AN82.25-P-0001-09CW Retrofit rental vehicle wiring harness

AN82.25-P-0001-09CW Retrofit Rental Vehicle Wiring Harness
- except CODE (498) Japan version
- except CODE (494) USA version
- except CODE (990) AMG vehicles

Special Tools:

Repair Materials:

Component Identification:

The routing diagram shown here is displayed with maximum retrofitting equipment. In vehicles that do not have the maximum equipment, the branch-off lines that are not required are strapped down at defined positions in the vehicle.

Component Identification:

1 Remove cable duct cover (24) of center tunnel cable duct.
2 Open cable duct covers (23) of right rear cable duct.

3 Open cable duct covers (25) of left front footwell cable duct.
4 Open cable duct covers (26) of right front footwell cable duct.

Throughout the remainder of the work procedure make sure that all electrical lines and branch-off lines for the rental vehicle wiring harness (1) are routed without any kinks and without chafing. The electrical lines and branch-off lines must be routed without making contact with any other movable parts. Otherwise electrical lines may be damaged.

Installation of lines in luggage compartment

5 Route branch-off line (1c) of rental vehicle wiring harness (1) in the carrier plate (11), as shown, to the special-purpose vehicle multifunction control unit (N26/9) and join the two connectors for the branch-off line (1c) on the special-purpose vehicle multifunction control unit (N26/9).
6 Route branch-off line (1d) under the positive line (27) of the on-board electrical system battery (arrows).

Component Identification:

7 Route branch-off line (1d) as shown and attach to the trunk floor using the line clips (30).

The two-way radio can be installed either in the glove box or in the luggage compartment. The two-way radio speaker electrical connectors (X1/45) have to be connected to match the two-way radio's installation location. The assignment of the individual connectors is explained in greater detail in the supplementary instructions for the rental vehicle equipment.

8 Route branch-off line (1e) of rental vehicle wiring harness (1) along the vehicle's wiring harnesses, behind the rear SAM control unit with fuse and relay module (N10/2), to the ground point (trunk, right taillamp) (W7/1).
9 Screw ring-type eyelet of branch-off line (1e) onto the ground point (trunk, right taillamp) (W7/1).
10 Fasten the branch-off line (1e) onto the vehicle's existing wiring harness using cable ties.
11 Route the front section of the rental vehicle wiring harness (1) through the breakthrough (arrow) in the C-pillar forwards into the passenger compartment.
12 Fasten the rental vehicle wiring harness (1) onto the vehicle's existing wiring harness using cable ties.
13 Mount the fuse holder of the prefuse 112 (F33f112) and prefuse 115 (F33f115) onto the rear prefuse box (F33).
14 Unscrew nut (28), position the branch-off line (1g) on the positive terminal clamp (29) of the on-board electrical system battery (G1) and screw nut (28) back on.

If an emergency alarm system has not been installed into the vehicle, the branch-off line (1f) is to be rolled up into a loop and attached to a suitable point on a vehicle's wiring harness using cable ties.
The branch-off line (1f) contains the connectors for connection to the "Delete" button for the taxi emergency alarm system (S62/5).

Installation of lines into vehicle interior
Installation of lines shown with installed side paneling at right (13) and closed cable duct covers (23, 26).
Route rental vehicle wiring harness (1) with branch-off lines (1h, 1k) into the corresponding cable ducts and fasten to the vehicle's wiring harnesses using cable ties

15 Route rental vehicle wiring harness (1), as shown, under the seat belt (33) and forward.

Make sure that the rental vehicle wiring harness (1) is routed such that the function of the rear right sidebag is not impaired.

16 Route rental vehicle wiring harness (1), as shown, to the right B-pillar and then continue on with the branch-off line (1k) over the center tunnel to the left side of the vehicle.
17 Route branch-off line (1h), as shown, to the right A-pillar.

Installation of lines shown with cable duct covers (23, 26) closed.

18 Route branch-off line (1m) of rental vehicle wiring harness (1) to the right vehicle floor interior CAN voltage distributor and join with the connector of the right vehicle floor interior CAN voltage distributor electrical connector (X30/33).
19 Roll branch-off line (1n) with connector of international roof sign electrical connector (X40/2), as shown, into a loop and fasten using cable ties to the vehicle's wiring harness.

The loop's length of field must be at least 150 mm long. Otherwise electromagnetic-related interference may occur in the vicinity of the looped branch-off line (1n).

20 Route branch-off line (1h), as shown, along the A-pillar and upwards to the right outer side of the glove box and fasten using cable ties to the vehicle's wiring harness.

Component Identification:

21 Drill hole (7) to diameter of 34 mm to match dimension on glove box (8).

22 Route branch-off line (1h) of rental vehicle wiring harness over the strut (36) into the instrument panel.
23 Route branch-off line (1h) through the hole made in the glove box (8) and fit the grommet (31).
24 Position the glove box (8) on the installation location in the instrument panel.

Position the glove box (8) such that the glove box (8) retains its installation position. The glove box (8) will be permanently installed later on.

25 Fasten branch-off line (1h) of rental vehicle wiring harness, as shown, using a cable tie (38) and a cable positioning device (39) onto the instrument panel's crossmember (37).

Route branch-off line (1h) such that there is a sufficient gap (arrow) to the strut (36) and any sharp edges of the instrument panel's crossmember (37). Otherwise the branch off line (1h) may be damaged by chafing or kinking.

26 Position branch-off line (1h), as shown, in the glove box (8).

Component Identification:

Installation of lines shown with cable duct covers (25) closed.

27 Route branch-off line (1k), as shown, from the center tunnel towards the left A-pillar and into the cable ducts, and fasten to the vehicle's wiring harnesses using cable ties.
28 Position the branch-off line (1q) in the driver footwell such that it can be routed forwards later on into the housing of the front SAM control unit with fuse and relay module.

Located in the front plate, in the upper front area of the driver footwell, is the opening to the housing of the front SAM control unit with fuse and relay module.

29 Route the branch-off line (1p), as shown, along the branch-off line (1q).
30 Fasten the branch-off lines (1p, 1q) together on the vehicle's wiring harness using cable ties.

If an emergency alarm system has not been installed into the vehicle, the branch-off line (1p) is to be rolled up into a loop and attached to a suitable point on the vehicle's wiring harness using cable ties.
The branch-off line (1p) contains the connector for connection to the "Delete" button for the taxi emergency alarm system (S62/6).

31 Unclip protective hose (41) from front door (42) and the A-pillar.
32 Detach damping mat (40) far enough from the A-pillar to enable access to the access opening under it.
33 Using a pass-through aid, route the branch-off line (1o) through the access opening in the A-pillar through the protective hose (41) and into the front door (42).

Pull branch-off line (1o) through carefully, as otherwise the branch-off line (1o) may be damaged.

34 Fasten the damping mat (40) back onto the A-pillar after routing the branch-off line (1o).
35 Pull the branch-off line (1o) completely out of the front door (42).
36 Connect left front door electrical connector (X35/1).

The left front door electrical connector (X35/1) is used to connect the taxi's two-way radio speaker (H6) to the rental vehicle wiring harness.

Installation of lines into engine compartment

37 Remove cover (46) from housing (47) of front SAM control unit with fuse and relay module (N10/1).
38 Route the branch-off line (1q) of the rental vehicle wiring harness through the opening (arrow A) in the housing (47) and out of the vehicle interior into the engine compartment.
39 Cut the lines (red, black) of the branch-off line (1q).

Cut lines (red, black) offset to each other so that the cable connectors (43) can be mounted offset to each other later on, as shown. Apart from this, the lines (red, black) must be cut such that later on both cable connectors (43) are located in the housing (47).

40 Remove the sealing element (32) of the housing (47) and penetrate a free contact cavity (arrow B) of the sealing element (32).
41 Route the ends of the lines of the cut off connector-side branch-off line section from the outside through the penetrated contact cavity (arrow B) of the sealing element (32).
42 Join the lines (red, black), as shown, using cable connectors (43). When doing so, observe the color coding of the lines (red, black).

The cable connectors (43) are to be removed from the wiring harness repair kit.

43 Position the connector-side branch-off line section (1q) in the sealing element (32) such that the end of the line binding is located on the dry side of the sealing element (32).
44 Fill the penetrated contact cavity (arrow B) of the sealing element (32) from the inside using sealant so that no subsequent leakages can occur.
45 Route branch-off line (1q) of rental vehicle wiring harness, as shown, into the housing (47) and install the sealing element (32) into the housing (47).
46 Route branch-off line (1q) outside the housing (47), as shown, and fasten in place using a positioning device (44). Make sure that the connector of the roof sign lamp electrical connector (X40) is sealed with the plug (45).

47 Seal off housing (47) using the cover.

Make sure that the cover is closed correctly. Otherwise ingressing moisture may damage the front fuse and relay module (N10/1).

48 Close all cable ducts in the vehicle interior.