Work Procedure
1. Preparatory work.1.1 Remove right wheel housing liner --> Workshop Manual '505619' Removing and installing front wheel housing liner - section on 'Removing
1.2 Loosen carbon canister. --> Workshop Manual '202519 Removing and installing carbon canister - section on "Removing"
1.3 Remove PCM display and operator control unit, --> Workshop Manual '911019' Removing and installing PCM display and operator control unit - section on "Removing" or remove car radio "CD player". --> Workshop Manual '912419' Removing and installing car radio CD player. Section on "Removing"
1.4 Remove trim panel under dashboard on the driver's side. --> Workshop Manual '701919 Removing and installing trim panel under dashboard - section on "Removing"
1.5 Remove battery. --> Workshop Manual '270619 Removing and installing battery-section on "Removing"
1.6 Remove cover on right for plenum panel. --> Workshop Manual '852219 Removing and installing cover - section on 'Removing"
1.7 Punch service grommet in the bulkhead.
2. Drill cut-out for antenna base.
2.1 Mask area --> Figure 3 -A- for bore/hole with adhesive tape.
2.2 Mark point of intersection --> Figure 4 -B- and auxiliary line. --> Figure 4 -A- for cut-out for antenna base on adhesive tape.
2.2.1 Mark out a circular arc measuring "X" = 176.5 mm from the corner of the wing.
2.2.2 Mark out a circular arc measuring "Y" = 125.9 mm from the corner of the fender. (Point of intersection between the edge of the wing and the circular arc gives point S)
2.2.3 Mark out a circular arc from point S measuring "Z" = 75.4 mm. The circular arcs measuring "X, Z" form the point of intersection B.
2.2.4 Draw auxiliary line A by joining 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 and cutout the template (Shown not actual size) for the cut-out for the antenna base (Figure 18).
Note:
The middle point of Figure 18 -B- and the auxiliary line for Figure 18 -A- on the template must line up with the point of intersection of Figure 4 -B- and the auxiliary line for Figure 4 -A- on the adhesive tape, Figure 4.
The guide nut on Figure 5 -D- must point in the direction of the front wheel.
2.4 Place template in position and copy contour for cut-out for antenna base onto the adhesive tape.
2.5 Make the bore/hole using a suitable tool, e.g. paring drill bit. File out the guiding groove using a lock file or similar tool.
2.6 Pull off adhesive tape. de-burr bore hole and remove drilling shavings.
2.7 Carry out measures for maintaining long-term body protection on the edges of the bore hole. --> Workshop Manual '5000IN Corrosion protection measures during repairs'
3. Installation of electric wires for vehicles with antenna diversity.
3.1 Prepare parts list for electric wire harness F4.
3.1.1 Pull locking pin --> Figure 6 -B- out of the connector and remove antenna lead --> Figure 6 -C- out of chamber 2.
Note:
The connector and diversity antenna lead from the retrofit kit are not needed.
3.1.2 Disconnect diversity antenna lead --> Figure 6 -A- with connector from electric wire harness F4.
3.2 Join electric wire --> Figure 7 -F3- and antenna lead --> Figure 7 -F4- together with electrical tape in area "X", starting approx. 50 mm behind the connectors.
Dimension X = approx. 1,200 mm
3.3 Install electric wire harness.
3.3.1 Route wrapped electric wire harness (F3 and F4) as follows:
Antenna diversity control unit (right side of centre console) - underneath dashboard - to service grommet (left bulkhead) - through service grommet in bulkhead --> Figure 8 -A- - plenum panel - through rubber sleeve for wheel housing --> Figure 8 -B-.
3.3.2 Fit adhesive clip --> Figure 8 -C- on bulkhead and clip in electric wire harness.
3.3.3 Route electric wire F1:
PCM installation slot - left footwell
Note:
Ensure socket contact is seated securely.
3.4 Connect wire 8271 WH; 0.5 sq. cm (F1) to 8-pin connector A (PCM).
3.4.1 Pull locking pin --> Figure 10 -B- out of connector housing.
3.4.2 Press socket contact of wire 8242; WH; 0.35 sq. cm out of 8-pin connector A (PCM), chamber 5, using press-out tool 93001 and disconnect it.
3.4.3 Crimp wire 8271; WH; 0.5 sq. cm (retrofit kit) and wire 8242; WH; 0.35 sq. cm (vehicle side) together with a new socket contact (999.652.959.12).
Note:
Ensure socket contact is seated securely.
3.4.4 Insert socket contact --> Figure 10 -C- into 8-pin connector A (PCM), chamber 5.
3.4.5 Push locking pin --> Figure 10 -B- into the connector housing.
3.5 Crimp wires 8271; WH; 0.5 sq. cm (F1) and 8273; WH; 0.5 sq. cm (F3) together --> Figure 9.
3.5.1 Slide shrink-fit hose over the ends of the wires.
3.5.2 Crimp ends of wires together with a cable connection.
3.5.3 Slide shrink-fit hose over the cable connection and shrink the hose to make it water-tight with a hot-air gun.
3.6 Connect antenna lead to antenna diversity control unit.
3.6.1 Open Velcro fastener on the carpet underneath the center console.
3.6.2 Unlock connector --> Figure 11 -A- and pull it off the antenna diversity control unit.
3.6.3 Pull locking pin --> Figure 12 -B- out of connector.
Note:
Antenna lead remains functionless in the vehicle.
3.6.4 Remove diversity antenna lead for right windshield antenna --> Figure 12 -C- out of chamber land tie it back.
3.6.5 Remove diversity antenna lead for left windshield antenna --> Figure 12 -D- out of chamber 2 and install it in chamber 1.
3.6.6 Insert antenna lead (mast antenna) from retrofit kit into connector (antenna diversity control unit), chamber 2.
3.6.7 Insert locking pin --> Figure 12 -B- into the connector and plug connector into antenna diversity control unit.
3.6.8 Close Velcro fastener underneath the center console.
4. Installation of electric wire harness for vehicles without antenna diversity.
4.1 Route electric wire harness (997.612.308.00):
PCM installation slot - underneath dashboard - footwell - to service grommet (left bulkhead) - plenum panel - through rubber sleeve in wheel housing.
4.2 Fit adhesive clip (999.507.697.40) on bulkhead and clip in wire harness.
4.3 Connect wire 8271; WH; 0.5 sq. cm to 8-pin connector A (PCM).
4.3.1 Pull locking pin out of connector housing.
4.3.2 Press socket contact of wire 8242; WH; 0.35 sq. cm out of 8-pin connector A (PCM), chamber 5, using press-out tool 93001 and disconnect it.
4.3.3 Crimp wire 8271; WH; 0.5 sq. cm (retrofit kit) and wire 8242; WH; 0.35 sq. cm (vehicle side) together with a new socket contact (999.652.959.12).
Note:
Ensure socket contact is seated securely.
4.3.4 Insert socket contact into 8-pin connector A (PCM), chamber 5.
4.3.5 Push locking pin into the connector housing.
Note:
Antenna lead remains functionless in the vehicle.
4.4 Tie original antenna lead back in PCM installation slot and secure it as a permanent fixture.
5. Install mast antenna.
Note:
The locating pins, Figure 13 -A- on the seal must engage in the holes, Figure 13 -B- of the antenna base cover.
5.1 Place seal on the antenna base.
5.2 Route wrapped wire harness (F3 and F4) or wire harness (997.612.308.00) in the wheel housing as follows:
Rubber sleeve in wheel housing behind tank filler pipe and air-conditioning line antenna base connection
5.3 Connect connector for wire harness (997.612.308.00) or antenna connector --> Figure 15 -A- for wire F4 and connector --> Figure 15 -B- for wire F3 to the antenna base until the connectors engage securely.
5.4 Insert antenna base into cut-out. The bar of the antenna base must be inserted into the guiding groove --> 16 -A-.
Note:
The seal (arrow) must make contact all the way around on the antenna base cover.
5.5 Place antenna base cover --> Figure 17 -A- in position and tighten fastening nut --> Figure 17 -B-.
Tightening torque 4 (3 ft-lb.) Nm
5.6 Screw antenna mast hand-tight into cover of antenna base using assembly ring.
6. Use tie-wraps to secure all wires from the retrofit kit to existing wires (vehicle side) or components without tension and so that no chafing occurs.
7. Seal the hole on the service grommet with adhesive compound.
8. Complete the vehicle.
8.1 Install PCM display and operator control unit, Workshop Manual '911019' Removing and installing PCM display and operator control unit - section on "installing" or install car radio "CD player". --> Workshop Manual '912419 Removing and installing car radio "CD player"- section on 'Installing"'
8.2 Install trim panel under dashboard at the driver's side. --> Workshop Manual '701919 Removing and installing trim panel under dashboard - section on 'installing'
8.3 Install right cover for plenum panel. --> Workshop Manual '852219 Removing and installing cover - section on 'Installing'
8.4 Install battery. --> Workshop Manual 270619 Removing and installing battery - section on 'Installing"'
8.5 Connect battery charger.
8.6 Positioning and secure carbon canister. --> Workshop Manual 202519 Removing and installing carbon canister - section on "Installing"'
8.7 Install right wheel housing liner. --> Workshop Manual '505619 Removing and installing front wheel housing liner - section on 'installing"'
9. Perform a function test.
Note:
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 lid.