Repair wiring harness coupling on ESP control unit - SM42.45-P-0001B

MODEL 203 as of 1.8.01 up to 1.2.03, 209 up to 1.2.03 

Figure 1 

Figure 2 

Fig. 3 

Female contacts 

Fig. 4 

Fig. 5 

Fig. 6 

Figure 7 

Figure 8 

Figure 9 

Figure 10 

1	Disconnect ground cable of battery	MODEL 203	AR54.10-P-0003P
		MODEL 209	AR54.10-P-0003Q
2	Undo line from ground point (W9).	Only for vehicles as of production date 01/2002.
3	Detach ESP wiring harness coupling from ESP control unit.
4	Remove casing cover (A) of ESP wiring harness coupling (Figure 1).	Do not use a screwdriver to push the locking lugs outwards, as otherwise the cover may be destroyed. To do this open the locking lugs (1) on both sides by pushing back the locking bar towards the arrow while simultaneously removing the clutch casing cover (A) by turning in a circle towards the arrow (Figure 1).
5	Remove the spacer (B) from the ESP wiring harness coupling (Figure 2).	To do this the use the screwdriver to push the spacer upwards (Figure 2). Repeat the process on both sides (left/right), in order to avoid any damage. Remove the spacer completely from the ESP wiring harness coupling (Figure 2).
6	Undo the tie strap for the ESP wiring harness coupling and branch off the ESP wiring harness approx. 50 cm - from the point of the ESP wiring harness coupling.	Blade holder with clamping pliers	Figure
7	Remove female contacts 3, 5, 7 (pins 2, 4 and 6 of left male multi-point connector as counted from above) (G, H and I in Figure 3).	MQS connector	Figure
		Insert the MQS detent carefully from the front side of the coupling through the opening next to the contact cavity. Carefully push the tab on the female contact (plastic lug) outwards (Figure 5) while simultaneously withdrawing the attendant line backwards (Figure 6). When pulling the line, the plastic lug must be pressed outwards.
8	Cut the lines - in accordance with the length of the rep. line and strip back.	Note that an excess length (a) of 7 cm is required (Figure 4). The end of the lines are to be offset by approx. 5 cm each.	AR00.19-P-0100-09A
9	Join the ends of the lines on the ESP wiring harness with the ends of the repair wiring harness lines using Raychem connectors.	Note color coding.	*WH58.30-Z-1004-20A
10	Listen for an audible engagement of the female contacts at the same place after they have been replaced.	Note orientation of female contact when inserting into the contact cavity; check for correct engagement by pulling on line (Figure 6).
11	Check the resistance of the three lines using the continuity tester.	To this end, detach the plug from the diaphragm travel sensor and check the three modified lines using the MQS probes (Figure 7). Observe pin assignments. Resistance value must be < 0.5 ohm.	*WH58.30-Z-1001-09A
12	After all three female contacts have been repaired, insert the spacer again and start to seal the wiring harness to the ESP wiring harness coupling with fabric tape.	In doing so make sure that the heads of the Raychem connector face towards the firewall (Figure 4).
13	Apply approx. 4 drops of pure benzine to one of the two enclosed cleaners (Figure 8) outside the engine compartment at the cone point and then clean the contact pins 3, 5 and 7 (pins 2, 4 and 6 of left-hand male multi-point connector as counted from above) in the ESP control unit.	CAUTION: The contact pins must not be bent; for this reason hold the cleaning rods as near to the end as possible, so that a great force is not applied to the pins. The cleaners are to be disposed of after being used once only on the vehicle. Use pure benzine only  not commercially available benzine. Stick each contact pin four times into the cleaner wetted with pure benzine  and remove again (Figure 9 and 10). Wait for a minute. Stick contact pins four times into second cleaner and remove again (second cleaner must be dry  ).
14	Reattach connector housing cover. Fasten wiring harness to coupling connector using tie strap.
15	Connect ESP wiring harness coupling to ESP control unit again.	Mount ground line to ground point (W9 if available) and tighten to torque of approx. 10 Nm.
16	Connect ground line of battery again	MODEL 203	AR54.10-P-0003P
		MODEL 209	AR54.10-P-0003Q
17	Erase fault memory. Perform basic programming.

Number	Designation
WH58.30-Z-1001-09A	Multimeter
WH58.30-Z-1004-20A	Hot-air gun

Part no.	Designation	Quantity
001 997 83 90	Tie strap 150 x 4.6 mm	1
001 546 99 41	Solder connection (Raychem)	3
203 540 56 33	Cable set for rep. lines with different colors and cleaning kit	1
006 989 84 85 10	Fabric tape	1