Repairing wiring harness

AR54.18-P-0100GD

Repairing wiring harness

16.2.12



Removing

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A



Notes on battery

All models

AH54.10-P-0001-01A

1

Disconnect ground cable from battery

AR54.10-P-0003G

2

Remove cover of control module box (F23/1)

 Cable strap of engine wiring harness on the body side (1) to control module box (F23/1)

AR54.20-P-1257GC

3

Unclip cable strap (2)

4

Cut open cable strap of engine wiring harness to engine wiring harness on the body side and put engine wiring harness (3) to one side

5

Open fastening clips (4, 5) on the firewall

6

Open locking device of coupling (6) on traction systems control module (N47) and disconnect coupling (6)

7

Disconnect coupling (7) from traction systems control module (N47)

 CAN data bus

8

Expose branch-off lines of engine wiring harness on the body side (1)



Disassembling

9

Separate insulation of engine wiring harness on the body side (1)

 Separate from coupling (6) as far as the stabilized area (A)

10

Expose damaged individual cables

11

Remove contacts of damaged cables from coupling (7) on the traction systems control module (N47)

AR15.18-P-0115-02A

 Unlocking tool for SPT/JPT contacts

*210589023300



 Electric wiring diagram for electronic stability program (ESP) up to vehicle ident. end no. 016125

PE42.45-P-2000GD



 Electric wiring diagram for electronic stability program (ESP) from vehicle ident. end no. 016126

PE42.45-P-2000GC

 Danger!

Risk of injury to skin and eyes through handling hot or glowing objects

Wear safety gloves, protective clothing and if necessary safety glasses.

AS00.00-Z-0002-01A

 Danger!

Risk of injury from burns to the skin and eyes, risk of poisoning caused by inhaling vapors when processing shrink-fit sleeves.

Only carry out work in well ventilated areas. Wear safety glasses with side protection and safety gloves.

AS00.19-Z-0001-01A

12

Repair wiring harness by means of soldered terminal sleeves

AR54.18-P-0100-02A

Hot air gun

*WH58.30-Z-1004-20A

13

Perform function check after the repair

AR54.18-P-0600-01A

 Electrical connection set

*220589009900



Assembling

14

Insert contacts of the repaired cables in coupling (7) in the traction systems control module (N47)

 No tools required

15

Insulate separated area of fabric insulation with fabric insulating tape



Installing

16

Plug coupling (7) into traction systems control module (N47)

 CAN data bus

17

Plug coupling (6) into traction systems control module (N47) and close locking device of coupling (6)

18

Close fastening clips (4, 5) on the firewall

19

Attach cable strap of engine wiring harness to engine wiring harness on the body side

 Installation: Replace cable strap

20

Clip in cable strap (2)

Cable strap of engine wiring harness on the body side (1) to control module box (F23/1)

21

Install cover of control module box (F23/1)



AR54.20-P-1257GC

22

Connect ground cable to battery

AR54.10-P-0003G

23

Tie up engine wiring harness on the body side(1)

AR15.18-P-0002-07GD

24

Read out fault memory with HHT

Stored faults which can be caused during assembly or test work due to disconnected cables or a simulation must be processed in the fault memories and then erased after the work is finished.



AD00.00-P-2000-03C

Hand-Held Tester (HHT)

*WH58.30-Z-1036-13A

Test cable (Multiplexer)

*WH58.30-Z-1037-13A

Adapter cable (HHT) for data link connector (X11/4, 16-pin)

*WH58.30-Z-1044-13A

Number

Designation

WH58.30-Z-1036-13A

Handheld tester (HHT)

651 100 01 99

WH58.30-Z-1037-13A

Test cable (multiplexer)

651 100 40 99

WH58.30-Z-1044-13A

Adapter cable (HHT) for datalink connector (X11/4, 16-pin)

WH58.30-Z-1004-20A

Hot-air gun