Service Procedure

IMPORTANT:
Before beginning this wiring modification, it is important to understand the changes that are being made. Take a moment to review the wiring diagram below before beginning this repair.





NOTE:
The two silver spade terminals provided in the Relay and Wiring Package will not be used.





1. Disconnect and isolate the negative battery cable ground connection located under the instrument panel, next to the accelerator pedal. This will disconnect the main battery located under the floor pan (Figure 2).

NOTE:
Some Sprinters are equipped with two batteries. The main battery is located in a battery compartment under the floor pan and the auxiliary battery is located in the engine compartment. The auxiliary battery has a relay wired into the positive cable circuit that connects the auxiliary battery to the vehicle's electrical system only when the engine is running. There is no need to disconnect the under hood battery.

2. Remove the left front seatbelt anchor cover and seat belt mounting bolt from the side of the seat frame.

3. Remove the four (4) mounting bolts that retain the driver's seat to the seat base.

4. Disconnect the driver's seat wiring and remove the seat assembly from the vehicle.

5. Remove the foam top cover on the seat base.





6. Remove the two relay support bar mounting screws from the seat base (Figure 3).





7. Remove the tape from the wiring that leads up to the number 10 relay (Figure 4).

8. Remove and save relay number 10 from the relay connector (Figure 4).

9. Unclip the number 10 relay connector from the relay support bar (Figure 4).

10. Pull the red connector lock from the number 10 relay connector (Figure 4).





11. Remove the large black wire and terminal from the number 10 relay connector by inserting a paper clip into each of the two terminal release slots (Figures 4 and 5). Carefully compress the lock tabs on the terminal and pull the terminal from the connector.

NOTE:
The terminal on the red wire of the new relay harness is the same style terminal being removed from the connector. Study the terminal on the red wire of the new relay harness to better understand how the terminal lock tabs release.





12. Cut off and discard the electrical terminal on the black wire removed from the number 10 relay connector in Step 11 (Figure 6).

13. Remove approximately 3/4 inch (19 mm) of insulation from the black wire that was removed from the number 10 relay connector.

14. Remove the partially stripped wire insulation from both large red wires on the new relay wiring harness.





15. Place the two large red wires from the new relay harness together with the black wire that was removed from the number 10 relay connector. Place the barrel connector over all three wires (Figure 7).





16. Using rosin core solder and a soldering gun, heat the three wires and barrel connector. Fill the barrel connector with molten solder (Figure 8).

17. Allow the wire barrel connection to cool and then install the yellow insulating boot (provided) over the barrel connector.





18. Cut the brown wire and the black (with brown trace) wire approximately 2 inches (50 mm) from the number 10 relay connector (Figure 9).

19. Remove approximately 1/2 inch (13 mm) of insulation from both sides of both wires cut in Step 18.





20. Place a piece of shrink tube over both the brown wire and the black (with brown trace) wire coming from the vehicle's wiring harness (Figure 10).

21. Insert both brown wires from the original relay harness and the brown wire from the new relay harness into a small brass splice band and crimp them together using wire splice crimp tool 10042 (Figure 10).

22. Using rosin core solder and a soldering gun, solder the wiring connection at the brass crimp splice band (Figure 10).

23. Slide the shrink tube over the soldered wire connection made in Step 22.

24. Heat the shrink tube with a heat gun until it shrinks around the wire and glue comes out of both ends of the shrink tube.

25. In the same manner as Step 21, insert both black (with brown trace) wires from the original relay harness and the black (with brown trace) wire from the new relay harness into a small brass splice band and crimp them together using wire splice crimp tool 10042 (Figure 10).

26. Using rosin core solder and a soldering gun, solder the wiring connection at the brass crimp splice band (Figure 10).

27. Slide the shrink tube over the soldered wire connection made in Step 26.

28. Heat the shrink tube with a heat gun until it shrinks around the wire and glue comes out of both ends of the shrink tube.





29. Insert the large red wire with the square electrical terminal from the new relay harness into the open cavity of the original number 10 relay connector (Figure 11).

30. Install the red terminal lock into the number 10 relay connector (Figure 4).

31. Install the number 10 relay removed in Step 8 into the number 10 relay connector.

32. Install relay number 10 onto location number 10 on the relay support bar (Figure 3).

33. Install the new relay onto location number 11 of the relay support bar (Figure 3).





34. Remove the fuse block access cover located on the side of the seat base (Figure 12).





35. Remove the right and left side center fuse block retaining screws located on the seat base (Figure 13).

36. Pull the center row fuse block out of the seat base.





37. Locate the large black wire in the 8th cavity of the fuse block (Figure 14).





38. Cut the black wire coming out of the 8th cavity from the left approximately three inches (75 mm) from the fuse block (Figure 15).

39. Place a piece of shrink tube over the harness side of the black wire cut in Step 38. Heat the shrink tube so that the end of the wire is sealed. Tape the wire back into the vehicle wiring harness (it will no longer be used).

40. Route the black (with yellow trace) wire from the new relay wiring harness along the fuse block wiring harness and through the seat base opening.





41. Cut off and discard the electrical terminal located on the end of the black (with yellow trace) wire from the new relay wiring harness (Figure 16).

42. Remove approximately 1/2 inch (13 mm) of insulation from both the black wire on the fuse block (cavity 8) and the end of the black (with yellow trace) wire.

43. Slide a piece of shrink tube over the black (with yellow trace) wire.





44. Insert the black wire from cavity 8 of the fuse block and the black (with yellow trace) wire from the new relay wiring harness into the large supplied brass crimp splice band and crimp them together using wire splice crimp tool 10042 (Figure 17).

45. Solder the wires and brass crimp splice band connection with rosin core solder.

46. Slide the shrink tube over the soldered connection and heat the shrink tube with a heat gun. Continue heating until the shrink tube shrinks around the wire and glue comes out of both ends of the shrink tube.

47. Tape the new relay electrical harness to the vehicle body wiring harness as required.

48. Install the fuse block into the seat base and install both mounting screws (Figure 13). Tighten the fuse block mounting screws securely.

49. Install the fuse block cover onto the seat base (Figure 12).

50. Install the relay support bar to the seat base (Figure 3).

51. Install the foam access cover to the seat base.

52. Install the driver's seat. Tighten the seat track bolts to 27 ft. lbs. (37 N.m).

53. Connect all seat electrical connections.

54. Install the left front seatbelt anchor to the seat frame. Tighten the bolt to 27 ft. lbs. (37 N.m).

55. Install the seatbelt anchor cover.

56. Connect the negative battery cable (Figure 2).

57. Check for proper roof ventilator fan operation.