Repairing wiring harness

AR54.18-P-0100GC

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)



AR54.20-P-1257GC

4

Cut open cable strap on the engine wiring harness to the engine wiring harness on the body side

5

Disconnect coupling (24) on CDI control module (N3/9)

6

Unlock and disconnect coupling (25) on CDI control module (N3/9)

7

Disconnect circulation pump connector (X73/2)

8

Disconnect coupling (26) on glow output stage (N14/2)

9

Expose branch-off lines of engine wiring harness (1)



Disassembling

10

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

 Separate from the control module box (F23/1) as far as the stabilized area (A)

11

Expose damaged individual cables

12

Remove contacts of damaged cables from the each of the couplings or connector affected

Couplings on CDI control module (N3/9)

AR15.18-P-0115-02C

Coupling on glow output stage (N14/2)

AR15.18-P-0115-02B

Circulation pump connector (X73/2)

AR15.18-P-0115-03A

 Unlocking tool for SPT/JPT contacts

*210589023300



 Electric wiring diagram for common rail diesel injection (CDI), engine block wiring harnesses

PE07.16-P-2000GD



 Electric wiring diagram for common rail diesel injection (CDI), engine compartment/frame-floor system wiring harnesses

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

13

Repair wiring harness by means of soldered terminal sleeves

AR54.18-P-0100-02A

Hot air gun

*WH58.30-Z-1004-20A

14

Perform function check after the repair

AR54.18-P-0600-01A

 Electrical connection set

*220589009900



Assembling

15

Insert contacts of the repaired cables in each of the couplings/connectors affected

 No tools required

16

Insulate separated area of fabric insulation with fabric insulating tape



Installing

17

Plug coupling (26) into glow output stage (N14/2)

18

Connect circulation pump connector (X73/2)

19

Plug coupling (25) into CDI control module (N3/9) and lock

20

Plug coupling (24) into CDI control module (N3/9)

21

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

 Installation: Replace cable strap

22

Install cover of control module box (F23/1)

 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.

AR54.20-P-1257GC

23

Connect ground cable to battery

AR54.10-P-0003G

24

Tie up engine wiring harness (1)

AR15.18-P-0002-07GD

25

Read out fault memory with HHT



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