2005 MERCEDES E-Class W211 Service and Repair Manual

2004 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems DESCRIPTION & OPERATION The main components of the Supplemental Restraint System (SRS) are dual-stage driver-side and passenger- side air bag modules, side impact air bag modules, head impact air bag modules, front impact sensors, side impact sensors, SRS control module, SRS warning light and driver-side and passenger-side Emergency Tensioning Retractors (ETR). See COMPONENT LOCATIONS . COMPONENT LOCATIONS COMPONENT LOCATIONS SERVICING SRS AIR BAG label on driver-side door latch post indicates SRS replacement date for air bag units. All SRS components must be thoroughly inspected, including wiring harness. Before component replacement, check for SRS fault codes by performing system operation check. See SYSTEM OPERATION CHECK . SRS service life is 10 years from manufactured date or 10 years from SRS replacement date after accident related repairs are completed. SYSTEM OPERATION CHECK WARNING: Accidental air bag deployment is possible. Personal injury may result. Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS before working on air bag system or related components. Component Location AIR BAG warning light Instrument cluster Clockspring Under steering wheel Driver-side air bag module On steering wheel Emergency Tensioning Retractor (ETR) Driver-side & passenger-side lower B- & C-pillars Front impact sensor Driver-side & passenger-side engine compartment, behind headlights Head impact air bag modules Driver-side & passenger-side roof rails Occupant classification sensor In passenger-side front seat cushion Passenger-side air bag module Passenger-side instrument panel Side impact air bag modules (1) Side impact sensors Driver-side & passenger-side cross member under front seats (1) Depending on application, side impact air bag modules are located in front seat outer seat backs or in front and rear door panels. 2003-2007 MERCEDES E-CLASS REPAIR MANUAL ACCESSORIES/SAFETY EES/SAFETY EQQUIPMENT

SRS warning light indicates SRS and Emergency Tensioning Retractor (ETR) system readiness. Turn ignition on. SRS warning light will illuminate, then turn off after approximately 4-20 seconds indicating SRS system is functioning properly. If SRS warning light does not illuminate, illuminates while driving or is continuously illuminated, there is a system fault. Repair malfunctioning system. AIR BAG SAFETY PRECAUTIONS Observe these precautions when servicing the air bag system:  When working around SRS components and before any repairs are performed, disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .  Before straightening any damage to body, or before performing electrical arc-welding, disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .  Always wear safety glasses and gloves when handling a deployed air bag module. Air bag module may contain sodium hydroxide deposits which are irritating to the skin.  Always use control module and impact sensors made by same manufacturer. Using components produced by different manufacturers could cause accidental air bag or ETR deployment.  DO NOT repair any portion of SRS wiring harness.  If any SRS component is dropped from a height greater than 1.6 feet (0.5 m), it must be replaced.  If SRS components show signs of damage, they must be replaced.  Always handle air bag module with trim cover facing away from your body.  Always place air bag module on workbench with trim cover up, away from loose objects.  DO NOT expose any SRS component to temperatures in excess of 212°F (100°C ).  DO NOT expose any SRS component to grease, oil or cleaning agents. DISABLING & ACTIVATING AIR BAG SYSTEM DISABLING SYSTEM Turn ignition off and remove key. Disconnect negative battery cable and shield cable end. ACTIVATING SYSTEM Ensure no one is in vehicle. Turn ignition on. Connect negative battery cable. Go to SYSTEM OPERATION CHECK . DISPOSAL PROCEDURES Several situations may arise requiring some form of disposal action, including:  Scrapping a vehicle containing deployed air bag modules and Emergency Tensioning Retractors (ETR).  Scrapping a vehicle with live air bag modules and ETRs.  Disposal of a live but electrically faulty air bag module and/or ETR. 2004 Mercedes-Benz E320 4Matic 2004 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

 Disposal of a deployed air bag module and/or ETR. DEPLOYED AIR BAG MODULE OR EMERGENCY TENSIONING RETRACTOR (ETR) Deployed air bag modules and ETRs can be disposed of like any other part. SCRAPPED VEHICLE Undeployed air bag modules and ETRs CANNOT be disposed of without first being deployed. UNDEPLOYED AIR BAG MODULE OR EMERGENCY TENSIONING RETRACTOR (ETR) Undeployed air bag modules and Emergency Tensioning Retractor (ETR) seat belts CANNOT be disposed of without first being deployed. ON-VEHICLE DEPLOYMENT (SCRAPPED VEHICLE) 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Park vehicle outdoors with at least 33 feet (10 m) of open space around vehicle. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Place a fully-charged 12-volt battery 33 feet (10 m) from vehicle. 2. Disconnect all air bag module and Emergency Tensioning Retractor (ETR) connectors. See REMOVAL & INSTALLATION . Fabricate a deployment harness using 2 wires, each 33 feet (10 m) in length. Connect deployment harness to selected component to be deployed. Twist opposite ends of deployment harness together to prevent accidental deployment. Dual stage air bag modules will require 2 deployment harnesses. 3. Ensure no one is within 33 feet (10 m) of air bag module. Untwist ends of deployment harness. Connect wires to battery. Component should deploy. Repeat deployment procedure for remaining components. OFF-VEHICLE DEPLOYMENT 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove component to be deployed. See REMOVAL & INSTALLATION . Place component in the center of an area with at least 33 feet (10 m) of clearance on all sides. 2. Attach component to a suitable object, such as a tire and wheel assembly, to prevent movement. Fabricate a deployment harness using 2 wires, each 33 feet (10 m) in length. Connect deployment harness to WARNING: Components are very hot after deployment. Personal injury may result. Allow sufficient time for components to cool before touching. NOTE: Deploy only one component at a time. WARNING: Components are very hot after deployment. Personal injury may result. Allow sufficient time for components to cool before touching. 2004 Mercedes-Benz E320 4Matic 2004 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

selected component. Twist opposite ends of deployment harness together to prevent accidental deployment. Dual stage air bag modules will require 2 deployment harnesses. 3. Ensure no one is within 33 feet (10 m) of component. Untwist ends of deployment harness. Connect wires to battery. Component should deploy. Repeat deployment procedure for remaining components. POST-COLLISION INSPECTION When a vehicle has been involved in a collision, certain components of the passive restraint system must be inspected or replaced. See AIR BAG/SRS COMPONENT INSPECTION & REPLACEMENT TABLES article in the GENERAL INFORMATION section. REMOVAL & INSTALLATION CLOCKSPRING Information is not available. CONTROL MODULE Removal & Installation 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . 2. Remove ashtray assembly from center console. Remove control module screws. Pull control module up and out of center console. Disconnect control module electrical connectors. Remove control module. 3. To install, reverse removal procedure. Tighten control module bolts to specification. See TORQUE SPECIFICATIONS . Activate air bag system. Program control module. See DIAGNOSTICS . DRIVER-SIDE AIR BAG MODULE Removal & Installation 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . 2. Move steering wheel to full rearward position. Using Torx Bit (126-589-00-10-00), remove bolts securing driver-side air bag module to steering wheel from rear of steering wheel. Pull driver-side air bag module away from steering wheel. Disconnect driver-side air bag module electrical connectors. Remove driver- side air bag module. 3. To install, reverse removal procedure. Tighten driver-side air bag module bolts to specification. See TORQUE SPECIFICATIONS . Activate air bag system. Read diagnostic codes and erase memory. See DIAGNOSTICS . WARNING: Accidental air bag deployment is possible. Personal injury may result. Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS before working on air bag system or related components. 2004 Mercedes-Benz E320 4Matic 2004 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

EMERGENCY TENSIONING RETRACTOR (ETR) Removal & Installation (Front Seat) 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . 2. Remove appropriate B-pillar trim panel. Remove nut from upper seat belt guide bracket and remove bracket. Disconnect ETR electrical connector. Remove ETR bolts. Remove ETR. 3. To install, reverse removal procedure. Tighten ETR bolts and upper seat belt bracket nut to specification. See TORQUE SPECIFICATIONS . Activate air bag system. Read diagnostic codes and erase memory. See DIAGNOSTICS . Removal & Installation (Rear Seat) 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . 2. Remove appropriate quarter panel trim. Remove nut from upper rear seat belt guide bracket. Remove rear seat belt guide bracket. Disconnect ETR electrical connector. Remove bolts from ETR. Remove ETR. 3. To install, reverse removal procedure. Activate air bag system. Tighten ETR bolts and upper rear seat belt guide bracket to specification. See TORQUE SPECIFICATIONS . Read diagnostic codes and erase memory. See DIAGNOSTICS . FRONT IMPACT SENSOR (REAR SEAT) Removal & Installation 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . 2. Remove air intake hose. Disconnect electrical connector from hot water circulation pump. Remove bolts from appropriate front impact sensor. Disconnect front impact sensor electrical connector. Remove front impact sensor. 3. To install, reverse removal procedure. Tighten front impact sensor bolts to specification. See TORQUE SPECIFICATIONS . Activate air bag system. Read diagnostic codes and erase memory. See DIAGNOSTICS . HEAD IMPACT AIR BAG MODULE Removal & Installation (Sedan) 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . 2. Remove headliner. See HEADLINER . Disconnect appropriate head impact air bag module electrical connector. Remove nuts securing head impact air bag module to roof rail. Detach head impact air bag module from clips. Remove head impact air bag module. 3. To install, reverse removal procedure. Tighten head impact nuts and bolts to specification. See TORQUE 2004 Mercedes-Benz E320 4Matic 2004 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

SPECIFICATIONS . Activate air bag system. Read diagnostic codes and erase memory. See DIAGNOSTICS . Removal & Installation (Wagon) 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . 2. Remove headliner. See HEADLINER . Disconnect appropriate head impact air bag module electrical connector. Remove nuts from head impact air bag module. Remove check strap screws. Using Wedge (110-589-03-59-00), unclip head impact air bag module from roof rail clips. Remove head impact air bag module. 3. To install, reverse removal procedure. Use NEW head impact air bag module supports. Tighten head impact air bag module nuts and bolts to specification. See TORQUE SPECIFICATIONS . Activate air bag system. Read diagnostic codes and erase memory. See DIAGNOSTICS . HEADLINER (WAGON) Removal & Installation (Sedan) 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Open tilting/sliding roof. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . 2. Remove rail from tilting/sliding roof. Remove inside rear view mirror assembly. Remove overhead control panel module. Remove sun visors and mounting brackets. Remove rear dome light. Remove left and right grab handles. Remove load anchors. Remove door edge guards. Remove left and right A-, B- and C-pillar trim panels. Lower front seat backrests. Remove head restraints from rear seats. 3. Tape edge of center console to prevent damage from headliner. See Fig. 1 . Unhook headliner from tilting/sliding roof assembly. Slide headliner forward. Carefully lower headliner, rotate and remove through passenger-side front door. See Fig. 2 . 4. To install, reverse removal procedure. Activate air bag system. Read diagnostic codes and erase memory. See DIAGNOSTICS . 2004 Mercedes-Benz E320 4Matic 2004 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

Fig. 1: Identifying Tape On Edge Of Center Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 2004 Mercedes-Benz E320 4Matic 2004 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

Fig. 2: Identifying Headliner Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Removal & Installation (Wagon) 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Open tilting/sliding roof. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . 2. Remove left A-pillar trim panel. Remove left front grip handle. Remove left front door edge guard. Remove left B-pillar trim panel. Remove left rear door edge guard. Remove left rear grip handle. Remove left and right safety net screws. Remove safety net frame. 3. Remove left C-pillar and D-pillar trim. Remove left quarter panel trim. Remove right rear grip handle. Remove right rear door edge guard. Remove right B-pillar trim panel. Remove right front door edge guard. Remove right A-pillar trim panel. Remove right front grip handle. 4. Remove right D-pillar trim panel. Remove right quarter panel trim. Remove left C-pillar trim panel. Remove rear dome light. Remove left and right sun visors. Remove overhead control panel module. Remove inside rear view mirror assembly. Remove front sealing strip from tilting/sliding roof. 2004 Mercedes-Benz E320 4Matic 2004 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

wire connectors, located on left D-pillar. Release headliner retaining clips. Slide headliner towards front of vehicle until retaining hooks disconnect. Carefully lower headliner. Remove headliner through rear of vehicle. 5. To install, reverse removal procedure. Tighten safety net screws to specification. See TORQUE SPECIFICATIONS . Activate air bag system. Read diagnostic codes and erase memory. See DIAGNOSTICS . OCCUPANT CLASSIFICATION SENSOR (WAGON) Removal & Installation 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Open tilting/sliding roof. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . 2. Remove front seat cushion cover. Unhook clips on seat assembly as necessary. Remove occupant classification sensor by pulling upward, out of seat cushion. Ensure electrical connector is not damaged during removal while pulling through seat cushion. 3. To install, reverse removal procedure. Ensure occupant classification sensor is positioned evenly and squarely on passenger seat. Activate air bag system. Read diagnostic codes and erase memory. See DIAGNOSTICS . UPPER INSTRUMENT PANEL Removal & Installation 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . 2. Remove instrument cluster. Remove left A-pillar trim panel. Using Wedge (110-589-03-59-00), remove left end panel from instrument panel. Remove trim strip, located below instrument cluster opening. Remove right A-pillar trim panel. Using wedge, remove right end panel from instrument panel. Remove center instrument panel trim plate and control head assembly. 3. Remove bolts securing upper instrument panel to main instrument panel. Lift up on upper instrument panel. Disconnect electrical connectors. Remove upper section of instrument panel. 4. To install, reverse removal procedure. Tighten passenger-side air bag module nuts to specification. See TORQUE SPECIFICATIONS . Activate air bag system. Read diagnostic codes and erase memory. See DIAGNOSTICS . PASSENGER-SIDE AIR BAG MODULE Removal & Installation 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . 2. Remove upper section of instrument panel. See UPPER INSTRUMENT PANEL . Disconnect passenger-side air bag module electrical connectors. Remove bolts securing passenger-side air bag module to instrument panel crossmember. Remove passenger-side air bag module. See Fig. 3 . 2004 Mercedes-Benz E320 4Matic 2004 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

3. To install, reverse removal procedure. Tighten passenger-side air bag module bolts to specification. See TORQUE SPECIFICATIONS . Activate air bag system. Read diagnostic codes and erase memory. See DIAGNOSTICS . Fig. 3: Identifying Passenger - side Air Bag Module Courtesy of MERCEDES-BENZ OF NORTH AMERICA. SIDE IMPACT AIR BAG MODULE Removal & Installation (Door Mounted) 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See 2004 Mercedes-Benz E320 4Matic 2004 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

2005 MERCEDES E-Class W211 Service and Repair Manual

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