2.6.1

Remove rear spring strut. ⇒ Workshop Manual '427119 Remove and install spring
strut, rear'

2.6.2

Check height dimension X and adjust if necessary.
Rear axle

Dimension X

Lower edge of spring seat to shoulder of
damper-valve foot

72 mm

The adjustment dimensions are used for presetting.
Do not yet complete the vehicle interior.
3

Assembly of brake pads and steel flex lines

WARNING
Personal injury and material damage from brake fluid

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Poisonous if swallowed

•

Irritation and damage to skin

•

Dissolving paint surfaces

Þ
⇒

Only store brake fluid in suitable, labelled containers

Þ
⇒

Wear protective gloves and goggles

Þ
⇒

In the event of contact (eyes or skin), wash immediately with water

Þ
⇒

If contact is made with paint surfaces, wash off immediately with water, do not wipe off
3.1

Replace front brake pads ⇒ Workshop Manual '427119 Replace front disc brake pads'.

3.2

Replace rear brake pads ⇒ Workshop Manual '427119 Replace rear disc brake pads'.

3.3

Replace front brake lines (part)

1.
2.
3.
4.
3.4

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Front axle brake line assembly
Þ Front axle brake line assembly -2- and remove brake
– Loosen threaded connections ⇒
Þ Front axle brake line assembly -1-.
line ⇒
Þ Front axle brake line assembly -1- without tension and ensure
– Install new brake line ⇒
that no abrasion occurs.
Þ Front axle brake line assembly -2-. Line routing
– Tighten threaded connections ⇒
downwards approx. 45 degrees. Tightening torque: 10 Nm (7.4 ftlb)
– Clean adjacent components of any brake fluid that may have leaked out.

Replace rear brake lines (part)

Tequipment

Installation and Conversion Instructions

5.
6.
7.
3.5
4

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Rear axle brake line assembly
Þ Rear axle brake line assembly -2- and
– Loosen brake line threaded connection ⇒
Þ Rear axle brake line assembly -1-.
remove brake line ⇒
Þ Rear axle brake line assembly -1- in the same way as
– Route the new brake line ⇒
Þ Rear axle brake line
the standard brake line and tighten the threaded connection ⇒
assembly -2– Clean adjacent components of any brake fluid that may have leaked out.

Bleed the brake system ⇒ Workshop Manual '427119 Bleed the brake system'.

Installing wire harness and resistors (chassis)
Information
•

Stickers, general adhesive surfaces and adhesive tape only reach their full adhesive strength after
72 hours.

•

The vehicle must not come into contact with water, splash water or a car wash within 72 hours.

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2.
3.

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Installation and Conversion Instructions

Installing rear right resistor
– Clean adhesive surface on the vehicle and make it grease-free. Rear right part number:
670.108.10 . Plug is inserted on the included cable set for wire output relay.
Þ Installing rear right
– Pull off protective film on the adhesive surface from the resistor and ⇒
resistor -1- bond resistor as shown in the diagram.
Þ Installing rear right resistor -2-.
– Secure the cable with the cable tie clamp ⇒

Installing rear left resistor

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Installation and Conversion Instructions
4.
5.
6.

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– Clean adhesive surface on the vehicle and make it grease-free. Rear left part number:
670.107.29
Þ Installing rear left
– Pull off protective film on the adhesive surface from the resistor and ⇒
resistor -1- bond resistor as shown in the diagram.
Þ Installing rear left resistor -2– Connect resistor to the vehicle wire harness (PASM plug) and ⇒
secure the cable with the cable tie clamp.

For the front axle, please observe the following work steps; convert both original plugs from the wire
harness:

Þ 10 -2- on locking lugs ⇒
Þ 10 -5-.
Release safety cap ⇒
Þ 10 -4- on connector ⇒
Þ 10 -3-.
Release fuse ⇒
1
2
3
4
5

–
–
–
–
–

Electric lines
Locking cap
Connector
Fuse
Locking lugs

10

Þ 11 -2- on connector ⇒
Þ 11 -1- and
Release fuse ⇒
Þ 11 -3-.
unpin electric lines ⇒
1
2
3

– Connector
– Fuse
– Electric lines

Þ 12 -2- (no longer required).
Remove safety cap ⇒

11

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Þ 12 -1- into new connector ⇒
Þ 12
Plug electric lines ⇒
Þ 12 -3-.
-2- and lock fuse ⇒
1
2
3

– Electric lines
– Connector
– Fuse

12

7.

8.

9.
—

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Tequipment

Front right resistor fitting
– Clean adhesive surface on the
vehicle and make it grease-free.
Front axle part number:
670.107.85
– Pull off protective film from the
resistor on the adhesive surface
and bond the resistor as shown in
the diagram.
– Connect resistor to vehicle wire
harness (PASM plug).
– 1: New connector 2: Vehicle
connector 3: Electric wire harness
4: Resistance

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12.
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Front left resistor fitting
– Clean adhesive surface on the
vehicle and make it grease-free.
Front axle part number:
670.107.85
– Pull off protective film from the
resistor on the adhesive surface
and bond the resistor as shown in
the diagram.
– Connect resistor to vehicle wire
harness (PASM plug).
– 1: New connector 2: Vehicle
connector 3: Electric wire harness
4: Resistance

Fit holder on control unit

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Installation and Conversion Instructions

Þ Fit holder on control unit -1- on control unit. Tighten screws (4x). Tightening
– Fit holder ⇒
torque: 2,6 Nm (1.92 ftlb)

14.

Preparing control unit
Þ Preparing control unit -1- to the holder (do not pull).
– Attach cable ties on the left and right ⇒

15.

Þ Installing control unit and CAN clip -1-.
– Fit control unit ⇒

Installing control unit and CAN clip

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Installation and Conversion Instructions
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17.
18.

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Þ Installing control unit and CAN clip -2- and tighten both cable
– Fit and align CAN Clip module ⇒
Þ Installing control unit and CAN clip -3-. Cut off surplus cable ties.
ties ⇒

Preparation of wire harness
– Prepare wire harness on the workbench as shown.
Þ Preparation of wire harness -1-.
– Fit relay ⇒

Lay out wire harness in the vehicle and connect

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20.

Installation and Conversion Instructions

Þ Lay out wire
– Place wire harness in the vehicle as shown and connect plug connection ⇒
harness in the vehicle and connect -1- on the control unit.
– Place the wire harness running outside the vehicle into the vehicle recess on the left and right
Þ Lay out wire harness in the vehicle and connect -a and b⇒

Cable color/Can Clip installation

21.
22.

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Can Clip assembly
Þ Can Clip assembly -1-. Unwind twisted cable
– Uncover wire harness at the place shown ⇒
color Blue (Can High) and Brown (Can Low) up approximately 5 cm.
– Insert CAN line into the respective guide of the CAN Clip module (see CAN High and CAN Low
Þ Cable color/Can Clip installation. Connect CAN Clip line to wire harness.
lettering) ⇒

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Installation and Conversion Instructions

23.
24.

25.
26.
27.

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Cable routing in interior area of control unit
Þ Cable routing in interior area of
– Fix the left and right wire harness using the cable tie clamp ⇒
control unit -1- as shown.
Þ Cable routing in interior area of control unit -2- and mount and
– Loosen ground pin (2x) ⇒
Þ Cable routing in interior area of control unit -3-, connect
tighten acceleration sensor ⇒
Þ Cable routing in interior area of control unit -3-. Observe installation
acceleration sensor ⇒
direction, otherwise possible collision with carpet.
Þ Cable routing in interior area of control unit -4- nut
– Remove ground bolt (unoccupied bolt) ⇒
and mount ground line from the new wire harness on the threaded bolt. Tightening torque: 13
Þ Cable routing in interior area of control unit -4Nm (9.5 ftlb)⇒
Þ Cable routing in interior area
– Thoroughly clean and grease-free adhesive surface for relays ⇒
of control unit -5-. Glue Velcro adhesive strips on the vehicle side and then fix relay using
Þ Cable routing in interior area of control unit -5-. Plug in rear right resistor on relay.
Velcro ⇒
Þ Cable routing in interior area of control
– Lay power supply (2 lines with pins) to the fuse box ⇒
unit -6-. Connect surplus cables to the vehicle wire harness using cable ties, paying attention
to kinks and potential chafing points.

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29.
30.
31.

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Installation and Conversion Instructions

Power supply fuse box
Þ Power supply fuse box -1- in the direction of travel.
– Pull fuse box ⇒
– Insert “smaller“ pin in upper fuse box (black) from the rear and insert fuse 5A terminal 15.
Þ Power supply fuse box -ASlot:⇒
– Insert “larger“ pin in lower fuse box (beige) from behind and insert fuse 20A terminal 30.
Þ Power supply fuse box -BSlot:⇒
Þ Power supply fuse box -1- in assembly location and make sure cable is laid
– Insert fuse box ⇒