, the key before any broke Job or other service work can be performed. This is turned on, the brakes are app li ed, or reduces SBC pressure, and fluid lines can be opened. when the parking brake is released . - A self-check is performed when the system wakes up. Pressure is app li ed to the calipers while the system cycles solenoids and checks for leaks. This feature coupled with high brake pressures means we need to be extra carefu l while repairing these systems. SBC needs to be deactivated while servicing the system, even if only the brake pads and rotors are being replaced. Thi s way the technician wil l not in advertently activate the system whil e components are apart, which would cause damage and be a safety threat. This is done with a Mercedes-Benz SDS tool available for purchase from the company. Once work is comp leted, SBC While picking up SBC components at your Mercedes-Benz dealer; you must be reactivated. Also, if the hydrau li c should purchase at least two liters of approved broke fluid to completely system is opened for service, a specific bleed the system. Since broke fluid is hydroscopic, it is recommended bleed procedure using the SDS must be that it be replaced every two years as normal maintenance. followed . You will need somewhat less than two liters of approved brake fluid, which you may want to add to your orde r from your Mercedes-Benz dealer. Keep it Genuine, and - When the driver steps on the brake pedal, he or she is really engaging Pedal you'll keep the customer. USE MERCEDES-BENZ PARTS: UNSURPASSED QUALITY I FACTORY BUILT & TESTED I Value sensors. These two hall-effect COMPETITIVE PRICE I PROVEN RELIABILITY I PRECISION FIT I LIMITED WARRANTY 4 St arTu ned
  • 5. sensors tell how much pressure is applied how quickly to the brake pedal. This information is sent to the software in the SBe hydraulic unit, which determines how much pressure is appl ied to each whee l. A pedal simulator gives the driver the feel of a conve ntional brake pedal. Th ere is sti ll a rod that applies pressure to the piston in the tandem master cyl ind er, so in the event of SBe power loss this brake pressure is app lied mechanica lly to the two front wheels through valves in the hydraulic unit. - You can eva lu ate sensor inputs by look in g at data in the SBe system, and When the 5BC is deactivated, or there is a failure in the system, you will you can read the Pedal Value sensor see a warning message in the instrument cluster. Pull codes and look at signa l and individual whee l brake pressure in the system before disconnecting any broke lines. pressures. Thi s information can lead to quicker and more accurate diagnosis . Vehicle 1211.070 Control unit Isec - Bleeding the system and checking for IGeneral servicing air after replacing any components is Check operating time of component A7t3 (SBC hydraulic unit). eplace hydraulic brake system fluid t Bleed brake system criti ca l to prope r performance and wi ll Inspect brake system for air. Pressure reservoir: check pretension pressure. elimin ate any possib le fault codes after work is comp leted. All of the steps are in the SDS when you select to bleed the system. You wi ll need other specia l tools to complete the job, however. A Mercedes-Benz-approved power bleeder wi ll have to be attached to the brake fluid reservoir to insure that the hydraulic circuits do not run dry whi le bleed ing. The sequence starts at the right front whee l, followed by the right rear, left rear Follow the steps outlined in the bleed procedure in your 5DS unit. Make and left front whee ls. You will need to sure to secure your broke bleeder lines to the screws since high pressure secure a hose to the bleeder screw since broke fluid comes out when opened. high pressure fluid comes out when it is opened. After the process is comp lete, clear the codes and verify that you have no codes left in the SBe system. A test drive should be performed before the vehicle is delivered . A complete job wi ll provide your customer with al l of the benefits SBe has to offer in safety and car control, and that's a job wel l done . Mercedes-Benz Marchi April 2011 5
  • 6. • • Corne - From the moment a vehicle comes into your damage. The front and rear crumple zones are shop for repair, the clock is ticking. The insurance co ll apsib le structures. They are meant to absorb company has its agenda, the customer wants his the energy of an impact and not pass it on to or her car back, and you have to make them both the occupants. Even if the impact appears light happy. With new insurance and EPA regulations, it enough and one or two corners are written off, seems you don't have a moment's rest from running you must get this vehic le on a lift. Mercedes-Benz you r business, keeping your people employed, and insists on the use of a chassis alignment jig when turning a profit. You must return the car with the frame straightening to assure accuracy. Traditional same crash-worthiness and finish it had before the measurement methods, such as those taken off the accident. This is certainly possible, but nothing centerline of the chassis to various pick-up points, can reduce profits more than having to go back and do something over, or realizing that there is Vehicle Body Information more damage than you'd seen before. To prevent 216 th is from happening, you need to come up with a plan the moment the vehicle comes in for repairs. This is not always easy depending on the damage. Mercedes-Benz veh icles have higher monetary va lue than ordinary cars, and as a consequence are more li ke ly to be repaired instead of tota led, so it's very important that you get it right the first time . Mgd$leel "'300 N/rnm'ttn~511t11cth HI&h·~ ' ttl.lh.lecl"'S5n ~ /mnllensllclluent1h Modem hfJ/>-Rll'1!ithsteel -> l000 H/mm' l.ef$iIe.sDmtth Ulluhl&fHlren~h $tCd, hot ~~ -> ISao N/fIW!I' IffUIk.uenath Step One "''''''''m - Of course, every accident is different, but The first step before performing any repair work is a visit yo u should focus on what is similar about every to www.mbcollisioncenters.com for a look at the vehicle's one. There are accidents where on ly the body is construction materials.This is an essential safety step and contacted, others that include suspension pieces. will let you know when magnesium or ultro-high-strength Either way, you need to check for structural steel is used. Repair procedures will be different as a result. 6 StarTuned
  • 7. Opposite Page: Here we have a front-end hit on a 2002 and repair processes . This information wil l allow 208 chassis eLK. There is the obvious damage to the you to give the adjuster a tru ly accurate account of hood, center support, and front crash box, but what about the time involved. EPC (Electronic Parts Catalog) is underlying damage ?The headlight frame mounting was also an essentia l tool for doing estimates. You can damaged on the passenger's side and may not have been look at the repair parts that Mercedes-Benz makes put on the estimate. available to ma ke sure you're ordering exactly the are simply too crude for "the best engineered cars right things . in the world." In fact , the company doesn't even publish these dimensions. - Also, be prepared to remove fenders so the adjuster can look at possible damage under the surface paneling. Your goal is to put as much Crash Analysis needed work on the origina l estimate and reduce - The use of jig sets prevents any surprises when the cost of any supplements. WIS gives detailed the bodywork is complete, such as finding that repair instructions for the job so you can give wheel alignment can't be accomplished because the adjuster a truly accurate account of the time there isn't enough range of adjustment to make up involved . EPC is also an essential tool for doing for dimensional discrepanc ies. This is especial ly estimates. You can look at the repair parts that true if a wheel, upright spindle, or suspension arm Mercedes-Benz makes avai lable. has been bent. Also, be prepared to remove fenders so the adjuster can look at possible damage under the surface paneling. Using Your Tools - Our example here is a 2002 208 chassis ClK - This prevents any surprises when th e bod ywork that has been in a front-end collision. It appears on is complete, but wheel alignment cannot be the surface that it wil l need a hood, upper radiator accomplished because there is not enough range of support, center support, and a front bumper cover. adjustment. This is especially true if a wheel, upright A deeper inspection, however, showed that the spindle, or suspension arm has been bent. crossmember support, lower radiator support, - Your goal is to not miss any needed work on the original estimate and reduce the cost of any supplements. Use WIS (Workshop Information System, availab le with a paid subscription to www.startekinfo.com ) ~~ to identify any repairs and procedures not included in the estimating guides (and, of course, to fi x the 12~ :~'if~j '~:;J ~ " 4 D rJ ' car right) . It gives detailed ~ . ~. repair instructions for '5 it-e '. r!F,3 . ~5 the job, and tells you the 4 • H . materials involved in the vehicle's construction that Before you start to take the damaged section apart, look at the repair may necessitate the use of instructions at www.startekinfo.com. and the parts information on EPCnet special tools, equipment, (http://epc.startekinfo.com).This will help you generate an accurate estimate. Also, by quickly removing panels, you con look for further damage to the structure. Mercedes-Benz Marchi April 2011 7
  • 8. ANATOMY O F A COLLISION RE P IR A and passenger side headlight stiffening support for work in struction s, you know the materials were all damaged. After reviewing the cost of the you may cut and reform, and you can now begin components and the cost in labor of straighten ing tearing down the crash damage. Following the them, it was agreed with the adjuster that each steps out lined in Startekinfo, you can begin with the damaged component shou ld be replaced in stead front crash box. If there had been frame damage, of being repaired . This saved a sign ificant amo unt you may need to put the veh icle on a CarBench or of labor time and ended up being cost-effective for Celette bench and reposition it. everyone involved . - We rea lize you probably don't get paid for the - If you are a Mercedes-Benz co llision shop, yo ur time spent coming up with an efficient repair plan . next step should be to visit the Mercedes-Benz While in negotiations with the in surance adjuster, Co llision website, www.mbcolissioncenters.com . you shou ld not let him or her dictate how this Here you wil l find specific information, especia lly particular veh icle will be repaired. By investing some about tools and body construction materials. This time and resea rching Mercedes-Benz Startekinfo, is an important safety step. Mercedes-Benz uses EPC and th e co llision website, yo u have armed hybrid construction in many models. This means yourse lf with the specifi c information about what panels may be made of severa l different materia ls. the manufacturer requires to restore this vehicle to its previous cras hworthin ess, fit, and finish. With an accurate assessment of time and money, jobs Hybrid Construction remain profitable and customers are happy. I - Checki ng what materia ls are used is 31 ftotJmo6e" I.e. " 2'lJ836SClK320:0J:320JAl'~:cu:.320 U .,. " 2:05.365 ... 62 FRONT PANEl. .. OOOWtfilHOUSE,FJl.ONT5U!fRA/'E '" critica l before starting any ~ ~. * '1 - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - L-1 repa ir. Mercedes-Benz , nnn." Plllt n.rrb:f - r , uses ultra-high-strength, WHU LHOUSE lEFT high-strength, and r , ~ ~ IGO " ~IOI!~ . mi ld steels, aluminum, r " r A 208620 2261 . WllfiLHOUSE magnesium, and plastics " Rt'"' r 17 A 1296Z600 II •• PlATE to bu ild a vehicle. If you r 20 A 208626 01 16 FRONTI'UaA TOWHEfI.HOlJ5f 104~ decided to cut an inner r 20 A20862602 16 •• REJNfORaMfHT ENGlt.£HOOOHlNGf,RIGHT 00 1 door panel on a 215 r " A2:05620OSn . . STIFfENJHG ,....,.,..., FRONT FEtaA TO lEfT FRONT chassis CL-C lass, for r " A 208620 06 n " STlffEl'llNG FRONT f EMJER T RIGHTFRONT O instance, you need to r J2 A2!l26268B 14 """"""" •• DRAnEr HVllRAU.ICLMTBRAO:!:TT Ol EFT ~A8S/ETSJASA know th at it is made of r 3S AOCIl99CJI ZIO " SCIlfW magnesium . This material Looking at EPC, you con see the many stiffening support brackets in the front crash box that con burns a bright hot white be replaced instead of worked straight. It may be cheaper and foster to replace components and may ignite whi le instead of straightening them, and you get o.E. crashworthiness, too. being cut. The panel is also on ly available as a whole pi ece, so it does not make any sense to work it. In the case of the 208 chassis CLK320, th e body is constructed of mild steel. If you have looked at EPC for parts Even with light hits, using OEM ports like this ML rear bumper cover will reduce labor time. ordering and Startekinfo You will not have to modify the port to make it fit. It comes already primed so all you have to do is prep it for pointing. 8 StarTuned
  • 9.
  • 10. Picking Parts Perfectly @ Mercedes-Benz EPC is a great tool fo r streamlining your work and avoiding errors. And it's free. - A common element of most repa irs is t he need - You probab ly know t hat your loca l Me rcedes-Benz for rep lacement parts. Sin ce t here are so many dea ler has access to a comp rehensive Electronic differe nt pa rts , each one has its own number. Parts Cata log, known as EPCnet, which lists th e Find ing the rig ht number - qui ck ly and acc urate ly - pa rts for eve ry Me rcedes-Benz vehic le since about is of the utmost import ance if you wan t to provid e 1946. Bu t did yo u know t hat you can also acce ss qua lity repairs quick ly. Of co urse, we always thi s pa rts ca t alog - for f ree? recommend (a nd use) Genu ine Mercedes-Benz replacement parts for every j ob sin ce t hey always - To regu lar reade rs of StarTun ed, the STAR fit and perform perfect ly, not to me nti on having a Tek lnfo web site (www.startekinfo.com ) - superb warranty to set your custo mers at ease. But wh ich inc ludes EP Cnet access - isn't anything findin g exactly t he right part ca n sometim es present new. But t here is a sister site, epc.sta rtekinfo. a challenge. com, t hat offe rs free access to EPCnet to an yo ne 10 StarTuned
  • 11. • •• . . . on all eight with www.startekinfo.coffi. Mercedes-Benz USA Dealer Workshop Services is the source for all the technical information needed to support, service, and maintain Mercedes-Benz vehicles. Mercedes-Benz workshops rely on DWS products and services for getting jobs done quickly and more efficiently. Our products include: • STAR TekInfo with WIS-net (Workshop • Maintenance Manuals and Sheets Information System) • STAR Service Manual Library CDs • Electrical Troubleshooting Manuals • WIS and DAS software updates • Installation Instructions • Star Diagnosis System (SDS) • Technical Bulletins • Operator's Manuals and COMAND Manuals • Campaigns • Mercedes-Benz Equipment • Mercedes-Benz Special Tools • Inventory of technical publications STAR TekInfo Dealer Workshop Services Engineering Services, Mercedes-Benz USA, LLC. @ Mercedes-Benz
  • 12. P ICKIN G PARTS P ERFECTLY in the United Sta tes, courtesy of Mercedees-Be nz USA. Although you do have to prov ide a major EPCnet Online _ _ Gellltl StanId AboutSlul Account credit card numbe r, th is is used on ly to verify that You .... !tOt tlilftntly l ogg.d Inf I.£II..!n Mercedes·Benz your mai ling address is within Mercedes-Benz ... Welcom e login USA's assigned territo ry, not to assess charges. Subscribe STAR reklnfo Me Classic Cenle' If you live in another country, contact your sa les Site Map organization to ask about EPCnet access. Welcome to EPCnet Online EPCnet Online is the official Mertedes-8enz USA, LlC sIIe for hoslJng spare parts documentallon for Mercedes-8enz cars and - For most of us, it's often easier to have the light trucks sold In the USA, EPCnet Is a bfowser-based Electronic Parts catalog Which allows dealer look up whatever parts we need. Thi s the user to specify virtually every spare part for the models coversd. Art intuitive graphical user Interface pennlts easy navigation through usua lly works fine for common parts, like oil the extensrve parts catalog. Tutorials are avaIlable at no charge to help familiarize both new and experienced users with !he Mel'Cedes-Senz :spare part.6 groJp system and the selErCtlon or the fi lters and shock absorbers. But have you ever appropriate part for your particular vehicle, A subscription is necessary to USB thls application. Before had the fr ustration of trying to exp lain some sUbscribing, we fjlrongtv recommend thaI yoo review aUof Itse Informa tion under the Getting Started and About Site tabs. arcane or unusua l part you need to someone on Please be advIsed that you need 1 Install the necessary plug-Ins to 0 view the site content, as explaIned on the About Slie I Tech RequIrements pages, th e phone? Spending time trying to get it right is A dBtaffed IIsU of models covered by this Information can be ng found on the About SIt. I Coverage page. t ime better spent ma king money. EPCnet Online is a free ports catalog available to - Instead of faxin g images bac k and fo rth, or anyone within MBUSA's sales territory.Just go to STAR risking delivery of the wrong part, j ust have your Teklnfo's sister site -- http://epc.startekinfo .com -- to Merced es-Benz parts person te ll you which EPC sign up. This is the some catalog used by Authorized image he or she is looking at. With your free EPCnet Mercedes-Benz dealers. Identifkotion nunber fWOB3 11210321C137181 ::::J IWll6EA32EtSCI3746t & I ~' I ~ ~ I f3i I ' u. ~ ~ MDmode ~ 1. Car'" 121032 300 E USA; E 320 USA:32O E / E 32O:E 320 JAPAN ~ 121.032 ~ 16 STEERING ~ 015 STEERING GEAR ~ ~ ~ ~. *~ ---,."~- ~. I ~ 1J 1at 0.-: 60% · 11 ~ -/ j Item ... j Parl number j Des91alion/desaiptJon j Quantity j verslon ~ ! 2 3 1 5 6 7 8 9 10 ~I I 11 816015000015 r J 5 A 121 160 62 01 STEERING BOX ASSEMBL V 001 WITH PITMAN ARM @" 1 16971 PART IS ONLY OR ALSO SUPPLI ""1 .,.,." c:il 71 500 ~6 ~ 13I , ~ ! r 8 N 000960 01 0027 • SCREW d;» 68 1l <!I> 65 • 'OP r Replaced by: N 308676 010017 32~ 137 .ll. 62 • 53 Ohn 38 % r 8 N 308676 010017 • SCREW 001 .g:;:>59a 3~~~ 290 PITMAN ARM TO STEERING BOX ~ ASSEMBlY 44t! r 11 N 913001 01 0010 • NUT r Replaced by: N 910113 010002 125 128t! 4~~ ~~L r 11 N 910113 01 0002 • NUT 001 (i;!i)0 @ Il PITMAN ARM 10 STEERING BOX ~143 119 122 D ~~ ASSEMBlY 5 ~7 r 11 A 121991 32 11 • LOCK 001 ' 04 101 @~3" ,. PITMAN ARM TO STEERING BOX &> <i!>' 1l 1l.1 10 ASSEMBlY ~ diI>'O' e " 3 92~e;,9:lfPJ"6 r 17 A 1219934601 • SPRING CONTROL VAlVE 001 . . <5 @labO 98~(!!fl891l , A 1169970115 001 ~ 20 • SEAL RING ~ ,.. ~ ... . . . ..."'.' '''' I ...... ~~ ) '1...1 ~ : ~ i1iJ I !4 IShopping list t..nsfer file ~ ....) Write protection I ShoppinQ 1st IDate/Time · I No. l oam .. ·lltemno. I Port number IESI IES2 I Des9lotion/description I Quont~y I Qty 0... J 3 11 A 11646601 60 SEAL RING I J of .. T_ory shopplng 1st .. ill December 2010 12/20/10 12:05 PM ill left mirror cover 07/12/10 07:31 AM 2 38 A 003 990 39 10 WASHER I ill WOB2 100s51.ll31 01/05/10 10:11 AM ~ (I I ~ Market: North America C.tolo9: ISV ·As 01 09/69 EPCnet illustrations can be useful in reminding you how certain assemblies fit bock together While the illustrations are not meant to be exact reproductions of the port, they are close enough to provide the details you need. 12 StarTuned
  • 13. subscription, you and your dea ler can litera lly "be Transmissions each have their own parts groups, as on the same page" as you work your way through do some older steering boxes and rear differentials. your parts list. There are several tutorials, including a listing of parts groups and what's in them, under the "Getting - Got some customers who are more technica lly- Started" tab, which is visib le at epc.startekinfo.com incl ined than average? Let them know about the before logging in. free EPC subscription, and they'l l thank you for it. Information like this he lps bu ild customer loya lty - The third step is to find the illustration that and demonstrates that your shop is linked in to shows your part. Most parts groups have several official Mercedes-Benz resources. subgroups, which will help you narrow your search. Just remember that the drawings in EPCnet aren't - In many cases, the EPC illustrations can help meant to be photo-rea listic images of the parts in remind you how certa in assemblies fit back the car. Instead, they are meant to be a genera lized together. Even t hough the ill ustrations are not representation of the part. intended to be exact reproductions of the part, they are general ly very close, as are exp loded views. - The last step is to pick the part and determine the correct part number. Often, on ly one part number - And, of course, sometimes you may just want is shown when you click on the illustration, but in to look up your own parts. With the latest version cases where more t han one number is shown, read of EPCnet avai lab le to you on line, it's easier than the footnotes and codes carefu lly, since these will ever before. The first step, once you've logged tel l you whether the part applies to the car you're in and started EPCnet, is to type in the Vehicle working on, or not. Identification Number (V IN) at the top. By do ing this, you are harnessing the powerful fi lters in EPCnet, - One nice feature of EPCnet is the ability to build which remove from view parts that don't app ly to a "shopp ing list." After you've found the right part the car in question. number, just click the checkbox to add it to the shopping list. Later, you can edit, save and print - The second step is to pick the Parts Group where the list, making order placement that much easier. you think you' ll find the desired item. Engines and You can fax or e-mai l the parts list directly to your • SHOPPING LIST· dealer, not only saving time, but reducing any chances for mistakes. Shopping list: - Temporary shopping lisl- Dale/time: 01112111 10:54 AM Customer name: Created by: - EPCnet is a valuab le Contact Changed by: angelo Order no.: Wor1<shop 1 :: 0 resource you can use to Note: repa ir your customers' veh icles faster and DDmagecode Item no. Port no. ES1 ES2 DeslgnDtion/descriptlon Quanmy Qty on hDnd Price Warranty/goodwill code more efficiently - SPRING 17 A 124 993 46 01 CONTROlVflJ...VE 001 and best of all, it's T7 A 000 990 40 50 NUT 001 free! Check into it at 44 35 A 201 461 00 60 A201 4500186 SE/lJ...RJNG THREADED INSERT 001 001 hlli>.:JLwc.startekinfo.com. _ I 41 A 116466 0160 SE/lJ...RJNG 001 38 A 003990 3940 WASHER 001 If you specify your own ports, you can build a Shopping List like this one. Print it, e-mail it or fox it to your dealer to save time and reduce any chances for errors. Mercedes-Benz Marchi April 2011 13
  • 14. · What's New : Accessories tab added for direct access to the item s that enhance your Mercedes-Benz vehicle . Sourcing Mercedes-Benz Repair and Parts Information · Page with helpful parts information . ... ~ · Links to other informative site s like the Mercedes-Benz Service and Parts ----------------------------------- - --- _. - ~-~~-~ -- SERVICING YOUR VEHICLE ...... -. Keep It Genuine with Mercedes-Benz Service and Parts ~orP9lfot .... IR'.ex~.oty'_• ....:Icutt~ild9f:t~ ..... luotyoU~. PKlfrom~_Befu. 'O •• I"""" drt.otyO'.lr~, ou'«>mrnitlncnt to ,.,..conIlnuol .. M"ooor1d_da.. Men:edcl·Bo>. "noIcoI,p,orU..,.,_ric" .......... · Direct link to the El ectronic Parts Catalog (EPC) c..,.I0!,... "~ .. Icn. T..."ftiN... ~ .• ",~" ,," l~ """oC',,,"'.' .,.. O"<;,,'~ :,~'m~o. "v' ~ ~." t~ .. y " ..... '1 . ,Iv ' ... '-' ,1.'C' to look up parts. .r, ". , ..... t., ~. ~~ .;,-.... , '. p."' Y' " '" Y, · , .... ,,-s · Downloadable Remanufactured Parts Catalog Superior performance, exquisite style, and cutting- and Reman Parts policies. edge technology are what you expect from Mercedes-Benz. · User friendly links to tools such as STAR Tekinfo and WIS. Certified Mercedes-Benz Technicians are required to participate in ongoing training, assuri ng that they · WebParts online ordering information and how-to master the use of state-of-the-art diagnostics, tools, video tutorial. and equ ipment to properly repair Mercedes-Benz veh icles. . Search feature to find archived StarTuned Magazine articles & information. Genuine Mercedes-Benz replacement parts and Please visit us at www.mbwholesaleparts .com accessories insta ll ed by certified technicians preserve the performance and integrity of your vehicle. As well, keeping it genuine with Mercedes-Benz parts wil l help maintain your vehicle ' s residua l value. Accessories Detai Is Show your customer why you recommend Mercedes-Benz OE Parts. & link 10 MBU S A ACClllotlts --- Please visit us at www.mbusa.com / mercedes / service and pa rts / genu ine parts
  • 15. R E • M · • •• - A = • • • N Remanufacturing Process --=":'-0. __ - " 1. Dismantle core 2. Rep lace key 3. Test all 4. Replace and clean all components 100% other critical components that components. with new OE part. components. do not meet Rebuilt Process (Typical ~~~~======~ 1. Identify damaged part or parts. Available through your local Mercedes : - . -- -
  • 16. COMPLIMENTS OF R B M OF ATLANTA, INC. 770-390-0601 Keep it Genuine, and you'll Your Mercedes-Benz customers expect the best without excuses or that's at stake when you use inferior pieces in place of Genuine Merc:e(lles...HelB2 trusts you enough to give you their Mercedes-Benz to work on, there's a Mercedes-Benz when you give it back: Use Genuine Mercedes-Benz Parts. your local Mercedes-Benz Wholesale Parts Dealer or visit us at WWW.11I11... 1I11I1. . . . . UNSURPASSED QUALITY I FACTORY BUILT & TESTED I COMPETITIVE PRICE I PROVEN RELIABILITY I ?~¢J$i'oN~ © 20 10 Mercedes-Benz USA. LLC.