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StarTuned Magazine June 2014


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June Edition of StarTuned Magazine

Published in: Automotive, Sports
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StarTuned Magazine June 2014

  1. 1. Who's Your Partner in Success? Mercedes-Benz's f!)PartsPro You've chosen your career as an ISP (Independent Service Provider) because you enjoy maintaining, diagnosing, and repairing motor vehicles. One of the most challenging pieces of your business is parts procurement. Finding the right parts at the right price and being certain they will arrive when promised can be a challenge. Wouldn't it be nice if there were a way to get the parts you need w ithout the hassle and uncertainty, so you can get back to the important business of actually fixing cars and taking care of your customers? With the Mercedes-Benz PartsPro wholesale certi Fication program, now there is! PartsPro is a rigorous program intended to train Mercedes-Benz dealership parts departments on how to better take care of you and ultimately your customers. PartsPro certified dealers have elevated their commitment to supporting the independent repair channel, and will provide you with the highest level of customer ser vice. They focus on the things that matter most to you! CONVENIENCE...AccuRACY... PROFITABILITY...DELIVERY A PartsPro dealer has the tools in place to better meet the needs of their esteemed wholesale customers. For a dealership to achieve PartsPro Certification, parts department person nel must first undergo intensive "customer-centric" 2 Mercedes-Benz StarTuned training which teaches person nel how to better help YOU. There's far more to PartsPro than just customer-service tra ini ng. The dealership must make specific commitments to provide "Best in Class" service in areas such as logistics, which includes ISP-focused parts availability, regular delivery service, outside sales people to provide you personalized service, as well as a dedicated phone line and "w ill ca ll" pick up area. THEN THERE'S TECHNICAL HELP. On occasion we all need a helping hand. Your PartsPro dealer is there to assist. Whether it means providing, diagnostic assistance, information on supplies or special tools, or anything else you may need to assist you in repairing your customers' Mercedes-Benz vehicles and get them back on the road as fast as possible. Only those dealerships that meet the stringent certification requirements earn the right to display the "PartsPro" logo. Additionally, they receive ongoing consultation and tra in ing to ensure that they are consistently providing the very best support to you, the ISP customer. We hope you are already receiving indust ry leading service from your Mercedes-Benz dealer; however, once PartsPro Certified, we believe you' ll be thri lled w ith the new "Best in Class" parts-procurement experience! Of course, you'll continue to have the peace of mind that installing only Genuine Mercedes-Benz parts can prov ide. I ..
  2. 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 eaoh 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 technical sources combine to make this possible. Feature articles, derived from approved company sources, focus on being useful and interesting. Our digest of technical information can help you solve unanticipated problems quickly and expertly. We want STARTUNED to be both helpful and informative, so please let us know just what kinds offeatures 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 One Mercedes Drive Montvale, New Jersey 07645 Phone: 1201.263.7284 E-mail: STARTUNED is apublication of Mercedes-Benz USA, LLC ("MBUSA"). No part of this magazine may be reproduced without the express written permission of MBUSA. Editorial and Circulation Offices: 1348 River Road, Montague, NJ 07827. CAUTION: Vehicle servicing performed by untrained persons could result in serious injury to those persons or others. Information contained in this magazine isIntended for use by trained, professional auto repairtechnicians ONLY. This informationisprovided to inform these technicians of conditions which may occur in some vehicles or to provide information which could assistthem in proper servicing ofthesevehicles. Property trained technicians have the equipment, tools, safety instru:tions, and know-how to perform repairs correctly and safety. If acondition is described, DO NOT assume that atopic covered in these pages automatically applies toyour vehicle or that your vehicle has that condition. STARTUNED is aregistered trademart of MBUSA. Group Publisher Christopher M. Ayers, Jr. Contributing Editors Bob Chabot Kerry Jonnson Michael Klaas Tom Nash Frank Walker Editorial Director Bob Freudenberger Technical Advisor Tim Amun MBUSA Technical Content Advisor Donald Rotolo MBUSA Project Manager Stefanie Schweigler Art Director &Circulation Mgr. Christopher M. Ayers Ill Visit us at our web site to view this issue and past issues ofStarTuned, along with a wealth of information on Genuine Mercedes-Benz Parts. To locate a Mercedes-Benz dealer near you, go to IN THIS Issue 4 WHY You SHOULD Use ONLY GENUINE MERCEDES-BENZ PARTS There's a lot more substance to this topic than you might think - it's not just marketing hype. The rigorous "Genuine Parts" testing program is especially interesting and relevant to the price/ value relationship. 12 MODERN MOTOR MOUNTS Mercedes-Benz has always been an innovator in the automotive industry, and its powertrain technology shows this clearly. But besides the great leaps in engines that have produced the wonderful performance and efficiency of today, has anybody ever given any thought to how those engines are mounted in the chassis? Yes, indeed, and to a larger extent than you probably suspect. 20 MOST DEFINITELY, FROM D2B The addition of electronics has turned the average vehicle into a technological marvel, but a Mercedes-Benz is no average vehicle. At the cutting edge of technology since its founding, the company has added fiber optics that allow it to process large amounts of digital media. What do we need to know if it stops doing that? 28 BUMPER TECH The safety sensors are embedded in or attached to the bumper and front grille, which makes bumper repair after a collision very different from the procedures of only a decade ago.
  3. 3. Why You Should Use Only Genuine Mercedes-Benz Parts There's a lot more substance to this topic than you might think - it's notjust marketing hype. The rigorous "Genuine Parts" testing program is especially interesting and relevant to the price/value relationship. 4 Mercedes-Benz StarTuned Fuel pumps need to be j ust right, or there's potential for noise.
  4. 4. In the last issue of StarTuned, we talked about why you should use only genuine Mercedes-Benz brake parts from your local dealer in your service work, and we believe the reasons we gave were pretty compelling. We found the subject so interesting and important that we decided to do an additional article to explore the parts situation in Mark Boege, a NewJersey ISP, tells StarTuned that he's always satisfied with Genuine Mercedes-Benz parts. general, and the rationale behind you, the ISP (Independent Service Provider), staying with genuine M-B O.E. components. Much of this has to do with the company's commendable U.S. parts-testing programs. In the previous article, we mentioned how genuine Mercedes-Benz brake parts were the best things to use because they were engineered and tailored for the characteristics of the speci fie model involved, not just generically one-size-fits-all. It turns out that that's the case with most of the parts you buy from your local M-B dealer. OBVIOUSLY, SEEING THE ROAD CLEARLY IS IMPORTANT TO SAFETY Take windshield wipers, for example. With Genuine M-B parts, their cu rve matches that of the w indscreen of each model, so the pressure on the blade/glass interface is optimized. Whi le competing wiper blades are made of poured rubber, Genuine M-B blades are extruded, which gives better performance and a 20%lower wear rate -- they're tested for 1.5M cycles! They also have a helpful wear indicator that changes When sourced from Mercedes-Benz, big assemblies, such as this 7G-TRONIC transmission ... June 2014 5
  5. 5. .. or this remanufactured engine have the industry's strictest quality control, and carry unequalled warranties. They're also often the subject of aggressive price-cutting programs. color when replacement is needed, which amounts to a great sales tool. Installation is far easier and faster, too, without all the confusion of the various attachment parts of aftermarket versions. If you look at it over the course of a year, this can add up to hundreds of dollars worth of labor. Or, how about fi lters? With cabin air filters, the time required for installation also adds up. Genuine Mercedes-Benz cabin filters can be installed more quick ly because they don't have to be modified to make them fit. Sealing is optim ized, as well. The seal is tested for blow-by with special equipment that measures particles in the air. Air filters are tested for 2,000 miles over the same route. The tests have proved that the use 6 Mercedes-Benz StarTuned The cost of replacement engine management computers (PCMs for Powertrain Control Modules, to use SAE's standardized terminology) is another thing on which Mercedes-Benz has instituted money-saving programs.
  6. 6. o... · o t!l t;l p ,_,. *'-'"e '" g • Al)hu 14tl~:l/KJ(•t•l'lo.«:l'!I MercedesBenz ~ w•lcom• l .... Subsalbe STAR tet:Ha •Oassk:Cn• Sit..... EPCnet Online ~ c.a...... Atl!MS- Acco.... y., ....... __...~~Mt '-..11 Welcome to EPCnet Online EPCnftOl*1e IsRM ollcJoll MttctdH-89n: USA,, LLCIde'°' hOSlno spat9parts ooumtnu:ionllOr M1rc ~ts- Btrc car1 and i9N11t(;S 1014 Inh USA. EPCntitsa brown,.DHtOEJtO'Ofl(P.acts:CatatogwNch lilowsIll UHt lO t.HCitrwtlJtnrt:WfYtp.ttf Plrtb'N rnooelt "'"'Id. An RAlllwe gr<lOhle:,IUH f SUrtaoptnn,11 ...., N"t4Qa:.onIW'OUgh N "*"""Patts C"1ak>9 Tutortlls ... av-Matlle <II no chat;t IOMIP fil~ DOlh newand elPM!t nt.0 USl._ Wlf.... Mtrc.U.Btn: lpatf parts group m•m and lht Htecton OftM 1opropn11t oartfOJYoUr patkul11 vthklt At ubsctiptlon ,, ""'"'"'toUH Intl •Pl>fkation Befol• IUbl Ctbing, wt3tronQtrft<QfflD)fDd that yoo 11'Qw111Oflhl Wonm!lonundtt tn.Gtnlng Stl31119d 11dAbot.CSlit tatlt PM-a-stbeac:Msedlhlt)'Ol.lnttd1Dmta1Nnec:1ssary~ lO.....hlSUCon&tt'C. lt ~onh ~ Slt l T ICtl ~ftntfllS p,J2ff ·-The EPC (Electronic Parts Catalog) is sophisticated and comprehensive. You'll always get the right part the first time. It's free, too. Just visit http:/ of genuine air fi lters has a substantial impact on fuel efficiency. Especial ly with diesels, performance also goes down when a non- genuine part is installed. INDEPENDENT TESTING IN THE U.S.A. We've mentioned testing, but the Mercedes- Benz Genuine Parts Testing Program is much more comprehensive and appropriate to our market than you probabl y know. The testing is designed to measure the actual impact the quality of the part has on the customer. In other words, for real-world situations, not for some ivory-tower idea. Testing is done in the U.S., which assures that the findings are really market-appropriate. Not only does Mercedes-Benz sell more vehicles in this country than anywhere else, the U.S. also has special conditions (there's nothing in Europe equal to Death Valley), different fuel blends, bigger engines, and un ique regulations. Th is is true road testing; it's not done on a dynamometer. The location within the U.S. is chosen according to the type of part being tested. For example, testing brake pads in the brutal stop-and-go traffic of Los Angeles is ideal. Both genu ine O.E. and aftermarket linings are installed on vehicles that are cl riven on a predefined route for one month. The driver has a "clicker," which he or she can hit during a braking event that exhibits issues such Ifyou've been in the auto service business for any length of time, you've seen problems with the quality of aftermarket remanufactured alternators. This is never an issue with Genuine Mercedes-Benz parts. as noise or vibration so that the on-board equipment records it. Microphones are used for brake noise, and brake dust is measured with a photometer. Even something as subjective as pedal feel is evaluated. Once again, testing is for impact on the customer. June 2014 7
  7. 7. Who conducts a this disciplined testing? In every case, Mercedes-Benz employs independent laboratories to be sure the resuIts are from an objective third party and are not skewed by brand loyalty. CONVENIENCE, SPEED, AND ACCURACY MBUSA offers a powerfu l tool that can streamline your parts-sourci ng research efforts: The EPC (Electronic Parts Catalog), a comprehensive and easy-to-use parts look- up system. It's a big help and time-saver in searching for exactly the right part, assuring that you'll always get the correct thing the first time (which is often not the case in the aftermarket). This will go a long way toward avoiding the scheduling disasters that can make customers unhappy with you. The download is free -- visit http:/Jepc.startel<i We believe you'll actually enjoy using it. Something that's not often mentioned is the problem you may have finding a specific part for an older model -- Mercedes-Benz owners typically keep their vehicles for a long, long time, so it's likely that you'll often have cars in you bays that almost qualify as vintage, or even classic. You can waste a lot of time and end up frustrated searching for parts for these venerable vehicles from the aftermarket, whereas the EPC covers them in detail, and inventories are scrupulously maintained even for what are sometimes called "heritage automobiles" (they may very well be used as daily drivers). There's more to electronic parts sourcing aids. MBUSA has launched the new Among its useful features are model designation charts and technical information resources that will help you order the right parts and make installations easier. Those electron ic aids combined with the superior quality, competitive pricing, and excellent warranty protection you get when you make the commendable decision to purchase 8 Mercedes-Benz StarTuned genuine Mercedes-Benz parts will contribute to your peace of mind and reputation. PRICE/VALUE Over the years, we've seen various carmakers overcharge for their O.E. parts to an egregious extent, trusting that obedient motorists or shop owners wouldn't question the amount. One example that we especially remember was a sensor for one upscale make that the dealers charged over five times more for than the same Robert Bosch part number could be bought elsewhere. That's not the kind of high-handed pricing policy Mercedes-Benz fol lows. The company does a yearly evaluation to make sure its Genuine Mercedes-Benz replacement batteries are made by the best European manufacturers. Basic aftermarket catalytic converters that barely meet EPA guidelines are notorious for having short lives. This genuine replacement unit will last as long as the original.
  8. 8. ¥:cotr Workshop Resource to Get the Job Done • WIS-net (Workshop Information • Maintenance Sheets System} • Wiring Diagrams • Technical Bulletins • Mercedes-Benz Special Tools • Star Diagnosis System (SDS) • Mercedes-Benz Workshop Equipment @ Mercedes-Benz
  9. 9. prices are competitive. lt's often found that certain parts, fuel filters for instance, are more expensive from aftermarket suppliers. And there's never an issue with quality, fit, or warranty protection when you go genuine. ® Mercedes-Benz Anticorrosion/ Antifreeze AGENT l'tulects ••a tr 'ldl1tor and ~••zing and ra engine from corrosion tar~nda to Merc, 1 381• lhe bolllng polnl. ce Products sh::,~enz Specmcattons p o. 325.0 an Numbef !~1030004 • -..._ Guo.,.3185UTREs ~"'..~ --·--·-- With today's strict guidelines for antifreeze, is there ever a reason to use anything but the exact O.E. formula? It can be difficult to find parts for an older model, such as this Klima relay, from aftermarket sources. Searching for them takes your valuable time when you could simply go genuine and have easy sourcing from Mercedes-Benz. 10 Mercedes-Benz StarTuned As Kerry Jonnson, one of our esteemed technical contri butors to StarTuned, has stated, "In the automotive repair business, our customers rely on us to provide the type of service that allows them worry-free operation of their vehicles. They don't understand how complex these vehicles have become. They just know they need their vehicles to operate in a safe and predictable manner. Here is one buying decision you can make that will help you achieve this goal." That means "partnering" with your local Mercedes-Benz dealer's parts department. We'll conclude with a statement from another Mercedes-Benz expert: "Say you have a customer who's spent lots of money to buy a nice E-Class. Using non-genuine parts wou ld be like replacing a link in a chain with a paper clip. It impacts the entire performance level of the car." I It's not only parts, but also tools and equipment. Where else can you get something like this comprehensive electrical connection kit but from your local Mercedes-Benz dealer?
  10. 10. It seems to be in the genes of Mercedes-Benz engineers to continuously look for any possible way to improve the company's veh icles. Every aspect of those vehicles is thoroughly evaluated and an incredible amount of thought goes into every component, both ex isting and yet to come. Even something as simple as a door handle is studied and improvements are made. Most people don't give much thought to door handles, but Mercedes-Benz has engineered a stronger one so that in the event of an accident you can get a good grip and open the door even if it has been damaged. This may seem like a small improvement, but we're sure first responders appreciate th is simple feature. This is how Mercedes-Benz approaches everything that its vehicles are composed of. Over the years, all ki nds of dramatic technological advancements have been introduced into the automotive industry, and Mercedes-Benz has typically been a leader in th is. Tn recent decades, the world of personal transportation has gone through such rapid evolution that perhaps "revolution" is a more accurate word. As high technology has taken over, service technicians have seen more clearly than ever before the need to keep pace with it. Modern electronics started with fuel injection, ignition, and feedback engine management systems to control emissions and increase fuel economy. The electronics revolution continued with anti-lock brake systems (ABS), then traction control and the Electronic Stability Program (ESP). Mercedes-Benz was one of the fi rst manufacturers that, in conjunction with Robert Bosch A.G., developed CAN (Controller Area Networks). Th is led the way for indiv idual computerized systems to become integrated and work with each other to form systems like ESP. A ll this computerization, of course, adds a certain level of complexity to our jobs when something goes wrong. It's our responsibility as technicians to learn continuously so we can provide competent diagnosis and service to our customers. There are some components, however, that you probably never wouId associate with electronic controls -- motor mounts, for example. PROACTIVE There is a debate in th is country over whether the automotive industry has suffered more from government bureaucracy forcing unnecessary change, or from the market forcing more socially-responsible developments. Regardless, Mercedes-Benz has responded admirably to these challenges. One of its major initiatives has been the development of diesel engines that give luxury vehicles levels of fuel efficiency previously achieved only by sub-compacts, along with astonishing performance and low emissions. Those attributes still
  11. 11. wouldn't sway the American consumer, however, if NVH (Noise, Vibration, Harshness) hadn't been reduced al most to the levels of a gasoline burners. One of the factors in the success of that effort was the invention of an entirely new type of motor mount. Through most of automotive history, motor mounts have been mundane. In early cars, they were simply brackets, bolts, and nuts that held the engine rigidly to the chassis. Of course, that meant that all the vibrations, jerks, and shocks that originated with internal combustion were transferred directly to the unfortunate driver and passengers. It wasn't long before mitigating that motoring unpleasantness became a priority. The first, and longest-running, attempt at accomplishing this reduction in vibration was the adoption of mounts that incorporated rubber isolators to absorb part of the unwanted harshness any reciprocating assembly transmits. Starting in the early 1930s, this idea was reasonably successfu l, if not ideal. Much more could be done to isolate the delicate occupants of a vehicle from internal combustion's basic brutality. So, Mercedes-Benz engineers developed motor mounts that did just that. Most of the company's vehicles currently on the road have hyd rauIic engine mounts that Engine mount design: 1. Flange 7. Hub 2. Seal bellows 8. Retaining ring 3. Diaphragm 9. Cover 4. Check ball 10. Bore 5. Buffer stop 11. Solenoid 6. Protective cap go beyond the simple idea of using rubber's compressibility to reduce roughness -- oiI is the medium used to dampen the vibration a running The two-wire harness is a surefire give-away that this is a computer- controlled mount. It is powered up by fuse F58. Ifyou unplug the fuse and plug it back in with the key on, you should hear the mounts click. 14 Mercedes-Benz StarTuned
  12. 12. ---- ;-_:: ... - ~· ,,._.,,..... "•'• With a paid subscription to you can access wiring diagrams. Here, you can see that components Y123 and Y123/1 are the switchable engine mounts. They're wired together so both mounts get grounded at the same time by the ME. Ml (Fuel pump) M4n (Combustion engine and air conditioning with Integrated control fan motor) M16/6 (Throttle valve actuator) M55 (Intake port shutoff actuator a motor) Ulll R39/1 (Vent line heating element) • R4B (Coolant thermostat heating l!!!I element •!--II Y77/1 (Boost pressure posttloner) YB5 (Exhaust gas recirculation cooler bypass SWltchover valve) Y2719 (Exhaust gas recirculation actuator) Diagnostic glowing Injector shuto!T Status of associated actual value Name Actual value Spacllledl4•• Switchable engine mounts Fault. 53336/6058 I:> Actuate components ·y123 (Len switchable engine mount)' and 'Y123/1 (Right switchable engine mount)'. Terminate actuation. Ifyou have made the investment in Xentry, you have the ability to bi-directionally control outputs. One of these is the switchable engine mounts. June 2014 15
  13. 13. ................,. _ _ _ ~..all ---===:.:::i·•...:::::=======-.=.:::IP- C:...•"'9flll .. CN1 • t"'1• 0lN....l"IC: t• '11:C»,.._ .. t.llr.t • .io:l1ntcl1'fP C,. • Wlf 1 0 - .MM(tl. - J...,M_ - - - engine generates. Somewhat similar to the principle 0 ... . - . ~ c:> o:o: t...- ·]a lil f- ·,;..,:Jc.:i - · - · ,.,.,., -~ • O.- ~1°"**"....,.Jr.,._....,.. ... ENGINE 642 In MODEL 166 of a suspension shock absorber, the oi I is forced through an orifice between two chambers at the top and bottom of the mount as they are compressed and expanded ;11~R!ii!iliim!!i=iliiiil... [ by engine shake. When these fail, it's from a loss of fluid, and typically causes a more sudden These modern motor mounts are still serviced in the same way as a conventional unit with the minor exception that there is an electrical connector to unplug. With your paid subscription to, you can access WIS and get a step-by-step procedure for diagnosing and replacing the new mounts. and pronounced clunking than you'd get from a gradually- dissolving rubber mount. Diagnosis is mostly a matter of observation. ls the bottom chamber flat? Is there oil present? Speaking of the working fluid, whenever you're trying to track down an oil leak, say from a cam or timing chain cover, don't overlook the possibility that the real culprit is a ruptured motor mount. We should also mention that some aftermarket parts suppliers substitute ordinary rubber mounts for the hydrau lic type, wh ich is another reason you should stick with Genuine Mercedes-Benz parts. COMPUTER CONTROL? While hydraulic motor mounts work quite well, they're still passive. They have no ability to adapt to the differi ng cond itions encountered as engine modes change. Since transforming the public perception of the characteristics of diesel-powered cars is turning out to be a lengthy process, Mercedes-Benz has been doing everyth ing possible to reach that goal. Not only with sophisticated common-rail injection 16 Mercedes-Benz StarTuned with multiple events and ingenious after- treatment of the exhaust, but also by givi ng an unsung and overlooked part a fresh look: the lowly motor mount. In order to endow its diesels with a smoothness that rivals that of a gasoline engine, Mercedes-Benz has developed computer-controlled mounts. These new "electric" or "switchable" engine mounts were introduced in 2011 on the Mercedes-Benz M-Class with the 642 diesel (166 Chassis). Instead of hyd raulic oil, they use air contained in three bellows. An internal electrical solenoid valve either connects the air chambers together, offering a large volume of air for the compression and expansion that absorbs vibrations, or closes off the chambers from one another for a firmer mounting (the default position is the "hard" setti ng with the chambers isolated). Two wires run from the harness to the solenoid, one 12V, and the other ground, which is controlled by the ME (Motor Electronics). Even with sophisticated common-rail injection, diesels can be rough during cranking and
  14. 14. '""v oc ~D 30D ,.,, lOD •• ·100 .>OD .J.OD ...,, ·SOD OD O.l o..a o..s G.6 '"' 1D Pko ff'QWW)to;y ww-.octtd'com Here we are looking at the activation of the switchable engine mounts with the Xentry software. Notice how the ME simply grounds the solenoids in the upper trace. The lower trace shows the amperage draw of a single engine mount. starting, and tend to shudder when shut down. So, the ME is programmed to activate the solenoid during these modes, making a relatively-large volume of air available to absorb any harshness. This is ca lled the "soft" setting. The solenoid is either energized or off, there's no in-between. XENTRY AND DMM Although you may not be seeing these mounts for years, you shou Id sti11 know how to diagnose them. If you've invested in Xentry software, you can activate the solenoid at w ill and monitor both the amp draw and the computer's ability to control the ground side of the circu it. You can also use your DMM (Digital Multi-Meter) to check the resistance of the solenoid and look for an open windi ng. You should read about 27 ohms with a good solenoid. The power feed is fuse F58. This fuse also supplies the diesel fuel injection system solenoids, the pressure regulating valve, and the quantity control valve. So, a short circuit or any other fai lure that causes the fuse to blow wi ll cause a no-start cond ition, and the mounts wi ll default to "hard," which won't be noticed with the engine stopped. These mounts may be incorporated into other models in the future, so be sure to check the w iring diagrams for the car at hand by visiting StarTek Removal and replacement is basically the same as with any other engine mount. There are two fasteners that hold it to the engine sub-frame, and a single fastener to the engine mounting bracket. The only additional step is unplugging the electrica l connector. As we said earlier, with modern technology being applied to more and more aspects of automobiles, it is your responsibility as an ISP (Independent Ser vice Provider) to keep pace with these changes and continue your education. This allows you to keep giving your customers what they expect from you. It's also in your own best financial interests. I June 2014 17
  15. 15. er ormance. uccess.With our competitively priced Genuine Remanufactured Parts, you no longer have to settle for anything less than Mercedes-Benz quality. But that's just part of the story. You see, our airmatic struts, catalytic convertors, turbochargers and steering racks all carry a 12-month, no mileage-restriction warranty. So our parts are not only a great deal. They're agreat value. And since they're genuine Mercedes-Benz, you can have confidence they'll last, and so will your relationship with your customers. Contact an authorized Mercedes-Benz dealer or learn more at . . __.r..jY .-;. t_,"" ~W. . / ~. .·'. ~'"'' ' , -..- "'*."·i' '• . ;-i· 1111~ ,I ~l '•Y , I , . Oi .~, 0 .1 , I I ';. ~ ' ..' JI • ' · '' A 000 230 7011 80 @-- ft One remanufactured engine pulls the plug on climate-damaging ~I C02 and saves 447 days of power for one laptop. A 163 '490 971'4 80 @- •MSRP excludes state and local taxes and freight if applicable. Price excludes core deposit. Price valid as of February 2014. Prices may vary by dealer. See your authorized Mercedcs·Benz dealer for additional details or a copy of the Mercedes-Benz parts limited warranty.
  16. 16. A 164 460 0300 80 Mercedes-Benz
  17. 17. MOST Definitely, from D2B The addition ofelectronics has turned the average vehicle into a technological marvel, but a Mercedes-Benz is no average vehicle. At the cutting edge oftechnology since its founding, the company has added fiber optics that allow it to process large amounts ofdigital media. What do we need to know ifit stops doing that? One of the first steps in diagnosing a problem with the MOST bus system is to establish communication with the MOST master control unit. In this case, it is the COMAND®radio. Verify communication first. If you do not have communications, check the fuses, power, and ground to the control unit. If you have communication, you can move on to the next step. 20 Mercedes-Benz StarTuned
  18. 18. We've all seen electronics take hold of our industry. It started with electronic ignition (mandated in 1975), then fuel injection, and now seemingly every component on the car is either controlled or monitored by electronics. This generally makes systems more complicated. There are sensor inputs, a processor, and computer- controlled outputs. While this added complexity can make your life more difficult when something breaks, it can also make it easier. SDS XENTRY software is designed to interpret the data of the processors and can retrieve diagnostic trouble codes, give you real-time data, and also allow you to bi-directionally control computer outputs so you can find out if the components receiving commands are actually working. Having this in formation allows you to quickly look at data you may find useful in diagnosing the problem. Once you isolate where the trouble is, you can then do more specific electrical testing to verify your conclusions. You'd feel pretty silly if you spent hours doing high-tech diagnosis only to find out that an electrical connector was not plugged in properly. GETTING THE MOST Nowhere is this technology more evident than in the entertainment system. These have different needs from body control or powertrain systems. Powertrain systems need high-speed data transfer because traction control, engine management, and suspension features need to work together to keep the car under control during spirited drivi ng. Body control systems ca n operate at a much slower speed and the vehicle's occupants won't notice the difference. Entertainment systems do not need high speed, but there is a whole lot of in formation that needs to be moved around --visual and audio media files are large. This in formation must be sent from the digital media reader (CD/ DVD player), the display screen, and the sound system. If these systems transferred information across electrica l lines the w iring involved would have to be very complex. For this and other reasons, Mercedes-Benz has chosen to use fiber optics for transferring digital media. Fiber-optic systems offer many advantages over conventional electrica l wiring. Number With a paid subscription to, you can pull up a chassis-specific wiring diagram. You can compare the wiring to the MOST bus list of control modules and locate each component. Notice that the Orange lines are wired in series. This is the fiber-optic line. The purple wire is the electrical "Star" wiring electrical bus the MOST master uses to see which control units are waking up and which are not.
  19. 19. one, they are capable of carrying large amounts of data very quickly. Number two, fiber-optic systems send Iight messages along a cable, so they're not subject to magnetic interference, or RF!. They do require a discrete fiber-optic line routed with the wiring harness, which does acid a level of complexity. Fiber-optic cable is fairly sturdy, however, and is not subject to corrosion from water intrusion as electrical wiring is. The main rule for routing fiber-optic cable is simply not to bend it enough to crimp it. Usually, you don't have to worry about the cable unless accident damage has compromised it. In that event, replace it. MASTER Mercedes-Benz started its adoption of fiber- optics with the D2B (Domestic Digital Bus) system, which was developed exclusively by the company. The network is routed in series -- there is one fiber-optic cable coming in and another coming out. In order for this system to work, "someone" has to be in charge, so every D2B system has a "master." This is the one control unit that is in charge of all the others. Th is is important to know because th is is the control unit you are talking to when you communicate with it using the XENTRY diagnostic software. Since the fiber-optic network is routed in series, it is important for the coding of the master control un it to not only k now all of the components on the fiber-optic ring, but also the order in which they are connected. Not every D2B system is the same --someone may have ordered a car with or without a multiple-disc CD changer, for example. Another thing that's important to know about a series-wound fiber-optic system is that if one component fails it can bring down the whole system. Nothing will work. You may th ink it would be a big undertaking to diagnose a whole system that is not working, but it is really not that di fficuIt. The First th ing you need to establish is communication with the master 22 Mercedes-Benz StarTuned Locate the first component on the fiber-optic bus and unplug the connection to that unit. When you turn on the ignition key, you should see one of the cables light up with the fiber-optic signal as shown here. Plug it back in and move on to the next control unit untily ou no longer see the cable light up. This means either the cable is bad, or the control unit before it is not putting out a fiber- optic signal.
  20. 20. control unit. In the case of the D2B system, the master is the COMAND® control unit -- the interface mounted in the center of the dash. Use your XENTRY software, or equiva lent, to try to establish communication w ith the master. If you do have communication, then you can assess live data about the other control units on the 028, pu11diagnostic trouble codes that may lead you to the problem, or "ping" the control units on the D2B bus and see what answers back. STARTING POINT If you do not have commun ication w ith the master COMAND® un it, that's the first thing you must fix. Start with check ing power, ground, and the wake-up signal to the control unit. Remember, if the master is not functioning then nothing else will, either. The first thing you should check are the fuses that power up the master COMAND® unit. If the fuses have power, the next step would be to pull the COMAND® unit out and veri fy the power and ground supply to it -- check for damaged or corroded wiring. lf you have power and ground, then you may want to put a lab scope on the CA lines to the COMAND® unit and verify that the scan tool communication signal is making it to the module. If everything is there, then you may simply have a bad COMAND® unit. Mercedes-Benz offers remanu factu red units through you r Mercedes-Benz dealer's pa rts department. If you have commun ication with the COMA ND® unit, then the diagnosis is even easier. If the system is down, it has probably set a diagnostic trouble code in the COMAND® unit. This will probably lead you to the trouble, but even if it doesn't there is testing you can perform to isolate the problem. From the master COMAND® unit, you ca n cal l up the coding for the unit and you w ill k now what options are installed in the vehicle you are work ing on. This is a big help in diagnosing the fiber-optic system. What you ca n do at this point is access the first control unit the fiber-optic signal is sent to and unplug the cable from that control unit. Turn the ignition l<ey on and observe the Ifyou purchase a fiber-optic loop, you can bypass a possibly bad control unit. If the system starts to work, you'll know the control unit is the problem. Before replacing the control unit, verify that it has the proper power supply feed, ground, and wake-up signal. June 2014 23
  21. 21. cable plug. You should see one of the cables blinking. This is the optical wake-up signal from the master. THE NEXT STEP If you see the blinking light, you know the master is putting out the optical wake-up signal. You can then plug the connector back in and move on to the next control unit on the fiber-optic bus. Unplug that connector, turn the ignition key back on, and watch for the same bl inks. Keep moving on through the next control units until you no longer observe the blinking. Remember, the Fiber-optic network is in series. So, the control unit that you just unplugged is not the one you're testing. You're looking for the output signal from the control unit before it's on the bus. If you no longer see the wake-up call, it is either not coming out of the control unit before it's in the network, or the cable has a break in it. You can purchase a special fiber-optic loop tool, which is sort of like a jumper wire. You can plug it into the fiber-optic connector of each control unit the fiber-optic network with an electrical wake-up line. This signal is generated by the master control unit, but it is conventionally wired in parallel. The wake-up signal is sent and each control unit answers on this wake- up line. The control unit that does not respond has failed. This is how the master control unit senses the system failure and sets diagnostic trouble codes. Veri fy power and ground and you have diagnosed the problem. EVOLUTION, NOT REVOLUTION The only real difference between the D2B bus and the next evolutionary stage, the MOST (Media Oriented System Transport), is the communication protocol. The diagnosis is exactly the same. Use XENTRY to compare the electrical wake-up signal and compare it to the fiber-optic network. The two special tools for the D2B and MOST system are inexpensive and available from your local Mercedes-Benz dealer's part department -- remember, they're happy to help. I on the network. If you turn the key on and the system starts to work, then the control unit you just bypassed is . Transport Screvv Rernova l Advice the problem. This does not mean the control unit is necessaril y bad. You sti 11 need to verify power, grounds, and the wake-up signal at that control unit, starting with the fuses that power it up. Mercedes-Benz has made diagnosis even easier by backing up 24 Mercedes-Benz StarTuned !I! B o fo r o rns tollin g C O C h o n g o r II! rm mg Scr<rw., *"tt 11u1t11llud to pro1ec1Iha co chunoof trorn dttmaon Ing •h•pptng bul m1111l bo ,omovC-'d for thd .mll· vlbrutloo m ochoniflm V n c:I 101) PfOp&rt)' t I • J 0 ,..., ,_.IU•• U. J ._IWfJ1«'g UC••,..~jl lJUn• 1) tANINO: r.,...,. l.J IWftO w.. ti• M'JIPOl'lV Sc-ntw• ....i ••wll In w.1.~u.lve &.t..lf.plJlV •Id n~r '"""'" Ul P.•MM•lt &Ulll-U- to ltMI &..Mr :tSMm bl>r' A'J1 ~ • "'11 II K,_'1111 UU, ~M ._tl¥11 lrlWfl n lho 1Jo 1J1;e unrt 11 li<;h t11 ti-"1 r1 tur1..U RNING: e.. •""' tu .nu... .it1 tN" tct.wt. ,.. t;t,,. bot1urnvf "*"h"•..• ,~..ftilld f ..._. to In•..... AU. 3 su.... na.y ~ INkkOUnllf Ind ~· ~lO th• unit The MOST bus is programmable with XENTRY software. Remember, ifyou want to add a component to the MOST bus you need to go into the MOST master and change the coding for the new configuration. You must get the order right in the fiber-optic loop for stable MOST bus operation.
  22. 22. Mercedes-Benz Mobil 1 Product Name Part Number Quantity Product Description Recommended Consumer Applications MercedeirBenz SPEC. BQ 1090144 Bulk - No Equipment Mobil 1 BQ 1090162 6/1 Quart Cases Fully synthetic formulas designed Low SPAsh. Available at most MB dealers Formula M 5W-40 specifically for gasoline passenger cars BQ 1090151 55 Gallon Drum Genuine A0009898301USB6 12x1 Quart Cases · Mercedes-Benz Oil Fully Synthetic formula specifically . . MB 229.5 A0009898301USBB 55 Gallon Drum designed for Mercedes-Benz engines Engines that require Specification that require the 229.5 Specification 229·5 Specification Oil SAE 5W-40 A0009898301 USB9 Bulk - No Equipment BQ 1090010 Bulk - No Equipment Fully synthetic formulation designed Porsche A40. Many European vehicles. Mobil 1 OW-40 BQ 1 09 0015 6/1 Quart Cases to meet the requirements of many European vehicles HT/TS applications. BQ 1090016 55 Gallon Drum Mobil 1 ESP BQ 1090135 Bulk - No Equipment Formula M 5W-40 Advanced full synthetic formulas designed specifically for diesel Low SPAsh. Available at most MB dealers BO 1 09 0142 6/1 Quart Cases passenger cars that have particulate BQ 1 09 0143 55 Gallon Drum filters Higher viscosity, advanced full synthetic BQ 109 0134 6/1 Quart Cases formula designed for performance Porsche A40. HT/HS applications. vehicles Extra high performance automatic Recommended tor use in Mercedes-Benz BO 1 09 0166 55 Gallon Drum transmission fluid formulated with selected HVI base oils automatic gearboxes Advanced full synthetic formulas Low SPAsh. Available at most BQ 109 0165 12x1 Liter Cases designed specifically for passenger car MB dealers. diesels that have particulate filters 1 AdBlue• 1/2 Gal. A 000 583 0107 1/2 Gallon Bottle Non-toxic solution that transforms Recommended for use in Mercedes- harmful Nitrogen Oxide (NOx) emissions Diesel Exhaust Fluid BQ 1470002 55 Gallon Drum from diesel-powered vehicles into Benz, Volkswagen + BMW AdBlue• (DEF) 55 Gal harmless water vapor and nitrogen applications BQ 1090017 6/1 Quart Cases Advanced full synthetic formulation designed to meet the requirements Vehicles that require 5W-30. Corvette BQ 1090018 55 Gallon Drum of many domestic, including GM, and approved. im orted vehicles BQ 1 09 0019 6/1 Quart Cases Mobil 1 lOW-30 BQ 1090020 16 Gallon Keg Advanced full synthetic formula designed for domestics and imports Vehicles that require 5W-30 or lOW-30 BQ 1090021 55 Gallon Drum BQ 1090083 6/1 Quart Cases vance u synt et1c ormu at1on Mobil 1 5W-20 designed to meet the requirements of Vehicles that require 5W-20 BQ 1090084 55 Gallon Drum many newer vehicles including Hondas, Eords Cbr>!slers aad aewer Iaimtas BO 109 0169 6/1 Quart Cases Advanced full synthetic formulation Most vehicles that specify OW-20 (newer Mobil 1OW-20 AFE designed for enhanced fuel economy Toyotas and Hondas), 5W-20 and certain BQ 109 0168 55 Gallon Drum and cold weather performance hybrids Mobil 1 OW-30 AFE BQ 1090174 6I1 Quart Cases Advanced full synthetic formulation Most vehicles that specify 5W-30 ordesigned for enhanced fuel economy and cold weather performance lOW-30 BQ 1090164 6/1 Quart Cases Multi-vehicle, fully synthetic fluid Vehicles that require Dexron Ill, Ford Mobil 1 Synthetic ATF designed to meet the demanding BQ 1090163 requirements of modern passenger Mercon and Mercon V performance 55 Gallon Drum vehicles levels Mobil 1 15W-50 BQ 1090023 55 Gallon Drum Boosted, higher viscosity, advanced HT/HS applications. Racing and Flatfull synthetic formula designed for performance vehicles tappet applications Mobil 1Gear Oil Exceeds the most severe service SUITABLE for use in modern high (Mobil 1 Gear Lube BO 1 09 0085 12/1 Quart Cases requirements in both conventional and performance automobiles like SUV's, 75W-90) limited slip applications Vans and Light duty trucks requiring API GL-5 level performance
  23. 23. M ercedes-Benz automobiles are designed to perform on the most challenging roads and conditions. Shouldn't the oil used in Mercedes-Benz engines do the same? We think so. That's why Mercedes-Benz and Mobil 1 have partnered to offer an unbeatable combination of total engine performance and driving luxury. Please have a look at our oil portfolio which is available through your local Mercedes-Benz dealer. Our dealers are able to offer you a wide variety of oil grades at competitive prices. Product Name Part Number Quantit Product Descri tlon Mercedes·Benz SPEC. Mobil 1 Gear Oil Exceeds the most severe service (Mobil 1 Gear Lube BO 109 0085 12/1 Quart Cases requirements in both conventional and 75W-90) limited slip applications BO 1 09 002464 Bulk - No Equipment Formulated from quality base stocks BO 1090171 12/1 Quart Cases combined with modern performance Mobil Special 5W-30 additives to give the engine the expected BO 1 09 003064 55 Gallon Drum protection and performance under a wide variety of operating conditions BO l 09 003164 Bulk - No Equipment Formulated from quality base stocks BO 1090172 12/1 Quart Cases combined with modern performance Mobil Special lOW-30 additives to give the engine the expected BO 1 09 003764 55 Gallon Drum protection and performance under a wide variety of operating conditions BO 1 09 003864 Bulk - No Equipment Formulated from quality base stocks BO 1090173 12/1 Quart Cases combined with modern performance Mobil Special lOW-40 additives to give the engine the expected BO 109 004464 55 Gallon Drum protection and performance under a wide variety of operating conditions BO 1 09 012464 Bulk - No Equipment Formulated from quality base stocks BO 1090170 12/1 Quart Cases combined with modern performance Mobil Special 5W-20 additives to give the engine the expected BO 109 013264 55 Gallon Drum protection and performance under a wide variety of operating conditions Formulated from quality base stocks combined with modern performance Mobil Special 20W-50 BO 1 09 004664 55 Gallon Drum additives to give the engine the expected protection and performance under a wide variety of operating conditions BO 1090053 Bulk - No Equipment Extra high performance diesel engine BO 1 09 0058 12/1 Quart Cases oils that help extend engine life in Mobil Oelvac 1300 the most severe on and off-highway Super 15W40 BO l 09 0059 4/ l Gallon Cases applications while delivering outstanding performance in modern, high-output, BO 1090060 55 Gallon Drum low-emission engines including those with Exhaust Gas Recirculation (EGR) Mobil Delvac 1300 and Aftertreatment Systems with Diesel Super 10W30 BO 1090086 Bulk - No Equipment Particulate Filters (DPFs) and Diesel Oxidation Catalysts (OOCs) BO 1 09 0051 4/ 1 Gallon Cases Fully synthetic supreme performance heavy duty diesel engine oil that helps Mobil Delvac l 5W40 extend engine life while providing long BO 1090052 55 Gallon Orum drain capability and fuel economy for modern diesel engines operating in severe applications BO 1 09 0078 60/14 oz Cartridge BO 1090079 120 lb Keg Formulated to provide excellent high Mobil Grease temperature performance with superb XHP 222 BO 1090080 400 lb Drum adhesion, structural stability and resistance to water contamination BO 1090098 40/14 oz Cartridge BO 1090096 120 lb Keg Extra high performance. automotive Mobil Lube HD lubricant formulated from select base Plus BOW90 BO 1 09 0097 400 lb Orum oils and an advanced additive system specifically for limited-slip differentials Recommended Consumer Applications SUITABLE for use in modern high performance automobiles like SUV's, Vans and light duty trucks requiring API GL-5 level performance Recommended for gasoline fueled automobiles and light duty trucks requiring an API SN/SM/SL/SJ Recommended for gasoline fueled automobiles and light duty trucks requiring an API SN/SM/SL/SJ Recommended for gasoline fueled automobiles and light duty trucks where a higher viscosity API SN/SMSL/SJ oil is preferred or recommended Recommended for gasoline fueled automobiles and light duty trucks requiring an API SN/SM/SL/SJ Recommended for gasoline fueled automobiles and light duty trucks where a higher viscosity API SN/SMSL/SJ oil is preferred or recommended Specifically recommended for the latest low-emissions, high performance diesel applications equipped with aftertreatment systems using Diesel Particulate Filter (DPF) and Diesel Oxidation Catalyst (DOC) technologies Recommended for use in all super high performance diesel applications, including modern low emission engine designs with Exhaust Gas Recirculation (EGR) Recommended for industrial and marine applications, chassis components and farm equipment Recommended for use in limited-slip differentials, axles, and final drives requiring APl GL-5 level performance
  24. 24. Bumper Tech Mercedes-Benz Safety Systems Help Avoid Accidents and Significantly Change Bumper Repair Mercedes-Benz safety technologyfeatures state-ofthe-art sensors that constantly monitor the position ofthe vehicle relative to other vehicles and obstacles. Software analyzes sensor data and, ifnecessary, sends commands to various safety systems to alert the driver to a potential problem. If the driver does not respond quickly, the system can pre-pressurize the brake master cylinder, reduce speed, or stop the vehicle, apply the brakes in a manner that prevents an unsafe lane change, or backing into an already- occupied space, and adjust seat belts, seat position, head rests, and other supplemental restraint components in preparation for a possible collision. All ofthis is made possible by short- and long- range radar and other sensor technologies. The safety sensors are embedded in or attached to the bumper and front grille, which makes bumper repair after a collision very different from the procedures ofonly a decade ago. There are six Parktronic sensors in the front bumper of this 2010 GL 450. The small round sensor heads blend beautifully into the bumper, and enable several different safety functions, including adaptive cruise control, lane departure warning, and other collision avoidance systems. 28 Mercedes-Benz StarTuned
  25. 25. Mercedes-Benz safety technology features state-of-the-art sensors that constantl y monitor the position of the vehicle relative to other vehicles and obstacles. Software analyzes sensor data and, if necessary, sends commands to various safety systems to alert the driver to a potential problem. If the driver does not respond quick ly, the system can pre-pressu ri ze the brake master cylinder, reduce speed, or stop the vehicle, apply the brakes in a man ner that prevents an unsafe lane change, or backing into an already-occupied space, and adjust seat belts, seat position, head rests, and other supplemental restraint components in preparation for a possible collision. A ll of this is made possible by short- and long-range radar and other sensor technologies. The safety sensors are embedded in or attached to the bumper and front grille, which makes bumper repair after a collision very different from the procedures of only a decade ago. Automotive safety strategies have historica lly been passive in nature. Seatbelts, ai rbags, bumpers, and other devices sought simpl y to reduce the impact of a collision on the vehicle and its passengers. Over the past 15 years or so, however, new safety technologies have been developed that emphasize accident avoidance, and in more active ways than could be imagined only a few decades ago. Much of th is new safety technology features high-tech sensors that see th rough the Mercedes-Benz front and rear bumpers, so bumper repair is no longer a simple straighten, patch, and re-paint job. For example, ordinary cruise control keeps driving speed at a pre-set pace, but Adaptive Cruise Control helps maintain the desired distance between the vehicle and the one immediately ahead. This function is enabled by the Mercedes-Benz Distronic Plus system. Distronic Plus features a combi nation of short-range radar sensors beh ind the bumper cover and a long-range sensor in the front griIle. These sensors together measure the distance between vehicles, and allow the electronic logic to determine whether or not that gap is decreasing. The software assesses how quickly the gap is decreasing and determines how much braking power is needed to restore the gap to the preferred length. The system then progressively applies the brakes to slow the vehicle and restore the gap to the desired distance. There are four Parktronic sensors in the rear bumper of this 2010 GL 450. Parktronic sensors in the rear help with lane departure warning and Parking Assist functions. There are similar sensors in the front bumper on many Mercedes-Benz models.
  26. 26. A vehicle traveling at 50 k mh (31 mph) covers 20 m (65 ft.) in two seconds. Adaptive Cru ise Control alerts the driver to a dangerous situation via flashing lights in the dash or Head- Up Display, but does not wait for him or her to take action. Mercedes-Benz Distronic Plus radar technology is never vu lnerable to the things that sometimes distract humans from the road ahead, and it responds faster and w ith more precise application of braking force than any driver could, no matter how skilled. Mercedes-Benz Pre-Safe Brake is another example of active safety strategy. Pre-Safe Brake sensors scan the road ahead for potential problems. If they detect a vehicle ahead slowing, stopped, or crossing its path, or "see" pedestrians or other obstacle, the system alerts the driver. Pre-Safe Brake simultaneously initiates up to 40%of the available braking power. When the driver brakes, the appropriate amount of braking pressure is instantly applied, all the way up to 100% if the driver so chooses. And should the driver fail to respond, the system will apply full braking on its own, to help avoid or reduce the intensity of a collision. Independent studies show that this pre- charging of the brakes shaves enough off of the driver's reaction ti me to effectively increase the occupant survival rate in an accident by 10 to 15%. This ability to take control of vehicle brak ing is only part of the Mercedes-Benz active safety strategy. Pre-Safe also adjusts vehicle restraint systems withi n milliseconds, to prepare for a potential accident. Tt tightens the front seat belts, adjusts the front head restrai nts and passenger seat, and, if the vehicle is equ ipped with the Mercedes-Benz Memory System, can even close the windows and sun roof. HIGH-TECH BUMPER CARE Suppose a customer comes in with the complaint that after a minor front collision, the Adaptive Cruise Control no longer works. You'll need to add to your traditional coll ision-repair knowledge in order to help this motorist. Mounted in the front bumper cover on vehicles eq uipped with the Parktronic system are six ultrasonic sensors. They can not Collision avoidance sensors sit behind plastic grille covers in each side of the front bumper of this 2014 ML 350. 30 Mercedes-Benz StarTuned
  27. 27. > be repaired. If one has been impacted in a collision, it must be replaced. Even if only a few scratches penetrate the paint and dig into the sensor surface, complete replacement of the sensor is required. If the repair involved replacement of the Distronic (DTR) control un it, the sensors that monitor rotationa l speed, yaw rate, and lateral acceleration, or of the steering column tube module, the DTR control unit must be initialized and recalibrated. Another possible cause of problems with the short-range radar sensors is the sealing ring where the sensor seats into the bumper. The sensors and con nectors are designed to be waterproof, and to resist a high degree of vibration and shock. If the sealing ring is damaged, it may allow vibration or moisture to overwhelm the sensor. A damaged seali ng ring should be replaced. PAINTING BUMPERS Have you had a customer bring in a vehicle with the complaint that after another shop repaired a bumper, the backup assist, lane departure warning, or other collision avoidance system no longer works? It could be the paint job. When painting the bumpers, it is important to ensure that the paint coat on the short-range radar sensors is of only minimal thickness. Too thick a coat can lead to malfunctions because the sensors see it as an obstacle in the vehicle's path, rather than as merely excessive paint thickness. The system will respond by either keeping the warning lights or beepers constantly on, or shutting down completely after a certain amount of time to prevent full-time appl ication of the brakes and activation of key elements of the supplemental restraint system. The maximum paint thickness allowed at the sensors is the primer and two coats of paint (color and clear). Primer, color, and clear together count as one refinish, but the painter MUST be mind fu I of keeping each coat as minimal as possible. We shou Id mention that pre-painted sensors are available for certain popular colors. When it detects an obstacle (like the two-by-four stud we placed in front of this vehicle), the Parktronic system begins flashing red lights in two places on the dashboard. June 2014 31
  28. 28. The scuffing over the Parktronic sensor in the rear bumper of this 2010 GL 450 is enough to require sensor replacement. PLASTIC: REPAIR OR REPLACE? Damage to bumper covers and protective bumper strips in the form of cracks, holes, and scuff marks deeper than one millimeter can be fi xed using the Teroson plastics repair k it (see the approved materials Iist at http://portal.aftersales.i.daim! in the paint technology guidelines section). The Teroson kit includes a cleaner that removes dirt, grease, and other contam inants, a primer that prepares the surface for fi ller, a two- part adhesive filler, and a glass fiber mesh. The filler hardens in 15 minutes under an infrared lamp. The fiber mesh rei nforces the adhesive to help resist repair failure due to expansion and contraction of the plastic over ti me. With six sensors in the front and four in the rear bumper, it is easy for filler that is feathered out from the damaged spot to overlap one or more sensors. The addition of primer, basecoat, and clearcoat can then quickly build up to levels in excess of paint thickness maximums, renderi ng the affected sensors inoperable. If the damaged area is close enough so that the fi ller would overlap the sensor, replace rather than repair the bumper. 32 Mercedes-Benz StarTuned Mercedes-Benz short-range ultrasonic Parktronic sensors insert directly into the back of the plastic bumper, and include a seal that helps them resist road-induced vibration and shock.
  29. 29. BUMPER BASICS A MJrcedes-Benz bumper consists of three or four basic components: a decorative plastic bumper cover, a foam impact absorber bar, a steel or aluminum reinforcement bar, and, depending on the vehicle model, outer protective strips. The foam impact absorber bar is located between the decorative cover and the metal reinforcement. Its purpose is to compress and absorb some of the damage in a low-impact col lision. Be careful when handling the foam inserts, as they snap easily. The metal reinforcement bar attaches to the front crossmember and is designed to absorb some of the energy of a low-impact collision. In a two or three mile per hour "parking lot" incident, the damage to the vehicle may be limited to the bumper cover, impact absorber, and reinforcement bar. The Mercedes-Benz reinforcement bar is a si ngle-use component, and cannot be repaired. If it has been damaged, it must be replaced. Some models feature outer protective strips. A lthough primarily decorative, t hey are sacrificial plastic pieces. They are inexpensive and snap on using clips, so they are easil y replaceable i n the event of mi nor impact or scratch damage. BOLT-ON MODULES Front and rear modu Jes absorb and deflect some of the impact energy of a col Iision away from valuable mechan ical components. The modules bolt on to the upper and lower longitudinal members (frame rai ls). The bolt-on design helps reduce repair ti me and cost ver sus a welded fu 11 frame. An aluminum reinforcement bar is built onto the crossmember of the front module. A foam impact absorber sits between the decorative bumper cover and the reinforcement bar. June 2014 33
  30. 30. ADDITIONAL CONNECTORS IN MERCEDES-BENZ FRONT BUMPERS • Washer Fluid Reservoir - On vehicles with a Headlamp Washer System, you must detach the electrical and fluid hose connections from the windshield washer fluid level indicator switch and pump, and remove the Washer Fluid Reservoir in order to access and replace the front bumper. • The Outside Temperature Sensor - clips to the front bumper, and must be disconnected in order to remove the bumper. THE FEW, THE PROUD, THE KNOWLEDGEABLE These new safety features are based on cutting-edge sensor technology and are now being seen for the first time by many coll ision repair technicians. Dig into your Mercedes-Benz train ing information and learn how the systems work. You'll find that knowing where a sensor is located, how it must be positioned to "see" so it can accurately esti mate the vehicle's position relative to nearby objects, and how your repair prep and painting procedures must adjust to avoid interference with sensor operation will make you an in-demand expert in your market. I The Mercedes-Benz front module bolts onto the upper and lower frame rails. In a low impact (up to eight mph) accident, the front module may absorb all of the collision energy as it crumples, leaving the frame rails undamaged. In that scenario, repair involves simply bolting on a new front module. 34 Mercedes-Benz StarTuned
  31. 31. Parts Overview 0*""'9< how Genuine, ClaSSiC and R.manufactured Merooda.&lnz Parts""'.art-· Sourcing Mercedes-Benz Repair and Parts Information Parts Ordering Find outhow to on:ter from '(OIJI local dealersrup "' ont1ne With WebP11t1S. Technical Information Get ac<»oa to STAR Teklnlo l'or an '(OIJI MMc:e and repa.r needs. PartsPro Learn all about Ille t>oneftts ol Otdenng from a awt.n.d PartsPro dealeflllp Model Indicator Index provides the ability to find chassis, model year and engine detail from the VIN which assures proper catalog identification of the vehicle when using the EPC. STARTUNED magazine section with archive search functionality and downloadable articles Enjoy easy access to technical information and resources. At STAR Teklnfo you'll find all the technical documentation you need on servicing and repairing Mercedes-Benz vehicles. @ Mercedes-Benz
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