Procedure

A. MODEL 170 - REPLACE SECONDARY AIR INJECTION PUMP RELAY





1. Access fuse and relay box (arrow, Figure 1) in engine compartment.





2. Replace relay module K40 (A, Figure 2).

3. Assemble in reverse order.

4. Proceed to SUBJECT I.

B. MODEL 199 - REPLACE SECONDARY AIR INJECTION PUMP RELAY





1. Remove floor covering (A, Figure 3) and panel (B) underneath instrument cluster in front right footwell; refer to WIS document AR68.20-P-2070SLR.





2. Access passenger-side fuse and relay module (Figure 4)

3. Replace air injection pump relay (A, Figure 4).

4. Assemble in reverse order.

5. Proceed to SUBJECT I.

C. MODEL 203 - REPLACE SECONDARY AIR INJECTION PUMP RELAY





1. Open hood to access fuse and relay box (arrow, Figure 5) located on left side of engine compartment.

2. Open fuse and relay box cover.





3. Replace air injection pump relay (A, Figure 6).

4. Assemble in reverse order.

5. Proceed to SUBJECT I.

D. MODEL 211 - WITH CODE 803 OR 804 - REPLACE SECONDARY AIR INJECTION PUMP RELAY





1. Open hood; remove dust filter for heating/ventilation (arrow, Figure 7) located on right side of engine compartment.








2. Unclip relay holder (arrow, Figure 8) and disconnect bracket (A, Figure 8) from relay socket (B, Figure 9).

3. Replace air injection pump relay (A, Figure 9).

4. Assemble in reverse order.

5. Proceed to SUBJECT I.

E. MODEL 211 - AS OF CODE 805/MODEL 219 - REPLACE SECONDARY AIR INJECTION PUMP RELAY





1. Detach right side paneling (arrow, Figure 10) in luggage compartment.





2. Replace air injection pump relay in white slot (A, Figure 11).

3. Assemble in reverse order.

4. Proceed to SUBJECT I.

F. MODEL 215/220 - REPLACE SECONDARY AIR INJECTION PUMP RELAY





1. Open hood to access fuse and relay box (arrow, Figure 12) located on right side of engine compartment.

2. Remove fuse and relay box cover.





3. Replace air injection pump relay (A, Figure 13).

4. Assemble in reverse order.

5. Proceed to SUBJECT I.

G. MODEL 230 - REPLACE SECONDARY AIR INJECTION PUMP RELAY





1. Open hood to access fuse and relay box (arrow, Figure 14) located on right side of engine compartment.

2. Remove fuse and relay box cover.

3. Replace air injection pump relay:





^ A. (Figure 15) for vehicles up to and including production date 05/2002.

^ B. (Figure 15) for vehicles from production date 06/2002.

4. Assemble in reverse order.

5. Proceed to SUBJECT I.

H. MODEL 463 - REPLACE SECONDARY AIR INJECTION PUMP RELAY





1. Remove paneling under instrument panel in right footwell to access fuse and relay box (arrow, Figure 16); refer to WIS document AR68.10-P-1520GM.

2. Replace air injection pump relay (A).

3. Assemble in reverse order.

4. Proceed to SUBJECT I.

I. ALL MODELS - INSTALL ENGINE CONTROL UNIT SOFTWARE

1. Connect Star Diagnosis.

2. Check software version of DAS.

^ Ensure to use DAS version 10/2005 or later.

^ Model 199: Ensure to have patch 2006-05-04-0561 installed.

^ Connect battery charger to ensure vehicle power is> 12.5 volts.

^ Ensure to follow DAS steps exactly as described.

3. Install engine control unit software; follow the following DAS path: "Control units/Drive/ME - SFI2.8 Motor electronics 2.8/ Control unit adaptation/Control unit programming/Hard disk".

CAUTION!
If SDS is disconnected during the programming, the control unit will not be operational and will need to be reprogrammed.

4. Code control unit:

^ Model year 2003-2006 vehicles: Select "Variant coding/SCN Coding" and follow on-screen steps to perform SCN coding; refer to latest versions of S-B-58.00/144 for Online SCN coding or S-B-07.61/38 for Office SCN coding.

^ Model year 2002 vehicles: Select "Control unit adaptations/Version coding/Read coding and change if necessary" to code the control unit.

5. Erase event codes and fault memory; disconnect Star Diagnosis.