Mercedes - G-Class - Workshop Manual - 2003 - 2003

G Class Electrical Systems 11/02/01 217 HO Electrical (ICC OP TF) 2-17-03 1 These technical training materials are current as of the date noted on the materials, and may be revised or updated without notice. Always check for revised or updated information. To help avoid personal injury to you or others, and to avoid damage to the vehicle on which you are working, you must always refer to the latest MercedesBenz Technical Publication and follow all pertinent instructions when testing, diagnosing or making repair. Illustrations and descriptions in this training reference are based on preliminary information and may not correspond to the final US version vehicles. Refer to the official introduction manual and WIS when available. Copyright Mercedes-Benz USA, LLC, 2003 Reproduction by any means or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Mercedes-Benz USA, LLC or its successors. Published by Mercedes-Benz USA, LLC Printed in U. S.A. 2 Power Distribution F32 - Pre-fuse box F34 - Fuse box G1 - Battery G2 - Alternator M1 - Starter N10/1 - Front SAM N10/2 - Rear SAM W10 - Battery ground 50 - Starter signal W10 M1 G1 50 F32 60A G2 200A 200A 125A N10/1 N10/1 F34 N10/2 3 Battery Battery (G1): • AGM (absorbent glass mat) - 12 V 90 Ah Pre-fuse Box (F32): • Power distribution point • Reduce fire risk in an accident • Fuses not replaceable (replace complete assembly) 4 AGM / VRLA Battery Construction The major differences in construction between a AGM battery and standard lead acid automotive battery are: • Completely sealed case construction • No liquid electrolyte • Absorbent glass mat (V) holds electrolyte in contact with positive and negative plates • Vent valve is normally sealed no gases can escape during normal charging • Vent valve is only opened if internal pressure exceeds predetermined level 5 AGM / VRLA Battery Properties • Longer service life • Improved cold starting characteristics • Improved deep cycle performance • No liquid acid spills or leaks • Fast recharge time • Completely maintenance free How to Identify AGM Battery: • Battery label (VRLA) Valve Regulated Lead Acid • No fill marks • No fill caps 6 AGM / VRLA Battery Testing • AGM batteries cannot be tested using previous methods (load and acid density tests) • Requires the new Midtronics MCR 717 tester and printer • Tester measures battery conductance by inducing A/C voltage of a given frequency and amplitude on the battery posts and monitoring the current flow in response to it • Discard the acid density sheet, and enter test code (recorded by tester) on warranty claim forms • Battery replaced under warranty must have a test printout attached to the R.O. • Detailed information about testing, and using the MCR717 can be found in WIS SI54.10-P-0003-01 7 Fuse & Relay Location F2 Front SAM (N10/1) I 8 7 6 5 4 3 2 1 K L M P Q N O R S F34 v A B Relays T U V iv iii C D ii E i F Relays over rear SAM G H Rear SAM (N10/2) 8 Fuse and Relay Legend F34 Fuse data 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 - DCM FL - DCM FR - Rear reading light F2 Fuse data 30A 30A 5A 1 2 3 4 5 6 7 8 - ESP / Stop lamp switch N.C. - Steering angle sensor / Stop lamp switch N.O.15A - UCP / Front seat heaters - Illuminated door sill - LF ESA - Interior socket 10A 7.5A 30A 30A - HVAC blower - EIS - LR DCM - RR DCM - TELE AID 40A 20A 30A 30A 7.5A Relays (at left rear of vehicle) - Diff. lock relay - RF ESA - Transfer case module 15A 30A 40A Relays (over rear SAM) - UCP / AC - Inst. cluster 7.5A 7.5A T U V i ii iii iv V 10A - Rear seat heating module - L Auxiliary fan / Steering angle sensor - R Auxiliary fan 20A 20A 20A - Transmission output speed sensor ballast (N36) - Tailgate central locking (K44) - Rear window wiper (K68) - L Auxiliary fan (K9/1) - R Auxiliary fan (K9/2) - High pressure pump relay ESP (K60) - Stop lamp suppression (K55) - Diff. lock & vac. pump (K36) 9 Front SAM (N10/1) Legend 43A 43B 44 45 46 47 48 49 50 51 52 53a 53b 54a 54b 55 56 57 58 59 60 - Fanfare horns term. 15R - Fanfare horns term. 30 - Cell phone cradle term. 15R - Airbag term. 15R - Wiper on / off - Cigar lighter / glove term. 15R - Ignition Coils term. 15 - Airbag term. 15 - Rear HS / lights term. 15R - Instrument cluster - Starter - Engine / M1 term. 87 15A 15A 5A 10A 20A 15A 15A 10A 5A 7.5A 15A 15A - Engine / M2 term. 87 15A - TC / ETC - Diff, locks / PTS - EIS term. 30Z - F2 - ABS return pump - ABS valve block 7.5A 7.5A 5A 40A 50A 40A 61 62 63 64 65 - Light switch term 15R - Diff. lock / lights - Radio / COMAND - Air injection pump 5A 5A 10A 40A Relays I K L M N O P Q R S - Fanfare horns - Chassis term. 87 (ETC,ESM,TC, diff. switch) - Wiper speeds 1 & 2 - Terminal 15 (IC, AB, TELE AID, light switch) - F2 supply - Air pump - Terminal 15R (AB, RSH, glove box light, cigar) - Wiper on / off (cutoff to L) - Engine term. 87 (engine, R SAM, wiper) - Starter 10 Rear SAM (N10/2) Legend 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 - Terminal 15R2 / Tes left - Terminal 15R2 / Tes right 30A 30A Relays - Antenna module, ATA siren tilt sensor - OCP - Rear window defroster 7.5A A B C D E F 25A 20A G H - Pressure pump term. 15 - Rear wiper - Filler cap - VCS - Trailer ECM - Trailer socket - Pressure pump term. 30 - Central locking tailgate 20A 15A 10A 5A 20A 20A 20A 10A - Fuel pump 15A - Fuel pump - Relay 2 terminal 15R - Rear window defroster - Relay 1 terminal 15R (TELE AID, ETC speed sensor ballast, rear wiper - Filler cap polarity reverser 1 - Filler cap polarity reverser 2 11 F2 & F34 Fuse Box F2 F34 Location : left instrument panel (cover removed) Note: fuse chart can be found in F34 12 Front SAM (N10/1) To remove N10/1, remove nut & pivot down Location: under dash on passenger side 13 Rear SAM (N10/2) • Rear SAM fuses are accessible from right side • Right front seat fuse located in F34 (left of instrument panel) • Rear SAM located under center console Front of vehicle • Additional relays (i - v) above rear SAM are not accessible through cover 14 Additional Relays T - Transmission output speed sensor ballast (N36) U - Tailgate central locking (K44) V - Rear window wiper (K68) Location: left rear trunk 15 Networking Legend A1 A2/6 A2/13 A35 A35/8 A35/11 A40/3 - Instrument cluster - Compact disc changer - Sound amp (Harman/Kardon option) - HSE / PSE - TELE AID module - Voice control module - COMAND N2/7 N3/10 N10/1 N10/2 N15/3 N15/5 N15/7 N22 N25/6 - SRS module - ME-SFI module - Front SAM - Rear SAM - Electronic transmission control - Electronic shifter module - Transfer case module (VG) - Air conditioning module - Rear seat heater module N32/1 N32/2 N47/5 N69/1 N69/2 N69/3 N69/4 N70 N72/1 N73 N80 - Left ESA - Right ESA - ESP module (from DAS) - LF door control module - RF door control module - LR door control module - RR door control module - Overhead control panel - Upper control panel - Electronic ignition switch - Steering column module S76 - Differential lock switch group X30/4 X30/6 X30/7 - CAN B connector - CAN B connector - CAN B connector Note: ESP module listed as N30/4 in USA ETM and on STAR Tek ETM 16 Networking N80 S76 Not on CAN A2/13 A2/6 A2/6 A35/8 A35 Networking based on W203 Note: D2B components configuration - refer to T-I-82.70/185A 17 CAN B Diagram All CAN H wires are red except for “jumpers” All CAN L wires are brown N73 N80 N69/1 A1 A35/8 X30/4 N72/1 X30/6 N69/4 “jumpers” CAN H wire black X30/7 N69/2 N32/2 N22 N10/2 A40/3 N32/1 N69/3 N10/1 CAN H voltage = ~ 0 volts (sleep) CAN L voltage = ~11 volts (sleep) ~0.65 volts (active) ~4.65 volts (active) N70 18 CAN B Connector X30/6 Most CAN wires are labeled near the plug connector with German acronyms EZS Kombi E-Call TSG - Electronic ignition switch (N73) - Instrument cluster (A1) - TELE AID - Jumper to X30/4 - LF Door control module (N69/1) - Steering column module (N80) Location: under drivers dash (shown with underdash trim removed) 19 CAN B Connector X30/4 & X30/7 Location: in passenger kick panel behind water protection sheet 20 X30/4 & X30/7 Label Legend X30/4 OBF Ver POT V3 DBE TSG H re Sitz Ver POT V1 KLA TSG V re - Upper control panel (N72/1) - Jumper to X30/7 - Overhead control panel (N70) - RR Door control module (N69/4) - LF Electric seat adjuster (N32/2) - Jumper to X30/6 - Air conditioning module (N22) - RF Door control module (N69/2) X30/7 Radio COMAND SAM V Ver POT V3 TSG HL Sitz SAM H - Radio (not used) - COMAND (A40/3) - Front SAM (N10/1) - Jumper to X30/4 - LR Door control module (N69/3) - LF Electric seat adjuster (N32/1) - Rear SAM (N10/2) 21 CAN C Connector (X63/4) Location: right side of center console Label Legend: EZS Kombi ME VGS - Electronic ignition switch (N73) - Instrument cluster (A1) - ME-SFI control module (N3/10) - Transfer case control module (N15/7) EWM NAG - Electronic shifter module (N15/5) - ESP control module (N47/5) - ETC module (N15/3) - Steering column module (N80) 22 Telephone & GPS Antenna A2/22 Î Front roof edge • • Portable telephone TELE AID back up A2/23 Î Behind left headlight surround • GPS antenna for NAV & TELE AID A2/50 Î Rear bumper end caps • TELE AID primary 23 AM/FM Antenna A2/18 Î Left rear window • Antenna in window • Amplifier 24 Central Locking Antenna & Amplifier Antenna in windshield Amplifier at base of windshield on right side 25 Electric Central Locking • RF antenna in front windshield • IR receiver in LF door only • Door closure monitored by micro switches in door latch assemblies • Door central locking motor incorporated in latch assemblies 26 Anti Theft Alarm (ATA) E6/12 E6/2 E6/1 E6/11 • Rear SAM is the primary ATA module • Door latch micro switch in latch assembly • Hood contact switch (not micro switch) • Alarm siren hard wired to rear SAM 27 CL & ATA Legend A1 A2/65 A8/1 A26/1 B33 E3e1 E4e1 E6/1 E6/2 E6/11 E6/12 H3/1 M14/5 M14/6 M14/7 M14/8 M14/9 M14/10 - Instrument cluster - CL antenna - SmartKey - IR receiver - ATA tilt sensor - LR Turn signal lamp - RR Turn signal lamp - LF Turn signal lamp (front fender) - RF Turn signal lamp (front fender) - Left turn signal lamp (A pillar) - Right turn signal lamp (A pillar) - ATA siren - RF door latch motor / micro switch - LF door latch motor / micro switch - Tailgate latch motor / micro switch - LR door latch motor / micro switch - RR door latch motor / micro switch - Fuel filler flap lock motor N10/1 - Front SAM N10/2 - Rear SAM N69/1 - LF Door control module N69/2 - RF Door control module N69/3 - LR Door control module N69/4 - RR Door control module N70 - Overhead control panel N72/1 - Upper control panel N72/1s7 - Tow sensor off switch N73 - Electronic ignition switch S62 - Hood contact switch X11/4 - Diagnostic connector 28 ATA Siren • Hard wired to rear SAM - 12 V fused power supply (N10/2 f8) for operation and charging battery - Bi-directional communication with rear SAM (arm/disarm) • Built in battery back up - If ATA armed and battery disconnected siren will still work Location: in left front fender 29 Outside Lighting E6/8 E6/10 E6/2 E6/12 E7 E5/2 E3/1 E5/1 E6/1 E6/11 E6/7 E6/9 • Circuit protection by electronic fuses in SAM’s • 1 reverse lamp lens (right side) • 1 rear fog lamp lens (left side) • Lamp substitution only for tail lamps (activate stop lamps with PWM) 30 A1 B32/1 E1e1 E1e2 E1e3 E2e1 E2e2 E2e3 E3e1 E3e2 E3e4 E3/1 E4e1 E4e2 E4e4 E5/1 E5/2 E6/1 E6/2 E6/7 E6/8 Legend - Instrument cluster - Light sensor - LF High beam - LF Low beam - LF Standing / Parking lamp - RF High beam - RF Low beam - RF Standing / Parking lamp - LR Turn signal lamp - LR Standing / Parking lamp - LR Stop lamp - Rear Fog lamp - RR Turn signal lamp - RR Standing / Parking lamp - RR Stop lamp - LF Fog lamp - RF Fog lamp - LF Turn signal lamp (top of fender) - RF Turn signal lamp (top of fender) - LR side marker lamp - RR side marker lamp E6/9 - LF side marker lamp E6/10 - RF side marker lamp E6/11 - Left turn signal lamp (A pillar) E6/12 - Right turn signal lamp (A pillar) E7 - Reverse lamp E19/1 - Left license plate lamp E19/2 - Right license plate lamp E21 - Third stop lamp N10/1 - Front SAM N10/2 - Rear SAM N47/5 - ESP control module N69/1 - LF Door control module N69/2 - RF Door control module N70 - Overhead control panel N72/1 - Upper control panel N72/1s5 - Hazard warning switch N73 - Electronic ignition switch S1 - Light switch S4 - Combination switch S9/1 - Stop lamp switch 1 - CAN B 31 Convenience Electronics • Easy entry / exit feature for steering wheel only • “Tip” / touch flash directional signals • Automatic exterior lighting • Night security illumination - Locator lighting - Headlamp delay • Climate control is the same as found on C240 (AAC) • Front and rear seat heaters are standard • Key dependant memory feature can be activated 32 Reversing Aid (BA) Distance warning system when reversing at slow speeds. Alerts the driver: - visually - audible Location: right rear D pillar 33 BA Control Module & Sensors Reversing aid control module (N62) located in left rear cargo area (near CD changer) • Evaluates signals from rear bumper sensors • Operates warning indicator display (A44) • No self diagnostics • SDS / DAS has guided tests Rear Bumper sensors (A43/_) • 4 Ultrasonic bumper sensors • Optimal sensor range Î 11 - 70 inches 34 Drivers Multicontour Seat (MCS) • Adjust air volume in various bladders within drivers seat using control valve • MCS pump (M14/11) supplies air volume to control valve as required 1 - Seat base 2 - Lower back 3 - Upper back 4 - Back side • M14/11 located under cover plate (2), right side of the battery (G1) 35 Service Tip Cover above front SAM & ME-SFI control modules must be watertight or electrical problems will occur Location: under AAC air intake 36