W215 ABC Pump/Valve Block/HPE Hose Repair (21 Pictures)

Oxygen · 07-03-2009, 04:07 PM

A few months back a member from this board came to our shop ( TTMotorsports / http://www.mbworld.org/forums/member...torsports.html ) with a 2003 CL600 that had a serious problem with the front end sinking after being turned off for a few minutes.

The car also make a crazy crunching/cracking/dinging sound coming from the ABC pump and would not rodeo for more than a few minutes because the pump would not produce enough pressure.

Our first attempt to remedy the problem was to filter the ABC fluid but that had no effect and the car would sink to the ground after being off for about 3 minutes.

The front axle valve block was obviously malfunctioning and needs to be replaced along with the pump and the leaky high pressure expansion hose.

One of the first things you must do is suction off the hydraulic fluid in the ABC and PS tanks...

The front axle ABC valve clock hiding behind a maze of hydraulic hoses...

Front driver's side wheel well needs to be removed to provide access to the front axle valve block and the pressure accumulator...

The black bulb is the front axle pressure accumulator and it is on the same plate as the front axel valve block. The whole assembly is removed once the hydraulic hoses are disconnected from the valve block...

Here is what 7 years of improvement look like... the valve blocks are not manufactured by the same company...

Here is the new valve block assembled with the mounting plate and the pressure accumulator.

The valve block has 4 electrical connections and 5 hydraulic connections.. they are as follows:

SP: Pressure Accumulator
S: High Pressure Feed
T: Low Pressure Return
FB1: Front Left Strut
FB2 Front Right Strut

The new valve block installed and all hydraulic and electrical connections are assembled:

When I initially diagnosed the car I noticed that the high pressure expansion hose that connects to the pump was sweating a lot of hydraulic fluid on the surface and would eventually fail, causing the same failure that happened to my S600 months back. With the new pump working correctly I did not want to subject the old hose to the high pressure and it needed to be replaced.

Here's a comparison between the old and the new hoses...

Installation of the hose is a bit tricky.. the motor mount needs to be unbolted from the subframe and the motor needs to be raised a few inches since the hose runs underneath the crank pulley and the subframe...

Here is the new and the old pump. The older pumps were manufactured by LuK but they were since bought and are now manufactured by a company called Ixetic. Exterior case is exactly the same. The suction restrictor valve looks to be updated..

New pump installed and awaiting feed lines to be connected..

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Oxygen · 07-03-2009, 04:10 PM

We also discovered that the IC pump has failed. The pump was replaced with a newer model...

The rear axle made clunking sounds when the car would be engaged in gear.. I discovered that there were 2 bolts missing on the rear axle connecting to the differential. The other 4 bolts were loose or half way out....

Cleaned the rear axle, replaced the washers and the 6 bolts.. torque to correct specs...

Oxygen · 07-03-2009, 04:12 PM

Of course after the car was assembled there are many more procedures before the car was "ready to drive"...

-Flush/Fill/Bleed Power Steering
-Flush/Fill/Bleed ABC
-Flush/Fill/Bleed Intercoolers
-Engine Oil Change
-New Belt
-Recharge A/C

Oxygen · 07-03-2009, 04:13 PM

We are located in Farmingdale, Long Island so if any of you guys are looking for expert ABC service/repair and don't want to pay out of your nose at the dealership, please call or come see us!

We are sponsors on MBW and have a ton of references for the work that we've done over the years.

Oxygen · 07-03-2009, 04:41 PM

Link to Ixetic (hydraulic pumps): http://www.ixetic.com
Link to RAPA (hydraulic solenoid valves): http://www.baika.de/portal/baika_pro...64,detail.html

bentleyboy · 07-03-2009, 04:44 PM

Looks good to me but it's a hell of a drive from London.

benz_addict · 07-03-2009, 05:23 PM

Man, YOU ARE THE MAN! And damn that car was messed up. Is it a members car? How do the bolts from the rear axle just come off?
*bookmarked*

SebaCL600 · 07-03-2009, 06:46 PM

Quote:

Originally Posted by benz_addict

Man, YOU ARE THE MAN! And damn that car was messed up. Is it a members car? How do the bolts from the rear axle just come off?
*bookmarked*

Yes, it's my car. I only have the car for a few months so I don't know how the bolts came loose. These guys are really great and provide service that no dealer will ever match. They checked out the car from front to back and fixed whatever needed to be done. They also kept me updated on the process of the repairs few times a day. So if anyone wants any work done to their car I highly recommend them. I know that I'm going back there in a few months for new lower/upper control arms, rotors, pads, lowering module and a tune. Thanks again Chris and Bruce.

JDB · 07-04-2009, 12:09 AM

Hi Oxygen,

I just want to compliment you on the highly documented repairs on that CL. It's truly rare that someone takes the care that you do, and also takes the time and extra effort to document things as you have done.

If I were located anywhere near your shop, I would certainly be dropping by to have you maintain my vehicles.

Great job!

JDB

V12Godspeed · 07-04-2009, 12:35 AM

As always Chris, you and Bruce are top Notch! Very well documented and nice work on fixing these issues.

BlownV8 · 07-04-2009, 02:19 AM

Awesome work. The next thing that will fail is the upper idler pulley. Should have replaced that while you were in there.

~CL500~ · 07-06-2009, 03:54 PM

First class post man. Very nicely done.

Busa196 · 07-11-2009, 12:02 PM

Quote:

Originally Posted by JDB

Hi Oxygen,

I just want to compliment you on the highly documented repairs on that CL. It's truly rare that someone takes the care that you do, and also takes the time and extra effort to document things as you have done.

If I were located anywhere near your shop, I would certainly be dropping by to have you maintain my vehicles.

Great job!

JDB

+1 for sure

Mercedes22 · 07-13-2009, 06:03 AM

Quote:

Originally Posted by bentleyboy

Looks good to me but it's a hell of a drive from London.

Yes a long way from the UK. A great job, many thanks.

ivanj · 07-16-2009, 02:10 PM

Is an ABC fluid flush part of the recommended service? What is the interval? What should the dealer or independent charge?

When I purchased my new 2005 CL55 in 2006 it had been sitting so long I had the problem of a droppy suspension. The dealer ended up replacing the enite system except for the hoses. Alas, it took 4 trips to the dealership until they finally fixed the problem.

They told me that if the car sits for months the ABC filters, valves etc. get gummed up with bits from the manufacturing process.
MB has the free initial oil change in the engine so these bits are removed from the engine.
I think that MB should do the same to the ABC system so these bits are flushed from the system.

I almost insisted on returning the car under the NH lemon law but they finally made it right under waranty. The two AMG specialists at the dealer took it as personal insult that they couldn't fix the problem piecemeal as MBUSA wants them to under waranty so they really worked hard to fix the thing. Thank G*d I have another vehicle!

Oxygen · 07-17-2009, 06:42 PM

I don't know what the dealer's procedures are... I know the fluid and the filters are expensive so I doubt any of them would want to do this for free.

Maybe someone who works for MB can pitch in.

~CL500~ · 08-08-2009, 10:19 PM

Regarding the axle bolts...

I just checked mine and all but two of them were loose! This seems like something we need to keep an eye on once in a while. Clunking noises when shifting may be indicative of the problem. Check your bolts!

benz_addict · 08-08-2009, 10:59 PM

Quote:

Originally Posted by ~CL500~

Regarding the axle bolts...

I just checked mine and all but two of them were loose! This seems like something we need to keep an eye on once in a while. Clunking noises when shifting may be indicative of the problem. Check your bolts!

Thanks for the heads up I will do this right now

blahuh · 08-08-2009, 11:01 PM

There is no recommend service interval for the ABC system. For the sagging suspension problem MB says flush, then if still present, replace corresponding valve block. I personally flush or filter the ABC fluid on any repair; strut, line, valve block, etc... I also recalibrate the level stored in the ABC control module after repairs to help keep down on comebacks. Don't know if MB approves but they havent denied any claims yet so Ill keep on doing what I am doing.

Exotic-metal55 · 08-10-2009, 06:05 PM

Great info!! Will save people lots of money!!

sprins · 08-10-2009, 06:24 PM

Impressive description. Oxygen definitely knows his ABCs ;-)

ivanj · 08-10-2009, 08:06 PM

Quote:

Originally Posted by benz_addict

Thanks for the heads up I will do this right now

Thank you - will have them check this - it seems to be a common problem that some dealers are aware of.

Oxygen · 08-12-2009, 03:21 AM

I will be writing more articles like these as cars come in and out. I should be installing a new ABC tandem pump in a W220.176 S600 soon.

Interested in doing it on either a W221 or a W216, but most of those are still under factory warranty.

07-03-2009, 04:10 PM	#2
Oxygen MBWorld Fanatic! Join Date: Mar 2005 Location: Long Island, NY Posts: 2,735 Drives: w220 S600 V12 Biturbo - TUNED	We also discovered that the IC pump has failed. The pump was replaced with a newer model... The rear axle made clunking sounds when the car would be engaged in gear.. I discovered that there were 2 bolts missing on the rear axle connecting to the differential. The other 4 bolts were loose or half way out.... Cleaned the rear axle, replaced the washers and the 6 bolts.. torque to correct specs... __________________ \| Photos \| TTMotorsports Team #27 \| ν = μ / ρ, [m² s-1] \| '05 Mercedes-Benz S600 - 5.5L 36V SOHC V12 Biturbo Designed & Built @ TTMotorsports \| ///AMG \| RENNtech \| PES \| Meisterschaft \| Snow Performance \| BMC \| Rädenergie

07-03-2009, 04:12 PM	#3
Oxygen MBWorld Fanatic! Join Date: Mar 2005 Location: Long Island, NY Posts: 2,735 Drives: w220 S600 V12 Biturbo - TUNED	Of course after the car was assembled there are many more procedures before the car was "ready to drive"... -Flush/Fill/Bleed Power Steering -Flush/Fill/Bleed ABC -Flush/Fill/Bleed Intercoolers -Engine Oil Change -New Belt -Recharge A/C __________________ \| Photos \| TTMotorsports Team #27 \| ν = μ / ρ, [m² s-1] \| '05 Mercedes-Benz S600 - 5.5L 36V SOHC V12 Biturbo Designed & Built @ TTMotorsports \| ///AMG \| RENNtech \| PES \| Meisterschaft \| Snow Performance \| BMC \| Rädenergie

07-03-2009, 04:13 PM	#4
Oxygen MBWorld Fanatic! Join Date: Mar 2005 Location: Long Island, NY Posts: 2,735 Drives: w220 S600 V12 Biturbo - TUNED	We are located in Farmingdale, Long Island so if any of you guys are looking for expert ABC service/repair and don't want to pay out of your nose at the dealership, please call or come see us! We are sponsors on MBW and have a ton of references for the work that we've done over the years. __________________ \| Photos \| TTMotorsports Team #27 \| ν = μ / ρ, [m² s-1] \| '05 Mercedes-Benz S600 - 5.5L 36V SOHC V12 Biturbo Designed & Built @ TTMotorsports \| ///AMG \| RENNtech \| PES \| Meisterschaft \| Snow Performance \| BMC \| Rädenergie

07-03-2009, 04:41 PM	#5
Oxygen MBWorld Fanatic! Join Date: Mar 2005 Location: Long Island, NY Posts: 2,735 Drives: w220 S600 V12 Biturbo - TUNED	Link to Ixetic (hydraulic pumps): http://www.ixetic.com Link to RAPA (hydraulic solenoid valves): http://www.baika.de/portal/baika_pro...64,detail.html __________________ \| Photos \| TTMotorsports Team #27 \| ν = μ / ρ, [m² s-1] \| '05 Mercedes-Benz S600 - 5.5L 36V SOHC V12 Biturbo Designed & Built @ TTMotorsports \| ///AMG \| RENNtech \| PES \| Meisterschaft \| Snow Performance \| BMC \| Rädenergie

07-03-2009, 05:23 PM	#7
benz_addict Super Member Join Date: Jan 2007 Location: Toronto, Mississauga Posts: 943 Drives: CL55 ///AMG	Man, YOU ARE THE MAN! And damn that car was messed up. Is it a members car? How do the bolts from the rear axle just come off? bookmarked Last edited by benz_addict; 07-03-2009 at 05:31 PM.

07-03-2009, 04:44 PM	#6
bentleyboy Newbie Join Date: Jul 2009 Posts: 16 Drives: CL600 bi-turbo W215	Looks good to me but it's a hell of a drive from London.

07-04-2009, 12:09 AM	#9
JDB Member Join Date: Nov 2002 Posts: 218 Drives: 2008 CLK63 BS, 2004 CL55, 2006 C350, 1999 E430	Excellent Documentation Hi Oxygen, I just want to compliment you on the highly documented repairs on that CL. It's truly rare that someone takes the care that you do, and also takes the time and extra effort to document things as you have done. If I were located anywhere near your shop, I would certainly be dropping by to have you maintain my vehicles. Great job! JDB

07-04-2009, 12:35 AM	#10
V12Godspeed MBWorld Fanatic! Join Date: Mar 2004 Location: Nowhere Land Posts: 3,846 Drives: E55	As always Chris, you and Bruce are top Notch! Very well documented and nice work on fixing these issues. __________________ *Current:* 04- E55- White/ Pano w/all options/ Stock for now... *Previous Rides:* 05- CL65- "The Black Bison" VRP 825 - 10.72 @ 128.08 http://www.youtube.com/watch?v=caoztJbtaZA "Capo Regime North (Member# 3)" Gone but not forgotten.... 2004 E55 Evotech Stage 4+ - Silver 11.5 @ 120.96 http://www.youtube.com/watch?v=AgNFUdDMQHw *2002 C32- Black*

07-04-2009, 02:19 AM	#11
BlownV8 MBWorld Fanatic! Join Date: Aug 2003 Location: In my garage Posts: 1,483 Drives: E55, Renntech CL600(sold), GL450	Awesome work. The next thing that will fail is the upper idler pulley. Should have replaced that while you were in there.

07-06-2009, 03:54 PM	#12
~CL500~ Super Member Join Date: Oct 2005 Location: Northern NJ Posts: 563 Drives: W215 & W251	First class post man. Very nicely done. __________________ 2001 CL500 (Horizon Blue / Charcoal, Parktronic, Linguatronic, Wood Pkg) 2008 R350 (Iriduim Silver / Charcoal, P2, Pano, iPod, RSE, 7-Seat, 6-Disc CD, Htd Seats) Are you an MBWorld member in the IT industry? Join the MB Owners IT Group here on MBWorld!

07-16-2009, 02:10 PM	#15
ivanj Member Join Date: Jun 2009 Posts: 133 Drives: CL55, G500, NSX	Is an ABC fluid flush part of the recommended service? What is the interval? What should the dealer or independent charge? When I purchased my new 2005 CL55 in 2006 it had been sitting so long I had the problem of a droppy suspension. The dealer ended up replacing the enite system except for the hoses. Alas, it took 4 trips to the dealership until they finally fixed the problem. They told me that if the car sits for months the ABC filters, valves etc. get gummed up with bits from the manufacturing process. MB has the free initial oil change in the engine so these bits are removed from the engine. I think that MB should do the same to the ABC system so these bits are flushed from the system. I almost insisted on returning the car under the NH lemon law but they finally made it right under waranty. The two AMG specialists at the dealer took it as personal insult that they couldn't fix the problem piecemeal as MBUSA wants them to under waranty so they really worked hard to fix the thing. Thank G*d I have another vehicle!

07-17-2009, 06:42 PM	#16
Oxygen MBWorld Fanatic! Join Date: Mar 2005 Location: Long Island, NY Posts: 2,735 Drives: w220 S600 V12 Biturbo - TUNED	I don't know what the dealer's procedures are... I know the fluid and the filters are expensive so I doubt any of them would want to do this for free. Maybe someone who works for MB can pitch in. __________________ \| Photos \| TTMotorsports Team #27 \| ν = μ / ρ, [m² s-1] \| '05 Mercedes-Benz S600 - 5.5L 36V SOHC V12 Biturbo Designed & Built @ TTMotorsports \| ///AMG \| RENNtech \| PES \| Meisterschaft \| Snow Performance \| BMC \| Rädenergie

08-08-2009, 10:19 PM	#17
~CL500~ Super Member Join Date: Oct 2005 Location: Northern NJ Posts: 563 Drives: W215 & W251	Regarding the axle bolts... I just checked mine and all but two of them were loose! This seems like something we need to keep an eye on once in a while. Clunking noises when shifting may be indicative of the problem. Check your bolts! __________________ 2001 CL500 (Horizon Blue / Charcoal, Parktronic, Linguatronic, Wood Pkg) 2008 R350 (Iriduim Silver / Charcoal, P2, Pano, iPod, RSE, 7-Seat, 6-Disc CD, Htd Seats) Are you an MBWorld member in the IT industry? Join the MB Owners IT Group here on MBWorld! Last edited by ~CL500~; 08-08-2009 at 10:23 PM.

08-08-2009, 11:01 PM	#19
blahuh Junior Member Join Date: Apr 2009 Location: San Diego Posts: 37 Drives: 1998 C43	There is no recommend service interval for the ABC system. For the sagging suspension problem MB says flush, then if still present, replace corresponding valve block. I personally flush or filter the ABC fluid on any repair; strut, line, valve block, etc... I also recalibrate the level stored in the ABC control module after repairs to help keep down on comebacks. Don't know if MB approves but they havent denied any claims yet so Ill keep on doing what I am doing.

08-10-2009, 06:05 PM	#20
Exotic-metal55 Super Member Join Date: Jun 2008 Location: Texas Posts: 813 Drives: 2003 CL55	Great info!! Will save people lots of money!! __________________ CL55, 1/4 mile time 11.61@120.26mph, 1.75 sixty. ASP 180mm pulley, LET tune, 82mm TB, CF airbox, Aux.Garrett H/E, Meziere 20 gpa I/C pump, filters, Nitto Invos 275/40/18 rear (street tires), Wiseco Forged pistons/Nikasil coated bore. Updated Sig. 7/12/09

08-10-2009, 06:24 PM	#21
sprins MBWorld Fanatic! Join Date: Jan 2005 Posts: 1,399 Drives: AMG	Impressive description. Oxygen definitely knows his ABCs ;-) __________________

08-12-2009, 03:21 AM	#23
Oxygen MBWorld Fanatic! Join Date: Mar 2005 Location: Long Island, NY Posts: 2,735 Drives: w220 S600 V12 Biturbo - TUNED	I will be writing more articles like these as cars come in and out. I should be installing a new ABC tandem pump in a W220.176 S600 soon. Interested in doing it on either a W221 or a W216, but most of those are still under factory warranty. __________________ \| Photos \| TTMotorsports Team #27 \| ν = μ / ρ, [m² s-1] \| '05 Mercedes-Benz S600 - 5.5L 36V SOHC V12 Biturbo Designed & Built @ TTMotorsports \| ///AMG \| RENNtech \| PES \| Meisterschaft \| Snow Performance \| BMC \| Rädenergie

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