B. Installation of Ground Wires & 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. Loosen hose mounting strap (A, Figure 3) and reposition hose and strap (A) to create more working space.

3. Disconnect harness connector (C, Figure 3) from the SBC hydraulic unit (D).

4. Detach the SBC hydraulic unit ground wire (arrow, Figure 3) at ground terminal (B).





5. Remove cable tie (arrow, Figure 4) securing SBC wire harness (A) to SBC connector housing (B).





6. Remove fabric tape (circled area Figure 5) from wire harness up to rubber grommet.





7. Remove SBC connector housing cover (A, Figure 6):

^ 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 7a, b) installed in vehicles involved with this campaign.





8. Open the (gray) secondary lock in the SBC connector housing (A, Figure 8) by sliding the lock in the direction indicated by the arrows (Figure 8) using a small screwdriver.





9. Remove SBC ground wires (arrows, Figure 9) from SBC harness connector (A):

^ Unpin ground wire connectors (position 37 and 44) 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 wiring harness; it is no longer needed.

10. Insert the new ground wire harness (arrows Figure 9) 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 10) by sliding the lock in the direction indicated by the arrows (Figure 10) using a small screwdriver until it locks into place.





12. Loosely wrap the exposed SBC wire harness using fabric tape (arrows). Do not wrap the ground wiring harness (A, Figure 11) into the SBC wire harness.

13. Reinstall the SBC wire harness connector cover in reverse order.

Note:
Ensure the locking lugs (arrows, Figure 6) on the harness connector are properly engaged into the harness connector cover.





14. Secure the SBC wiring harness (A, Figure 12) (excluding the ground wiring harness) to the SBC connector cover harness receptacle (D) using a new cable tie (arrow).

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" (C) must be located outside of the connector cover harness receptacle (D) as depicted.





15. Secure ground wiring harness (arrow, Figure 13) to SBC wire harness (A) using two layers of fabric tape (B) in the circled area. Start taping approximately 35 mm (X = 35 mm, Figure 13) from end of connector cover receptacle (C).

Note:
See last bullet of step 23 note concerning fabric tape placement.





16. Remount the SBC wiring harness (A, Figure 14) in the wire harness guide (B):

^ Remove wire guide cover (C) and remove SBC wiring harness with grommet (D) from harness guide (B).





^ Reposition wiring harness with grommet (A, Figure 15) into the forward wall opening (B) in the wire guide (C).





^ Insert new routing clip (A, Figure 16) into wire guide (B) until top of clip (A) is flush with top of wire harness guide (B).

^ Reinstall top of wire harness guide (C, Figure 14).

17. Attach bracket to the SBC hydraulic unit:





Note:
If mounting bores (arrows, Figure 18) are not present in hydraulic unit proceed to step 18, if bores are present continue with this step.





Using hand tools, tap threads into SBC hydraulic unit bores by running self tapping screw (B, Figure 17) into lower bore without mounting bracket positioned on SBC unit.

Note:

^ In order to avoid breaking the self-tapping screw (B) during installation, the screw (B) must be positioned absolutely straight.

^ Do not use power tools to install self tapping screw.

^ In the event self tapping screw (B) is broken during installation of bracket (A) perform step 18 then continue with campaign (installation of bracket due to breakage of mounting screw will not be covered under warranty).

^ Remove self tapping screw (B).

^ Position bracket (A) on SBC hydraulic unit, reinstall self tapping screw (B) and torque to 7 Nm.





18. Install clamp-on mounting bracket (B, Figure 19):

^ Position mounting bracket (B) onto SBC hydraulic unit (A) as shown in Figure 19.

Note:

^ Ensure mounting bracket (B) is flush with SBC hydraulic unit (A).

^ Torque mounting clamp screw to 5 Nm while pressing bracket (B) onto SBC unit (A).

19. Insert a cable tie through slots (arrows, Figure 17) in bracket, do not close cable tie.

Note:
Cable tie installation shown on "bolt-on" type mounting bracket, cable tie installation for clamp-on type bracket is similar.





20. Connect the SBC wire harness connector (D, Figure 20) to the SBC hydraulic unit and secure with connector locking mechanism.

21. Position ground wiring harness parallel to the vehicle longitudinal axis (X-axis) on the body ground terminal. Torque the M6 nut to 10 Nm.

Note:





^ Ring connector (A, Figure 21) must be positioned as shown to avoid contact with water hose (B) and chafing the wire harness (C).

^ This ground terminal (D) is to be used only for mounting the SBC ground wire.

22. 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 (Model 211) and AR42.46-P-0010TX (Model 219)

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.

23. Secure ground wiring harness and SBC wiring harness (A, Figure 22) to SBC hydraulic unit bracket (B) with cable tie (arrow). Tighten cable tie (arrow) with Hellermann MK9 cable tie pliers (Special Tool: W 352 589 02 37 00) using setting 3 on pliers.

Note:

^ The cable tie buckle (C) must not touch the bracket (B).

^ When mounting the wiring harness set (A) to the bracket (B), ensure that the wiring harness set (A) touches the bracket (B) and is mounted there tension free, ensuring the wiring harness set (A) does not pull on the SBC connector (E).

^ After the cable set (A) is secured, it must no longer be possible to move it in the longitudinal direction toward the bracket.

^ Disregard WIS notes regarding toque settings on cable tie pliers. Use settings specified in this step.

^ The ground wires (A) must be completely wrapped with fabric tape (as performed in step 15) in the area adjacent to the SBC hydraulic unit bracket (B) to ensure that the ground wires do not become chafed. Readjust tape as necessary to prevent chafing.

CAUTION!
Ensure harness is properly mounted to allow cable strain relief in area between cable tie and connector.

24. Attach hose mounting strap (D, Figure 22) to mounting stud, secure with nut.

25. Proceed to SUBJECT C - QUALITY ASSURANCE MEASURES.