Retrofitting wiring harness of headlamp range adjustment - AN82.10-P-0002-03FB

Model 210 as of 1.7.99

For models fitted with headlamp cleaning system (code 600)

1. Prepare wiring harness (10) as shown in illustration.
  Insulate the lacings of the HCS not shown and tie back (they are not required).
  
  Fig 1: Headlamp Wiring Harness Diagram
  Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Prepare wiring harness (10) as shown in illustration.
  Connect the lacings of the HCS marked with "HCS (SRA)" as specified in the description "Headlamp cleaning system".
  
  Fig 2: Headlamp Wiring Harness Diagram
  Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Extend brown cable (H) to right footwell ground (W15/1) with brown cable 1.5 m² and soldered connector (A) by about 2 m.
Route wiring harness of headlamp range adjustment (10) in vehicle as shown in illustration.

Fig 3: Identifying Headlamp Wiring Harness
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Route wiring harness (10) through a vacant cable leadthrough grommet (arrow) into the fuse and relay box (F1).

Fig 4: Identifying Fuse And Relay Box
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Route branch from wiring harness (10) to the front fuse and relay box (F1) and to the data link connector (X11/4) in fuse box.
Connect black/purple cable (sw/vi) in fuse and relay box (F1) to fuse 15.
Fuse 15 must be fitted with a 15A fuse.
Open data link connector (X11/4). Insert purple cable (vi) into receptacle 35 of data link connector (X11/4).
Close data link connector (X11/4).

Fig 5: Identifying Data Link Connector
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Route 6-pin sockets at left wheelhousing to the left headlamp opening and attach.

Fig 6: Identifying Left Leadlamp Unit
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Route other branches from wiring harness (10) of 6-pin sockets in front of the radiator to the right headlamp opening and attach with cable straps (arrows).

Fig 7: Identifying Wiring Harness And Cable Straps
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Route longest branch from wiring harness (10) with 6-pin socket from the right headlamp opening along the main wiring harness to the right of the front axle and attach.
Route branch to right headlamp unit (E2) into headlamp opening as shown in illustration.

Fig 8: Identifying Headlamp Range Adjusting Front Axle Sensor
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Route branch from wiring harness through the fuse box into the interior.
Route yellow/black cable (ge/sw) to the light module.
Open socket A at light module (N7).
Insert yellow/black cable (ge/sw) into receptacle 10 of the 21-pin socket "A" of the light module (N7).
Install new trim ring at light module (N7).

Fig 9: Identifying Yellow/Black Cable And Light Module
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Tie back positioning wheel (11) of the old headlamp range adjustment below the instrument panel (do not disconnect cables).

Fig 10: Identifying Headlamp Range Wheel
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Route branch from wiring harness (10) in left cable duct to the rear seat bench.
Route branch to the headlamp range adjustment control module (N71) into the area of the left of the rear seat bench as shown in the illustration.

Fig 11: Identifying Headlamp Range Adjustment Control Module
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Place headlamp range adjustment control module (N71), in the area below left rear seat, into a free part of the foam cover.
Fix headlamp range adjustment control module (N71) tight, if necessary (double-sided adhesive tape).
Connect socket to the headlamp range adjustment control module (N71).

Fig 12: Identifying Headlamp Range Adjustment Control Module
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Route branch of wiring harness (10) below the rear seat bench to the right side of vehicle.
Route wiring harness (10) below the plate (F) of the rear seat bench behind the rear fuse box (F4) and attach with omega clips (E).
Rework plate (F) so that wiring harness does not chafe or is squeezed.

Fig 13: Identifying Rear Fuse Box
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Route extended brown cable and green/black (gn/sw) cable in right cable duct to the right A-pillar.
Expose the green/black cables (gr/sw) to the rear axle wheel speed sensor connector sleeve (Z90) in the right cable duct in the area of the A-pillar.
There are 3 cables tied together with a red adhesive tape (arrow) in the area of the A-pillar at bottom right. These are a green cable (gn) front right wheel speed signal, a green/white cable (gn/ws) front left wheel speed signal and a green/black cable (gn/sw) rear left wheel speed signal. Test wheel speed signal at the connector sleeve.
Solder green/black cable (gn/sw) from headlamp range adjustment wiring harness with a soldered connector.

Fig 14: Identifying Green/Black Cable And Rear Axle Wheel Speed Sensor Connector Sleeve
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Connect extended brown cable at the right footwell ground (W15/1) to the top of the right A-pillar.

Fig 15: Identifying Right Footwell Ground Point
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

In the area of the A-pillar there is a red vacuum line (arrow) (differs according to vehicle equipment).
Cut off red vacuum line (rt) just downstream of the distributor and seal the short end to the distributor with a cap (S).
Tie back red vacuum line.

Fig 16: Identifying Red Vacuum Line
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Models without stationary heater/ heater booster

1. Make hole (15) in area of fuel pump assembly at spacing G and widen to ø 28 mm and prime.
2. Use grommet of fuel metering pump.
Route 6-pin socket to rear axle sensor (A51) behind the rear fuse box to the outside and insert grommet of wiring harness into hole.

Fig 17: Identifying Rear Axle Sensor
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.