Repair wiring harness connector on ESP control module - SM42.45-P-0001GH

MODEL 163.113 /128 /154 /157 /175 #A as of 371935 up to 442083 with ESP control unit MK25 

Figure 1 

Figure 2 

Figure 3 

Contact sockets, Brake booster piston travel sensor 

Figure 4 

Contact sockets, Brake pressure sensor 

Figure 5 

Figure 6 

Figure 7 

Brake pressure sensor 

Range	Op. no.	Operation text	Flat rate	Acc. no.	Code
P	541011	Perform quick test	004 WU	-	-
P	024170	Replace contact sockets in connector for ESP control module MK25 (after testing)	018WU	-	-

	Remove, install
1	Connect quiescent current retention unit		AR54.10-P-1030-07I
			*WH58.30-Z-1012-09A
2	Disconnect battery		AR54.10-P-0003A
3	Remove leftheadlamp		AR82.10-P-4730GH
4	Loosen windshield washer reservoir from lower grommets	Remove screw on side.
5	Disconnect Electronic Stability Program (ESP) wiring harness coupling from ESP control unit
6	Detach ESP wiring harness from clip on side of headlamp opening
7	Remove housing cover (A) of ESP wiring harness coupling (Figure 1)	Do not use screwdriver to press tabs outward, otherwise cover is damaged. Release tabs (1) by pressing on latch at top and simultaneously remove coupling housing cover (A) by lifting upward (arrow).
8	Remove spacer (B) from Electronic Stability Program (ESP) wiring harness coupling (Figure 2)	Repeat process on both sides (left/right) in order to prevent damage. Remove spacer completely from wiring harness coupling (Figure 2). Press spacer upward and out with a screwdriver (Figure 2).
9	Loosen tie straps for ESP wiring harness coupling and untie ESP wiring harness approx. 20 cm - starting from ESP wiring harness coupling
10	Disconnect contact socket 3 in Figure 3)	Blade holder with clamping pliers	Fig 9
		MQS blade Carefully insert MQS blade from front side of connector through opening next to contact chamber. Press tab on contact socket (plastic lug) outwards gently (Figure 5) and simultaneously pull out the associated wire from the rear (Figure 6). When pulling wire, ensure that plastic lug is pressed outward.	Fig 8
11	Cut off terminal	Cut wire as close to terminal as possible.
12	Strip insulation from end of wire and crimp new terminal onto wire		AR00.19-P-0100-03A
13	After replacing, insert terminal into ESP coupling and ensure contact socket arrests audibly at the same point	Observe orientation of contact socket when inserting into contact chamber. Check to ensure that wire is caught securely (Figure 6).
14	Repeat worksteps 10 - 13 for contact sockets 5, 7, 18, 19, and 20	Sockets 5 and 7 = H and I in Figure 3. Sockets 18, 19, 20 = C, D and E in Figure 4.
15	Check transition resistance of wires in contact sockets 18, 19, and 20 with continuity tester	Unplug brake pressure sensor and check all wires using MQS [micro quadlock system] probes (Figure 7). Observe pin assignments. Resistance reading should be < 0.5 Ω.	*WH58.30-Z-1001-09A
16	Repeat workstep 15 for brake booster piston travel sensor (contact sockets 3, 5, and 7)
17	After repairing all contact sockets, reinsert spacer and seal wiring harness with fabric tape starting at ESP wiring harness coupling
18	Reattach coupling housing cover and fasten wiring harness to coupling with cable strap	Release tension on wiring harness before attaching cable strap.
19	Reconnect ESP wiring harness coupling to ESP control unit
20	Reattach ESP wiring harness to clip on side of headlamp opening
21	Install removed components in reverse order
22	Erase fault memory and perform basic programming

Number	Designation
WH58.30-Z-1001-09A	Multimeter
WH58.30-Z-1012-09A	Quiescent current retention unit

Part no.	Designation	Quantity
001 997 83 90	Tie strap, 150 x 4.6 mm	1
020 545 31 26	Terminals	1
006 989 84 85 10	Fabric tape	1