Retrofit front illuminated Mercedes star wiring harness - AZ88.40-P-0010-01EW

MODEL 212.0## (except 212.074/077/092) 1# as of 3/1/13, 212.1## 1# as of 3/1/13, 212.2## (except 212.274/277/292) 1# as of 3/1/13 

with CODE 954 (Avantgarde) 

except CODE 233 (DISTRONIC PLUS) 

except CODE 239 (DISTRONIC PLUS) 

MODEL 218.3 (except 218.374/392), 218.9## (except 218.974/992) 1# 

except CODE 233 (DISTRONIC PLUS) 

except CODE 239 (DISTRONIC PLUS) 

Fig 1: Identifying Passenger Car Wiring Harness Repair Kit (220 589 04 99 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Illuminated Mercedes Star Connection Scheme

Courtesy of MERCEDES-BENZ USA

Fig 4: Illuminated Mercedes Star Routing Diagram

Courtesy of MERCEDES-BENZ USA

The following work procedure is shown on MODEL 212.

Fig 5: Control Unit, Felt Strip And Velcro Strip

Courtesy of MERCEDES-BENZ USA

1. Glue felt strip (8) to front of control unit (3).

   The bonding surfaces must be free of dust and grease.

2. Glue velcro strip (9) to rear of control unit (3).

   The bonding surfaces must be free of dust and grease.

3. Remove carrier foil from velcro strip (9).
Fig 6: Illuminated Mercedes Star Electrical Routing
Courtesy of MERCEDES-BENZ USA
4. Connect black, 18-pin coupling (2.3) on wiring harness for illuminated Mercedes star (2) to control unit (3) and lock.
5. Clean contact surfaces on control unit (3) on instrument panel crossmember (4).

   The bonding surfaces must be free of dust and grease.

6. Glue control unit (3) to instrument panel control unit (4) and fix in place with cable tie.
7. Route brown line (BN) from control unit (3) to left front seat crossmember ground point (W18/) and fix in place using cable ties.
8. Connect brown line (br) of Mercedes star illuminated wiring harness (2) at left front seat crossmember ground point CAN (W18).
9. Route twisted brown line (BN) and brown/red line (BN/RD) on wiring harness for illuminated Mercedes star (2) from control unit (3) to left vehicle floor interior CAN potential distributor (CAN) electrical connector (X30/32) and fix in place using cable ties.
10. Connect black 2-pin coupling (2.1) to free slot on electrical connection for left vehicle floor interior CAN potential distributor (X30/32).
Fig 7: Routing Through Opening Through Passage In Firewall
Courtesy of MERCEDES-BENZ USA
11. Route red line (rt) through opening (sw) through passage in firewall to front SAM control unit with fuse and relay module and fix in place with cable ties.

    Use a pull-through device.

Fig 8: Front SAM Control Unit
Courtesy of MERCEDES-BENZ USA
12. Unclip side insert (5) upward on front SAM control unit with fuse and relay module (N10/1).
13. Drill Ø 19 mm hole on side insert (5) (center of drilled hole, arrow A).
Fig 9: Side Insert, Cable Grommet And Front SAM Control Unit
Courtesy of MERCEDES-BENZ USA
14. Install cable grommet (7) on black line (sw) in previously drilled hole on side insert (5) of front SAM control unit with fuse and relay module (N10/1).
Fig 10: Disconnecting 14-Pin Connector At Front SAM Control Unit
Courtesy of MERCEDES-BENZ USA
15. Disconnect pink 14-pin connector (6) at front SAM control unit with fuse and relay module (N10/1).
Fig 11: 14-Pin Connector, Red Line And Front SAM Control Unit
Courtesy of MERCEDES-BENZ USA
16. • (16.1)  If contact cavity "5" of pink 14-pin connector (6) is not used. Install red line (rt) in contact cavity "5" of pink 14-pin connector (6).

      Contact cavity "5" is labeled.

    • (16.2)  If contact cavity "5" of pink 14-pin connector (6) is used. Remove contact spring on red line (rt) and connect red line (rt) to present line in contact cavity "5" of pink 14-pin connector (6) with potential distributor.

      Contact cavity "5" is labeled.

      The potential distributor can be found in the basic wiring harness repair kit or the supplementary wiring harness repair kit for passenger cars.

17. Connect pink 14-pin connector (6) to front SAM control unit with fuse and relay module (N10/1).
Fig 12: Route Black Line Starting At Side Insert From Front SAM Control Unit
Courtesy of MERCEDES-BENZ USA
18. Route black line (sw) starting at side insert (5) from front SAM control unit with fuse and relay module (N10/1) along fender in direction of vehicle front and fix in place with cable ties.
Fig 13: Routing Black Line Along Present Line Toward Front From Installation Location
Courtesy of MERCEDES-BENZ USA
19. Route black line (sw) along present line toward front from installation location of illuminated Mercedes star and fix in place with cable ties.
20. Install black line (sw) into black connector housing (2.4). - Chamber 1 = white line tieout (ws) - Chamber 2 = black line tieout (sw1) The black line (sw) is connected to the black 2-pin connector on the illuminated Mercedes star later.

    Contact cavity assignment:

    - Chamber 1 = white line tieout (ws)

    - Chamber 2 = black line tieout (sw1)

    The black line (sw) is connected to the black 2-pin connector on the illuminated Mercedes star later.