Work Procedure
1. Preparatory work.1.1 Remove right wheel housing liner, see Workshop Manual 505619 Removing and installing front wheel housing liner - chapter on Removing.
1.2 Loosen activated carbon canister, see Workshop Manual 202519 Removing and installing carbon canister - chapter on Removing.
1.3 Remove display for PCM operator control unit, see Workshop Manual 911019 Removing and installing display + PCM operator control unit - chapter on Removing or remove "CD player" car radio, see Workshop Manual 912419 Removing and installing "CD player car radio - chapter on Removing.
1.4 Remove trim panel under dashboard on the driver's side, see Workshop Manual 701919 Removing and installing trim panel under dashboard. chapter on Removing.
1.5 Remove battery, see Workshop Manual 270619 Removing and installing battery - chapter on Removing.
1.6 Remove cover on right for plenum chamber, see Workshop Manual 852219 Removing and installing cover - chapter on Removing.
1.7 Punch service grommet in the bulkhead,
2. Cut-out opening for antenna base.
2.1 Mask area, Figure 3, item A for antenna hole with masking tape.
2.2 Mark point of intersection, Figure 4, item B and auxiliary line, Figure 4, item A for cutout of antenna base on masking tape.
2.2.1 From the corner of the fender make an arc with dimension "X = 176.7 mm.
2.2.2 From the corner of the fender make an arc with dimension "Y" = 118.8 mm. (The point of intersection from the edge of the fender and the arc is point SI.
2.2.3 From point S make an arc with the dimension "Z" = 80.1 mm. The arcs with dimensions "X", "Z" form the point of intersection B.
2.2.4 Draw the auxiliary line A by connecting the points S and B.
Note!
Due to the different printing characteristics of printers, the dimensions of the template could deviate from the specified values after printing it out. Therefore, the template dimensions must be checked and corrected if necessary after printing,
2.3 Print out and cutout the template for the antenna base cutout, Figure 18 shown in this bulletin.
Note!
The middle point of Figure 18, item B and the auxiliary line for Figure 18, item A on the template must line up with the point of intersection of Figure 4, item B and the auxiliary line for Figure 4, item A on the masking tape, Figure 4. The guide notch on Figure 5, item - must point in the direction of the front wheel.
2.4 Position the template and transfer the contour for the antenna base cut-out onto the adhesive tape.
2.5 Make a bore/hole with a suitable tool, e.g. a center bit. Make a guide notch with a lock file or something similar. Test fit antenna base.
2.6 Remove masking tape, deburr opening, and vacuum up the metal shavings.
2.7 Carry out measures for maintaining long-term body protection on the edges of the bore hole. See Workshop Manual 5000IN Corrosion protection measures during repairs.
3. Installing the electric wiring harnesses for vehicles with antenna diversity.
3.1 Prepare the electrical wiring harness, parts list, item F4.
3.1.1 Pull the locking pin, Figure 6, item B from the connector and remove antenna lead, Figure 6, item C from chamber 2.
Note!
The connector and diversity antenna lead from the retrofit kit are not required.
3.1.2 Disconnect diversity antenna lead, Figure 6, item A with the connector from the wire harness F4.
3.2 Bundle the electric wires, Figure 7, item F3 and antenna lead, Figure 7, item F4 with electrical tape, approx. 50 mm behind the connectors beginning in the "X" area. Dimension X = approx. 1,200 mm
3.3 Install wiring harness.
3.3.1 Route wrapped wire harness (F3 and F4) as follows:
CU antenna diversity (right on the center console) - underneath the dashboard - to the service grommet (left bulkhead) - through the service grommet for the bulkhead, Figure 8, item A - plenum panel - through the rubber sleeve for the wheel housing, Figure 8, item B.
3.3.2 Mount adhesive clip, Figure 8, item C on bulkhead and clip in electric wire harness.
3.3.3 Route harness F1:
PCM installation slot - left footwell
Note!
Ensure socket contact is seated securely.
3.4 Connect wire 8271; WH; 0.5sq (F1) to the 8-pin connector A (PCM).
3.4.1 Pull locking pin, see Figure 10, item B from plug housing.
3.4.2 Press out socket contact of wire 8242; WH; 0.35sq with press-out tool 93001 from the 8-pin connector A (PCM) chamber 5 and separate.
3.4.3 Crimp together wire 8271; WH; 0.5sq (retrofit kit) and wire 8242; WH; 0.35sq (vehicle side) with new socket contact (999.652.959.12).
Note!
Ensure socket contact is seated securely.
3.4.4 Insert socket contact, Figure 10, item C in the 8-pin connector A (PCM) chamber 5.
3.4.5 Push locking pin, Figure 10, B into plug housing.
3.5 Crimp together wire 8271; WH; 0.5sq (F1) and 8273; WH; 0.5sq (F3), see Figure 9.
3.5.1 Slide shrink tubing over the ends of the wire.
3.5.2 Crimp together ends of the wire with cable connection.
3.5.3 Slide shrink tubing over the cable connection and shrink with hot air gun to be watertight.
3.6 Connect antenna lead onto antenna diversity CU.
3.6.1 Undo the Velcro strip on the carpet underneath the center console.
3.6.2 Release connector, Figure 11, item A and pull off from antenna diversity CU.
3.6.3 Pull locking pin, Figure 12, item B from connector.
Note!
Antenna lead remains functionless in the vehicle.
3.6.4 Remove diversity antenna lead for right windshield antenna, Figure 12, item C from chamber 1 and tie back.
3.6.5 Remove diversity antenna lead for left windshield antenna, Figure 12, D from chamber 2 and install in chamber 1.
3.6.6 Insert antenna lead (mast antenna) from retrofit kit into connector (antenna diversity CU) chamber 2.
3.6.7 Insert locking pin, Figure 12, item B in connector and connect connector to antenna diversity CU.
3.6.8 Close Velcro fastener underneath the center console.
4. Install wire harness for vehicles without antenna diversity.
4.1 Routing wire harness (997.612.308.00):
PCM installation slot - underneath dashboard - footwell - to service grommet (left bulkhead) - plenum panel - through rubber sleeve for wheel housing.
4.2 Mount adhesive clip (999.507.697.40) on bulkhead and clip in wire harness.
4.3 Connect line 8271; WH; 0.5sq to 8-pin connector A (PCM).
4.3.1 Pull locking pin from plug housing.
4.3.2 Press out socket contact of line 8242; WH; 0.35sq with press-out tool 93001 from the 8-pin connector A (PCM) chamber 5 and separate.
4.3.3 Crimp together line 8271; WH; 0.5sq (retrofit kit) and line 8242; WH; 0.35sq (vehicle side) with new socket contact (999.652.959.12).
Note!
Ensure socket contact is seated securely.
4.3.4 Insert socket contact in the 8-pin connector A (PCM) chamber 5.
4.3.5 Push locking pin into plug housing.
Note!
Antenna lead remains functionless in the vehicle.
4.4 Tie back original antenna lead in PCM installation slot and permanently secure.
5. Install mast antenna.
Note!
The locating pins, Figure 13, item A on the seal must engage in the holes, Figure 13, item B of the antenna base cover.
5.1 Position seal on the antenna base.
5.2 Route the wound wire harness (F3 and F4) or wire harness (997.612.308.00) in the wheel housing as follows: wheel housing rubber sleeve - behind tank filler pipe and air conditioning line - antenna base connection.
5.3 Connect connector from wire harness (997.612.308.00) or antenna connector, Figure 15, item A from F4 wire and connector, Figure 15, item B from F3 wire onto antenna base until the connectors are felt to engage.
5.4 Insert antenna base in cutout. The bar of the antenna base must be inserted in the guide notch, Figure 16, item A.
5.5 Position antenna base cover, Figure 17, item A and tighten fastening nut, Figure 17, item B. Tightening torque 4 (3 ft-lb.) Nm.
Note!
The seal (arrow) must make contact all the way around on the antenna base cover.
5.5 Screw in antenna mast in antenna base cover hand-tight with assembly ring.
6. Secure all wires of the retrofit kit with tie-wraps on the exsiting wires (vehicle side) or on components so that they are not subject to tension or chafing.
7. Seal the hole on the service grommet with adhesive compound.
8. Complete the vehicle.
8.1 Install display and PCM operator control unit, see Workshop Manual 911019 Removing and installing display + PCM operator control unit - chapter on Installing or install "CD player" car radio, see Workshop Manual 912419 Removing and installing "CD player" car radio - chapter on Installing.
8.2 Install trim panel under dashboard on the driver's side. See Workshop Manual 701919 Removing and installing trim panel for dashboard - chapter on Installing.
8.3 Install right cover for plenum panel. See Workshop Manual 852219 Removing and installing cover-chapter on Installing.
8.4 Install battery. See Workshop Manual 270619 Removing and installing battery - chapter on Installing.
8.5 Connect battery charger.
8.6 Position and secure active carbon canister. See Workshop Manual 202519 Removing and installing carbon canister - chapter on Installing.
8.7 Install right wheel housing liner. See Workshop Manual 505619 Removing and installing front wheel housing liner - chapter on Installing.
9. Carry out function test. For further information and instructions on carrying out the individual menu items: see Workshop Manual.
10. Read out the fault memory of all Systems, correct any existing faults, and erase the fault memory.
11. Disconnect battery charger and close the hood.