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Replacement Of Secondary Air Injection Relay Module (94-0431)

Publication date: 1994-04-01
Reference number: 94-0431

REPLACEMENT OF SECONDARY AIR INJECTION RELAY MODULE

REPLACEMENT OF SECONDARY AIR INJECTION RELAY MODULE

TECHNICAL SERVICE BULLETIN

Reference Number(s): 94-0431, Date of Issue:  April 1994

MODEL 202.028 REPLACEMENT OF SECONDARY AIR INJECTION (AIR) RELAY MODULE (K17)

Model(s): 1994 Mercedes-Benz C 280

Group: 00 Of Service Information Binder; I Of Information - Parts & Accessories Binder

Campaign No.: 94-0431

Date: April 1994

SERVICE INFORMATION

This Service Campaign is initiated because MBAG has determined that in vehicles within the Effective Serial Number Range below, the secondary air injection (AIR) relay module (K17) may fail.

Therefore, in vehicles within the Effective Serial Number Range below, the secondary air injection (AIR) relay module must be replaced if the production date stamped on the relay module is prior to 21.10.93.

See attached Work Instructions 317, Group 14.

EFFECTIVE SERIAL NUMBER RANGE

Model Engine From To
202.028 104.941 F 000001 F 028695

WORK INSTRUCTIONS NO 317 MODEL 202.028 REPLACEMENT OF SECONDARY AIR INJECTION (AIR) RELAY MODULE (K17)

Model(s): 1994 Mercedes-Benz C 280

Group: 14

Number: 317

Date: April 1994

SERVICE INFORMATION

In vehicles within the Effective Serial Number Range below, the secondary air injection (AIR) relay module must be replaced if the production date stamped on the relay module is prior to 21.10.93.

This procedure should be performed during the vehicle's next scheduled maintenance or repair.

EFFECTIVE SERIAL NUMBER RANGE

Model Engine From To
202.028 104.941 F 000001 F 028695
  1. Remove previous version (prior to 21.10.93 production) secondary air injection relay module (K17. Fig. Fig 1 ) from fuse box.
  2. Check amperage draw of secondary air injection pump and AIR pump circuit using a multimeter.
    • Multimeter with inductive pickup: Using a 10 AWG (4 mm2 ) jumper wire, jump circuit 30 (pin 3) to circuit 87 (pin 1) at the relay module harness connector then clamp on inductive pickup around jumper wire.
    • Multimeter without inductive pickup: Connect one lead of multimeter to circuit 30 (pin 3) and the other lead to circuit 87 (pin 1) at the relay module harness connector.
    • Test results: Nominal value: 22 amps minimum (at 11-13 volts) after approx. 4 seconds. Amperage draw < 22 amps, replace AIR pump (see procedure below). Amperage draw = "0", check voltage supply starting with fuse 17 in fuse box 2.
  3. Install new version relay module (stamped with production date 21.10.93) and mark with white paint for identification purposes.

REPLACEMENT OF PUMP (M33)

  1. Disconnect battery ground cable.
  2. Remove (plastic) from engine cover.
  3. Unplug secondary air injection pump electrical connector and unbolt air pump ground wire.
  4. Loosen poly-V-belt and slide off generator pulley.
  5. Remove generator bolt securing secondary air injection pump harness clamp.
  6. Lift vehicle.
  7. Remove lower encapsulation panel.
  8. Remove secondary air injection pump hose at pump.
  9. Replace secondary air injection pump (M33, Fig. Fig 2 ) with modified version.
  10. Mark the new version pump with a white paint dot for identification purposes.
  11. Connect electrical connector to harness and reinstall bolt previously mentioned in step 3 (which bolted the ground wire to the front of the cylinder head).
    NOTE: The ground wire for the new version air pump is located inside the pump's electrical connector and is no longer separately bolted to front of the cylinder head.
  12. Further installation is in reverse order of removal.
  13. Erase engine codes using Hand-Held Tester (HHT).
  14. Actuate secondary air injection pump with HHT and check readings according to HHT display.

PARTS INFORMATION

PARTS INFORMATION - W.I. 317

Part Name Part Number
Secondary air injection relay module 001 542 74 19
Secondary air injection pump 000 140 33 85

WARRANTY CLAIM SUBMISSION INFORMATION

Operation:

Check production date of secondary air injection relay module (Repair Code 10).

Check production date of secondary air injection relay module, perform test and replace relay module (Repair Code 11).

Check production date of secondary air injection relay module, perform test and replace relay module and secondary air injection pump (Repair Code 12).

WARRANTY CLAIM SUBMISSION INFORMATION

Campaign No. Damage Code Repair Code Time (hrs.) Model Indicator(s)
94-0431 14930 30 10 0.1 C2
94-0431 14930 30 11 0.3 C2
94-0431 14930 30 12 1.0 C2
Fig 1: Secondary Air Injection Relay Module Location In Fuse Box
G94C59537
Fig 2: Secondary Air Injection Pump
G94D59538
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