Instrument Cluster
Instrument Cluster
=> [ Instrument Cluster ]
=> [ Adapter Cable, Installing ]
Instrument Cluster
• Before removing an instrument cluster, read the notes and work procedure for malfunction recognition and malfunction display. Refer to => [ Instrument Cluster ] Instrument Cluster .
• It is not necessary to remove the steering wheel. The steering wheel is not shown in the illustration.
CAUTION!
• Turn off the ignition and all electrical components.
• Remove the ignition key.
Removing
- Release the adjustment mechanism, pull the steering column all the way and down and then lock it this position.
- Loosen the trim - 1 - from the clips in the instrument cluster mount - 2 - remove it in - direction of arrow -.
- Remove screws - arrows -.
- Pull the instrument panel insert outward slightly and separate the connectors on the backside of the instrument panel insert.
- Remove the instrument cluster.
Installing
Install in reverse order of removal, noting the following:
- After installing, test the functions of the instrument cluster.
Adapter Cable, Installing
The following applies to vehicles built between 07.04.2005 and 07.13.2007.
If the Generator (C) has to be replaced on these vehicles, then it is necessary to install an adapter cable between the blue connector/contact 16 on the instrument cluster and the brown/black wire. The adapter cable has a semiconductor diode.
The technician will have to make the adapter cable if necessary.
Material
• Semiconductor diode 1N4002 (100 V/1 A)
• Wire N.037.098.9 brown/black, length: approximately 100 mm
• Wire N.037.098.8 brown, length: approximately 100 mm
• Crimp connector 111.971.941.A, quantity: 2
• Adhesive tape N.103.113.02
• Cable tie N.101.636.01
• Heat-shrinkable tube
Identification Semiconductor Diode
1. Semiconductor switching characters
2. Semiconductor diode design
3. Thick color ring, identified as K connection (cathode)
4. Anode connection
5. Cathode connection
Special tools, testers and auxiliary items required
• Wiring Harness Repair Set VAS 1978/A (VAS 1978 B )
• 40 W soldering iron
Adapter Cable Overview
1 Heat-Shrinkable Tube
2 Crimp Connector 111.971.941.A
3 Wire N.037.098.9 (Brown/Black)
4 Heat-Shrinkable Tube
5 Semiconductor Diode 1N4002
6 Wire N.037.098.8 (Brown)
7 Crimp Connector 111.971.941.A
8 Heat-Shrinkable Tube
A - Length 100 mm
B - Length 100 mm
Procedure for making the adapter cable
- First cut two wires, each 100 mm long (N.037.098.9 and N.037.098.8)
- Remove 6 to 7 mm of insulation on the ends of the wires using the (VAS 1978/3) in the (VAS 1978 B).
- Coat both ends for the semiconductor diode with tin.
CAUTION!
Never use any liquids that contain acid!
- Solder the semiconductor diode to the wire ends coated with tin. Pay close attention to the correct connections according to the overview.
• Brown/black wire to the cathode (K) connection
• Brown wire to the anode (A) connection
- Slide a heat-shrinkable tube over the soldered connections and the semiconductor diode and then warm it up starting the center and workout outward using the (VAS 1978/14A) included in the (VAS 1978 B) until it is completely sealed and adhesive starts to leak out.
- Remove the instrument cluster. Refer to => [ Instrument Cluster ].
- Remove the connector housing - 1 - on the blue connector (T32a) - 7 -
- Remove approximately 120 mm of insulation from the blue connector (T32a) on the wiring harness.
- Remove the brown/black wire - 6 - on contact 16 approximately 80 mm from the contact housing - 7 -.
- Remove 6 to 7 mm of insulation on the ends of the wires using the (VAS 1978/3) in the (VAS 1978 B).
- Make the crimp connections between the wire ends - 2 -, - 6 - and the adapter cable - 4 -.
• Brown wire, adapter cable - 5 - with the brown/black wire - 6 - on the contact housing - 7 -
• brown/black wire, adapter cable - 3 - with the brown/black wire, wiring harness - 2 -
- Use the (VAS 1978/1-2) and (VAS 1978/1-1 ).
- Crimp the connector with the (VAS 1978/1-2).
After crimping, crimp connections must be heat-shrunk using ( VAS 1978/14A) to prevent moisture penetration.
- Attach the (VAS 1978/15A) on the (VAS 1978/14A) and warm the crimp connector starting in the center and working outward until it is completely sealed and adhesive starts to run out.
- Assemble the contact housing - 7 - and the connector housing - 1 -.
- Wrap the wiring harness for the blue connector - 1 - with tape - 3 - until the wiring harness - 4 - is completely wrapped.
- Secure the wiring harness on the blue connector - 1 - using a cable tie - 2 -.
- Install the instrument cluster.