Fuel Pump Shutdown May Cause Loss of Drive Power – 2021-2024 Mercedes-Benz GLE, GLS, C-Class, E-Class, S-Class, SL, GLC, CLS, AMG GT, & G-Class

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December 21, 2023 NHTSA CAMPAIGN NUMBER: 23V880000

Fuel Pump Shutdown May Cause Loss of Drive Power

A loss of drive power can increase the risk of a crash.

 

NHTSA Campaign Number: 23V880

Manufacturer Mercedes-Benz USA, LLC

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 79,676

 

Summary

Mercedes-Benz USA, LLC (MBUSA) is recalling certain 2021-2024 GLE, GLS, C-Class, E-Class, S-Class, SL, GLC, CLS, AMG GT, and G-Class vehicles. Please refer to MBUSA’s recall report for specific vehicle details. The fuel pump may shutdown, causing a loss of drive power.

 

Remedy

Dealers will replace the fuel pump, free of charge. Interim letters notifying owners of the safety risk, were mailed February 13, 2024. A second notice will be sent once the final remedy is available. Owners may contact MBUSA customer service at 1-800-367-6372. This recall is an expansion of NHTSA recall number 23V-445.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Mercedes-Benz has a Recall

 


Frequently Asked Questions (FAQ’s)

What vehicles are included in the recall?

Model Year (“MY”) 2021-2024 C-Class, E-Class, S-Class, SL, GT, GLC, GLE, GLS and G-Class (205/206, 213/238, 223, 232, 290, 253/254, 167 and 463 platforms) vehicles.

Will the recall be rolled out in waves?

Yes, the campaign will be rolled out in waves. Vehicles in hot regions will be prioritized.

 

How can I determine if a vehicle is included in the recall?

VINs will be flagged as “PENDING” in Netstar-VMI under damage code 23P2197662.

 

Will this Recall expire?

No, recalls do not expire.

 

Does the vehicle need to be brought to the dealer to have the recall completed?

Only an authorized Mercedes-Benz dealer may perform this recall repair.

 

Which parts should dealers order?

Refer to NCU part designation based on model. Parts can only be ordered for vehicles in open status in Netstar-VMI.

 

What about customer vehicles that are still in VMI “pending” status but are down due to the described issue?

Dealers – Please contact your AOM for further information.

AOMs – Please submit a request to the recall inbox. Further analysis will be conducted based on wave and parts supply.

 

Is this a stop drive recall?

No, customers may continue to drive the vehicle.

 


February 9, 2024

2024010011

Replace Fuel Pump Delivery Module – Wave 1 

This is to notify you of the Recall Campaign Launch to replace the fuel pump delivery module on 13,432 Model Year (“MY”) 2021-2024 C-Class, E-Class, S-Class, SL, GT, GLC, GLE, GLS and G-Class vehicles (205/206, 213/238, 223, 232, 290, 253/254, 167 and 463 platforms). The recall campaign will be visible on the www.NHTSA.gov website and may generate questions from customers.  Affected VINs will be flagged in VMI as “OPEN” on February 9, 2024.

 

Issue

Mercedes-Benz AG (“MBAG”), the manufacturer of Mercedes-Benz vehicles, has determined that on certain MY 2021-2024 C-Class, E-Class, S-Class, SL, GT, GLC, GLE, GLS and G-Class vehicles (205/206, 213/238, 223, 232, 290, 253/254, 167 and 463 platforms), the fuel pump impeller might not meet current specifications in regards to material characteristics. As a consequence, the impeller might deform and contact the fuel pump housing and result in mechanical resistance on the impeller. In some instances, this could cause the fuel pump to stop operating.

As a result, the vehicle could lose propulsion, which could increase the risk of crash or injury. Before the fuel pump is switched off, the driver may be made aware of a malfunction by a warning message in the instrument cluster and might notice a roughly running engine.

 

What We’re Doing

MBUSA will conduct a voluntary recall. An authorized Mercedes-Benz dealer will replace the fuel pump delivery module on the affected vehicles.

 

Parts

The remedy is available and can be performed.

 

Given this notice, it is a violation of Federal law for a dealer to sell or lease any new vehicles in dealer inventory covered by this notification until the vehicle has been repaired. Once the remedy is available, the vehicles will be flagged as “OPEN” and Work Instructions will be available in NetStar VMI and Xentry Portal. Once the repair is complete, the vehicle may be sold or leased.

Loaner and demonstrator vehicles may continue to be driven, but must not be retailed until repaired. As a matter of normal service process, please check for other repair measures which might be applicable to the vehicle(s).

Additionally, given this notice, it is a violation of Federal Law for car rental companies to rent new vehicles covered by this notification until the vehicle has been repaired.

 

Customer Notification Timeline

Customer letters will be mailed on February 16, 2024.

 


Replace Fuel Pump Delivery Module

 

Work Procedure

The fuel tank may only be filled up to a maximum of 20%.

This corresponds to two lines (A) on the fuel display (Figure 1).

 

Figure 1 (shown on model 205)

 

  1. Replace fuel pump.

For basic data, see AR47.20-P-5710*.

* Select the WIS document according to the vehicle model.

No quick test has to be performed.

Only model 206, 232: Note on disassembly of suction jet pump drive line quick connector.

The procedure steps 1-3 should only be performed when the quick disconnect is not working (Figure 2).

 

Only for model 167

Contrary to the WIS document (AR88.60-P-2001ME – Remove/install tank filler recess), the tank filler recess must not be removed. Disconnecting the hose lines at the activated charcoal canister and the sealing bellows on the inside at the tank filler recess is sufficient.

 

Installation:

For all vehicles with code 228 stationary heater, the connection for the fuel supply system must be cut off before installing the fuel pump (Figure 3).

 

Figure 4 (remove electric lines from routing clip)

 

Figure 5 (release corresponding connector and disconnect    the contacts)

 

Figure 6 (remove lines from routing clip)

 

Figure 7 (using a screwdriver, carefully push float-and-lever sensor housing away from module housing and at the same time push float-and-lever sensor housing upwards.)

 

  1. Assemble in reverse order.

 

Primary Parts Information

If one of the following delivery modules in column 1 was determined by the Vehicle Identification Number (VIN) in the XENTRY parts process, the delivery module in column 2 should be ordered and installed!

If the determined delivery module from column 2 is not available for order due to parts constraints, the delivery module from column 1 can be ordered.

The delivery module in column 1 is supplied with float-and-lever sensor, and the delivery module in column 2 is supplied without float-and-lever sensor.

If the delivery module from column 2 is ordered and installed, proceed as per the operation item “12-1973”.

If the required delivery module, as determined in the XENTRY parts process is not listed in column 1, please order the required delivery module according to the XENTRY parts process.

 

Column 1 Column 2
Delivery module as determined by VIN in the XENTRY parts process:

* If the part number has 12 digits, the last two digits can be ignored and the part from column 2 must be ordered!

Order and install delivery module without float-and-lever sensor:
A 167 470 03 94 /* A 167 470 07 06
A 167 470 45 00 /* A 167 470 06 06
A 167 470 69 00 /* A 167 470 05 06
A 205 470 27 02 /* A 205 470 52 03
A 205 470 49 00 /* A 205 470 51 03
A 205 470 85 01 /* A 205 470 50 03

 

The fuel pump locking ring is not required to be replaced and will not be covered under warranty.

Qty. Part Name Part Number
1 Delivery unit in right fuel tank *
1 O-RING between delivery unit and fuel tank *
6 Cap bolt, propeller shaft to transfer case (Model 167) *
As required Cap bolt, propeller shaft to rear axle (Model 167) *
As required Cap bolt, flex disk to rear propeller shaft (Model 167) *
1 Bolt and washer assembly, rear axle carrier to rear frame floor assembly.  (Model 167) *
3 MOUNTING PLATE PARTS KIT propeller shaft to transmission (Model 463) *
3 MOUNTING PLATE PARTS KIT propeller shaft to rear axle (Model 463) *

* The replacement parts must be determined according to the equipment variant for the vehicle identification number via the parts process in the Xentry Portal.

Small parts such as screws, lock nuts, sealing rings, cable ties, fluids, sealant, etc. are not listed in the parts list. The required small parts are taken into account in the budgeting.

 


Chronology Supplement for ODI  23-00855-30219-10

In the beginning of June 2022, MBAG launched initial investigations based on individual field reports from outside the US alleging inconsistent power delivery. MBAG hypothesized that, the function of the fuel pump might have been impaired without having any initial indications in regards to common influencing factors on the field cases in this relation. In July 2022, MBAG began retrieving fuel pumps from affected vehicles in the field and analyzing them in coordination with the supplier. Over the next several months, MBAG conducted analyses of the material together with the supplier, as well as the production processes at the supplier and its sub-suppliers. Through the end of the year, MBAG conducted numerous and varied tests in coordination with its tier one supplier, including fuel swelling behavior, structural damage and notched impact resistance tests. In December 2022, these intensive analyses and tests identified an irregularity in individual raw material batches used for the suspect fuel pump impellers, sourced from a sub-supplier. Based on that determination, in January 2023, MBAG’s supplier of the suspect fuel pump started investigations to identify the potentially affected vehicle population by tracking the material flow within the multi-supplier chain from the raw material sub-supplier up to the fuel pump manufacturer. At the same time, the fuel pump supplier implemented several changes in its production process, including a replacement of the raw material supplier, changing the injection molding process at the injection molding supplier and implementing more quality controls within the supplier chain. Through May 2023, MBAG and its fuel pump supplier conducted further testing and analyses to identify potential influencing factors and determine potential consequences of material and process anomalies at different steps of the production process. In May 2023, MBAG’s fuel pump supplier determined the scope of potentially affected fuel pumps, which was then used to identify the potentially affected vehicle population.

On June 16, 2023, MBAG determined that a potential safety risk cannot be ruled out and decided to conduct a recall.

MBAG is currently aware of 2,031 warranty claims/field reports/service reports received from 30.08.2021 to 23.05.2023 in the USA. MBAG is not aware of any claims of injury, crashes or death worldwide due to this malfunction.

In July 2023, during the course of its worldwide product monitoring, MBAG identified additional field reports alleging inconsistent power delivery. MBAG’s initial review of these field reports determined that some of the vehicles involved in these reports were outside the recall population determined earlier in May 2023.

Based on a detailed analysis of field data, MBAG hypothesized that the occurrences described in these new field reports might be related to a supplier error similar to that identified in recall NHTSA # 23V-445. During October and November 2023, MBAG and its supplier conducted additional investigations to identify a potential root cause for the reported incidents, including retrieving damaged parts from vehicles for examination and analysis.

Based on these analyses, MBAG determined that additional batches of raw material used by its fuel pump supplier may also have deviated from specifications, and thus resulted in similar consequences as described before. As a result, the number of potentially affected vehicles is larger than the population initially identified by MBAG’s fuel pump supplier. On December 8, 2023, MBAG determined that a potential safety risk for the identified additional vehicles cannot be ruled out. Therefore, the company decided to expand the vehicle population for this recall to include additional vehicles whose fuel pump impellers were manufactured using batches of raw materials that were identified as containing this defect.

MBAG is aware of 1,901 related warranty claims or field reports received between May 14, 2022 to November 15, 2023. These claims and reports are in addition to the 2,031 claims and reports that MBAG received between August 30, 2021 and May 5, 2023 (identified in the Report submitted by MBAG on June 27, 2023). MBAG is not aware of any claims or reports of injury, fatality, or property damage worldwide related to this defect.

 


Loss of Drive Power from Fuel Pump Shutdown – 2021-2023 Mercedes-Benz C-Class, E-Class, S-Class, CLS, SL, GT, GLC, GLE, GLS, & G-Class

 

Loss of Drive Power from Fuel Pump Shutdown – 2021-2023 Mercedes-Benz C-Class, E-Class, S-Class, CLS, SL, GT, GLC, GLE, GLS, & G-Class

 


59 Affected Products

Vehicles

MAKE MODEL YEAR
MERCEDES-BENZ AMG C43 2023
MERCEDES-BENZ AMG E53 2021-2023
MERCEDES-BENZ AMG E63 2021-2023
MERCEDES-BENZ AMG G63 2022-2023
MERCEDES-BENZ AMG GLC43 2023
MERCEDES-BENZ AMG GLE53 2022-2024
MERCEDES-BENZ AMG GLE63 2022-2024
MERCEDES-BENZ AMG GLS63 2022-2023
MERCEDES-BENZ AMG GT43 2021-2023
MERCEDES-BENZ AMG GT53 2022-2023
MERCEDES-BENZ AMG GT63 2023
MERCEDES-BENZ AMG SL43 2023
MERCEDES-BENZ AMG SL55 2022-2023
MERCEDES-BENZ AMG SL63 2022-2023
MERCEDES-BENZ C300 2022-2024
MERCEDES-BENZ E350 2022-2023
MERCEDES-BENZ E450 2022-2023
MERCEDES-BENZ G550 2022-2023
MERCEDES-BENZ GLC300 2023
MERCEDES-BENZ GLE350 2021-2023
MERCEDES-BENZ GLE450 2022-2024
MERCEDES-BENZ GLE580 2022-2023
MERCEDES-BENZ GLS450 2022-2023
MERCEDES-BENZ GLS580 2022-2023
MERCEDES-BENZ S500 2022-2023
MERCEDES-BENZ S580 2022-2023
MERCEDES-MAYBACH GLS600 2022-2023
MERCEDES-MAYBACH S580 2022-2023

 


5 Associated Documents

Recall Acknowledgement

RCAK-23V880-6225.pdf 645.859KB

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Defect Notice 573 Report

RCLRPT-23V880-5016.PDF 232.712KB

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Chronology Report

RMISC-23V880-3304.pdf 85.616KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V880-5048.pdf 133.473KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-23V880-8366.pdf 220.679KB

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Latest Recalls Documents

For the Latest and Most recent Recall Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V880&docType=RCL

 


 

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BOSCH 66150 OE Electric Fuel Pump - Compatible With Select Mercedes-Benz C230, CL500, CL600, CLK430, E320, E420, E430, G500, G550, S320, S420, S430, S500, SL320, SL500, SL600, SLK230, SLK320 + More

Last update on 2024-06-28 / Affiliate links / Images from Amazon Product Advertising API

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