AR54.18-P-0100GC | Repairing wiring harness | 16.2.12 |
MODEL 168.007 with ENGINE 668.941
engine wiring harness
MODEL 168.008 with ENGINE 668.940
engine wiring harness
P54.18-2598-08
| 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. | |
| Notes on battery | All models | |
1 | Disconnect ground cable from battery | ||
2 | Remove cover of control module box (F23/1) | | |
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) | |
Coupling on glow output stage (N14/2) | |||
Circulation pump connector (X73/2) | |||
Unlocking tool for SPT/JPT contacts | |||
| Electric wiring diagram for common rail diesel injection (CDI), engine block wiring harnesses | ||
| Electric wiring diagram for common rail diesel injection (CDI), engine compartment/frame-floor system wiring harnesses | ||
Danger! | Risk of injury to skin and eyes through handling hot or glowing objects | Wear safety gloves, protective clothing and if necessary safety glasses. | |
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. | |
13 | Repair wiring harness by means of soldered terminal sleeves | ||
Hot air gun | |||
14 | Perform function check after the repair | ||
Electrical connection set | |||
| 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. | |
23 | Connect ground cable to battery | ||
24 | Tie up engine wiring harness (1) | ||
25 | Read out fault memory with HHT | ||
| |||
Hand-Held Tester (HHT) | |||
Test cable (Multiplexer) | |||
Adapter cable (HHT) for data link connector (X11/4, 16-pin) |
220 589 00 99 00
Electrical connection set
Unlocking tool for SPT/JPT contacts
210 589 02 33 00
Commercially available tools