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Home >> Mercedes Benz >> 1998 >> S500 >> Repair and Diagnosis >> Accessories & Equipment >> Wiring System (Data Link Connectors, Pwr Dist., Grnd Dist.) >> Electrical System, Equipment & Instructions - 140 Chassis >> Testing & Repair >> Installing wiring harness - AR54.18-P-0056A

Installing wiring harness - AR54.18-P-0056A

MODEL 140.051 /057 with CODE (979) special protection version 

Fig 1: Identifying Wiring Harness Components
G05438993Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Wiring Harness Circuit Diagram
G05438994Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
INSTALLING Installing     
1 Remove brake booster hydraulic unit   AR42.10-P-0302A
2 Insert cage nut (5) into punched hole on headlamp cross member IMPORTANT Use inner or outer punched hole depending on the version (engine 119 or engine 120).  
IMPORTANT Connector part no. 168 545 37 28 from the wiring harness A 140 540 25 34 is not required. The connector is already fitted to the brake booster hydraulic unit.    
3 Install bracket (1) with relay (F) on headlamp cross member IMPORTANT Tie relay (F) and coupler plug together with cable strap (7) before assembling on the relay bracket (1). Cable strap is not included in the scope of the parts.  
4 Install wiring harness along main wiring harness IMPORTANT Remove armoring in the area of the spring strut (6) if necessary.  
IMPORTANT The colors of the cables to be soldered must match    
5 Connect ground cable (brown) to ground (W) in the area of the spring strut (6) IMPORTANT Remove plastic cap on ground (W) if necessary and connect ground cable (brown) with new nut.  
6 Solder cable (black/red) onto the hydraulic unit relay (K37), pin 5 (D).    
7 Dismantle headlamps/brake booster hydraulic unit connector (X88/9) IMPORTANT Cut insulation if necessary.  
8 Check brake fluid level switch intermediate connector (X88/4) and cables for corrosion IMPORTANT Replace connector and if necessary cut off cables to the point where corrosion is no longer visible. Check cable is the correct length and extend if necessary.  
9 Solder together cable (brown/white) of brake fluid level switch intermediate connector (X88/4), pin 2 with new sleeve and cable (brown/white) from wiring harness. IMPORTANT Cable (brown/white) from brake fluid level switch intermediate connector (X88/4) has an extra marking (with lug).  
10 Repair wiring harness using connector NOTES Only use connectors approved by Daimler-Benz AG AR54.18-P-0100-02A 
11 Connect cable (brown/black) of headlamps/brake booster hydraulic unit connector (X88/9), pin 4 and cable (brown/black) from wiring harness. IMPORTANT Use green connector.  
12 Connect cable (brown/black) of headlamps/brake booster hydraulic unit connector (X88/9), pin 2 and cable (brown/white) from wiring harness IMPORTANT Use green connector.  
13 Connect cable (brown) from headlamps/brake booster hydraulic unit connector (X88/9), pin 1 and cable (brown) from wiring harness IMPORTANT Use green connector.  
14 Connect cable (black/red 4.0 mm 2 ) from headlamps/brake booster hydraulic unit connector (X88/9) to cable (black/red 4.0 mm2 from new motor/pump unit connector (C). IMPORTANT Use blue connector.  
15 Connect cable (brown 4.0 mm2 ) from headlamps/brake booster hydraulic unit connector (X88/9) to cable (brown 4.0 mm2 ) from new motor/pump unit connector (C). IMPORTANT Use blue connector.  
16 Insulate all cables and connectors with textile tape    
17 Install brake booster hydraulic unit, connecting the motor/pump unit connector (C) to the brake booster hydraulic unit connector IMPORTANT Assemble plug connection carefully and check PINS contact correctly. The cables must not be pushed out of the connectors. AR42.10-P-0302A
18 Check function of relay   AR54.15-P-3000A 
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