Cell Phone - Telephone Module Installation
Cayman (987)1/05 ENU 9155
Date: Dec 14, 2005
Telephone Module Installation Instructions (I No.666)
Vehicle Type:
Cayman S
Model Year:
As of 2006
Situation:
Installation Instructions
Restriction:
Only for vehicles with PCM (I No. P16)
Information:
The sound quality of the hands-free equipment was improved on the new tri-band telephone module (900, 1,800 and 1,900 MHz), which is also available for the US market. The position of the hands-free microphone was changed from the instrument cluster to the steering column, thereby orienting the directional characteristic more towards the driver.
If the telephone module was retrofitted, it can only be used with the ignition switched on.
Before ordering parts (telephone module and optical waveguide), the vehicle equipment must be clarified and taken into consideration!
Parts Info:
Parts List
Risk of short circuit and fire
^ due to work on vehicle electrical system.
--> When working on the electrical system, the battery must always be disconnected and covered.
--> Always route electric wires without tension and so that no chafing occurs and secure to existing wires/components with tie-wraps/electrical tape.
ATTENTION
The optical waveguide can become damaged due to incorrect installation or if the requirements for handling optical waveguides are disregarded.
--> Observe the requirements for working with optical waveguides --> Workshop Manual "9772IN Optical waveguide - MOST bus"
Materials:
Tools:
Work Procedure
1 Preparatory work.
1.1 Remove battery. --> Workshop Manual "270619 Removing and installing battery - section on "Removing""
1.2 Remove right front seat. --> Workshop Manual "720779 Removing and installing front seat section on "Removing""
1.3 Remove right inner door sill trim. Workshop Manual "680519 Removing and installing inner door sill trim - section on "Removing""
1.4 Remove rear right side trim panel. --> Workshop Manual "707519 Removing and instaling side trim panel- section on "Removing""
1.5 Remove trim panel for front side section (passenger's side). --> Workshop Manual "702479 Removing and instaling front side section trim - section on "Removing""
1.6 Remove right wiring duct.
1.7 Remove glove compartment. --> Workshop Manual "681579 Removing and installing glove compartment - section on "Removing""
1.8 Remove air duct for right footwell.
1.9 Remove PCM display and operator control unit. --> Workshop Manual "917079 Removing and installing PCM display and operator control unit-section on "Removing""
1.10 Remove center air vents. --> Workshop Manual "855319 Removing and installing centre air vent-section on "Removing""
1.11 Unclip center air duct from the dashboard.
1.12 Loosen fuse box. -->Workshop Manual "978409 Loosening and securing fuse box - section on "Loosening""
1.13 Remove trim panel under dashboard. --> Workshop Manual 707979 Removing and installing trim panel underdashboard-section on "Removing"
1.14 Remove luggage compartment cover. --> Workshop Manual "703019 Removing and installing luggage compartment cover - section on "Removing""
1.15 Remove covers at the right and left close to the cowl panel. --> Workshop Manual "852219 Removing and installing cover - section on "Removing""
1.16 Remove cover for cowl panel. --> Workshop Manual "508719 Removing and installing cover-section on "Removing""
1.17 Punch service grommet in the bulkhead.
2 Install antenna. --> Workshop Manual "914779 Removing and installing radio antenna - section on "Installing""
2.1 Insert speed nuts (999.507.441.02) --> Figure 2 -M- in cowl panel cover.
2.2 Clip antenna into cowl panel cover --> Figure 2-Arrows- and secure with screws (999.073.210.00) --> Figure 2-K-.
2.3 Install cover for cowl panel. --> Workshop Manual "508719 Removing and installing cover-section on "Installing""
2.4 Fit speed nut (999.507.550.0A) --> Figure 3-H- for antenna support on bulkhead.
2.5 Fit antenna support (997.647.127.00) --> Figure 3-S- and secure with screws (999.073.236.0A) --> Figure 3-G-.
2.6 Route antenna cable as follows:
Right seat baseframe --> right wiring duct --> right A-pillar --> dashboard bracket (along original wire harness) --> through service grommet into the bulkhead --> antenna.
2.7 Connect antenna cable to antenna.
3 Install optical waveguide.
3.1 Route optical waveguide:
Right seat baseframe --> right wiring duct --> right A-pillar --> dashboard bracket (along original wire harness) --> PCM installation slot --> through service grommet in the bulkhead plenum panel
3.2 Only for vehicles with optical waveguide component (navigation/audio) in luggage compartment:
Disconnect optical waveguide connection point in the front luggage compartment.
3.3 Remove connection point holder --> Figure 6-A- from plenum panel using needle-nose pliers and open clip --> Figure 6-B-.
3.4 Cut open sheath for optical waveguide in the plenum panel in area --> Figure 7-X- by approx. 5 cm.
3.5 Cut through the original optical waveguide and pull forward out of the sheath with plug socket and connection point holder --> Figure 8-A-.
3.6 Route optical waveguide in the plenum panel.
3.7 Guide optical waveguide --> Figure 8-A-through the sheath.
3.8 Install optical contacts.
3.8.1 Pull off protective caps --> Figure 9-A-.
Note
Arrows on plug socket and optical waveguide indicate the optical input/output.
3.8.2 Insert optical contact input --> Figure 9-Band optical output --> Figure 9-C-into the plug socket --> Figure 9-D- until they are felt to engage.
3.8.3 Close secondary lock --> Figure 9-E-.
3.8.4 Remove plastic cap --> Figure 9-F-.
3.8.5 Clip plug socket into new connection point holder (997.610.1 22.00) if necessary. Secure connection point holder on plenum panel and connect plug connection for optical waveguide connection point.
3.8.6 Wrap electrical tape around sheath in area --> Figure 7-X-.
4 Route electric wire harness:
Right seat baseframe --> wiring duct --> right A-pillar --> dashboard bracket (along original wire harness) --> PCM installation slot
Item: --> Figure 10-A-; component: OG wire
Item:--> Figure 10-B-; component: WH/RD wire, RD/GN wires
Item:--> Figure 10-C-; component: Telephone module plug
Item:--> Figure 10-D-; component: 3x BN wire
Note
Secure electric wires, antenna cable and optical waveguide with tie-wraps.
5 Attach ground connection.
5.1 Crimp three BN wires, 2 x 0.75sq./1 x 0.5sq. (term. 31), of the electric wire harness for the telephone module together with a cable ring eyelet (999.650.535.00).
5.2 Secure cable ring eyelet to ground point "6" (seat baseframe).
6 Install telephone module. --> Workshop Manual "919019 Removing and installing telephone control unit - section on Installing""
6.1 Slide telephone module (997.646.208.04) --> Figure 11-B-into holder (997.642.216.00) --> Figure 11-A- and secure with screws (900.378.035.09) --> Figure 11-D-.
6.2 Insert electric plug --> Figure 12-A-, antenna connector --> Figure 12-B- and optical waveguide connector --> Figure 12-C- into telephone module.
Note
Pay attention to wire routing.
6.3 Press sheetmetal press nuts (999.500.078.00) --> Figure 72-E- into the holes in the floorpan assembly.
6.4 Align holder with telephone module to floorpan assembly and secure with screws (900.378.035.09) --> Figure 12-D-.
7 Fit adhesive clip (999.507.697.40) --> Figure 13-A- on bulkhead and clip in antenna cable.
7.1 Secure electric wire harness, antenna cable and optical waveguide with tie-wraps.
8 Connect electric wires.
8.1 Join two wires RD/GN 0.75sq. (supply +) to wire RD/GN 2.5sq. (term. 30) of 8-pin connector A, chamber 4 (PCM).
8.1.1 Open secondary lock on 8-pin connector A (PCM).
8.1.2 Press socket contact of wire RD/GN 2.5sq. (term. 30) out of 8-pin connector A, chamber 4 (PCM) using press-out tool 90006.
8.1.3 Crimp wire RD/GN 2.5sq. (term. 30) and wires RD/GN 0.75sq. (supply +) together as a splice --> Figure 14-A-.
8.1.4 Slide on shrink-fit hose and shrink hose with hot-air gun to make it watertight.
Note
Ensure socket contact is seated securely.
8.1.5 Insert socket contact into the 8-pin connector A (PCM), chamber 4.
8.1.6 Close secondary lock.
8.2 Connect wire WH/RD 0.35sq. (Wake Up) to the 20-pin connector C (PCM).
8.2.1 Open secondary lock on 20-pin connector C (PCM).
8.2.2 Press socket contact of wire WH/RD 0.35sq. (Wake Up) out of the 20-pin connector, chamber 4 (PCM) using press-out tool 93005 and cut it off.
8.2.3 Crimp wires WH/RD 0.35sq. (Wake Up) together with a new socket contact (N 103.358.01).
8.2.4 Insert socket contact into chamber 4 of 20-pin connector C (PCM).
8.3 Join wire OR 0.5sq. (term. 86s) with wire BK/OR 0.35sq. (term. 15) of 10-pin connector X (air-conditioning control)
8.3.1 Disconnect plug connection and expose wires.
8.3.2 Open secondary lock of 10-pin connector X (air-conditioning control).
8.3.3 Press socket contact of wire BK/OR 0.35sq. (term. 15) out of 10-pin connector X, chamber 5 (air-conditioning control) using press-out tool 90006 and cut it off.
8.3.4 Crimp wire OR 0.52 (term. 86s) and wire BK/OR 0.35sq. (term. 15) together with socket contact (999.650.356.12).
Note:
Ensure socket contact is seated securely.
8.3.5 Insert socket contact into chamber 5 of the 10-pin connector X (air-conditioning control).
8.3.6 Lock secondary lock of 10-pin connector X (air-conditioning control).
8.3.7 Wrap electrical tape around wires and connect plug connection --> Figure 16.
9 Install microphone. --> Workshop Manual "915779 Removing and installing microphone for telephone - section on "Installing""
9.1 Only for vehicles with BOSE Surround Sound System (I No.680) or Sound Package Plus (I No.490):
Replace the installed microphone with the microphone from the retrofit kit.
9.2 Unscrew fastening screws on the steering column trim panel and remove top section of the steering column trim panel.
9.3 Fit microphone into the upper section of the steering column trim panel and secure microphone and connector.
9.4 Route wire harness for microphone:
Steering column > wiring duct > PCM installation slot
Note
Ensure socket contact is seated securely.
9.5 Insert socket contacts of wire BU 0.35sq. and
wire YE 0.352 from the microphone wire harness
(retrofit kit) into 20-pin connector C (PCM)
--> Figure 15.
Wire YE 0.35sq. into slot C 8
Wire BU 0.35sq. into slot C 9
9.6 Close secondary lock of 20.pin connector C (PCM).
Note
Ensure socket contact is seated securely.
9.7 Insert socket contacts of wires BU 0.35sq. and YE 0.35sq. from microphone wire harness (retrofit kit) into plug socket (999.650.512.40).
Wire BU 0.35sq. into slot A 1
Wire YE 0.35sq. into slot A 2
9.8 Crimp cable ring eyelet (999.650.529.00) to the shielding wire BN 0.5sq. of the microphone wire harness.
9.9 Fit cable ring eyelet to ground point "5" --> Figure 18-A- of the dashboard bracket.
9.10 Only for vehicles with BOSE Surround Sound System (I No.680).
9.10.1 Press socket contacts of wires RD 0.35sq. and BN/RD 0.35sq. out of the plug socket for the microphone wire harness on the vehicle side using press.out tool 90207.
Note
Ensure socket contact is seated securely.
9.10.2 Insert socket contacts of wires RD 0.35sq. and BN/RD 0.35sq. into plug socket for electric wire harness for microphone (retrofit kit).
Wire RD 0.35sq. into slot A 3
Wire BN/RD 0.35sq. into slot A 4
10 Complete the vehicle.
10.1 Install the A-pillar trim panel on lower left and fuse carrier cover.
10.2 Install trim panel under dashboard. --> Workshop Manual "701979 Removing and installing trim panel under dashboard. --> section on "Installing""
10.3 Install air duct for right footwell, center air duct in dashboard and center air vent. --> Workshop Manual "855379 Removing and installing centre air vent-section on "Installing""
10.4 Install PCM display and operator control unit. --> Workshop Manual "911079 Removing and installing PCM display and operator control unit - section on "Installing""
10.5 Install trim panel for front side section (passenger's side). --> Workshop Manual "702479 Removing and installing front side section trim - section on "Installing""
10.6 Install glove compartment. --> Workshop Manual "681519 Removing and installing glove compartment - section on "Installing""
10.7 Install right wiring duct.
10.8 Install inner door entry trim at the right. --> Workshop Manual "680519 Removing and installing inner door sill trim - section on "Installing""
10.9 Install rear right side trim panel. Workshop Manual "707519 Removing and installing side trim panel - section on "Installing""
10.10 Install right front seat. --> Workshop Manual "720119 Removing and installing front seat-section on "Installing""
10.11 Seal hole at service grommet with adhesive compound.
10.12 Install battery. --> Workshop Manual "270619 Removing and installing battery - section on "Installing""
10.13 Connect battery charger.
10.14 Install cover at the right and left close to the cowl panel. Workshop Manual "852279 Removing and installing cover - section on "Installing""
10.15 Install luggage compartment cover. --> Workshop Manual "703019 Removing and installing luggage compartment cover-section on "Installing""
WARNING
Sudden voltage interruption of the power supply to the control module.
^ Destruction of the control module.
--> During programming, it is essential to guarantee the power supply for the PIWIS Tester. It is essential to connect a battery charger with a current rating of at least 40 A to the vehicle battery.
--> Prior to disconnecting the control module, switch off the ignition and remove the ignition key.
Note
The PIWIS Tester 9718 instructions take precedence and in the event of a discrepancy these are the instructions that must be followed. Deviations may occur with later software versions.
The procedure described here has been structured in general terms; different text or additions may appear in the PIWIS tester 9718.
11 Code telephone module using PIWIS Tester P9718.
11.1 PIWIS Tester P9718 must be connected and ignition must be switched on.
11.2 Select and code vehicle and "Instrument cluster" control unit.
11.3 Select and code "Gateway" control unit.
11.4 Select and code "PCM2.1 MMI" control unit.
11.5 Select and code "Telephone" control unit.
11.6 Read out and erase PCM 2.1 fault memory.
11.7 Once programming is complete, read out the fault memories of all systems, correct any faults that are found and erase the fault memories.
12 Perform a function test.
Working Time:
References:
Disclaimer