W202 Oem Xenon Conversion

[bigasotonuk]

Hi,
Well i have the xenon lights now and its been a bit of hassle as it seems the levelling loom is not available any more new from MB, so i,m finding myself going up country tomorrow to take the loom out of the car before its destroyed while the car is broken up.
But now i know the self levelling wiring loom is not available anymore (even though inchcape site gave a price for it, which i thought meant it was still available) I,m a little concerned on whether the headlight wiper loom will still be available now. This loom would of been fitted as an accessory in conjunction with the xenon lights, and headlamp levelling system, and whilst i,m there i want to remove this loom as well.
If anyone on here has any information at all on this it would be so very much appreciated, it will be easier to remove if i know where the loom ties into the car.

 

[television]

I will look Andy but I dont think that this info is there

 

[bigasotonuk]

I hope you can find something Malc, as it will be really helpful tomorrow.

 

[television]

I have 3 papers for you including the harness and front and rear sensors and they have been sent quite small so should come through by the time you read this

 

[bigasotonuk]

Hi Malc,
Many thanks, your a star.
I have just recieved the files, though it describes the levelling loom to a tee, and will assist me greatly in removing it, have you by chance the same info headlight wash/wipe loom?

 

[television]

What a life I lead just sitting here sending out papers,,thats 18 tonight,, if only I had something warm and soft that smells nice in my life

You will need to take the motors as well and 3 more papers sent

 

[television]

The bottle paper sent tonight

 

[bigasotonuk]

Well i visited the breakers in Birmingham with a friend of mine, and after 3 tortuious hours managed to remove the washer bottle C/W additional washer pump for the headlights and the hoses to the headlight wash/wipe motor, headlight levelling loom, control unit and the front and rear suspension sensors though some of the rear sensor bracketry we were unable to remove, but these I will source new from MB.
Head light wash/wipe on the doner vehicle was fitted from new so this loom was not a separate loom to remove but incorporated in the under bonnet wiring, I have spoken too MB, and they say that this factory loom is still available, and there will be a MB worksheet to install it for this.
I am determined that this retro-fit will include all aspects of the Installation, auto electric headlight levelling, headlight wash/wipe, fitting of the headlights and their control units.
I do have some concerns, Is that fitting the sensors it says i should have pre-existing holes in my suspension wishbones, but i have never noticed these before so i hope they are there if not i,ll be attempting to drill my own. Also regarding the alignment of the headlights as regarding the electric levelling, I believe it states the car needs to be driven a short distance with headlights off (i think this is to settle the suspension after being jacked up and dissassembled) then align headlights as a normal car, and with a HHT tell the headlight levelling control unit that the lights are at their lowest position.
Can any one confirm this is correct?
I am presuming that the HHT is a device for accessing information from the headlight levelling control unit.
Thanks to everyone who replied to this post and to malcolm and whitenemesis for the worksheets they managed to locate for me.

 

[television]

HHT is the hand held tester that has been overtaken by STAR

 

[bigasotonuk]

HHT is the hand held tester that has been overtaken by STAR

Thanks Malcolm, I thought that may of been the case.
Regarding the holes in my suspension arms to mount the sensors, it appears a new front upper wishbone has the holes present but is a superseded pt. no. so it maybe that mine has,nt got them, so i may have to replace it.
I wonder what i,ll find on the rear.

 

[television]

Thanks Malcolm, I thought that may of been the case.
Regarding the holes in my suspension arms to mount the sensors, it appears a new front upper wishbone has the holes present but is a superseded pt. no. so it maybe that mine has,nt got them, so i may have to replace it.
I wonder what i,ll find on the rear.

I admire you courage in doing it by the book Andy,,,if you need anymore info always ask

 

[whitenemesis]

Andy,

The sensors mount to the bodywork and the reaction arms fit to the suspension. I'm sure you will find the holes in the wishbones (front and rear). You will though have to drill routing holes the the body into the car for the loom. (on the 203 there are through connectors already present).

To align the headlights, settle the suspesion and using STAR read off the sensor values. They will have to be within the specified range or STAR will not set the zero level. (Olly had to adjust my senor at the front to get within range, very fiddly!). Once the zero position is set get the lamps adjusted at the testing station. Mine were spot on, without adjustment, probably just lucky

 

[bigasotonuk]

Hi,
I have made a start to this mod this week, by starting to install the Headlight wash/wipe system, at present the wiper motors and wipers are fitted, headlamp wash pump is fitted and plumbed into the wiper motors, I am now just waiting for three clips to secure the hoses in front of the radiator and by the washer bottle. The clips i,m picking up tomorrow from MB together with a new piece of trim under the headlight.
I,m wiring the motors tomorrow as well, weather permitting.
Many thanks to be both Whitenemesis and Malcolm for all their valuable info they have supplied me, on how to do this mod.

 

[television]

Hi,
I have made a start to this mod this week, by starting to install the Headlight wash/wipe system, at present the wiper motors and wipers are fitted, headlamp wash pump is fitted and plumbed into the wiper motors, I am now just waiting for three clips to secure the hoses in front of the radiator and by the washer bottle. The clips i,m picking up tomorrow from MB together with a new piece of trim under the headlight.
I,m wiring the motors tomorrow as well, weather permitting.
Many thanks to be both Whitenemesis and Malcolm for all their valuable info they have supplied me, on how to do this mod.

I trust that you have a nice warm garage Andy

 

[Cole@MBS]

Well you have a star to use as and when you need it!!!

 

[bigasotonuk]

Hi,
I,m doing it on the open driveway to my house, its a bit chilly but if i keep working I keep warm. lol.
SAM you are a "star" man, many thanks.
I should have said my health permitting tomorrow really as i,m feeling like "sh*t" at the moment as i have come down what is commonly called man flu, can,t stop coughing at the moment.

 

[television]

Hi,
I,m doing it on the open driveway to my house, its a bit chilly but if i keep working I keep warm. lol.
SAM you are a "star" man, many thanks.
I should have said my health permitting tomorrow really as i,m feeling like "sh*t" at the moment as i have come down what is commonly called man flu, can,t stop coughing at the moment.

I have that and some friends as well..mind over matter Andy

 

[bigasotonuk]

Hi,
Well I still have the manflu, but as its been the first dry day here since Thursday I decided to wire the wash/wipe system up.
It was very straightforward to be honest (made even easier by the documents sent to me by Malcolm) but running the loom across the back of the engine seems almost impossible as the factory cable route would require the removal of all the lower windscreen trim, the complete wiper assembly, and removal of the entire heater box assembly, then the loom still has to be fed under the duo-valve and brake master cylinder and the mass of pipes that are fitted in this area.
I decided to run the loom in front of this route rather than open it up again where I will have to run the electric levelling loom in the not too distant future, so will re-route the wash/wipe loom at this time.
The loom came with all connectors and crimps fitted and once the loom was fitted I connected the wiper motors and the washer pump, and 2 ring crimps to be connected to the existing earth studs fitted on the O/S & N/S inner wings. The connections at the fuse box could,nt have been simpler. The loom simply plugged into an existing socket under the relay panel, fitting a new relay in an existing empty socket reassembly of the fuse panel and now all that remained was to install a 30A fuse.
Well I tested them and they worked straight away though the cover of the N/S wiper which acts as a washer jet as well was damaged so was shooting water all over the bumper, and on inspection the wiper blades have gone really hard so i,ll get a new cover and blades from MB in the week, but in the mean time I have disconnected the headlamp washer pump.
Well next job(s) is to run the levelling loom which I am not looking forward to at all, as this is a factory levelling loom it was run by a different route under the front seats and the center console, involving removal of the front seats, removal of the floor mounted heater ducting and the obviously the carpet and soundproofing in the 2 front foot wells.

 

[bigasotonuk]

Hi,
Well at long last all aspects of the OEM Xenons are completely fitted to my C43, Headlamp Wash/Wipe, Headlight auto levelling system, (inc. suspension atitude sensors) and of course the Xenon Headlights themselves C/W Xenon control packs, all OEM and you would be very hard pushed (if at all) to tell they were,nt fitted at the factory.
I did think about doing a detailled "HOW TO" but due to the expense and rarity of the items especially the levelling wiring loom, I decided that it would be of limited help to people as because of the age of the 202 and the prolification of cheap non approved HID kits, there would be very few, if any people would want to do such a mod.
A big "thank you" to S-A-M-U-N-I-T for fitting my atitude sensors on the suspension, whilst replacing my Pilot bush on the gearbox, which I found to be leaking and had wicked oil into the passenger side footwell, which I found whilst fitting the levelling loom.
Though after all this work, I still have an issue, as though the Xenon lights themselves are just plug and play and even the lower wattage does,nt activate the lamp failure circuit, STAR was,nt able to communicate with the levelling ECU, so access to the front and rear suspension sensors, and to set the "0" point for the light level, after searching through various menus within STAR it then asked for a 12 or 16 digit option code, which of course I have,nt got a clue as the only option code I know is a 3/4 figure one from the datacards, but the funny thing is everything "appears" to be working correctly regarding the auto-levelling, but if I want to add the option codes to my Datacard with MB I want to ensure that everything works as it should.
Has anyone got any ideas, they would be greatly appreciated.

 

[silestanix]

Jesus... This is what I have ahead of me...

http://forums.mercedesclub.org.uk/index.php?threads/new-c250td-to-me-owner.123879/page-8