Work Procedure
Service Action 191
1. Raise vehicle on hoist and note radio presets.
2. Open engine lid, install fender covers and disconnect battery negative post and insulate.
3. Remove cover from central electric board.
4. Remove phillips screws and lift CEB from body.
5. Unlock the locking rail on CEB underside.
6. Pull off CEB plugs "L" and "F", if necessary, cut tie strap.
7. Remove the first element from CEB plug "L". Install the supplied wiring bridge with connector (800 mm long, 0.5 sq.mm, black/yellow) into element 1, position 5. Reassemble element and install plug "L" into CEB.
8. Disassemble wiring plug "F". Install the other connector from wiring bridge in element 2 position 3. Reassemble element and install plug "F" into CEB.
9. Remove two phillips screws from the cover for the wiring plug front/DME harness and remove cover.
10. Disconnect 14 pin plug. Open tie strap on partition wall. Disengage wiring plug from bracket on partition wall.
11. Remove cover from female part of wiring plug. Install solder terminal of wiring (800 mm long, 2.5 sq.mm, black/yellow) in position 11 of the wiring plug. Reinstall cover of wiring plug. Route wiring through additional hole of rubber grommet in partition wall into vehicle inside CEB area. Open up hole in grommet by pulling off rubber nipple. Pull wiring from body well. Install and solder connector (from kit). Part Number 999 652 475 22.
12. Remove wiring plug "E" from CEB and disassemble. Engage installed connector in element 2, position 1. Reassemble wiring plug and install plug into CEB.
13. Engage CEB locking rail.
14. Tie down additional wiring with tape and, if necessary, tie down wiring harnesses with tie strap. Part Number N 020 906 3.
15. Reinstall CEB and tighten the two phillips screws. Install 7.5A fuse in position 35. Reinstall CEB cover.
16. Remove upper cover from 14 pin plug (engine side). Install solder terminal of wiring (2,300 mm long, 2.5 sq.mm, black/yellow) in position 11. Reinstall plug cover.
17. Reconnect 14 pin plug. Engage housing in bracket on partition wall and reinstall tie strap. Reinstall 14 pin plug cover with two phillips screws.
18. Remove fuel rail cover.
19. Route new wire from 14 pin plug through tie straps on partition wall to fuel rail. Route wiring through tie straps on fuel rail towards the belt cover. Tie down wiring on fuel rail with additional tie strap. Part Number N 020 902 4.
20. Route wiring between belt cover and cylinder head parallel to the oil pressure switch wiring harness. Reinstall fuel rail cover.
21. Lift vehicle. Remove the engine cover plate screws and remove cover plate. Use tie strap to tie wiring to harness. Pull off rubber boot and angled connections from steering pump pressure switch. Cut terminal from 0.75 sq.mm, red/blue wire. Pull insulation hose through rubber boot and cut off approximately 50 mm. Loop red/blue wire and guide into insulation hose. Push newly installed wire through rubber boot.
22. Push shrink tubing from kit (approximately 35 mm long) over both insulation hoses. If necessary, bend the wire connection to permit installation of the shrink tube over the angled wire connector. Heat shrink tubing in the area of the wiring loop with hot air blower and press tight.
23. Cut newly installed wire to correct length and install angled connector from kit. Solder connector to cable end.
24. Cut a 3 mm diameter water drain hole at the lowest point of the rubber boot. Connect wiring terminals and install rubber boot.
25. Reinstall engine cover plate. Make sure wiring does not contact cover plate.
26. Lower vehicle.
27. Connect battery.
28. Remove fender covers and close engine lid.
29. Perform system adaption. Only from VIN # 94_JN465225.
Note: Set time clock and radio pre-sets (code radio where applicable.)