Install repair wiring harness for door - SM54.18-P-0016A

MODEL 215.### ## up to 015153

Fig 1: Identifying Door Speaker Connector, Side Bag Squib And Cable Duct

Fig 2: Identifying Foam Cube, Heavy-Duty Film, Wiring Harness And Foam Bag

OPERATION NO. OF OPERATION TEXTS OR STANDARD TEXTS AND FLAT RATES

Category	Op. no.	Operation text	Time	Acc. no.	Code
P	023867	Install repair wiring harness for driver door	053 WU	-	-
P	023868	Install repair wiring harness for front passenger door	045 WU	-	-

	Remove/install
1	Disconnect battery ground cable	Do not connect quiescent current retention device.	AR54.10-P-0003I
2	Remove/install front door lining		AR72.10-P-1000N
3.1	Remove antenna for Keyless Go	Only on vehicles with Keyless Go.
4	Disconnect left door speaker connector (X1/6), right door speaker connector (X1/7)
5	Remove rear in-door speaker
6	Unplug connector on the driver sidebag squib (R12/9), front passenger sidebag squib (R12/10)
7	Pull off damping mat (2) above the pneumatic line (3) and the electrical lines at the bottom and fix in position at the top of the side window using adhesive tape
8	Open cable ties of pneumatic line (3) and the electrical lines	Installation: Replace cable ties.
9	Unclip protective sleeve (4) on the front door (1) and A-pillar
10	Pull the wiring harness out of the front door (1) through the cable duct (5)
11	Remove door sill molding
12	Pull off door rubber seal in the area of the A-pillar
13.1	Remove cover below instrument panel	When repairing driver's side.	AR68.10-P-1500N
13.2	Remove cover below glove compartment	When repairing passenger side.	AR68.10-P-1520N
14	Remove foam bag (10) from inside the A-pillar	Do not install foam bag (10) again, it is replaced by foam cube (7) and heavy-duty foil (8).
15	Separate cable ties and separate the defective wiring harness (9) at a suitable point in the sill area	Select the repair point so that there is sufficient space for the RAYCHEM connector during the wiring harness repair.
16	Pull the defective wiring harness out of the door and A-pillar
17	Thread repair wiring harnesses through the A-pillar	Combine the white markings and close the cable strap on the marking.
18	Connect the repair wiring harness to the main wiring harness with Raychem connector		AH00.19-P-1000-04A
	Repair methods for wiring harnesses		AH00.19-P-1000-04A
19	Install foam cube (7) in A-pillar
20	Arrange the wiring harnesses in parallel	The lines must not be twisted.
21	Slide cable guide bellows over wiring harnesses
22	Thread the wiring harnesses through the doors
23	Install protective hose (4) in doors	Check the wiring harnesses again for parallel routing.
24	Mount the protective sleeve (4) on the A-pillar
25	Close the door one notch
26	Combine the branch-off lines of the wiring harness on the door and close on the white marking with cable strap
27	Open door again completely
28	Adjust the distance between the boot and hinge cover to approx. 5 mm
29	Unscrew lever of engine hood release and place to one side
30	Loosen pedal assembly of parking brake and place to one side		AR42.20-P-0510I
31	Seal opening on A-pillar with heavy-duty foil (8)	For soundproofing/sealing heavy-duty foil is a replacement for the foam bag.
32	Install in the reverse order

PARTS ORDERING NOTES

Part no.	Designation	Quantity
A 215 540 94 05	Left door repair wiring harness	1
A 215 540 95 05	Right door repair wiring harness	1
A 210 682 05 30	Heavy-duty foil, for soundproofing instead of foam bag	1
A 001 546 99 41	Raychem green connector, solder connector for 0.7 mm² up to 2.4 mm² cable cross section	20
A 002 546 00 41	Raychem red connector, solder connector for 2.0 mm² up to 4.0 mm² cable cross section	4
A 002 546 01 41	Raychem blue connector, solder connector for 3.5 mm² up to 8.0 mm² cable cross section	2
A 215 821 00 97	Boot, only when required, if boot is damaged during removal.	1