Headlamp cleaning system: Difference between revisions

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==Headlight Washer Removal==
== Headlamp cleaning system (HCS) ==
The purpose of headlamp cleaning system (HCS) is cleaning headlamp lenses.
 
<!-- GF82.15-P-0002-03S Headlamp cleaning system (HCS), location of components -->
Location of components:
 
{|
|[[File:W220_headlamp_cleaning_system_components.png|600px]]
|Illustrated on model 220:
* 1 - Telescoping nozzle
* 2 - Washing water hose for headlamp cleaning system
* M5/2 - Headlamp cleaning system pump
* N10/6 - Left front SAM control module
* N10/7 - Right front SAM control module
* S1s1 - Headlamp cleaning system switch
|}
 
<!-- GF82.15-P-0002-04S Headlamp cleaning system (HCS), interlinkage of components -->
 
{|
|[[File:W220_headlamp_cleaning_system_interlinkage.png|500px]]
|
Interlinkagae of components:
* CAN (B) - CAN (passenger compartment)
* M5/2 - Headlamp cleaning system pump
* N10/6 - Left front SAM control module
* N10/7 - Right front SAM control module
* S1s1 - Headlamp cleaning system switch
|}
 
<!-- GF82.15-P-0002S Headlamp cleaning system (HCS), function
MODEL 215, 220 with CODE (600a) Headlamp cleaning system -->
 
Function precondition:
* Circuit 15 ON
 
'''Manual operation'''
 
* The headlamp cleaning system (HCS) is switched on by pressing the HCS switch (S1s1).
* This connects the corresponding input of the left front SAM control unit (N10/6), which reads in the signal of the HCS switch (S1s1), to ground.
* The left front SAM control unit (N10/6) places the switch-on pulse onto the class B Controller Area Network bus (interior) (CAN-B) as a message.
* The right front SAM control unit (N10/7) reads in this message and connects circuit 15 to the HCS pump (M5/2) for a switch-on time of approx. 1 s via an electronic switch (transistor).
* The HCS pump (M5/2) builds up water pressure in the line.
* The water pressure acts against the return springs in the telescopic nozzle.
* Before the telescopic nozzles extend, spraying water on the headlamp lenses.
* After expiration of the switch-on time, the pressure in the water line decreases and the telescopic nozzles are retracted to their initial position by the spring force.
 
Pressing the HCS switch (S1s1) again when a headlamp cleaning cycle is being performed has no effect.
Another headlamp cleaning cycle cannot be activated until the preceding one has completed.
 
'''Automatic operation (in vehicles as of 1.6.04)'''
 
After the windshield washer system has been operated 15 times the HCS pump (M5/2) is actuated automatically.
This automatic control is performed by the right front SAM control unit (N10/7).
 
Function: For each actuation of the windshield washer fluid pump (M5/1) the internal counter in the right front SAM control unit (N10/7) is incremented by 1 until it reaches the value "15", then the HCS pump (M5/2) is actuated and the counter is reset to "0".
The internal counter is always reset to "0" whith circuit 15 off.
 
== Telescoping nozzles ==
 
<!-- GF82.15-P-2100-01S  Telescoping nozzle headlamp cleaning system, location -->
 
{|
|[[File:W220_headlamp_cleaning_system_nozzles.png|500px]]
|* 1 - Telescoping nozzles
|}
 
<!-- GF82.15-P-2100S
Telescoping nozzle headlamp cleaning system (HCS), location/purpose/design/ function
MODEL 215, 220 with CODE (600a) Headlamp cleaning system -->
 
The telescoping nozzles are hydraulically extending telescopic tubes with integrated return spring.
They are not connected electrically.
 
<!-- GF82.15-P-2100-04B
Telescoping nozzle headlamp cleaning system, function -->
When it starts running the washing water pump builds up pressure in the washing water line.
The nozzles extend in a telescopic manner at a pressure of 1-1.6 bar.
When a pressure of 3 bar is exceeded a valve opens on each telescoping nozzle
and a precise quantity of washing water is sprayed onto the headlamp lenses.
 
Eddy chambers are attached to the tips of the telescopic nozzles
which control the spray from the water jets even at high vehicle speeds.
Following the cleaning process the telescopes are retracted to the initial position by return springs.
 
=== Remove, install telescopic nozzle ===
<!-- AR82.15-P-6100M Remove, install telescopic nozzle of headlamp cleaning system 4.6.98
MODEL 220 with CODE (600a) Headlamp cleaning system -->
 
{|
|[[File:W220_telescopic_nozzle_headlamp_cleaning_system.jpg|600px]]
|
* 1 - Cover for telescoping nozzle
* 2 - Nozzle
* 2a - Retaining lug
* 3 - Pop-up mechanism
* 4 - Nut
* 5 - Washer fluid hose
* 6 - Retaining clamp
* 7 - Bolts
|}
 
Remove/install:
# Remove lower engine compartment lining
# Clamp off washing water hose (6) with clamp
# Pivot telescoping nozzle cover (1) toward front
# Pull out nozzle (2) until stop is reached
# Slightly lift retaining lug (2a) on nozzle (2) with suitable tool and remove nozzle (2) from telescoping unit (3). Do not lift retaining lug too far upward,
danger of breaking.
# Unscrew nut (4) from telescoping unit (3)
# Remove retaining clips (6) and remove washing water hose (5) from pop-up mechanism (3)
# Unscrew the bolts (7).
# Pull out pop-up mechanism (3) downward
# Install in the reverse order
# Check fluid level of windshield washer system and correct if necessary
# Carry out operational check


{{#ev:youtube|https://www.youtube.com/watch?v=B1_b6-ypTSM|320|left|Headlamp washer removal.|frame}}
{{#ev:youtube|https://www.youtube.com/watch?v=B1_b6-ypTSM|320|left|Headlamp washer removal.|frame}}
<br clear=all>
<br clear=all>
== Retrofitting headlamp cleaning system ==
<!-- AN82.15-P-0001M Retrofitting headlamp cleaning system 16.12.98 MODEL 220.### 1# -->
{|
|[[File:W220_retrofitting_headlamp_cleaning_system.jpg|500px]]
|
* 2 - Telescoping nozzle cover
* 3 - Nozzle
* 4 - Telescoping element
* 5 - Washer fluid hose
* 5b - Connector 110°
* 5c - Connector, straight
* 6 - Washer pump connector
* M5/2 - Headlamp washer fluid pump
* S1 - Exterior lamp switch
* S1x1 - Switch headlamp cleaning system
|}
Removal:
# Remove washer fluid reservoir of headlamp cleaning system and drain
# Remove bottom engine compartment paneling
# Remove front bumper
# Remove exterior lamp switch (S1)
Installation:
# Install telescoping nozzle headlamp of cleaning system
# Retrofit washer fluid reservoir and washer fluid hose
# Install front bumper with covers for headlamp cleaning system. Paint bumper to match color of car.
# Install exterior lamp switch (S1) with headlamp cleaning system switch (S1x1)
# Complete vehicle
Checking:
# Check headlamp cleaning system fluid level, correct
# Perform version coding for "headlamp cleaning system"
# Perform version coding for "headlamp cleaning system"
Parts ordering notes:
* KG54 - Exterior lamp switch
* KG88 - Front bumper with covers for headlamp cleaning system
* KG86 - Centrifugal pump
* KG86 - Telescoping nozzle with one insert nozzle each (right and left different) and mounting parts x2
* KG86 - T-fitting and hose (center, right and left) x4
* KG86 - Connector (110°) x2
* KG86 - Connector (straight)
* KG99 - Grommet for centrifugal pump
=== Retrofitting washer fluid reservoir and washer fluid hose ===
<!-- N82.15-P-0001-03M
Retrofitting washer fluid reservoir and washer fluid hose
Model 220 -->
{|
|[[File:W220_retrofitting_washer_fluid_reservoir_hose_1.jpg|600px]]
|[[File:W220_retrofitting_washer_fluid_reservoir_hose_2.jpg|200px]]
|}
# Remove existing grommet from washer fluid reservoir (see arrow) and install headlamp washer fluid pump (M5/2) with grommet.
# Connect existing connector (6) from engine wiring harness to headlamp washer fluid pump (M5/2).
# Install washer fluid reservoir and coolant expansion reservoir.
# Attach angular connector (5b) to washer fluid hose (5).
# Attach washer fluid hose to left telescoping nozzle (4) with connector (5b) and route below cross member on right side of vehicle and fasten with cable straps (see magnified section in figure at left).
# Install T-fitting (5a) and route washer fluid hose section to right telescoping unit (4), insert connector (5b) into washer fluid hose (5) and connect to telescoping unit (see center figure).
# Route washer fluid hose section (5) from T-fitting (5a) to headlamp washer fluid pump (M5/2), insert straight connection (5c) into washer fluid hose and connect to washer pump (see figures at right).
Actuate catch for locking/unlocking connector (5b) (see arrow in figure at bottom left).
Actuate catch for locking/unlocking connector (5c) (see arrow in figure at bottom right).
{{#ev:youtube|https://www.youtube.com/watch?v=natlDwWHudc|320|left|Headlamp washer hoses|frame}}
<br clear=all>
== Parts ==
[[File:W220_headlamp_washer_EPC.png|thumb|none|Parts in [[EPC]] related to headlamp washing system]]
Check also the [[windshield washing system]].
* Nozzle left A2208601747 - 36 EUR
* Nozzle right A2208601847 - 36 EUR
* Nozzle pop-up mechanism A2208601347 - 76 EUR
{|
|[[File:W220_A2208601347_headlamp_washing_system_popup_mechanisms.jpg|thumb|none|Pop-up mechanisms with nozzles]]
|[[File:W220_headlamp_nozzle_left_A2208601747_right_A2208601847.jpg|thumb|none|Nozzle left (A2208601747) and right (A2208601847)]]
|[[File:W220_A2208601347_headlamp_washing_nozzle_popup_mechanism.jpg|thumb|none|Nozzle pop-up mechanism A2208601347]]
|}

Latest revision as of 21:49, 11 February 2023

Headlamp cleaning system (HCS)

The purpose of headlamp cleaning system (HCS) is cleaning headlamp lenses.

Location of components:

Illustrated on model 220:
  • 1 - Telescoping nozzle
  • 2 - Washing water hose for headlamp cleaning system
  • M5/2 - Headlamp cleaning system pump
  • N10/6 - Left front SAM control module
  • N10/7 - Right front SAM control module
  • S1s1 - Headlamp cleaning system switch


Interlinkagae of components:

  • CAN (B) - CAN (passenger compartment)
  • M5/2 - Headlamp cleaning system pump
  • N10/6 - Left front SAM control module
  • N10/7 - Right front SAM control module
  • S1s1 - Headlamp cleaning system switch


Function precondition:

  • Circuit 15 ON

Manual operation

  • The headlamp cleaning system (HCS) is switched on by pressing the HCS switch (S1s1).
  • This connects the corresponding input of the left front SAM control unit (N10/6), which reads in the signal of the HCS switch (S1s1), to ground.
  • The left front SAM control unit (N10/6) places the switch-on pulse onto the class B Controller Area Network bus (interior) (CAN-B) as a message.
  • The right front SAM control unit (N10/7) reads in this message and connects circuit 15 to the HCS pump (M5/2) for a switch-on time of approx. 1 s via an electronic switch (transistor).
  • The HCS pump (M5/2) builds up water pressure in the line.
  • The water pressure acts against the return springs in the telescopic nozzle.
  • Before the telescopic nozzles extend, spraying water on the headlamp lenses.
  • After expiration of the switch-on time, the pressure in the water line decreases and the telescopic nozzles are retracted to their initial position by the spring force.

Pressing the HCS switch (S1s1) again when a headlamp cleaning cycle is being performed has no effect. Another headlamp cleaning cycle cannot be activated until the preceding one has completed.

Automatic operation (in vehicles as of 1.6.04)

After the windshield washer system has been operated 15 times the HCS pump (M5/2) is actuated automatically. This automatic control is performed by the right front SAM control unit (N10/7).

Function: For each actuation of the windshield washer fluid pump (M5/1) the internal counter in the right front SAM control unit (N10/7) is incremented by 1 until it reaches the value "15", then the HCS pump (M5/2) is actuated and the counter is reset to "0". The internal counter is always reset to "0" whith circuit 15 off.

Telescoping nozzles

* 1 - Telescoping nozzles


The telescoping nozzles are hydraulically extending telescopic tubes with integrated return spring. They are not connected electrically.

When it starts running the washing water pump builds up pressure in the washing water line. The nozzles extend in a telescopic manner at a pressure of 1-1.6 bar. When a pressure of 3 bar is exceeded a valve opens on each telescoping nozzle and a precise quantity of washing water is sprayed onto the headlamp lenses.

Eddy chambers are attached to the tips of the telescopic nozzles which control the spray from the water jets even at high vehicle speeds. Following the cleaning process the telescopes are retracted to the initial position by return springs.

Remove, install telescopic nozzle

  • 1 - Cover for telescoping nozzle
  • 2 - Nozzle
  • 2a - Retaining lug
  • 3 - Pop-up mechanism
  • 4 - Nut
  • 5 - Washer fluid hose
  • 6 - Retaining clamp
  • 7 - Bolts

Remove/install:

  1. Remove lower engine compartment lining
  2. Clamp off washing water hose (6) with clamp
  3. Pivot telescoping nozzle cover (1) toward front
  4. Pull out nozzle (2) until stop is reached
  5. Slightly lift retaining lug (2a) on nozzle (2) with suitable tool and remove nozzle (2) from telescoping unit (3). Do not lift retaining lug too far upward,

danger of breaking.

  1. Unscrew nut (4) from telescoping unit (3)
  2. Remove retaining clips (6) and remove washing water hose (5) from pop-up mechanism (3)
  3. Unscrew the bolts (7).
  4. Pull out pop-up mechanism (3) downward
  5. Install in the reverse order
  6. Check fluid level of windshield washer system and correct if necessary
  7. Carry out operational check
Load video
YouTube
Headlamp washer removal.


Retrofitting headlamp cleaning system

  • 2 - Telescoping nozzle cover
  • 3 - Nozzle
  • 4 - Telescoping element
  • 5 - Washer fluid hose
  • 5b - Connector 110°
  • 5c - Connector, straight
  • 6 - Washer pump connector
  • M5/2 - Headlamp washer fluid pump
  • S1 - Exterior lamp switch
  • S1x1 - Switch headlamp cleaning system

Removal:

  1. Remove washer fluid reservoir of headlamp cleaning system and drain
  2. Remove bottom engine compartment paneling
  3. Remove front bumper
  4. Remove exterior lamp switch (S1)

Installation:

  1. Install telescoping nozzle headlamp of cleaning system
  2. Retrofit washer fluid reservoir and washer fluid hose
  3. Install front bumper with covers for headlamp cleaning system. Paint bumper to match color of car.
  4. Install exterior lamp switch (S1) with headlamp cleaning system switch (S1x1)
  5. Complete vehicle

Checking:

  1. Check headlamp cleaning system fluid level, correct
  2. Perform version coding for "headlamp cleaning system"
  3. Perform version coding for "headlamp cleaning system"

Parts ordering notes:

  • KG54 - Exterior lamp switch
  • KG88 - Front bumper with covers for headlamp cleaning system
  • KG86 - Centrifugal pump
  • KG86 - Telescoping nozzle with one insert nozzle each (right and left different) and mounting parts x2
  • KG86 - T-fitting and hose (center, right and left) x4
  • KG86 - Connector (110°) x2
  • KG86 - Connector (straight)
  • KG99 - Grommet for centrifugal pump

Retrofitting washer fluid reservoir and washer fluid hose

  1. Remove existing grommet from washer fluid reservoir (see arrow) and install headlamp washer fluid pump (M5/2) with grommet.
  2. Connect existing connector (6) from engine wiring harness to headlamp washer fluid pump (M5/2).
  3. Install washer fluid reservoir and coolant expansion reservoir.
  4. Attach angular connector (5b) to washer fluid hose (5).
  5. Attach washer fluid hose to left telescoping nozzle (4) with connector (5b) and route below cross member on right side of vehicle and fasten with cable straps (see magnified section in figure at left).
  6. Install T-fitting (5a) and route washer fluid hose section to right telescoping unit (4), insert connector (5b) into washer fluid hose (5) and connect to telescoping unit (see center figure).
  7. Route washer fluid hose section (5) from T-fitting (5a) to headlamp washer fluid pump (M5/2), insert straight connection (5c) into washer fluid hose and connect to washer pump (see figures at right).

Actuate catch for locking/unlocking connector (5b) (see arrow in figure at bottom left). Actuate catch for locking/unlocking connector (5c) (see arrow in figure at bottom right).

Load video
YouTube
Headlamp washer hoses


Parts

Parts in EPC related to headlamp washing system

Check also the windshield washing system.

  • Nozzle left A2208601747 - 36 EUR
  • Nozzle right A2208601847 - 36 EUR
  • Nozzle pop-up mechanism A2208601347 - 76 EUR
Pop-up mechanisms with nozzles
Nozzle left (A2208601747) and right (A2208601847)
Nozzle pop-up mechanism A2208601347
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