Work Procedure
1. Preparatory work.1.1 Put convertible top in service position (Technical Manual, Parts ID 6101).
1.2 Remove battery cover. Disconnect and cover the battery.
1.3 Remove lower trim of left A-pillar, relay carrier, and fuse carrier.
1.4 Remove oddments tray below the convertible top, the carpet lining, and engine cover.
1.5 Remove rear spoiler (Part ID. 6658).
1.6 Remove rear apron (Part ID. 6355) and bumper (Part ID. 6350).
1.7 Remove rear luggage compartment trim (Part ID. 7006).
1.8 Remove rear muffler (Part ID. 2633).
2. Preparing and connecting electric wiring sets.
2.1 Preparatory work.
2.1.1 Bundle the RD/BU 0.5 wires (wiring harness switch) and GY/RD 0.5 wire (relay socket wiring harness) together with electrical tape.
2.1.2 Unlock locking tabs (A) on relay socket on both sides and pull relay socket apart.
2.1.3 Realign the socket contacts of the 3 wires (wiring harness switch) in the relay socket as shown.
2.2 Prepare fuse carrier.
2.2.1 Unlock locking lugs (A) on both sides and remove rear fuse carrier cover.
2.2.2 Unlock locking lugs (B) on both sides and remove fuse block B" from fuse carrier.
2.2.3 Pull locking pin (C) from fuse block "B".
2.3 Establish power supply fuse "B10/Term. 15".
2.3.1 Remove fuse "B10" from fuse carrier.
2.3.2 Press out the pin of wire BK/RD 1.5 with 88040 and disconnect socket contact (Figure 5, Item A).
2.3.3 Bundle RD/BU 0.35 lead from retrofit kit with BK/RD 0.15 wire (vehicle-side) and crimp together with a new socket contact (Figure 5, Item B).
2.3.4 Push pin in fuse carrier.
Note:
Ensure pin is seated securely.
2.3.5 Insert fuse "B10" in slot.
2.4 Complete the fuse carrier.
2.4.1 Push locking pin in fuse block "B".
2.4.2 Push fuse block "B" in fuse carrier.
2.4.3 Clip in rear fuse carrier cover.
Note:
Ensure correct seating of the locks.
2.5 Plug the relay socket into "slot 2" of relay carrier 1.
2.6 Realign jumper plug in relay carrier 1 with leads of the electrical wiring harness as shown.
2.7 Install fuse carrier and relay carrier.
2.8 Plug the relay from electrical retrofit kit into "slot 2" of relay carrier 1.
3. Route wiring harness for the switch.
3.1 Remove switch cover (Part ID. 7018) and sheet metal air guide for left footwell.
3.2 Route wiring harness from relay carrier (A) over the steering column to the installation opening in the switch cover (B) and affix.
3.3 Insert switch into the switch cover and connect plug.
3.4 Install switch cover and air duct for left footwell.
4. Route wiring harness for connector (from here on referred to as TS) for passenger compartment/rear.
4.1 Remove left door entry trim (Part ID. 6805).
4.2 Route wiring harness from fuse carrier to the B-pillar and secure.
4.3 Install the left door entry trim.
4.4 Remove right side-panel lining (Part ID. 7075).
4.5 Remove plug for water collection tray in convertible-top compartment and loosen water collection tray.
4.6 Route wiring harness (A) to the convertible-top compartment and secure.
4.7 Route wiring harness from convertible-top compartment (A) to TS X2/3 (6-pin) (B) in the rear luggage compartment and secure.
4.8 Position water collection tray in convertible top compartment and secure with plug.
4.9 Install side-panel lining.
5. Convert TS X2/3 (6-pin).
5.1 Remove TS X2/3 (A) from holder.
5.2 Unlock locking tabs (8) on both sides and disconnect X2/3.
5.3 Remove locking tabs (A) and housing lock (B).
5.4 Press out all pin contacts with 90016.
5.5 Press out all socket contacts with 87050.
5.6 Route pin housing and socket housing of TS X2/3 (8-pin) from retrofit kit as shown.
6. Install wiring harness (switch-over valve).
6.1 Route wiring harness (switch-over valve) over rear left axle support and secure (A).
6.2 Route wiring harness (switch-over valve) with the open lead ends through the rubber grommet from the brake hose in wheel housing (A) to TS X2/3 in rear luggage compartment and secure.
6.3 Note:
Stretch grommet with commercially available three-mandrel pliers.
6.4 Route socket housing of TS X2/3 (8-pin) with wiring harness (switch-over valve) as shown.
Note:
Ensure pins are seated securely.
6.5 Connect TS X2/3 and fasten to support.
7. Install vacuum line system.
7.1 Unscrew nuts (A) and remove heat shield.
7.2 Connect fastening clip (A) for the Tekalan lines on the right and left transmission holder.
7.3 Connect fastening clips (A) for the Tekalan line to the transmission.
7.4 Schematic diagram of of vacuum activation of exhaust flaps.
7.5 Insert Tekalan lines (Figure 16, Item J) in Y-Form branch piece (Figure 16, Item E).
7.6 Insert steel-armored hoses (Figure 16, Item K) with Tekalan line (40 mm) in Y form branch piece (Figure 16, Item E) and fasten with 6 mm hose clamp.
Note:
The hoses or lines are at least 20 mm deep in the connections.
7.7 Route steel-armored hoses from above right and left at the transmission downward and secure on the transmission using fastening clips.
7.8 Route steel-armored hoses at the installation position of the vacuum modulators (A) and secure in the fastening clips (B).
7.9 Insert heat shield and tighten nuts.
8. Install new rear muffler.
Note:
Position holding strut from removed rear muffler on new rear muffler and tighten nuts (A).
Tightening torque: 23 Nm (17 ft-lb.)
9. Fasten steel-armored hoses (Figure 16, Item K) on the vacuum modulators (Figure 16, Item F) using 6 mm hose clamps.
10. Route wiring harness (switch-over valve) from axle support in the engine compartment and secure.
11. Install vacuum components.
11.1 Place vacuum reservoir support (A) on the vacuum reservoir (B) and tighten screws (C).
11.2 Connect curved sheath (Figure 16, Item C) and the Tekalan line (Figure 16, Item H) on the vacuum reservoir (Figure 16, Item G).
Note:
The hoses or lines are at least 20 mm deep in the connections.
11.3 Insert vacuum reservoir in right engine compartment before the secondary-air pump and fasten screws and nuts (Figure 19, Item D).
11.4 Connect fastening clip for engine compartment cut-out (A).
11.5 Route and secure Tekalan line.
11.6 Replace distributor pipe rubber sleeve.
11.6.1 Remove previous distributor pipe rubber sleeve.
11.6.2 Connect together distributor pipe rubber sleeve (retrofit kit) with vacuum connection (A), check valve (B), curved sheath (C) and Tekalan line (I).
Note:
The black side of the check valve must point to the distributor pipe rubber sleeve.
11.6.3 Install distributor pipe rubber sleeve with vacuum connection.
11.7 Position support (A) for switch-over valve on the intake manifold from below and tighten nuts.
11.7.1 Position switch-over valve (B) on the support from below.
11.7.2 Trim the Tekalan lines and connect.
11.7.3 Insert the switch-over valve in the support and connect the plug (C).
12. Complete the vehicle.
12.1 Install bumper and rear apron.
12.2 Install exhaust tailpipe.
12.2.1 Remove exhaust tail pipe from original rear muffler.
12.2.2 Place exhaust tailpipe on new rear muffler, center on rear apron, and fasten.
12.3 Install rear luggage compartment trim.
12.4 Install engine cover, carpet lining, and oddments tray underneath the convertible top.
12.5 Install rear spoiler.
12.6 Install lower trim of left A-pillar.
12.7 Connect battery and install the battery cover.
12.8 Close convertible top.
13. Function test using PIWIS Tester.
13.1 Read out instrument cluster fault memory and erase.
13.2 Select "speedometer A signal" menu item.
13.3 Start engine.
13.4 Gradually increase A signal of speedometer up to 43 mph (70 km/h) using F5 key.
13.5 Visually inspect function of exhaust flaps:
- up to approx. 28 mph (45 km/h) ---> exhaust flaps open
- between approx. 28 mph - 42 mph (45 - 68 km/h) ---> exhaust flaps closed
- over approx. 42 mph (68 km/h) ---> exhaust flaps open
13.6 Gradually decrease A signal of speedometer down to 0 km/h using F6 key.
13.7 Perform function test of Sports exhaust system switch.
13.8 After programming is complete, read out the fault memory of all systems, correct any existing faults, and erase the fault memory.
13.9 Note:
For further information and instructions on carrying out the individual menu items - refer to the Technical Manual.