Notes On Replacement Of Safety-Relevant And Special Components - AH00.19-P-1000-08A

Model All (4xWD, CAR, Light transporter, smart) 

Model All (Heavy transporter, Light transporter) 

Yellow, orange or red-colored plugs and connectors are reserved for the supplemental restraint system (SRS), roll bars and high-voltage components.

Work on high-voltage components or hybrid components may only  be conducted by skilled workshop personnel. All electrical lines installed in the vehicle's high-voltage on-board electrical system are marked with the warning color orange. If the chafe protection on the electrical lines of the high-voltage on-board electrical system is damaged or the lines are damaged due to external influences (e.g. animal bite), the lines must be replaced immediately. Repair is not  permissible.

Always observe the following when repairing connectors for squibs (supplemental restraint system (SRS)):

The repair point must be between 100 mm and 1000 mm behind the squib. Lines which have already been repaired are provided with a yellow marking. This is to be applied retroactively to repair lines without color coding.

Before cutting through the lines, it is absolutely essential to assign the lines to the corresponding pins in accordance with the wiring diagram. Do not mix up the pin assignment.

The line colors of the repair kit may deviate from the original fitting.

Shielded lines and light plastic-sheathed lines must never be repaired.

In general, the following applies for line repairs:

If more than ten lines per branch-off line are damaged, the wiring harness module must be replaced.

Overview of lines/contacts which may not be repaired 

Any damage to the following lines/contacts always results in the replacement of the wiring harness or the line:

• Antenna lines
• Digital data bus (D2B)
• Media Oriented System Transport (MOST)
• Telephone receiver lines
• Electronic Stability Program (ESP®) control unit connector
• 115 V/230 V socket inverter
• Magic Sky inverter
• Solar roof inverter
• Dynamic seat
• Multicontour seat
• Supplemental restraint system (SRS) control unit connector
• Lines ≥ 6 mm²
• Aluminum lines
• "High Speed Data" video lines

Overview of lines/contacts which may be repaired using a repair wiring harness 

Damage to the following lines/contacts may only be repaired using genuine repair kits:

• SRS squib connector
• Pyrofuse connector
• LED ambient lighting
• Contacts on 0.13 mm² lines

Overview of shielded lines at the engine wiring harness, on which only the contacts may be repaired 

In case of damage to the following lines, the wiring harness must always be replaced. If only the contacts are damaged, these may be repaired:

• Knock sensor lines
• Injector lines
• Oxygen sensor lines

  Oxygen sensor lines are partially shielded; please observe the wiring diagram.

Differentiation and special features for safety-relevant electrical connections 

A differentiation is made into the two following types of connection for electrical connections on safety-relevant systems, components or connections at risk to short circuits:

• Positive connection
• Non-positive connection

Positive connection 

The electrical connection is latched into place, e.g. when connected through catch hooks, slides, clips, threaded connection or suchlike, and they can only be disconnected from the connected equipment again by operating a release or by unfastening the bolted connection. They cannot be disconnected by simply pulling on the connector housing under normal control forces.

A positive connection is checked using the "Push-Pull-Push" method (except for bolted connections).

Non-positive connection 

The electrical connection does not latch into place when connected, but it is simply clamped, for example, using a toggle-action clamp. Pulling on the electrical line or the electrical connection can disconnect the electrical connection.

A positive connection is checked using the "Push-Pull-Push" method.

In the "Push-Push" or "Push-Pull-Push" test, the line should not be tugged or pressed together. The electrical connection must be directly engaged. Otherwise, damage may occur or there may be contact problems with the electrical connection.