ar8285p7472p

Page 1 of 2

Removing and installing operating / display unit with control module

AR82.85- P- 7472P MODEL

1 A40/3

Removing and installing operating / display unit with control module

9.2.00

203 with CODE (352a) COMAND operating and display system

Bolts Remove COMAND operating, display COMAND control unit

P82.85- 5730- 12

1 2 A B D2B D D F S

RGB signal connector from TV tuner CAN connector to instrument cluster Voltage supply connector Speaker connector Digital databus connector FM/ AM antenna signal input connector GPS antenna signal input connector IF signal output connector Equipment fuse

P82.85- 5128- 06

Removing, installing Danger! Risk of explosion from gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury from caustic burns to eyes and skin from battery electrolyte or from handling damaged lead- acid batteries Notes on battery 1 2 3 4 5 6 7 Connect quiescent current retention device Disconnect ground cable of battery Remove cover from center console Unscrew screws (1) Remove COMAND operating, display Take out COMAND control unit (A40/ 3) Separate the connections (1, 2, A, B, D, E, F ) Disconnect connector on fiber optic cable (D2B) Do not kink or stretch D2B fiber optic cable. Fit fiber optic cable connector and radio connection with caps. Refer to: Cover optical waveguide AR68.20-P-2350P No fire, sparks, naked flames or smoking. Wear acid- resistant gloves, clothing and eye protection. Pour battery electrolyte only into suitable and appropriately marked containers. All models. AS54.10-Z-0001-01A

AH54.10-P-0001-01A AR54.10-P-1030-07I *WH58.30-Z-1005-09A

AR82.95-P-0005-01A

ar8285p7472p

Page 2 of 2

Removing and installing operating / display unit with control module

Notes on fiber optic cable 8 9 Install in the reverse order Read diagnostic trouble code memory and erase

Models 129, 168, 170, 202, 203, 208, 210, 215, 220, 463. Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed. Refer to: STAR DIAGNOSIS. Only if no quiescent current retention unit has been used. Refer to: Perform basic programming.

AH82.70-P-0001-02A

10

Make electrical system operational

AR00.19-P-0200P

Commercially available tools Number

WH58.30- Z- 100509A

(see Workshop Equipment Manual) Designation Quiescent current retention device CMP 12.2 Make (e. g.) Hans Zeheter Order number

COMAND Pinouts
Connector A Pin 01 GAL (non-CAN speed signal) Pin 02 K (diagnostics connector under hood) Pin 03 Telephone Mute Pin 04 Kl. 30 (+12V battery) Pin 05 +12V switched output (for automatic antenna) Pin 06 Kl. 58d (illumination) Pin 07 Kl. 15R (iginition) Pin 08 Kl. 31 (ground) Connector B Pin 01 LS rear right + Pin 02 LS rear right Pin 03 LS front right + Pin 04 LS front right Pin 05 LS front left + Pin 06 LS front left Pin 07 LS rear left + Pin 08 LS rear left Connector C1 Pin 01 TV Red Pin 02 TV Green Pin 03 TV Blue Pin 04 Pin 05 - power CD changer Pin 06 + power CD changer Pin 07 Pin 08 Connector C2 Pin 01 Wake up (Robert-Bosch CAN) Pin 02 sound TV right Pin 03 sound TV GND Pin 04 aux in right Pin 05 aux in GND (right) Pin 06 speedsensor (non-CAN) Pin 07 interior CAN shield Pin 08 interior CAN Lo (buttons on steering wheel, etc) Pin 09 interior CAN Hi (buttons on steering wheel, etc) Pin 10 D2B Wake up Pin 11 sound TV left Pin 12 sound TV Shield Pin 13 aux in left Pin 14 aux in shield (or aux in GND left) Pin 15 reverse signal Pin 16 Robert-Bosch CAN Shield Pin 17 Robert-Bosch CAN Lo Pin 18 Robert-Bosch CAN Hi

ar6820p2350p

Page 1 of 1

Removing and installing cover on center console

AR68.20- P- 2350P MODEL 203

Removing and installing cover on center console

23.8.99

Illustrated on model 203.0 1 2 3 N18 cc N22/ 7 N72/ 1 Cover on center console Lock Center air nozzle HEAT pushbutton control module AAC pushbutton control module convenience AAC pushbutton control module Upper control panel control module

P68.20- 2201- 02

P68.20- 2264- 02

Operation no. of operation texts or standard texts and flat rates Sector P Op. no. 683430 Operation text REPLACING COVER FOR HEATER/ VENTILATION SWITCH

Removing, installing 1 2 3 4 5 6.1 6.2 6.3 7 8 Remove center air nozzle (3) Remove ashtray at front of center console Open locks (2) in ashtray housing tunnel Remove cover from center console (1) Disconnect overhead control panel control module (N72/ 1) connectors at rear Unlock connectors for heater pushbutton control module (N18) from rear, disconnect Disconnect AAC pushbutton control module (N22) from rear Unlock AAC convenience pushbutton control module (N22/ 7) at rear, disconnect Remove cover from center console (1) Install in the reverse order With code (580b) convenience automatic air conditioning With code (581b) convenience automatic air conditioning AR68.10-P-1150P AR68.20-P-2400P

ar6810p1150p

Page 1 of 1

Removing and installing center air nozzle

AR68.10- P- 1150P MODEL 203

Removing and installing center air nozzle

23.8.99

P68.10- 2323- 07

Removing 1 2 3 4 5 6 7 8 9 10 11 12 13 Release lock (2) and pivot air nozzles (3, 4) out upward Unscrew screws (5) Release lock (1) and pivot air nozzles (3, 4) out downward Press catch lugs (6) down in air nozzle duct Remove air nozzle Remove connector from center air outlet illumination (E10/ 1) Lay air nozzle down Installing Pick up air nozzle Connect connector of center air outlet illumination (E10/ 1) Set air nozzle on air distribution guide rod and arrest Release lock (2) and pivot air nozzles (3, 4) out upward Fully tighten screws (5) Turn adjustment wheel (7) and arrest air distribution guide rod With code (581b) convenience automatic air conditioning With code (581b) convenience automatic air conditioning

Avoid damaging instrument panel.

It should be possible for the air distribution flap to open and close completely.

ar6820p2400p

Page 1 of 1

Remove/install ashtray housing in front center console

AR68.20- P- 2400P MODEL 203, 209

Remove/ install ashtray housing in front center console

23.8.99

Shown on model 203.0 1 2 E9/ 7 Catch lugs Ashtray housing Front ashtray illumination

P68.20- 2199- 01

P68.20- 2200- 01

Remove/ Install Danger! Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead- acid batteries Disconnect ground cable of battery Notes on battery 2 3.1 3.2 4 5 6 7 8 9 Remove cover on shift lever Actuate clutch pedal and engage second gear Actuate selector lever release actuator and move selector lever rod toward rear Open ashtray housing (2) Press catch lugs (1) back Remove ashtray housing (2) Disconnect connector for front ashtray illumination (E9/ 7) from ashtray housing (2) Install in the reverse order Perform basic programming No fire, sparks, open flames or smoking. Wear protective gloves, acid- resistant clothing and safety glasses. Pour battery electrolyte only into suitable and appropriately marked containers. Model 203 Model 209 All models Model 203 Model 209 with transmission 716.6. for transmission 722.6 AS54.10-Z-0001-01A

AR54.10-P-0003P AR54.10-P-0003Q AH54.10-P-0001-01A AR68.20-P-2310P AR68.20-P-2310Q

Model 209 Model 203 Only if no quiescent current retention device has been used.

AR00.19-P-0200Q AR00.19-P-0200P

10 11

Read DTC memory and erase Perform function check

STAR Diagnosis tool.

ar6820p2310p

Page 1 of 1

Remove/install gearshift lever cover

AR68.20- P- 2310P MODEL 203

Remove/ install gearshift lever cover

23.8.99

Shown on model 203 with selector lever for automatic transmission 1 2 3 Gearshift lever paneling Shift lever cover Clutches

P68.20- 2203- 01

P68.20- 2204- 01

Remove/ Install Danger! Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead- acid batteries Disconnect ground cable of battery Notes on battery Unclip gearshift lever paneling (1) out of gearshift lever cover (2) with long wedge Pull shift lever covering (1) upward Unclip gearshift lever cover (2) (arrows) Disconnect connectors (3) from rear of shift lever cover (2) Remove gearshift lever cover (2) Install in the reverse order Check for proper function No fire, sparks, naked flames or smoking. Wear protective gloves, acid- resistant clothing and safety glasses. Pour battery electrolyte only into suitable and appropriately marked containers. AS54.10-Z-0001-01A

1 2 3 4 5 6 7 8

All models Long wedge

AR54.10-P-0003P AH54.10-P-0001-01A *115589035900

115 589 03 59 00
Longitudinal wedge

Install

Date: Order No.: Supersedes: Group:

September 2002 T-I-82.85/191 82

SUBJECT:

MODEL 463.249 MODEL YEAR 2002 AUXILIARY INPUT HARNESS INSTALLATION (G-CLASS WITH COMAND)

We are interested in your comments and/or suggestions regarding these installation instructionsplease e-mail them to: technicalinformation@MBUSA.com Note: Installation of the auxiliary input harness is not covered under warranty; it is a customer pay option. 1. Remove the glove compartment. Refer to WIS: AR68.10-P-1400GM, Remove/install glove compartment 2. Measure and mark the glove compartment left side at the point where 80-mm (A, Figure 1) from the back edge and 30-mm (B, Figure 1) from the bottom edge meet. 3. Make an 18.8-mm hole at the measured mark (C, Figure 1).

Figure 1

P82.85-9758-01

This bulletin has been created and maintained in accordance with MBUSA-SLP 5.1, Document and Data Control, and MBUSA-SLP 16.1, Control of Quality Records.

2002 Mercedes-Benz USA, LLC Mercedes-Benz Canada, Inc. Technical Information www.MBUSA.com

All rights reserved. Reproduction or translation in whole or in part is not permitted without authorization from the publisher. Printed in the USA. 1-800-FOR-MERCedes

4. Remove the quick-release connector lock (A, Figure 2) from the auxiliary input harness connector (B, Figure 2).

Figure 2 5. Insert the auxiliary input connector into the drilled hole from outside the glove compartment (Figure 3). Note: Be sure the edge of the glove compartment hole inserts into the groove in the connector (C, Figure 2). 6. From inside the glove compartment, lock the connector in place by inserting the quickrelease connector lock into the connector face. Note: Be sure the spines (D, Figure 2) of the quick-release lock inserts into the corresponding notches (E, Figure 2) in the connector. 7. Clip off the terminals from the individual wires of the auxiliary input harness (Figure 4).

P82.85-9759-01

Figure 3

P82.85-9760-01

Figure 4

P82.85-9761-01

T-I-82.85/191 September 2002

8. Install the new terminals (part number: A 008 545 55 26) to the auxiliary input harness wires using the appropriate tools from the wiring harness repair kit (part number 220 589 01 99 00) (Figure 5). 9. Remove the COMAND unit. Refer to WIS: AR82.85-P-7472GM, Removing and installing operating and display system with control module

Figure 5 10. Position the glove compartment near its point of installation and feed the auxiliary input harness end through the glove compartment opening to the space vacated by the COMAND unit. 11. Reinstall the glove compartment. Refer to WIS: AR68.10-P-1400GM, Remove/install glove compartment 12. Locate the disconnected C-2 plug in the space vacated by the COMAND unit (A, Figure 6). 13. Remove the pin connector from the C-2 plug (B, Figure 6 and Figure 7). Figure 6 14. Connect the new terminals on the wires of the auxiliary input harness into the pin connector (A, Figure 7). a) Thin-gauge black wire into pin-13 (A, Figure 8) b) Thick-gauge black wire into pin-14 (B, Figure 8) c) Yellow wire into pin-04 (C, Figure 8) d) Brown wire into pin-05 (D, Figure 8)

P82.85-9762-01

P82.85-9763-01

Figure 7

P82.85-9764-01

T-I-82.85/191 September 2002

15. Reinsert the pin connector into the C-2 plug, making sure the arrow on the pin connector points toward the C-2 plug (B, Figure 7). 16. Reinstall the COMAND unit. Refer to WIS: AR82.85-P-7472GM, Removing and installing operating and display system with control module 17. See page 225 of the COMAND Operators Manual for instruction on switching on the auxiliary audio source.

Figure 8

P82.85-9765-01

Parts Information Qty. 1 4 Part Name Auxiliary input harness Terminals Part Number/Exchange A 203 540 61 07 A 008 545 55 26

T-I-82.85/191 September 2002

ar9112p1020pc

Page 1 of 1

Removing, installing rear seat cushion

AR91.12- P- 1020PC MODEL

1 2 3

Removing, installing rear seat cushion

10.7.00

203.0 except CODE (287a) Through- loading feature

Rear seat Nuts Covering caps

P91.12- 2254- 06

Operation no. of operation texts or standard texts and flat rates Division P Op. no. 915053 Operation text REMOVE AND INSTALL SEAT CUSHION FOR REAR SEAT

Removing, installing 1 2 3 4 Remove covering caps (3) Unscrew nuts (2) Remove rear seat cushion (1) Install in the reverse order

Installation: On installation, note the position of the seat belt locks.

ar9112p1620pc

Page 1 of 1

Removing, installing rear seat backrest

AR91.12- P- 1620PC MODEL

Removing, installing rear seat backrest

12.7.00

203.0 except CODE (287a) Through- loading feature

P91.12- 2252- 09

1 2

Rear seat backrest Center seat belt

3 4

Screw at belt end fitting Screws

5 6

Outer screws Catch

Operation no. of operation texts or standard texts and flat rates Division P Op. no. 915395 Operation text REMOVE AND INSTALL REAR SEAT BACKREST (SEAT CUSHION REMOVED)

Removing, installing 1 2 Remove rear seat cushion Unscrew the screw (3) at the center rear seat belt end fitting Installation: Ensure that the belt end fitting engages. Screw at belt end fitting Torx bit set 3 4 5 6 7 8 Unscrew screws (4) Unscrew bolts (5) Release rear seat backrest (1) at the catch (6) Disconnect head rest pneumatic connection Remove rear seat backrest (1) Install in the reverse order Lever pneumatic connection off with WAF 7 open- ended wrench. *BA91.40-P-1001-01A *000589011000 AR91.12-P-1020PC

Seat belts/ emergency Number

tensioning retractors Designation Model 203

BA91.40- P- 1001- 01A

Screw on belt end fitting

Nm

30

000 589 01 10 00
Torx bit set

ar6830p4490p

Page 1 of 1

Removing and installing C-pillar paneling

AR68.30- P- 4490P MODEL 203.0

Removing and installing C- pillar paneling

23.8.99

Illustrated for code (287a) Through- loadingfeature 1 2 3 4 5 Screw for belt end fitting Screw for C- pillar paneling C- pillar paneling Edge guard Seat belt

P68.30- 2256- 12

Operation no. of operation texts or standard texts and flat rates Sector P Op. no. 681105 Operation text REMOVING AND INSTALLING INTERIOR PANELING ON REAR PILLAR; LOCATION: .......

Removing, installing 1.1 1.2 2 3 4 5 6 Remove rear seat cushion Release rear seat cushion and fold forwards Unscrew screw from belt end fitting (1) Remove edge guard (4) in area of C- pillar paneling (3) Remove SRS airbag cover Unscrew screw (2) on C- pillar paneling (3) Unclip C- pillar paneling (3) at top to center of vehicle and pull out of rear shelf guide toward front Remove C- pillar (3) paneling Install in the reverse order External torx set *001589760900 AR91.12-P-1020P With code (287a) Through- loading feature Screw at belt end fitting Torx bit set *BA91.40-P-1001-01A *000589011000

7 8

Installation: Observe installation position for seat belt (5)

Seat belts/ emergency Number

tensioning retractors Designation Model 203

BA91.40- P- 1001- 01A

Belt end fitting screw

Nm

30

001 589 76 09 00
External torx set

000 589 01 10 00
Torx bit set

ar6820p4800p

Page 1 of 1

Remove/install rear floor covering

AR68.20- P- 4800P MODEL 203.0 / 2

Remove/ install rear floor covering

23.8.99

P68.20- 2678- 09

Shown in model 203.0 1 2 Front seats Center console

3 4 5

Rear seat cushion Front door sill molding Rear door sill molding

6 7 8

Air ducts Connection cable Floor covering

Remove, Install 1 2 3 Remove front seats (1) Remove center console (2) Remove rear seat cushion (3). Model 203.0 except CODE (287a) Throughloading feature Model 203.0 with CODE (287a) Through- loading feature, model 203.2 AR91.10-P-1000P AR68.20-P-2000P AR91.12-P-1020PC AR91.12-P-1020P

4 5 6 7 8

Unclip front door sill moldings (4) and rear door sill moldings (5), remove Remove air ducts (6) Route connection cable (7) through floor covering (8) Remove floor covering (8) Install in the reverse order

ar6820p2070p

Page 1 of 1

Remove/install front floor covering (right)

AR68.20- P- 2070P MODEL 203, 209

Remove/ install front floor covering (right)

23.8.99

Shown in model 203.0 1 2 3 4 5 Door sill molding Edge guard Bolt Cover of A- pillar Floor mat

P68.20- 2206- 11

Remove/ Install 1 2 3 4 5 6 7 8 Move right front seat toward rear Unclip door sill molding (1), remove Remove edge guard (2) in area of A- pillar cover (4) Unclip cap from A- pillar cover (4) Unscrew bolt (3) Unclip cap from A- pillar cover (4), remove Lift floor covering (5) at rear, remove Install in the reverse order Installation: Insert floor covering in area of center console.