Installation
1. Preliminary steps.1.1 Cover the front of the vehicle with protective covers to prevent paint damage. Remove battery cover panel. Disconnect the battery and cover the battery posts.
1.2 Remove spare wheel, brake booster cover, audio amplifier and CD changer, if equipped. Remove carpet from front luggage compartment.
1.3 Remove both headlights (see Technical Manual, Group 9, Section 94 15 19).
1.4 Drill a 3 mm hole in the grommet for the electrical harness (Figure 1, Item A).
1.5 Check for a plug on the left and right wall of the luggage compartment, near the headlight adjusters. (Figure 2 and 3, Item A)
If plugs exist, proceed to step 1.6 Only if plugs do not exist, perform the following:
- Bore a 20 mm hole at both positions marked "A" in Figures 3 and 4.
- De-burr both holes and apply etching-primer to prevent corrosion.
- Treat both holes with polish after the specified drying time has elapsed.
- Vacuum any drillings from the luggage compartment.
1.6 Remove plugs (Figure 2 and 3, Item A).
2. Perform voltage supply connections.
2.1 Insulate (wrap) the BK/RE wire (1.5 sq.mm) of the new Litronic harness with electrical tape. Route the BK/RE wire through the 3 mm hole (previously drilled in step 1.4) toward the right windshield washer spray jet.
2.2 Detach and disconnect the 2-pin plug for the right washer jet.
2.3 Locate the BK/YE wire (1.0 sq.mm) from the 2 pin spray jet plug housing (Pin 1, harness side). Strip back approx. 5 mm of the insulation.
2.4 Combine the BK/YE (1.0 sq.mm) spray jet wire with the BK/RE (1.5 sq.mm) Litronic harness wire. Solder the combined wires and insulate with electrical tape.
2.5 Reconnect spray jet connector and reattach to mounting bracket.
2.6 Attach the BK/RE wire to a nearby harness and/or components with electrical tape or tie wraps. Ensure the wire cannot be chafed. Wrap with electrical tape if necessary.
2.1 Route and connect the brown wire (1.5 sq.mm) of the Litronic harness to the lug of ground point 1. (Figure 4, Item A)
Tightening torque: 9.7 Nm (7 ft.lb).
3. Perform headlight connections.
Model years 1999 to 2001 use steps 3.11 to 3.16.
Model years 2002 and up, use steps 3.21 to 3.28
3.11 Detach and disconnect connector X1/2 on right wall of the luggage compartment. (Black 21-pin connector, Figure 4, Item B)
3.12 Locate the white wire (1.5 sq.mm) from connector X1/2 (Pin 2, harness side). Strip back approx. 5 mm of the insulation.
3.13 Combine the white wire (1.5 sq.mm) of the vehicle harness with the white Litronic harness wire (0.35 sq.mm). Solder the combined wires and insulate with electrical tape.
3.14 Reconnect connector X1/2 and reattach it to it's mount.
3.15 Run the 4-wire long branch of the Litronic harness through the hole on the left side of the luggage compartment. Secure harness grommet into the hole. Attach the harness to nearby components/wires with electrical tape or tie wraps, ensuring the wire cannot be chafed.
3.16 Go to step 3.3.
3.21 Locate the white wire in the Litronic wiring harness. You must extend the white Litronic wire to connector X1/1, located on the left side of the luggage compartment. Using a piece of white wire (0.35 sq.mm) in diameter, 4 feet long, strip one end and solder it to the white Litronic harness wire. Insulate the connection with electrical tape.
3.22 Secure the extended white wire to the 4-wire long branch of the Litronic harness using electrical tape.
3.23 Run the 4-wire long branch of the Litronic harness through the hole on the left side of the luggage compartment1 and run the extended white wire to the white 21-pin connector (X1/1). Secure harness grommet into the hole. Attach the harness to nearby components/wires with electrical tape or tie wraps, ensuring the wire cannot be chafed.
3.24 Detach and disconnect connector X1/1 on left wall of the luggage compartment.
3.25 Locate the white/black wire (1.5 sq.mm) from connector X1/1 (Pin 2, harness side). Strip back approx. 5 mm of the insulation.
3.26 Combine the white/black wire (1.5 sq.mm) of the vehicle harness with the extended white Litronic harness wire (0.35 sq.mm). Solder the combined wires and insulate with electrical tape.
3.27 Reconnect connector X1/1 and reattach it to it's mount.
3.28 Go to step 3.3.
3.3 Run the 4-wire short branch of the Litronic harness through the hole on the right side of the luggage compartment. Secure harness grommet into the hole.
3.4 Insert the 4 wires at each headlight into the supplied connectors according to the table shown.
3.5 Attach the harness in the wheel housings to nearby components/wires (Figure 5, Item A).
4. Install headlight control unit.
4.2 Remove the protective film from the Velcro strips on the control unit and attach the control unit to the side member/right wall of the luggage compartment. The plug should be facing upward as shown in Figure 6.
5. Install Litronic headlights.
5.1 Transfer the reflectors from the old headlights to the new.
5.2 Coat the side edges of the headlight with soap to ease installation.
5.3 Position Litronic headlights before mounting. Connect the 4-pin plug at the rear of each headlight. Ensure the plug fully engages. Insert headlights into the body and lock with locking tool. Note: If the headlights cannot be locked, or if a high degree of force is necessary to lock the headlights, the basic mounting position of the headlights must be adjusted.
5.4 Ensure correct seating of the headlights in the body (see Technical Manual, Group 9, Section 94 15 05).
6. Concluding work
6.1 Check fuses A9 and A10 for the left and right dipped beams (low beams). Both fuses must have a 15 amp rating. If 7.5 amp fuses exist in positions A9 and A10, they must be replaced with 15 amp fuses.
6.2 Connect battery and set clock.
6.3 Perform a function test.
6.4 Install the luggage compartment carpeting, brake booster cover panel, amplifier and CD changer, if equipped.
6.5 Install spare wheel.
6.6 Check headlight adjustment. Adjust if necessary. (Technical Manual, Group 0, pages 03-8 and 03-9).
6.7 Input radio code if necessary.