P-SC-2016090006

MERCEDES-BENZ USA, LLC
303 Perimeter Center North, Suite 202
Atlanta, GA, 30346
Phone: (770) 705-0600
Fax: (770) 705-0117
MBUSA.com
Mercedes-Benz Dealer Principals, General
Managers, Sales Managers, Service Managers, Parts
Managers
RE: Service Campaign 2016090006
Model 204 (C-Class) MY 2008 - 2009
Replace Driver-side and Passenger-side Airbag
TO:
Thomas Brunner, Department Manager,
Vehicle Compliance and Analysis, Engineering
Services
FROM:
DATE:
January 6, 2017
IMPORTANT SERVICE CAMPAIGN LAUNCH INFORMATION
Please see the attached document for the subject new service campaign.
SERVICE CAMPAIGN LAUNCH NOTIFICATION
Campaign No. :
January 6, 2017
Replace Driver and Passenger Airbag
2016090006
This is to notify you of the launch of a Service Campaign to replace the driver and passenger airbags on 654 MY08-09 C-Class
(204) vehicles. Please review the Service Campaign information below. The campaign will be launched on January 6, 2017 and all
affected VINs will be flagged in VMI.
Affected MY08 vehicles are in dealer inventory throughout the entire U.S.
Affected MY09 vehicles are exclusive to the following states: AL, CA, FL, GA, LA, MS, and TX.
This campaign only applies to W204 C-Class cars in dealer inventory under the retail hold with Takata driver-side and
passenger-side airbags. The cars will be taken off retail hold once the airbags are replaced. Dealer reimbursement for the
retail hold of these 654 vehicles will end on January 20, 2017.
Background
Based on the defect decision of TK Holdings, Inc (“Takata”), in certain driver-side airbags and passengercertain circumstances, the driver-side or passenger side airbag inflator housing may rupture during
deployment due to excessive internal pressure. Replacement driver and passenger airbags (Like-for-Like)
are available only for the 654 MY08-09 C-Class (W204) cars flagged in VMI currently in dealer inventory
under the retail hold.
MBUSA is conducting a service campaign. An authorized Mercedes-Benz dealer will replace the driver-side
and passenger-side airbag on the affected vehicles in dealer inventory.
Issue
What We’re Doing
Parts Status
Parts are available and can be ordered as required. Replacement rate is 100%.
Vehicles Affected
Vehicle Model Year
Vehicle Model
Model Year 2008-2009
C-Class (W204)
Vehicle Populations
Total Vehicle Population
654
Total Vehicles in Dealer Inventory
654
Dealer Notification (NCU)
Documentation pertaining to this recall
will be received by dealers in NetStar
and Star TekInfo on the following date:
January 6, 2017
Next Steps/Notes
AOMS
Notes:
AOMs – If your name is copied on this email, you may have a dealer that has a vehicle affected by this Service
Campaign in inventory. The VIN file will be forwarded by your AOM.
• A copy of the campaign bulletin is attached, and may also be found on Star TekInfo.
• There is a risk of injury or death when performing testing or repair work on vehicles and when handling vehicle
components. Be sure to read and observe all relevant safety instructions in WIS. This procedure must only be
performed by trained personnel using proper tools and equipment.
• VMI must always be checked before performing campaigns to verify that the campaign is required on a specific vehicle.
• Dealers may also identify vehicles subject to a campaign through NetStar by selecting “Campaign” under the Controlling
tab. Only vehicles that have been retailed by the respective dealer will be displayed within this program.
While we regret any inconvenience this may cause, MBUSA is determined to maintain a high level of vehicle quality and customer
satisfaction. Please refer all customer inquiries to the Customer Assistance Center at 1-800-FOR-MERCEDES. Please contact Allen
Ambulo (x2579) or me with any questions.
R. Thomas Brunner, Department Manager, Vehicle Compliance & Analysis
Campaign No. 2016090006, January 2016
TO:
ALL MERCEDES-BENZ CENTERS
SUBJECT:
Model 204
Model Years 2008 and 2009
Replace Driver-Side and Front Passenger Air Bag
Based on the defect decision of TK Holdings, Inc (“Takata”), in certain driver-side airbags and passenger
side airbags produced by Takata used in certain Model Year 2008–2009 Mercedes-Benz vehicles, under
certain circumstances, the driver-side or passenger side airbag inflator housing may rupture during
deployment due to excessive internal pressure. Replacement driver and passenger airbags (Like-forLike) are available only for the 654 MY08-09 C-Class (W204) cars flagged in VMI currently in dealer
inventory under the retail hold. An authorized Mercedes-Benz Dealer will replace the driver-side airbag
and passenger-side airbag on the affected vehicles.
Prior to performing this Service Campaign:

Please check VMI to determine if the vehicle is involved in the Campaign and if it has been
previously repaired.

Please review the entire Service Campaign bulletin and follow the repair procedure exactly as
described.
Approximately 654 vehicles are involved.
Order No. P-SC-2016090006
This bulletin has been created and maintained in accordance with MBUSA-SLP S423QH001, Document and Data
Control, and MBUSA-SLP S424HH001, Control of Quality Records.
2
Procedure
A. Replace Drivers-Side Airbag
WARNING!
There is a risk of injury or death when performing testing or repair work on vehicles and when handling
vehicle components. Be sure to read and observe all relevant safety instructions in WIS. This procedure
must only be performed by trained personnel using proper tools and equipment.



Note: View driver’s airbag replacement video prior to performing this procedure:
Location: The Learning Link.
®
Course Code: X0069E-US.MTA (AKUBIS : Driver’s Airbag Replacement).
Video is for reference purposes, be sure to follow work sequence and instructions in this Procedure.
®
1.
®
®
Load the Mercedes-Benz PartScan App. on Apple i-Phone or Android smart phone.
Note:

®
®
For Apple iPhone Users: The MB PartScan App is designed for generations of iPhone 5s and newer.
However, for optimal experience and performance, we advise that an iPhone 6 and newer be used for
scanning with the MB PartScan App.”

®
®
®
®
Download app from Apple store for iPhone or Google play for Andriod (same as any other app
download) then scan the QR code below to continue download (follow on-screen instructions).

To install and transmit the data a WiFi connection is required.

After downloading the App, a one-time security authentication is required by means of encrypted QR
code. Verification can be performed by scanning the QR code below, before using the application.

Ensure that only authorized personnel access to the QR Code the workshop receives.

The following e-mail address is provided in the event UHD App support is required for the MercedesBenz PartScan App process: [email protected]
P-SC-2016090006
3
®
®
2. Scan vehicle’s VIN at left B-pillar using i-phone or Android smart phone.
Note:

Ensure that smart phone is held parallel to barcode label (Figure 1) when scanning VIN bar code.

In the event the VIN barcode cannot be scanned when pressing the “Scan-Barcode” button or the
vehicle does not have a VIN bar code; scan using the “Text recognition button and letter/number
combination of the VIN (Figure 1).

The VIN can also be entered manually if required.
Figure 1
3.
Start engine and check whether Supplemental Restraint System (SRS) indicator lamp (Figure 2)
goes out after a few seconds.
Figure 2 (shown on model171)



Note: Prior to replacing airbag, it must be ensured that:
No errors are active in the SRS system (as described in this step).
No SRS error messages are active in the instrument cluster (as described in this step).
If an SRS error message is pending before start of work, it must be corrected. Fault corrections
(repairs) are not claimable under this campaign.
P-SC-2016090006
4
WARNING!

Prior to replacing airbag be sure to disconnect battery ground cable as described in the WIS
documents (below).
Be sure to follow instructions for prevention of electrostatic discharge as described in the WIS
documents (below) when handling airbags.

Replace driver’s airbag, refer to WIS: AR91.60-P-0660CW
4.
Note: Torque airbag mounting bolts to:

8 Nm when installing “new” airbag to steering wheel.
Supplemental information to above WIS instructions:
Scan airbag bar code (A, Figure 3) from “old” airbag immediately after removing it from steering wheel by
pressing “Scan Barcode button (Figure 3).




Note:
Ensure that smart phone is held parallel to bar code label (A, Figure 3) when scanning airbag bar code.
It must be ensured that the lower barcode is scanned.
The airbag part number can also be entered manually if required.
This step can be omitted ONLY if bar code is incomplete, illegible, or missing.
Figure 3 (Shown on model 203)
P-SC-2016090006
5

Scan airbag bar code from “new” airbag immediately after packaging “old” airbag.
Note:

Ensure that smart phone is held parallel to bar code label (A, Figure, 4) when scanning airbag bar
codes. The part number label that needs to be scanned starts with: 000 860 36 01 9116.


It must be ensured that the lower barcode (A, Figure 4) is scanned.
The airbag part number can also be entered manually if required.
Figure 4 (Shown on model 203)



Record the generated scan ID (Figure 5)
on the repair order.
The warranty claim must include
generated scan ID (Figure 5) in the DTC
field in NetStar.
If parts scan app process fails document
old part number, new part number and
serial numbers for both parts manually
on repair order include: “App submission
error” on RO in warranty claim text.
Figure 5


Ensure that clock is re-set after battery is reconnected.
Contrary to WIS instructions (on previous page), it is not necessary to check the SRS system with
Xentry diagnosis.
5. After installation of new airbag be sure to start engine and check whether SRS indicator lamp goes out
after a few seconds (Figure 2).
P-SC-2016090006
6
B. Replace Passenger-Side Airbag
1. Scan vehicle’s VIN at left B-pillar using
®
®
i-phone or Android smart phone.
Note:

Ensure that smart phone is held parallel to
barcode label (Figure 6) when scanning VIN
bar code.

In the event the VIN barcode cannot be
scanned when pressing the “Scan-Barcode”
button or the vehicle does not have a VIN bar
code; scan using the “Text recognition button
and letter/number combination of the VIN
(Figure 6).

The VIN can also be entered manually if
Figure 6
required.
2. Remove side cover (1, Figure 7) then loosen bolts (2) securing dashboard (A) to vehicle on right side.
eft
Figure 7
P-SC-2016090006
7
3. Remove panel (D, Figure 8) from around the instrument cluster; refer to WIS: AR54.30-P-6015CW (step
5.1).
Figure 8
4. Remove the two bottom instrument cluster mounting screws (E, Figure 9).


Note:
These screws (E) are simultaneously fastening screws for the instrument panel.
The upper two screws do not need to be loosened.
Figure 9
P-SC-2016090006
8
5. Remove A-pillar panel, right (A, Figure 10).
A
Figure 10
6. Remove glove box, refer to WIS: AR68.10-P-1200CW.
7. Remove air duct (B, Figure 11) above the glove box.
B
Figure 11
P-SC-2016090006
9
8. Unclip cover (C, Figure 12) on top of instrument panel and remove.
Note:
If equipped with sound system, also remove speaker under cover (C).
C
Figure 12
9. Remove center console, refer to WIS : AR68.20-P-2000CW.
10. Remove automatic air conditioning control and operating unit, refer to WIS: AR83.40-P-6350CW.
P-SC-2016090006
10
11. Remove four instrument panel mounting bolts (F, Figure 13).
Figure 13
12. Disconnect electrical connectors (H, Figure 14) from front passenger airbag.
Figure 14
P-SC-2016090006
11
13. Remove front passenger airbag mounting nuts (J, Figure 15).
Figure 15
14. Slightly raise the instrument panel on the passenger's side and remove front passenger airbag
downwards.
15. Carefully move “new” airbag in from below and bolt onto the instrument panel.

Note:
Be sure to install new airbag mounting nuts (J, Figure 15) when installing “new” airbag to instrument
panel.

Torque airbag mounting nuts (J) to:
5 Nm when installing “new” airbag to instrument panel.
16 Scan airbag bar code (arrow, Figure 16) from
“old” airbag immediately after removing it
from dashboard by pressing “Scan Barcode
button (Figure 16).




Note:
Ensure that smart phone is held parallel to
bar code label (arrow, Figure 16) when
scanning airbag bar code.
It must be ensured that the lower barcode
(arrow) is scanned.
The airbag part number can also be entered
manually if required.
This step can be omitted ONLY if bar code is
incomplete, illegible, or missing.
Figure 16
P-SC-2016090006
12
17. Scan airbag bar code from “new” airbag immediately after packaging “old” airbag
Note:

Ensure that smart phone is held parallel to bar code label (arrow, Figure, 17) when scanning airbag bar
code. The part number label that needs to be scanned starts with: A204 860 00 05.


It must be ensured that the lower barcode (arrow, Figure 17) is scanned.
The airbag part number can also be entered manually if required.
Figure 17
18. Place instrument panel back into position and install air guide ducts (K, Figure 18), ensuring position is
correct
Note:
The air guide ducts are pulled out when the instrument panel is raised.
Figure 18
19 Installation is in reverse order.
P-SC-2016090006
13
20. Reconnect ground cable to on-board system
battery.
21 Ensure that clock is re-set after battery is
reconnected.




Note:
It is not necessary to check the SRS system
with Xentry diagnosis.
Record the generated scan ID (Figure 19) on
the repair order.
The warranty claim must include generated
scan ID (Figure 19) in the DTC field in
NetStar.
If parts scan app process fails document old
part number, new part number and serial
numbers for both parts manually on repair
order include: “App submission error” on RO
in warranty claim text.
Figure 19
22. After installation of new airbag be sure to start engine and check whether SRS indicator lamp goes out
after a few seconds (Figure 20).
Figure 20 (shown on model171)
P-SC-2016090006
14


Note:
Requested parts must be returned to the designated QEC test center in accordance with the
warranty parts return requirements section found in the policy and procedures manual.
Use the attached hazmat shipping document as a guide for shipping airbags.
Note (regarding WIS documents referenced in this Procedure):
Replacement of parts not listed in the parts table of this Procedure are not claimable under this
campaign. If replacement of additional part(s) is necessary, check coverage prior to submitting
under warranty.
Special Tools
126 589 00 10 00
203 589 04 33 00
000 589 52 98 00
Screwdriver bit
Removal lever (or locally sourced
equivalent)
Electro Static Discharge (ESD) kit (or
locally sourced equivalent)
Primary Parts Information
Qty.
Part Name
Part Number
1
Driver-side airbag (Matt black)
A204 860 02 02 9116
1
Driver-side airbag (Matt black)
A 204 860 43 02 9116
1
Driver-side airbag (Matt black)
A 204 860 33 02 9116
1
Driver airbag (Steppe brown)
A 204 860 02 02 8490
1
Driver-side airbag (Landscape)
A 204 860 02 02 8465
1
Front passenger airbag
A204 860 00 05
4
Nuts, passenger airbag
A003 990 53 51
P-SC-2016090006
Estimated
Replacement Rate
100%
15
Note:

Please be aware that only the part number(s) referenced in the Campaign Bulletin is/are
approved for use to repair the vehicle. Repairs performed using any other part(s) will not
have been performed in accordance with the campaign. Accordingly, warranty claims
submitted with reference to an improper part number(s) will be denied.

The following allowable labor operation should be used when submitting a warranty claim for
this repair:
Warranty Information
Operation: Replace driver-side airbag and front passenger airbag (02-9674)
Damage Code
91 921 49 7
Operation Number
02-9674
Labor Time (hrs.)
(Includes: Disconnecting and connecting ground cable of on-board electrical system battery).
Note
Operation Number labor times are subject to change.
P-SC-2016090006
1.4
Hazardous Materials Shipping Instructions - GROUND
Part Name: Airbag
Part Numbers: A204 860 02 02 9116 (driver’s side),
A204 860 43 02 9116 (driver’s side), A204 860 33 02 9116
(driver’s side), A204 860 02 02 8490 & 8465 (driver’s side),
A204 860 00 05 (passenger’s side),
Hazardous Properties:
Contains initiating
component which deploys
(inflates) airbag.
STRAIGHT BILL OF LADING
ORIGINAL - NOT NEGOTIABLE
PIECES
1 box
IN
HM
X
DESCRIPTION
WEIGHT
UN3268, Safety devices, 9
Write gross
weight of
box here
RATE
CHARGES
CLASS
This is to certify that the above-named materials are properly classified, described, packaged, marked and labeled, and are in proper condition for transportation according
to the applicable regulations of the Department of Transportation.
SHIPPER
HazMat Employee Signs
CARRIER
Name of Carrier
EMERGENCY CONTACT: CHEMTREC 1-800-424-9300
Steps to Return an Airbag:
REQUIRED PACKAGING:

Carefully open received box and remove new
airbag. Keep box intact & save all contents!

Place used airbag into replacement airbag
box, re-using any packaging material (e.g.,
cardboard inserts) used for the new airbag.
Package as the new airbag was packaged.

Use plastic adhesive tape 50 mm wide to
secure the box closed. Do not obscure
labels or text on the box with the tape.

Ensure that the 4G fiberboard box is
not ripped or damaged.
DOCUMENTATION:
 Include a HAZMAT bill of lading (see above
example) with the package. For returns via
DDS or FedEx Ground, the system will
generate the Hazmat bill of lading.
COMMENTS:
 Note: The Packing Group and the EX# are no
longer required to be printed on the HAZMAT
bill of lading.
 Package example:
REQUIRED LABELS:

A Class 9 Miscellaneous label must be
clearly visible on one side of the box.
REQUIRED PACKAGE MARKINGS:

The following words (“marking”) must also be
clearly visible on the same side of the box as
the Class 9 label:
Safety devices
UN3268 (font size must be >= ½ inch)
 Affix "To/From" address label to same or
adjacent packaging face as the hazardous
markings/labels.
 The UN 4G code preprinted near the bottom
edge of the box must also be clearly visible.
Safety devices
UN3268
To:
From:
4G/Y...
Questions? Contact MBUSA Corporate EH&S at (630) 462-3440 or (770) 705-2578
12/5/2016
Hazardous Materials Shipping Instructions for
shipments using an Overpack - GROUND
Part Name: Airbag
Part Numbers: A204 860 02 02 9116 (driver’s side),
A204 860 43 02 9116 (driver’s side), A204 860 33 02 9116
(driver’s side), A204 860 02 02 8490 & 8465 (driver’s side),
A204 860 00 05 (passenger’s side),
Hazardous Properties:
Contains initiating
component which
deploys (inflates) airbags.
STRAIGHT BILL OF LADING
ORIGINAL - NOT NEGOTIABLE
PIECES
1 box
IN
HM
X
DESCRIPTION
UN3268, Safety
devices, 9
OVERPACK USED
WEIGHT
RATE
CHARGES
CLASS
Write
gross
weight of
box here
This is to certify that the above-named materials are properly classified, described, packaged, marked and labeled, and are in proper condition for transportation according to
the applicable regulations of the Department of Transportation.
SHIPPER
HazMat Employee Signs
Name of Carrier
CARRIER
EMERGENCY CONTACT: CHEMTREC 1-800-424-9300
Steps to Return Multiple Airbags in 1 Box:

REQUIRED PACKAGING:
 Carefully open received UN spec box and remove new

airbag. Keep the box intact & save all contents!
 Place used airbag back into replacement airbag box,
re-using any packaging material (e.g., cardboard
inserts) used for the new airbag. Package as the new
airbag was packaged.
 Use plastic adhesive packaging tape 50 mm wide to
secure box closed. Do not obscure labels or text on
box with tape.
REQUIRED LABELS:
 A Class 9 Miscellaneous label must be clearly visible
on one side of the box.
REQUIRED PACKAGE MARKINGS:
 The following words (“markings”) must also be clearly
visible on the same side of the box as the label:
Safety devices
UN3268 (font size must be >= ½ inch)
 Affix "To/From" address label to same or adjacent
packaging face as the hazardous markings/labels.
 The UN 4G code preprinted near the bottom edge of
the box must also be clearly visible.
OVERPACKS (more than 1 airbag sent as 1 shipment):
 Package each airbag in a separate UN spec box
prepared with the labels/markings described above.
 Place each individual airbag box inside a larger nonUN spec box to keep the shipment together.
 This larger box is called an "OVERPACK."
Questions? Contact MBUSA Corporate EH&S at (630) 462-3440 or (770) 705-2578
The OVERPACK must have the
identical markings and label as the
boxes contained inside.
The OVERPACK must have the
“OVERPACK” statement on the
same face as the hazard markings
and labels. Package example:
12/5/2016