Retrofitting and
upgrading Telephone systems in European MY2002-2004 Mercedes ML (W163).
Version 1.2 October 19,2005
Correct
LHD/RHD text for phone consoles
Version 1.1 October 18, 2005
More
part numbers, some clarifications after feedback.
Add
various pictures gathered from the net
Add
unanswered questions section
Add
cradles section
Cheaper
ways of buying parts
Version 1.0 October 10, 2005
Initial
version
Introduction
This document describes
retrofitting and upgrading portable (mobile/cell) telephones in Mercedes ML
vehicles, from the Model Year 2002 facelift (with turn signal indicators in the
door mirrors), to the end of the production of the W163 ML. This document refers to European vehicles,
but IÕm reasonably sure can be used to fit European phone systems into US
vehicles.
There are some hints and
fitting phones into older MLÕs, but these are collected from other peopleÕs
experiences, as IÕve only ever fitted a roof aerial to a Pre MY2002 ML.
There are also some hints
for US vehicle owners wishing to install Nokia 6310i phones or the UHI system.
I strongly recommend, that
if you want to install the UHI system (the one with different cradles for
different phones) in a MY2002/2003 car without an existing phone, or with just
a phone (no CD changer or digital BOSE system) , or in an older ML that you
contact Steve at MBenzNL (see www.mbenznl.com)
and use his retrofit kit. You may need to ask him for a D2B harness, and If you
have BOSE or CD in your vehicle you will need a D2B joiner. His retrofit kit
does not put control units under the seat, it puts it where MB dealers would
retrofit phones. You may find it easier to use my aerial harness converter than
to run a new aerial lead. If so, you will also need to join the male and female
aerial connectors under the front-right-hand seat.
WARNINGS
The vehicle must be on a
flat surface when working on it with the parking brake on and the wheels
chocked to prevent the vehicle from rolling if it is in neutral. The seat and
seat belt bolts must be re-tightened to the correct torque – they are
critical safety parts.
Disclaimer, I donÕt warranty
the information in this document, part numbers may be wrong. If they are,
please let me know, and I will update the document at some point in the future.
If you destroy your vehicle, that is your problem, and you understand that by
following these instructions I accept no liability for what happens to you,
your friends family, or anyone else or to your vehicle.
How do I tell what Model
Year my ML is ?
MY2002 vehicles were the
first MLÕs with indicators in the mirrors. Near the door hinges on one of the front doors is a black
sticker with the vehicle identification number and all the build options
printed on it. If you look at the
lower half of the label, there are many 3-digit codes. Look for the codes
starting 80x. 800 is MY2000, 801 is MY2001, 802 is MY 2002, 803 is MY 2003 and 804 is MY2004. (model year codes are 800 to 809)
– so 808 is MY1998 and 809 is MY1999 on W163 ML vehicles.
Other interesting codes are:
-
352
– Comand.
852
and 854 are the Nokia 6210/6310 installations
386
and 388 are the UHI phone installations.
810
- Bose sound system
819
- CD changer
What was fitted as
standard if a mobile phone was ordered from the factory?
MY2002 vehicles were fitted
with fixed Nokia 6210 or 6310i phone systems. IÕm not sure when vehicles
changed between the 6210i and the 6310i systems. At MY2003, the handset holder
was also changed to the newer 6310i type holder (curvey, not square).
Picture of MY2002 ML handset
cradle.
Picture of curvy cradle
similar to that fitted in MY2003
MY2004 saw the introduction
of the UHI interface, which has a changeable cradle, where different cradles
are used to support various different phones. A number of
Nokia/Siemens/Motorola/Sony handsets are supported.
Picture of MY2004 phone
console (UHI) without the handset cradle.
What parts make up a
phone system?
1) The phone itself
2) The cradle and itÕs clips and screws
3) The phone console
4) Wiring between the cradle and the control unit
mounting plate
5) Fibre optic loom to the control unit from the head
unit
6) The phone control unit (and mounting screws)
7) The E-Net compensator (and mounting screws)
8) The mounting plate for (6) and (7)
9) The wiring loom for (6) and (7)
10) Aerial and Aerial wiring
Was any of this pre-wired
by the factory ?
The European MLÕs were
pre-wired with the phone wiring ((4) in the above list) and the aerial wiring
(10). The MY2004 (UHI) wiring is different to the MY2002/2003 wiring, and the
UHI wiring is not available to order from Mercedes on itÕs own. The fibre optic loom was not
pre-fitted, and is different depending on which Audio options you specify.
There are 2 cables that go
from the roof (by aerial hole) with FAKRA connectors on them, one goes to
behind the dash and ends up as a WICLIC connector – this is for the GPS
connection to COMAND. The other goes to a WICLIC (MY2002/2003) or Black FAKRA
female (MY2004) under the seat. Then there is a cable from there (with the
opposite sex WICLIC or FAKRA) that goes to behind the dash for the phone. At
the dash end it is either a Mini-UHF (MY2002/2003) or a purple FAKRA female.
These are for the phone. The connectors under the seat will connect together if
you want an aerial connection from roof to behind the dash.
There are apparently some
MY2003 RHD MLÕs that seem to have the correct connectors behind the dash and
under the seat, but only the phone antenna seems to appear in the roof,
connected to an older style aerial connection at the grommet in the middle of
the roof. In fact, the blue GPS FAKRA is somewhere to the left of that, and if
you follow the coax from the aerial connection, you will find the purple FAKRA
connector for the phone aerial.
What parts do I need if I
want to install a phone system?
For all sections below, I
have assumed that you have a roof antenna – because I have assumed you
wouldnÕt be installing this unless you have COMAND. The roof aerial part number
is A163 820 15 75.
The phone console parts and
microphone/cover are colour coded to match the vehicle interior. These codes
are shown as WWW, XXXX or YYYY in the tables below.
Black (Anthracite) VVVV=7D05 XXXX=
7211 YYYY=9B96
Orion Grey VVVV=7D05 XXXX=
7214 YYYY=7E33
Java VVVV=8G13 XXXX=
1434 YYYY=1A68
General Notes for all
vehicles
Mercedes sell various
retrofit kits of parts, which are often significantly cheaper than purchasing
the parts separately.
These include the microphone
and itÕs surround, which is about 1/3 of the cost of buying the 2 parts
separately, and the MY2002/2003 E-Net Compensator (about half the cost
purchasing a kit with it in rather than the E-Net compensator on its own)
The part numbers in the
lists below show the pricing for the kits that I have found (which normally
start (B6 xxx xx xx).
US Vehicles may have the
microphone already installed. If you have the Garage Door opener, but no
microphone, then you should purchased the Microphone+surround as shown in the
parts sections later in this document, plus a surround with cut-outs for
microphone and garage door opener, and move those parts to the new cover, The
cover with the garage door opener and microphone cut-outs is part number A163
820 15 12 VVVV. (See above for
what VVVV is).
The factory standard fit
phone consoles shown below are slightly awkward to fit, and you may prefer to
use the parts in this table if you donÕt mind that it doesnÕt look identical to
the factory fitted version: -
|
Anthracite |
Left hand drive (right
side of console) |
B6 788 04 54 |
|
Anthracite |
Right hand drive (left
side of console) |
B6 788 04 59 |
|
Orion Grey |
Left hand drive |
B6 788 04 55 |
|
Orion Grey |
Right hand drive |
B6 788 04 58 |
|
Java |
Left hand drive |
B6 788 04 56 |
|
Java |
Right hand drive |
B6 788 04 57 |
MY2002 changing from a
6210 system to a 6310i system
|
Phone controller |
A203 820 25 85 or A203 820 51 85 |
|
All you need for this
upgrade is to replace the control unit under the front right hand seat. Wind
the seat fully forward, and you can see the old unit, and using a TORX T20
socket wrench, you can unscrew it. The big connector removes by squeezing the
sides, the fibre optic plug removes by pulling straight out – be careful
not to bend the fibre cable harnesses.
The part number required is
A203 820 25 85, or itÕs replacement A203 820 51 85.
Technically, the 6310i
handset can fall out of the original MY2002 6210 cradle, and a MB service
bulletin suggests changing the cradle to a newer part, however, this never
happened to me! If you are going to change it, change it to the MY2003 parts
shown below.
MY2002/2003 installing a
6310i system (with MY2003 phone cradle)
The following parts are
required: -
|
Phone Cradle |
A230 823 11 51 |
|
|
Phone cradle clip |
A230 823 00 60 |
|
|
Phone cradle clip surround |
A163 823 00 77 |
|
|
Phone cradle screws (2
needed) |
N000000 002359 |
|
|
Microphone + Surround |
B6 682 86 09 (Java) B6 682 86 10 (Grey) |
Grey part used in Orion
Grey and Anthracite interiors. |
|
Phone console (rear
section) |
A163 680 09 14 XXXX A163 680 10 14 XXXX |
Left Hand Drive Right Hand Drive |
|
Phone console (front
section) |
A163 680 32 17 YYYY A163 680 33 17 YYYY |
Left Hand Drive Right Hand Drive |
|
Phone console mounting
bracket |
A163 683 00 68 A163 683 01 68 |
Left Hand Drive Right Hand Drive |
|
Phone console bottom screw
eye |
|
|
|
Phone console screws
bracket to centre console (2) |
|
|
|
Phone console screws phone
console to bracket/screw-eye (2) |
N000000 000523 |
|
|
Phone console cable outlet |
A163 689 03 80 |
|
|
Phone controller |
A203 820 25 85 (replaced my A203 820 51
85) |
|
|
Phone controller screws
(2) |
N910143 006001 |
4 needed if using E-Net compensator |
|
Under seat bracket |
A163 820 11 14 |
|
|
Under seat wiring loom |
A153 540 74 10 |
|
|
D2B fibre loom |
A163 540 42 33 |
Connects head unit to
Phone module, this has re-inforced tubing in the ML |
|
D2B wiring joiner |
|
|
|
E-Net compensator |
B6 682 86 17 |
OPTIONAL – see below |
|
DC Separation filter |
A203 820 55 15 |
Ditto |
The E-Net compensator boosts
GSM1800 signals, (newer GSM networks use GSM1800, such as Orange and T-Mobile
in the UK) – the part number shown above is the cheapest way of ordering
it (it comes with a C class saloon Nokia 6310i (non UHI) wiring loom which you
can ignore, or send to me please!) – if you wanted to order it the
expensive way, itÕs part number A203 820 39 26 (although its always worth
checking one price against the other).
However, the system tends to
work fine without the E-NET compensator and in fact MB have stopped fitting it
in MY2005, so you may like to ignore it and the DC-Separation filter – it
is an expensive part.
MY2004 installing UHI
system
The following parts are required:
-
|
Phone Cradle |
Dependant on phone |
Ask MB dealer, and see
section below |
|
Phone cradle clip |
A463 820 07 11 |
|
|
Phone cradle surround |
A203 823 08 11 |
|
|
Phone cradle screws (2
needed) |
A001 984 58 29 |
|
|
Microphone + Surround |
B6 682 86 09 (Java) B6 682 86 10 (Grey) |
Grey part used in Orion
Grey and Anthracite interiors. |
|
Phone console (rear) |
A163 680 11 14 XXXX A163 680 12 14 XXXX |
Left Hand Drive Right Hand Drive |
|
Phone console (front) |
A163 680 34 17 YYYY A163 680 35 17 YYYY |
Left Hand Drive Right Hand Drive |
|
Phone console mounting
bracket |
A163 683 00 68 A163 683 01 68 |
Left Hand Drive Right Hand Drive |
|
Phone console screw eye |
|
|
|
Phone console screws (2) |
|
|
|
Phone console screws (2) |
N000000 000523 |
|
|
Phone controller |
A230 820 42 26 |
|
|
Phone controller screws
(2) |
N910143 006001 |
4 needed if installing
E-Net compensator |
|
Under seat bracket |
A163 820 11 14 |
|
|
Under seat wiring loom |
A163 540 80 33 |
|
|
E-Net compensator (MY2004
version) |
A211 820 08 85 |
OPTIONAL – see above |
|
D2B fibre joiner |
|
If you have BOSE or CD
changer |
MY2003/2003 installing
(or changing to) a UHI system
All the parts for the MY2004
UHI system are needed - however if you are upgrading from an existing
6210/6310i setup to a UHI system, then you will not need the phone console
mounting bracket and screws or screw eye, the under seat bracket, the
microphone or itÕs surround and the E-Net compensator as they are already in
your vehicle.
You will have to make up a
special wiring loom and modify the under-seat wiring loom so you also requires
the following: -
|
Shielded twisted pair
multi-strand 0.35mm cable |
Buy a 2 meter FTP Cat-5E
patch cable |
From computer shop. MUST
be FTP not UTP |
|
2 * 2 meters of 0.5mm
cable (suggest one red, one brown) |
|
|
|
Wiring loom covering tape |
|
Like insulation tape, but
cloth – ask MB dealer |
|
10 way Male connector |
A168 545 43 28 |
|
|
Male connector pins (10) |
A032 545 39 28 |
|
|
10 way Female connector
– shell |
A000 545 46 30 |
|
|
Ditto – connector |
A001 545 59 40 |
|
|
Ditto – cap |
A000 545 93 03 |
|
|
Female connector contacts
(10) |
A016 545 41 26 |
|
|
3 pin female connector |
A023 545 55 28 |
If youÕre using E-Net
compensator |
|
2 pin male connector |
A033 545 67 28 |
|
|
Pins for above (2) |
A032 545 39 28 |
|
|
2 pin female connector |
A030 545 28 28 |
|
|
Contacts for above (2) |
A008 545 55 26 |
|
|
FAKRA type D jack ->
male mini uhf adapter |
Aerial converter lead |
I can make/supply these. |
|
E-Net compensator (MY2003
version) |
B6 682 86 17 |
If you are going to use an
E-Net compensator |
|
DC-Separation filter |
A203 820 55 15 |
Ditto |
What Tools are Needed
?
|
COMAND release keys |
MB part nr. A000 833 05 61 |
|
Seat bolt socket (and
driver) E14 |
TORX Socket Screw |
|
Torx driver T20 |
Phone console TORX screws |
|
Torque wrench |
For tightening seat bolts
correctly |
|
Phillips screwdriver |
|
|
Wire Cutters (small) |
If installing UHI in
MY2002/2003 |
|
Tiny pointed screwdriver |
Ditto |
|
Soldering Iron + Solder |
Ditto |
|
Useful plastic wedge |
Ditto - MB part. W115 589
03 59 00 |
Fitting the phone
systems
MY2002 changing from a
6210 system to a 6310i system
All you need for this
upgrade is to replace the control unit under the front right hand seat.
1) I suggest you remove the
phone fuses first. The phone controllers can be a bit sensitive to power
surges. They are F21 and F10 in the engine compartment fuse box.
2) Wind the seat fully
forward, and you can see the old unit, and using a Torx T20 bit and socket
wrench, you can unscrew it. The big connector removes by squeezing the sides,
the fibre optic plug removes by pulling straight out – be careful not to
bend the fibre cable harnesses.
3) Reconnect the new part,
and screw it back in.
4) Reinstall fuse and test.
5) You should have the
COMAND system recoded by the Mercedes dealer at some point to tell it has an
extended phone system – then you will be able to use SMS functionality
from COMAND.
MY2002/2003/2004 Install
where no existing factory fitted phone
This section covers
installing the MY2003 phone (Nokia 6310i) in a MY2002 /2003 vehicle, or the
MY2004 (UHI) system in a MY2004 vehicle which does not have the factory fitted
phone installed. If for some reason you have the non-portable phone installed,
then the D2B wiring is already in place and you have the under-seat bracket,
and thus some steps do not need to be done.
Note also, that I have
assumed you already have the GPS aerial on the roof, because you have COMAND.
1) Remove the COMAND unit
using the release keys – be very careful removing the D2B connector
– you must avoid bending the orange fibres too much, or they will break
internally. Remove the release keys from the command by pushing them back in,
and pressing where the arrows shows on the side of the COMAND unit, and remove
the keys.
2) Find the phone harness,
which is taped somewhere below the COMAND, and the aerial connector. On
MY2002/2003 the aerial connector is a silver mini-uhf. On MY2004 it is a dark
red/purple ÒFAKRAÓ SMB connector. The handset connector is a black multi-way
connector.
Picture of MY2002/2003 Phone
connection behind dash
3) Wind right hand seat
fully forward, and you will be able to see a set of wires in a black Hessian
type cover, cable tied to the rear of
the seat frame. Cut the cable ties and then remove the seat and the
air-vent below the seat (by unscrewing the T20 torx screw).
Removing seat: -
Lower
or Remove headrest
Remove
the TORX bolts from the rear of the seat, wind seat fully rear and remove rear
ones.
Detach
electrical connector for seat electrics.
Remove
seat.
Note
seatbelt is still attached, so it has to stay near vehicle
4) Assemble all control
units and wiring loom onto mounting plate.
Here is picture of the
under-seat wiring loom – this is the UHI version. The non UHI version has
one less black connector (the one in the middle of the picture is not there)
and the connector at the top middle is different. The connector at the left of
the picture connects to the phone controller. The bottom connector is for the
E-Net compensator. The blue connector connects to the main car loom, providing
microphone, power and connection for voice-recognition switch. The other 2
black connectors connect to the phone cradle.
Picture of underside of
MY2002/2003 (nokia 6310i) loom, controller and mounting plate, with E-NET
compensator. The plate is fitted
in the car with the end at the top of the picture at the front of the car. The
holes in the plates go over the holes where the seat bolts fit.
if you are using the
MY2002/2003 E-Net compensator, then the DC separation filter is installed
connected to the picture of phone on the E-Net compensator. The MY2004
compensator does not need an external filter.
5) Install the D2B fibre
loom connecting between the seat and the COMAND unit.
Remove
the right hand door sill cover (lever up the chrome part of the door sill,
there are screws under it to remove the plastic bit)
Remove
right hand kick panel and under-dash panel
Run
the D2B fibre optic loom from the head unit (along dash panel, under carpet
along door frame, under carpet and pop out under removed seat) . If you look at
the loom, one end has a right angle radiused bend about 2-3 feet from the end
– that is the COMAND end.
Re-install
sill and kick panel etc.
6) Plug all connectors on
mounting plate, including the fibre optic one, and place the mounting plate in
position (it fits over the seat bolt holes). If you are not using the E-Net
compensator, plug the two aerial connectors under the seat together.
Picture of under-seat
mounting plate in position.
7) Install the phone
console, and plug in wires.
The pictures below are of a
right hand drive ML with the bracket installed. The purple clip at bottom left
of the dash-board is for the lower screw of the console.
In order to fit that bracket
two holes must be drilled in the centre console to mount it– These are
8.5mm holes, 32 mm apart. The front one is 35mm away from the front of the
console, 245mm below the top of the section of console it is mounted on (i.e to
the join below the vents just visible at the top of this picture). The rear hole is slightly lower, so that the
front of the bracket is roughly parallel to the front of the centre console, so
that the front of the phone console ends up parallel to the wood dash board.
Here is a picture of the
Right Hand Drive phone console not quite assembled.
It is not completely
assembled, because the bracket is fixed to the centre console first, then the
rear section fixed to the bracket, then the front section is clipped on,
followed by the UHI surround, which is screwed in (holding the front section to
the rear section), then the UHI connector is clipped in place, so you should
only clip all the parts together as you assemble it into the vehicle. The
wiring connections need to be made before the rear section is fixed to the
bracket on the centre console.
8) Connect the D2B wiring
loom
If vehicle does not have
Digital BOSE or CD, or Teleaid then there will not have been a fibre loom
plugged into the back of COMAND, so just plug in the one you installed for the phone.
If there is one already,
then you have to re-configure it to insert the phone controller into the loop.
You will need to: -
(a) open both of the fibre optic plugs at the COMAND end
(the new one and the pre-existing one. Remove both fibres from one connector,
and remove white one from other, and put the white lead from the other loom
into the connector and close it.
(b) Join the remaining 2 cables (one from each loom) with
the fibre joiner (red cable will only plug properly into one end, white into
the other). It is really important
that the fibre cables are not sharply bent, and you may have to free up some of
the fibre by carefully removing some of the black corrugated tube from each
fibre cable.
9) Install microphone.
Pull
down the cover in the centre of the over-head console
Remove
the cover
Attach
microphone to new cover
Microphone
plugs in to wiring that is above over-head console, you may have to unscrew it
to remove it.
Clip
new cover in place, and push closed.
10) Install phone fuse in
fuse box under bonnet.
They
are 15-amp in F21, and 10-amp in F10 – if they are not there already.
11) Re-install COMAND and
test that the phone works.
12) Re-install Seat. (The
seat bolts must be done up to 40Nm torque this is vital for safety purposes)