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

Model 210 up to 30.6.99 LHS

Prepare wiring harness as shown in illustration.

Fig 1: Headlamp Range Wiring Harness Diagram
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Modify wiring harness as shown in illustration. Cut open wiring harness insulation for this step (arrow).
Cut through brown cable about 10 cm behind the round cable lug and strip insulation on both sides over about 15 mm.
Cut commercially available brown cable with cross-section of 1.5 mm to length of 1.8 m² and strip insulation at both sides over about 15 mm.
Turn cable with round cable lug and brown cable together and solder together with cable connector (Z).
Connect other ends of the brown cables with cable connector (Z) as described in steps 3-4.
Re-enclose wiring harness with PVC insulating tape.
Route wiring harness of xenon headlamps in vehicle as shown in the illustration.

Fig 2: Identifying Headlamp Range Wiring Harness Components
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Route black/purple and purple cables into the fuse and relay box (F1).
Connect black/purple cable to fuse box receptacle "A" assignment 15.
Insert 15A fuse at fuse carrier assignment 15.
Insert purple cable at data link connector (X11/4) receptacle 35.
Route 6-pin sockets (3 in total) from interior through the fuse and relay box (F1) into the engine compartment.
Remove grommet of wiring harness; is not required.

Fig 3: Identifying Fuse And Relay Box And Data Link Connector Cable
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Route 6-pin sockets at left wheelhousing to the left headlamp opening and attach.

Fig 4: Identifying Left Headlamp Unit
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Route other branches of the 6-pin sockets in front of the radiator to the right headlamp opening and attach with cable straps (arrows).

Fig 5: Identifying Cable Straps
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Route longest branch with 6-pin socket from the right headlamp opening along the main wiring harness to the right of the front axle and attach.

Fig 6: Identifying Right Headlamp Unit And Headlamp Range Adjusting Front Axle Sensor
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Route extended brown cable, green/black cable and 6-pin socket below the plate (F) of the rear seat bench behind the rear fuse box (F4) to the right cable duct and attach with omega clips (E).
Rework plate (F) so that wiring harness does not chafe or is squeezed.

Fig 7: Identifying Rear Fuse Box
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Route extended brown cable and green/black cable in cable duct to the cable connector (X62/21).
Connect green/black cable to the cable connector (X62/21).

Fig 8: Identifying Cable Connector
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Connect extended brown cable at the ground point (W15/1).

Fig 9: Identifying Extended Brown Cable At Ground Point
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Detach purple vacuum line at vacuum distributor (arrow) ahead of the control module box (F23/1) (is no longer required).
Install xenon headlamps and connect wiring harness.

Fig 10: Identifying Vacuum Distributor And Control Module Box
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 with ø 28 mm.
2. Use grommet of fuel metering pump.
Route 6-pin socket to rear axle sensor behind rear fuse box to the outside.

Fig 11: Identifying Rear Axle Sensor
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Make holes for attaching headlamp range adjustment control module (N71) with a drift according to spacings C and D in the area below the left rear seat.
Use headlamp range adjustment control module (N71) as a template.
Attach headlamp range adjustment control module (N71) with bolts (3) and washers (4).
Connect socket to the headlamp range adjustment control module (N71).
Location below left rear seat

Fig 12: Identifying Headlamp Range Adjustment Control Module
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Insert yellow/black cable into receptacle 10 of the 21-pin socket "A" of the light module (N7-1).
Install new trim ring at light module (N7-1).
Tie back headlamp range adjuster (do not disconnect).

Fig 13: Identifying Trim Ring At Light Module
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.