Remove/Install Fuse and Relay Box

Removal, installation
1 Disconnect ground lead from battery


CAUTION: Insulate cable terminal on ground lead for protection against unintentional contact between disconnected ground lead and ground connection point W10


2 Remove cover (1)


NOTE: Ensure that gasket is not damaged


3 Unscrew screws (2) and remove cover (3) on fuse and relay box (F1)


NOTE: Ensure that gasket is not damaged


4 Unscrew screw (4) for data link connector (X11/4)
5 Unclip fuse blocks (A-F) from carrier (5)
6 Remove carrier (5) from fuse and relay box (F1)


NOTE: To do this guide fuse blocks downward out of carrier


7 Separate connector field on data link connector (X11/4)


NOTE: For this purpose unhook from bottom in middle of connector field and remove loose half of connector field


8 Disconnect leads with coded plugs on fuse blocks


NOTE: Triple plug on fuse block (B), fuses 15, 16 and 17


9.1 Remove diagnostic module (N59) and ADS control module (N51)


NOTE: Control module (N59) (USA) only, control module (N51) with ADS (code 217a)


10 Disconnect connectors from cycle module and relay box (F1) pull cycle module upward and remove from fuse and relay box (F1)
11 Unscrew screws (6) on carrier (7) and remove carrier from fuse and relay box (F1)
12 Unscrew screws (8) and remove relay holder (9)
13 Unclip connectors an relay holder (9) and disconnect
14 Remove cover below instrument panel (driver's side)
15 Remove front floor covering (driver's side)
16 Disconnect electrical connectors and connections in left footwell

Illustrated On Model 210:

NOTE: This step includes all leads arid wiring harnesses leading through the housing of the fuse and relay box without a separation point inside the housing


17 Remove instrument cluster
18 Open 30 and 25-pin connectors on instrument cluster and pull out multi-point male connectors


NOTE: 30-pin multi-point male connector
- Disconnect coding section B, 12-pin
- 25-pin multi-point male connector
- Disconnect coding sections A, D and H.


19 Pull leads and wiring harnesses for disconnected coding sections back to fuse and relay box (F1)
20.1 Disconnect electrical connectors on alarm horn and ATA engine hood switch
- with ATA (code 551a)

21.1 Disconnect electrical connections from stationary heater
- with stationary heater (code 228)

21.2 Disconnect electrical connections on heater booster
- with engine 602.982

22.1 Disconnect electrical connections for washer pump for headlamp cleaning system
- with headlamp cleaning system (code 600a)

23.1 Disconnect electrical connections on hydraulic oil level switch on oil supply reservoir
- with level control (code 480),
- with ADS (code 217a)

24 Pull leads and wiring harnesses leading from engine or component compartment without separating point at fuse and relay box (F1), back into former
25 Carefully remove disconnected fuse blocks, separated and disconnected leads and wiring harnesses from fuse and relay box housing (F1)
26 Unscrew nuts (10)
27 Remove fuse and relay box housing (F1) from component compartment


NOTE: For this purpose pull control cable for engine hood release out of housing


NOTE: Ensure that gasket (12) is in good condition and properly seated


28 Disconnect leads from fuse boxes or fuse blocks
Refer to Special Tool below


CAUTION: Disconnect leads only when replacing entire fuse and relay box. To prevent mix-ups tie disconnected leads to individual fuse blocks together and mark.


Reconnect leads to fuse boxes or fuse blocks
Fuse block pin assignments and lead connections
- Model 210

29 Reinstall in opposite order