B. Installation of Ground Wires and Bracket to SBC Wiring Harness
1. Lock the vehicle globally and then wait for 30 seconds for the SBC control module to power-down.
2. Remove right intake air duct (arrow, Figure 3).
3. Disconnect SBC hydraulic unit harness connector (arrow, Figure 4) from SBC hydraulic unit (A) and remove cable tie (B, Figure 5).
4. Detach the SBC hydraulic unit ground wire harness (arrow, Figure 5) at ground terminal stud (A).
5. Remove cable tie (arrow, Figure 6) securing SBC wire harness (A) to SBC connector housing (B).
6. Remove SBC connector housing cover (A, Figure 7):
^ Using a small screw driver, carefully pry cover (A) away from locking lugs (arrow) until it disengages.
^ Repeat the process on opposite side.
^ Remove the cover (A) from the housing (B).
Note:
There are two different versions of the SBC wiring harness connector (Figure 8a, b) installed in vehicles involved with this campaign.
7. Open the (gray) secondary lock in the SBC connector housing (A, Figure 9) by sliding the lock in the direction indicated by the arrows (Figure 9) using a small screwdriver.
8. Remove cable tie (arrow, Figure 10) securing ground wires (A) to SBC connector housing (B).
9. Remove SBC ground wires (arrows, Figure 11) from SBC harness connector (A):
^ Unpin ground wire connectors (position 37 and 44, Figure 11) using cable release tool and remove from SBC connector housing (A) (special tool nos.: W 000 589 13 99 30 and W 220 589 01 99 50).
^ Discard old ground wire harness (arrows), it is no longer needed.
10. Insert the new ground wire harness (arrows Figure 11) into the SBC connector housing (A):
^ Insert longer ground wire into position 44. Insert shorter ground wire into position 37.
Note:
Ensure ground wire connectors are properly locked into place.
11. Close the (gray) secondary lock of the SBC connector housing (A, Figure 12) by sliding the lock in the direction indicated by the arrows (Figure 12) using a small screwdriver until it locks into place.
12. Reinstall the SBC wire harness connector cover in reverse order.
Note:
Ensure the locking lugs (arrows, Figure 7) on the harness connector are properly engaged into the harness connector cover.
13. Secure SBC wiring harness (A, Figure 13) (excluding ground wires) to the SBC connector cover harness receptacle (arrow) using a new cable tie (B).
Note:
^ Ensure that the SBC wiring harness (A) is properly routed so that it is free of tension in the SBC connector housing.
^ The cable tie "buckle" (D) must be located at the side of the connector cover harness receptacle (arrow) as depicted.
14. Secure ground wiring harness (C, Figure 13) to the SBC connector housing receptacle (F) using a new cable tie (E).
15. Attach bracket (A, Figure 16) to the SBC hydraulic unit (B, Figure 16):
Note:
If mounting bores (arrows, Figure 15) are not present in hydraulic unit proceed to step 16, if bores are present continue with this step.
Using hand tools, tap threads into SBC hydraulic unit bore by running self tapping screw (arrow, Figure 14) into lower bore without mounting bracket positioned on SBC unit (A).
Note:
^ In order to avoid breaking the self-tapping screw (arrow) during installation, the screw (arrow) must be positioned absolutely straight.
^ Do not use power tools to install self tapping screw (arrow).
^ In the event self tapping screw (arrow) is broken during installation of bracket (A) perform step 16 then continue with campaign (installation of bracket due to breakage of mounting screw will not be covered under warranty).
^ Remove self tapping screw (arrow).
^ Position bracket (A, Figure 16) on SBC hydraulic unit (B), reinstall self tapping screw (arrow) and torque to 7 Nm.
16. Install clamp-on mounting bracket (B, Figure 17) if bores are not present in hydraulic unit:
Note:
Ensure sheathing (arrow) on mounting bracket clamp is positioned as shown in Figure 17.
Position mounting bracket (B) onto SBC hydraulic unit (A) as shown in Figure 18.
Note:
^ Ensure mounting bracket (B, Figure 18) is flush with SBC hydraulic unit (A).
^ Torque mounting clamp screw (C) to 5 Nm while pressing bracket (B) onto SBC unit (A).
17. Insert a cable tie through slots (C, Figure 16) in bracket (A), do not close cable tie.
Note:
Cable tie installation shown on "bolt-on" type mounting bracket, cable tie installation for clampon type bracket is similar
18. Connect the SBC wire harness connector (Arrow, Figure 19) to the SBC hydraulic unit and secure with connector locking mechanism.
19. Attach the ground wire harness ring connector (A, Figure 20) to the body ground terminal (B) with M6 nut. Torque the M6 nut to 10 Nm.
Note:
^ The ground wire harness (arrow) must be routed under the SBC suction hose (C). The ring connector (A) must be positioned as shown in Figure 20.
^ This ground terminal (B) is to be used only for mounting the SBC ground wire harness (arrow).
20. Connect SDS and check software release:
Note:
Ensure only the following versions of DAS are used:
^ 11/2005 with SBC patch 479 installed on SDS
^ Any DAS version after 11/2005
Navigate through the following menu items in DAS and follow on-screen instructions:
"Control units/Chassis/SBC - Sensotronic Brake Control/Control unit adaptations".
Note:
^ Ensure to follow the on-screen instructions in DAS for connecting programming and terminal inspection tool to the SBC hydraulic unit.
^ In the event of malfunctions during the SBC programming, a message will appear in the DAS display and a troubleshooting guide will be displayed.
^ In the event DAS indicates that the SBC hydraulic unit requires replacement after inspecting SBC connector terminals, refer to WIS: AR42.46-P-0010R (for replacement instructions).
^ Note (regarding above WIS instructions):
Disregard WIS notes regarding brake bleeder pressure. The maximum pressure for brake bleeder is 2.5 bar.
21. Secure SBC wiring harness (A, Figure 21) to SBC hydraulic unit bracket (B) with cable tie (arrow). Tighten cable tie (arrow) using Hellermann MK9 cable tie pliers (Special Tool W 352 589 02 37 00); use setting 3 on cable tie pliers.
Note
^ The cable tie buckle (C) must not touch the bracket (B).
^ When attaching SBC wire harness (A) to the bracket (B), ensure that the wire harness (A) touches the bracket (B) and is mounted there tension free.
^ After the SBC cable (A) is secured, it must no longer be possible to move it in the longitudinal direction toward the bracket.
^ Disregard WIS notes regarding torque settings on cable tie pliers. Use settings specified in this step.
CAUTION!
Ensure harness is properly mounted to allow cable strain relief in area between cable tie and connector.
22. Proceed to SUBJECT C - QUALITY ASSURANCE MEASURES.