Crank sensor & intake manifold problem: DTC 0522, DTC 0120
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Joined: Jan 2004
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C230 coupe 2003, 2014 GLK350, 2020 GLC63
Crank sensor & intake manifold problem: DTC 0522, DTC 0120
Hi All,
My friend has a 2006 C350 with around 90000 miles, M272 engine #216154.
She was driving the car, and it sputtered and stalled on the road. When she tried to restart the vehicle, it cranked but would not turn over and then a CEL briefly came on. She's not sure of any other "warning" symptoms. She had 1/4th gas left in the tank. She had the car towed to a gas station, added some gas, and the car was able to restart. The next day she drove the car to the dealer for diagnosis and repair.
The dealer found a faulty "crank hall sensor" and a broken linkage flap on the intake manifold. The error codes found were: DTC 0522, DTC 0120. They replaced the intake manifold, installed a new crank hall sensor, and performed campaign 2012070002 "Retrofit adapter wiring harness on camshaft adjustment solenoids." Repairs cost ~$2200.
After she got her car back, within 24 hours, it died on the road again. We are wondering: did the dealer make the wrong diagnosis? Could there be something wrong with the fuel pump? What else could be going on?
Also, any advice on how she should address the issue with the dealer? She is upset that she paid for costly repairs and yet the problem was not resolved. She feels she can not trust the dealer now.
Here are images of the service invoice:
My friend has a 2006 C350 with around 90000 miles, M272 engine #216154.
She was driving the car, and it sputtered and stalled on the road. When she tried to restart the vehicle, it cranked but would not turn over and then a CEL briefly came on. She's not sure of any other "warning" symptoms. She had 1/4th gas left in the tank. She had the car towed to a gas station, added some gas, and the car was able to restart. The next day she drove the car to the dealer for diagnosis and repair.
The dealer found a faulty "crank hall sensor" and a broken linkage flap on the intake manifold. The error codes found were: DTC 0522, DTC 0120. They replaced the intake manifold, installed a new crank hall sensor, and performed campaign 2012070002 "Retrofit adapter wiring harness on camshaft adjustment solenoids." Repairs cost ~$2200.
After she got her car back, within 24 hours, it died on the road again. We are wondering: did the dealer make the wrong diagnosis? Could there be something wrong with the fuel pump? What else could be going on?
Also, any advice on how she should address the issue with the dealer? She is upset that she paid for costly repairs and yet the problem was not resolved. She feels she can not trust the dealer now.
Here are images of the service invoice:
Last edited by REX0000; Oct 30, 2012 at 02:49 PM. Reason: removed unnecessary wording
MBworld Guru
Joined: Dec 2009
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NO LONGER ACTIVE
First of all, I'd suggest calling the service manager at the dealer to say that you either want them to fix the problem at no additional cost, or you want your money back because they did not fix the problem. If they give you any flack, ask them if they are highly trained MBZ mechanics, or just parts swappers.
The reality is that they did the right things here. The 0522 error is definitely a problem in the intake manifold tumble flaps. The 0120 error is an odd one. I think it could be related to the CPS failure, but I'm not sure. If the engine dies and there is no MIL or stored codes, then it's usually the CPS (it;s possible you got a bad one), or, a fuel delivery problem (i.e. fuel pump).
The reality is that they did the right things here. The 0522 error is definitely a problem in the intake manifold tumble flaps. The 0120 error is an odd one. I think it could be related to the CPS failure, but I'm not sure. If the engine dies and there is no MIL or stored codes, then it's usually the CPS (it;s possible you got a bad one), or, a fuel delivery problem (i.e. fuel pump).
Super Member
Joined: May 2009
Posts: 904
Likes: 22
From: Toronto, Ontario, Canada, eh!
2003 C230 Sports Coupe, Paprika Metallic Red, Auto, Pano, Leather
"crank hall sensor" sounds like one of the sensor near the top of the engine,.... Crankshaft Position Sensor near firewall at flywheel (MB 642-905-00-00 as per bill) is what was replaced.
Try doing a CPS calibration as follow,...
- turn on car as usual,...
- with car in PARK, slowly rev the engine from 700RPM to 2500RPM over 2 minutes (basically from 700RPM start applying enough pressure at the gas pedal to add another 100RPM every 6.6 seconds (or aim for adding another 150RPM for every 10 seconds))
- at 2 minute mark with 2500 RPM,... hold 2500RPM at idle for 30 seconds
- then drive around
It helps to chart it down,... with a stopwatch handy
adding 150 RPM every 10 sec
0 sec 700 RPM
10 sec 850 RPM
20 sec 1000 RPM
....
120 sec 2500 RPM
OR
adding 100 RPM every 6.6 sec
0 sec 700 RPM
7 sec 800 RPM
13 sec 900 RPM
....
120 sec 2500 RPM
NOTE: CPS recalibration is generally not required with a simple CPS change. But if the car had error codes prior to the CPS change, then a CPS recalibration should occur. BTW, dealer should have done the CPS recalibration via STAR. The above method is how you can do it yourself without STAR
Report back
Try doing a CPS calibration as follow,...
- turn on car as usual,...
- with car in PARK, slowly rev the engine from 700RPM to 2500RPM over 2 minutes (basically from 700RPM start applying enough pressure at the gas pedal to add another 100RPM every 6.6 seconds (or aim for adding another 150RPM for every 10 seconds))
- at 2 minute mark with 2500 RPM,... hold 2500RPM at idle for 30 seconds
- then drive around
It helps to chart it down,... with a stopwatch handy
adding 150 RPM every 10 sec
0 sec 700 RPM
10 sec 850 RPM
20 sec 1000 RPM
....
120 sec 2500 RPM
OR
adding 100 RPM every 6.6 sec
0 sec 700 RPM
7 sec 800 RPM
13 sec 900 RPM
....
120 sec 2500 RPM
NOTE: CPS recalibration is generally not required with a simple CPS change. But if the car had error codes prior to the CPS change, then a CPS recalibration should occur. BTW, dealer should have done the CPS recalibration via STAR. The above method is how you can do it yourself without STAR
Report back
Super Member
Joined: Dec 2010
Posts: 712
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From: chicago
2005 c230 kompressor 2003 s500 94 wrangler
i caught my dealership making up codes...the guy said 3 grand
my response: i just couldnt help myself to laugh and laugh and laugh
never had a problem since
my response: i just couldnt help myself to laugh and laugh and laugh
never had a problem since
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Joined: Jun 2008
Posts: 19,942
Likes: 192
From: Llandudno, Cape Town, South Africa
late 2009 CLK 350 Coupe Elegance, '65 Jaguar S Type wires
Likely bad CPS. The CPS is a hall effect sensor. Check fuel pressure on the front rail that connects the injectors s/b > 3.8 bar or 55 psi while cranking.
The "Retrofit adapter wiring harness on camshaft adjustment solenoids" is an M271 related issue not M272 engine.
Inlet manifold flap issues are common on early M272 engines but would not cause the car to stall.
The "Retrofit adapter wiring harness on camshaft adjustment solenoids" is an M271 related issue not M272 engine.
Inlet manifold flap issues are common on early M272 engines but would not cause the car to stall.
