GPS Navigation System Installation (82/103)

Publication date: 1999-08-01
Reference number: 82/103
Supersedes refnos: 82.85/103A

GPS NAVIGATION SYSTEM INSTALLATION

TECHNICAL SERVICE BULLETIN

Reference Number(s): 82.85/103A, 82/103, Date of Issue: August 1999
Superceded Bulletin(s): 82/103, Date of Issue: September 1997

INSTALLATION OF GPS NAVIGATION SYSTEM - MODEL 163.154/172

Model(s): 1998-1999 Mercedes-Benz ML 320; 1999 Mercedes-Benz ML 430

Group: 82 - Body Electrical System, Telephone (CTEL), Radio/CD Changer, Wiper/Washer System, Anti-Theft Alarm ATA), Convenience Feature

Bulletin No.: T-SI-MBUSA-82.85/103A

Date: August 1999

NOTE: This bulletin supersedes Service Information T-SI-MBNA-82/103 dated September 1997.

BULLETIN ILLUSTRATION LIST

Fig 1: Navigation System Component Locations - Model 163

Fig 2: Brackets Attached To Navigation Unit Housing

Fig 3: Navigation Unit Housing Mounting Brackets

Fig 4: Navigation Unit Housing In Storage Box

Fig 5: Felt Application To Storage Box

Fig 6: Harness Routed Under Bracket At Corner Of Lock Box

Fig 7: Harness/Antenna Cable Location At Center Console

Fig 8: Notch In Console For Wiring Harness

Fig 9: Wire Harness Routing In Console To Dashboard

Fig 10: Antenna Cable & Display Unit Cable At Air Vent

Fig 11: Bracket & Adapter On Rear Beam Of Center Console

Fig 12: Speaker Location In Center Console

Fig 13: Telephone Harness Adapter Installation

Fig 14: Transfer Case Control Module & Connector

Fig 15: CAN-Bus Adapter Connections

Fig 16: Notch In Air Vent For Display Unit & GPS Antenna Cables

Fig 17: Notch Location In Center Air Vent

Fig 18: Disassembling Air Vent

Fig 19: Display Unit & Antenna Cable In Center Vent

Fig 20: Display Unit Bracket On Center Vent

Fig 21: Display Unit On Dashboard

Fig 22: GPS Antenna Placement On Ground Plane

SERVICE INFORMATION

Attached are Work Instructions 377A for GPS Navigation System installation in Model 163 vehicles.

Individual replacement parts and exchange components are now available and should be used in lieu of assemblies or kits for all repairs. Exchange parts must be used for all warranty repairs.

GPS Navigation System installation kits do not include the map data CD. The appropriate map data CD must be ordered via fax from MBUSA Retailer Parts Services at 1-877-766-6262. Each map data CD must be ordered by VIN so the second of the two-CD subscription can be automatically mailed to the client at a later date.

NOTE: The limited warranty for the Navigation System applies only with respect to its operation in the vehicle in which it was initially installed. Interchanging GPS Navigation Systems from one vehicle to another, will render the warranty null and void.

WORK INSTRUCTIONS NO. 377A MODEL 163.154/172 - INSTALLATION OF GPS NAVIGATION SYSTEM

Model(s): 1998-1999 Mercedes-Benz ML 320; 1999 Mercedes-Benz ML 430

Group: 82

Number: 377A

Date: August 1999

INTRODUCTION

These Work Instructions outline installation procedure of the GPS Navigation System in Model 163 vehicles. Installation of the GPS Navigation System must be performed precisely as described in these Work Instructions using the only the hardware supplied (screws, lock washers, etc.). Be sure to order, via fax from MBUSA Retailer Parts Services (1-877-766-6262), the CD for the navigation unit according to the geographic area in which the system will be used before starting the installation procedure.

NOTE: If there is no storage box under passenger side seat, a new tray and storage box must be installed at additional expense to the client.

NOTE: If a Mercedes-Benz cellular telephone is to be installed, it should be done at this time.

As a safety measure, the installation location of GPS Navigation System components in the passenger compartment (Fig. Fig 1 ) must not be altered by the Mercedes-Benz Light Truck Center or client. Furthermore, the Display Unit must not be removed without the removal of the attachment parts by an authorized Mercedes-Benz Light Truck Center.

NOTE: Dark window tinting may affect GPS reception and system performance, please advise client accordingly.

B. PREPARATION FOR INSTALLATION

Remove center console.
Remove foam covering underneath console.
Remove center console air duct.
Remove radio and empty compartment below radio.
Remove center air vent by releasing two tabs on the bottom and two tabs on the top of the vent and unscrewing the attached webbing.
Remove storage box.

NOTE: If there is no storage box, a new tray and storage box must be installed at additional expense to the client.

C. NAVIGATION UNIT

Attach the two metal brackets onto the navigation unit housing using supplied screws (Fig. Fig 2 ). The top of the box is labeled; make sure the top side is up.
Using the navigation unit housing with mounting brackets as a template, position unit in the back of the storage box and mark the two inner holes on both brackets.(Figs. Fig 3 & 4). The back edge of the housing should be no more than 1 inch from the rear of the storage box.
Drill 3.5 mm holes for screws as marked.
Plug in 26-pin connector and gray GPS antenna connector into the back of the unit. Do not kink GPS antenna cable.
Attach unit by screwing into bracket from the bottom of the storage box with four M3 x 10 self-tapping screws provided.
Place felt around the back left corner of the storage box to protect the wire harness from chafing against the metal edge (Fig. Fig 5 ).

D. WIRING HARNESS

Run wiring harness and GPS antenna cable out the back left corner of the lock box. Route harness under the seat bracket (Fig. Fig 6 ).
Replace the storage box underneath the front passenger seat.
Run wiring harness and GPS antenna cable up to the right side of the center console. Approximately 178 mm (7 in) forward from the back corner of the console file a 16 mm notch in the bottom of the console for the harness (Figs. Fig 7 and Fig 8 ).
Run the harness on the right side of the console. Leave the connector for CAN-Bus adapter (connector with green and white wires) and the speaker connector (yellow) in the center console area. Run the rest of the harness and GPS antenna cable up the right side of the center console to the center of the dashboard (Fig. Fig 9 ).
The connector with the red, pink, and brown wires will connect near the radio. Run the GPS antenna cable (A, Fig. Fig 10 ) and display unit cable (B, Fig. Fig 10 ) up to and out of the air vent.

E. CAN-BUS ADAPTER

Place bracket and adapter on rear beam of center console and mark the two holes (Fig. Fig 11 ).
NOTE: The arrows in Fig. Fig 11 show the direction of the front of the center console.
Drill 6.5 mm holes for screws and secure bracket and adapter with supplied screws.
Attach CAN-Bus adapter by screwing from the underside of the console to bracket with two M6 x 12 self-tapping screws supplied.

F. SPEAKER

Cut a 76 mm (3 in) diameter hole into the left side of the center console for the speaker. Distance from the bottom of the console to the center of the speaker is approximately 105 mm (4 in). Distance from the corner of the console indicated in the Fig. Fig 12 to the center of the speaker is approximately 235 mm (9 in). Use the inside diameter of the fastening ring of the speaker as a template.
Insert speaker into cut hole and secure by screwing on the ring on the back side.

G. ELECTRICAL CONNECTIONS

Install the telephone harness adapter, part number Q 6 82 0365, (if not already installed in a previous telephone installation) between the radio and vehicle harness (A, Fig. Fig 13 ). If the harness is already installed, discard the adapter included in the kit.
The black power connector with the red, pink, and brown wires is connected to the telephone harness connector with the special GPS system adapter.
Pull out connector (A, Fig. Fig 14 ) to transfer case control module (B, Fig. Fig 14 ) in the center console area.
Plug the original connector into the female end of the adapter on the navigation harness.
Insert male end of the adapter into the transfer case control module.
Reinstall foam covering center console.
Reinstall the center console air ducts.
Reinstall the center console.
Plug connector with the green and white wires into the CAN-Bus adapter on the console (A, Fig. Fig 15 ).
NOTE: Connector is keyed and will only fit into the left side of the two-port female connector on the CAN-Bus adapter. The other port is unused.
Connect the black 18-pin connector to the CAN-Bus adapter as shown (B, Fig. Fig 15 ).
Plug yellow connector into the speaker.

H. CENTER AIR VENT MODIFICATION

File a notch between the 2nd and 3rd vent from the left for the display unit and GPS antenna cables (Fig. Fig 16 and Fig 17 ).
To accommodate the bracket, file 1 mm off from the front top edge of the middle vent. Place the bracket on the vent lining up the two notches and use the width of the front metal part of the bracket as a template.
Separate the front and back parts of the vent (Fig. Fig 18 ).
Place display unit cable and GPS antenna cable between the 2nd and 3rd vent (Fig. Fig 19 ).
Reattach the back of the vent with the display unit cable and GPS antenna cable pulled through the top of the vent.

I. DISPLAY UNIT BRACKET AND GPS ANTENNA

Slide the display unit bracket onto the back of the vent and position over the 2nd vent (Fig. Fig 20 ).
Replace center air vent making sure there is sufficient display unit cable and GPS antenna cable pulled through.
Attach display unit to bracket with two M6 x 12 screws and washers provided. Place the lock washer between the head of the screw and the flat washer. Plug the round 13 pin connector into the back of the display unit.
Peel tape off from the back of the ground plane. Stick the GPS ground plane on the dash board directly behind the display unit bracket with the single dot facing the window (Fig. Fig 21 ).
Place the GPS antenna (B, Fig. Fig 22 ) on the ground plane (A, Fig. Fig 22 ) centered inside the dots.

NOTE: Do not kink any GPS antenna cable as this will cause diminished satellite reception.

J. SYSTEM INITIALIZATION

LOAD SOFTWARE
1. Turn the ignition on.
2. Insert CD into navigation unit. (The CD is not part of this kit, and must be ordered directly from NavTech.)
3. Turn ignition off and wait until screen shuts off (approximately 30 sec).
4. Turn ignition on again and let system initialize. Process will take approximately 5 minutes.
  NOTE: Do not turn ignition off while system is initializing.

DIAGNOSTIC MODE
While in the caution screen, use the following sequence to get into the diagnostics mode: Up Arrow , Up Arrow , Right Arrow , Option Button .

SET CURRENT LOCATION
1. From the diagnostics menu, highlight Set Current Location , then press enter .
2. Select By Address and type in the city and address of your location.
3. Use the map function to accurately orient the car with the + - and arrow buttons.

SET VEHICLE PULSE SETTINGS
1. Select System configuration , press enter .
2. Highlight Vehicle Pulse Setting , press enter .
3. Set pulse rating to n x 6000 using the up and down arrows.
  NOTE: Do not set to 6000. Be sure to set to n x 6000 , which equals 36,000 pulses per mile.
4. Select Calibrate Distance , press enter .
5. Highlight Modify Calibration , press enter .
6. Set percent distance to + 6.4 .
  NOTE: This is only a preliminary setting. The system will fine-tune this parameter as the vehicle is driven.
If during test drive, the vehicle icon on the screen leaps forward or appears to lurch backward, then check the vehicle speed pulse. If the number above does not appear to be a correct value, the Vehicle Pulse will need to be calibrated manually. See procedure below:
1. In Diagnostics select System configuration , press enter .
2. Then select Calibrate Distance , press enter .
3. Highlight Start Calibration , when ready press enter and drive exactly one mile then press enter to End Calibration.
4. Enter in 5280 feet using the arrow button, press enter .
5. If percent distance is between -19.9% and 19.9% then system is able to calibrate.
6. Press enter to accept the value and then press enter again to complete calibration.

NOTE: If percent distance is less than -19.9% (i.e. -27%) increase the speed pulse manually by repeating steps 1, 2 & 3 in the Set Vehicle Pulse Settings . Then repeat the above procedure. If percent distance is greater than 19.9% (i.e. 42%) decrease the speed pulse manually by repeating steps 1, 2 & 3 in the Set Vehicle Pulse Settings . Then repeat the above procedure.

K. CHECK SYSTEM FUNCTION

CONFIRM UNIT READS REVERSE
1. From the diagnostics menu, use the arrows to highlight Reverse , then press enter .
2. Shift the gear shift lever between reverse and neutral. The screen should show the correct status. Check reverse connection if screen does not respond correctly.

CONFIRM GPS RECEPTION
Park vehicle in an unobscured area clear of large structures, high tension wires, and tree cover. Exit the diagnostic screen completely by using the cancel button. At the caution screen press enter , then press the map button. GPS is confirmed when the GPS light on the bottom of the display unit turns green while the car is stationary. Allow up to 15 minutes to confirm reception. GPS is not available in tunnels or covered roadways.

TURN VOLUME ON
While waiting for GPS reception press the option button. Use the arrows to scroll down to voice. Highlight volume setting 3 and press enter .

TEST DRIVE
Enter a destination. Highlight Points of Interest , then press enter . Select a destination and press enter . Keep in mind the system will save the address of the destination entered in memory. After the system is done calculating a route, listen for the voice prompt "Please proceed to the highlighted route." If no voice is heard, check the volume in the option screen or check the speaker connection.
If the above settings were done successfully, the car should track accurately. Depending on the initial position and orientation however, the car may need several minutes of driving time at a speed of 30mph or more with good GPS reception to correct any positioning errors.

Fig 23: TROUBLESHOOTING GUIDE - TABLE - W.I. 377A PART

Fig 24: TROUBLESHOOTING GUIDE - TABLE - W.I. 377A PART 2

Fig 25: TROUBLESHOOTING GUIDE - TABLE - W.I. 377A PART 3

PARTS INFORMATION

Fig 26: INDIVIDUAL REPLACEMENT PARTS - W.I. 377A

RECOMMENDED LABOR TIME

Fig 27: LABOR TIME INFORMATION TABLE - W.I. 377A