CC. Preparations

Disconnect and remove the battery from the car.

Remove the wiper arms.

Remove the cover from the wiper well.

Remove control module

Remove air filter housing and the pre-heater hose.

Removing control module





Clean the area around the connector to prevent dirt from entering the connectors.

REMOVE.

- Connections to the control module by pressing in the catch on the back of the cover (towards wheel housing). Then carefully turn the cover upward to release the catches.

- Pump motor connector.

- Remove four bolts.

- Remove the control module carefully from the car.

Cleaning the connector

CAUTION:
Safety glasses MUST be worn when the connector is blow dried with compressed air.





Clean the connector by rinsing it in a bowl of lukewarm water.

Blow dry with compressed air and set aside the connector to let remaining water evaporate.

NOTE:
DO NOT use an air source that is connected to an oil and/or water mist, ensure only dry air is used when blowing the connector clean/dry.

Replace harness kit





The wiring between the EBD switch and the 25-pole connector on the ABS control module must be replaced with service wiring that also contains new ground wires for the terminals 8 and 24 and positive power supply wires for 9 and 25.

Remove tie straps

- Cut off the tie straps at the connector.

Caution:
Make sure no wires are cut while cutting the tie straps.

Open the secondary lock





Disconnect wire terminal secondary lock by pushing the catch (in the shaded area) in the direction of the arrow with a small screwdriver.

Locate the wires in the connector





Remove the wires from slot No: 5, 7, 8, 9, 24, and 25 shown in the illustration.

NOTE
This is a rear view of the connector.

Tools for removing terminals





Use tool 951 2630 to remove the small terminals 5 and 7 in the connector.

Use tool 951 2631 to remove the large terminals 8, 9, 24 and 25 from the connector.

Removal of terminals





To release the terminal from the primary lock push back the terminal/wire into the slot, insert the tool from the face side and push it down the slot to release the tabs on the terminal, thereafter carefully pull in the wire to remove the terminal from the connector.

In the event of the terminal getting caught in the secondary lock, use the procedure in the next step.

Removal of stuck terminal in connector

If the terminal gets caught in the secondary lock gate, do the following.





- Push the wire up so that the terminal moves away from the lock gate.

- Move lock gate back and forth and pull carefully on the wire to release the terminal from the cavity.

If the terminal is stuck in the secondary lock gate and cannot be removed, do the following;





- Insert a 1.5 mm (1/16) punch (1) into the center of the slot for the terminal. (face side) Carefully tap on the punch and drive out the terminal past the lock gate as per illustration.

- Check that the lock gate moves freely after the terminal is removed.

Separate the wire duct





Remove plastic nut. (1)

Remove any tape used to secure the lock on the wire duct.

Carefully open the wire duct to locate the wires.

Remove the tie strap/tape, which is securing the wires at the fuse box.

Caution:
Make sure no wires are cut while cutting off the tie strap.

Remove the central electrical unit cover.





Remove the central electrical cover.

Release the harness





Remove the two straps (4 screws) holding down the harness.

Remove the four (4) screws holding the fuse/relay base. (arrows)

Remove relays





Carefully lift up the fuse/relay base so that the relays are accessible and remove the rest of the relays from the vertical socket base.

Lower the whole base down again and secure it with one (1) screw.

Lift up fuse panel





Remove the three (3) screws.

Remove the two rubber grommets. Carefully lift up the fuse panel to access the wires.

Release secondary lock





Open the central electrical unit secondary lock.

Push/snap the lower section of the fuse panel towards the center of the car (1) to release the wire terminals.

Disconnect wiring in central electrical unit





Disconnect from the underside of the central electrical unit, the wiring from the ABS control module:

- red from fuse 9 terminal 2

- red/black from fuse 14, terminal 1

Here's how to get the terminals out:

Insert a small screwdriver as per illustration and push down the tab and hold.

At the same time, pull the wire and terminal out of the cavity, with the screwdriver still holding down the tab.

Cut off the EBD switch connector





Cut off the existing EBD switch connector.

The wiring must be removed from the Packard tubing.

Cut off the existing ground leads





Cut the tape and open the Packard tube.

Remove the red and red/black wires, and then cut the remaining two black wires about 50 mm (2.0 inches) outside the point where they enter the wire duct.

Insulate the wiring





Fold the two black wires that previously were cut off and insulate with insulation tape.

Install a new cable harness





Open the rubber grommet (2) at the windscreen wiper well with expansion pliers. Insert the new red and red/black wires to the central electrical unit,

Install





Install the red wire in terminal 9/2 and the red/black wire in terminal 14/1,

Check that the wire terminal lock functions by carefully pulling on the wire. It should NOT be possible to pull off wire from the fuse terminal.

Secondary lock





Lock the central electrical unit secondary lock by pushing the lower section of the fuse panel towards the left front fender (2).

A click is heard when it locks.

Reinstalling relays





Reinstall the disconnected relays.

Press the central electrical unit into place.

Install the four screws holding the central electrical unit into the bodywork.

Reinstall fuse box cover.

Reinstall the central electrical unit





Fold back the central electrical unit fuse panel so that it locks in the track between the fuse panel and the relay holder.

Check that the black box for the central electrical unit is loosely secured with one screw. (This is to facilitate installing the central electrical unit).

Lower the central electrical unit into the black box/casing.

NOTE:
This may be difficult and may require careful adjustments. Be sure not to pinch any wires. Reinstall the fuse panel with three screws.

Check that all fuses are in place.

Install the clamp over the wire harness that runs out into the windshield wiper well.

Install





- Clamp for the harness exiting out to the engine compartment.

Install new wires to EBD switch





Route the new wire to the EBD connector parallel with the old wire, through the wire duct and exit at the firewall.

Secure the new wire to the old wire with a tie strap.

Route wire harness





There are two black ground leads (1) in the service wiring. These must be connected to the battery negative terminal (2).

Route the wiring in the cable duct to the place where the battery negative lead enters into the cable duct.

Route the ground leads parallel to the battery ground lead.

Install the ground lead loosely on the stud of the negative battery cable terminal. Leave terminal loose until after battery installation.

Insert new wiring to the 25-pole connector

NOTE:
This is a rear view of the connector. Check that the connector is clean and DRY.





Install the small wire terminals;

- White in slot 5.

- Violet/white in slot 7.

Install the large terminals:

- Red wire in slot 25.

- Red/black wire in slot 9.

- Black wires in slots 8 and 24.





Lock the wire terminal secondary lock by carefully pushing the catch (in the shaded area) in the direction of the arrow with a small screwdriver.

Secure wiring





Put the new wire bundle (within protective sheath) together with the old remaining wires to the 25-pole connector within the old protective sheath and tape together.

Secure the wiring to the 25-pin connector with tie-straps in the same way as the old wiring.

Wrap the wires with tape as necessary.

Large tie-strap P/N 948211

Small tie-strap P/N 948702.

Check that the cover over the connector can be opened and locked.

If necessary, adjust the wiring so that no wire is pinched when connector is closed and locked.

Wire duct





Close the wire duct.

Install the plastic nut (1)

Secure with tie straps at the points they were previously secured with insulation tape.

Reinstall

- Cowl cover

- Wiper arms (torque nut to 16 Nm 11.8 ft.lbs.)