Work Procedure
Work Procedure1. Preparatory work.
1.1 Raise door windows.
1.2 Remove inner door sill trim => Workshop Manual 680519 Removing and installing inner door sill trim section on "Removing".
1.3 Remove cover strip => Workshop Manual 680719 Removing and installing cover strip section on "Removing".
1.4 Removing front side section trim => Workshop Manual 702419 Removing and installing front side section trim section on "Removing"
1.5 Remove bass loudspeaker. => Workshop Manual 914119 Removing and installing front loudspeakers (door). section on "Removing".
1.6 Pull back carpet lining and loosen locating peg => Figure 3-1 - and fastening screws => Figure 3-2 on the support (wiring duct).
2. Route electric wire harness (=> Figure 2-B-).
2.1 Insert wire harness into the wiring duct => Figure 4 -A- and position inverter => Figure 4-B- in the first cut-out of the wiring duct.
3. Disconnect plug connection for door wire harness.
3.1 Driver's side:
3.1.1 Clip plug connection => Figure 5 -arrow- out of bracket and side protective hose over the plug connection.
3.2.1 Release lock => Figure 6 -A- and disconnect plug connection => Figure 6 -B-.
3.2 Passenger's side:
3.2.1. Disengage plug connection => Figure 7 -A- at the body and slide protective hose over plug connection.
3.2.2 Pull locking mechanism and disconnect plug connection (see Step 3.1.2).
4. Route electric wire harness (=> 2 -C-).
4.1 Push rubber sleeves => Figure 8 -A- and -B- out of A-pillar from the inside and carefully pull these and the door wire harness out through the openings.
4.2 Push rubber sleeve => Figure 8 -C- out of door and rubber sleeve => Figure 8 -D- out of door sub-frame and carefully pull these and the door wire harness out through the openings.
NOTE:
Observe direction of installation of electric wire harness. Open ends of lines (Figure 9 -A-)
4.3 Guide electric wire harness carefully through the rubber sleeve using a Teflon hose.
4.4 Replace protective hose for door wire harness.
4.4.1 Slide rubber sleeve back to the end of the protective hose => Figure 10 -arrow-, remove wrapping tape and pull protective hose => Figure 10 -A- off the door wire harness.
NOTE:
The electric wire harness for the illuminated sill cover is not covered by the protective hose.
4.4.2 Slide rubber sleeve back slightly => Figure 10 -arrow-. Pull new protective hose over the door wire harness as far as the rubber sleeve and secure in this position with wrapping tape. Pull protective hose tightly and wrap tape along the entire length of the rubber sleeve up to the door wire harness plug connection.
ATTENTION:
Laying the door wire harness!
^ Risk of damage to the door wire harness, protective hose or rubber sleeve.
=> Route door wire harness without tension and so that no chafing occurs.
=> Make sure that the rubber sleeve is not chafed at the edges.
4.5 Route door wire harness and rubber sleeve into the passenger compartment through the opening for the door sub-fram, door and A-pillar. Press rubber sleeves => Figure 11 -A, B, C and D- into the openings and check that the rubber sleeves fit snugly all the way round.
5. Connect electric wire harness (=> Figure 2 -C- and -D-).
5.1 Connect line RD 0.5 sq. from the wire harnesses.
5.1.1 Slide shrink-fit hose over line RD 0.5 sq. from the wire harness (=> Figure 2 -D-).
5.1.2 Crimp line RD 0.5 sq. from the wire harnesses (=> Figure 2 -C- and -D-) together using an insulated cable connection.
5.1.3 Slide shrink-fit hose over the insulated cable connection and shrink the hose with a hot-air gun.
5.2 Attach line BN 0.5 sq. from the wire harness (=> Figure 2 -C- and -D-) as described in Step 5.1.
5.3 Wind electrical tape around lines RD 0.5 sq. and BN 0.5 sq.
5.4 Connect plug connection from wire harnesses (=> Figure 2 -B- and -D-).
5.5 Secure wire harness to the vehicle wire harness with electrical tape.
6. Connect plug connection for door wire harness.
6.1 Passenger's side:
6.1.1 Stick a 40-mm length of adhesive sealing strip, Part No. 000.043.129.00, to the back of the connector housing => Figure 13 -A-.
6.1.2 Push back protective hose around the plug connection and then connect and lock the plug connection.
6.1.3 Pull the protective hose as far as possible over the plug connection and press down firmly on the adhesive strip.
6.1.4 Engage plug connection => Figure 14 -A- at the body.
6.2 Driver's side:
6.2.1 Push back protective hose around the plug connection and then connect and lock the plug connection.
6.2.2 Pull the protective hose as far as possible over the plug connection and clip onto the fuse carrier => Figure 15 -arrow-.
7. Connect and route electric wire harness (=> Figure 2 -E-).
7.1 Disassemble 32-pin door control unit connector.
7.1.1 Remove tie-wrap => Figure 16 -A-.
7.1.2 Release lock => Figure 16 -B-.
7.1.3 Pull plug carrier => Figure 16 -C- out of the connector housing.
7.2 Press socket contact of line BK/RD 0.75 sq., chamber 20=> Figure 17 -A- and socket contact of line BN 0.75 sq., chamber 21 => Figure 17 -B- out of the 32-pin door control unit connector.
7.3 Connect line RD 0.5 sq. from the wire harness (=> Figure 2 -E-).
7.3.1 Remove approx. 15 mm of insulation on line BK/RD 0.75 sq. (=> Figure 18 -A-).
7.3.2 Crimp line RD 0.5 sq. and line BK/RD 0.75 sq. together using an insulated cable connection => Figure 18 -B-.
7.3.3 Slide shrink-fit hose over the insulated cable connection and shrink the hose with a hot-air gun.
7.4 Attach line BN 0.5 sq. from the wire harness (=> Figure 2 -E-) and line BN 0.75 sq.of the 32-pin door control unit connector => Figure 18 -C- as described in Step 7.3.
7.5 Wind electrical tape around lines.
NOTE:
Make sure the socket contacts are seated securely.
7.6 Insert socket contact of line BK/RD 0.75 sq. in chamber 20 => Figure 19 -A- and socket contact of line BN 0.75 sq. in chamber 21 => Figure 19 -B- of the 32-pin door control unit connector.
7.7 Assemble 32-pin door control unit connector.
7.7.1 Push plug carrier => Figure 20 -C- into the connector housing.
7.7.2 Press in lock => Figure 20 -B-.
7.7.3 Secure wire harness to connector with a tie-wrap => 20 -A-.
7.8 Route wire harness along the door trim panel => Figure 21 and secure to standard door wire harness with electrical tape.
8. Install sill cover.
8.1 Remove residual adhesive from door sill and clean bonding surface to remove and dust and grease.
8.2 Pull protective film off the bonding area of the sill cover.
NOTE:
Center the notch in the scuff plate at bead height (Figure 22 -Arrow-).
8.3 Position sill cover at the contour of the door sill, stick it on and press down firmly.
8.4 Connect plug connection for sill cover => Figure 23 -A-.
8.5 Lay flat belt lead over sheetmetal flange => Figure 23 -arrow- and attach rubber seal for door. => Workshop Manual 576319 Removing and installing rubber seal for door, section on "Installing".
9. Concluding work:
9.1 Secure fastening screws => Figure 24 -2- and locating peg => Figure 24 -1- on the support (wiring duct) and fit carpet lining.
9.2 Install front side section trim, => Workshop Manual 702419 Removing and installing front side section trim section on "Installing".
9.3 Install inner door sill trim => Workshop Manual 680519 Removing and installing inner door sill trim section on "Installing".
9.4 Install bass loudspeaker, => Workshop Manual 914119 Removing and installing front loudspeakers (door) section on "Installing".
9.5 Position door trim panel, connect plug connection from wire harnesses (=> Figure 2 -C- and -E-) and wrap foam strips (-=> Figure 2 -F-) around it => Figure 25 -A-.
9.6 Secure door trim panel. => Workshop Manual 705919 Removing and installing door trim panel section on "Installing".
9.7 Carry out function test.
9.7.1 Close both doors and then open them again.
9.7.2 Both sill covers must light up for approx. 10 minutes.