MB Sprinter 907/910 Vehicle Specific Installation Manual · MB Sprinter, Vehicle Specific...

a product of the company Bozzio AG

MB Sprinter 907/910

Vehicle Specific Installation Manual

EN_MB_Sprinter_Specific_Installation_Manual_2_V06-190430.docx

Aarbergstrasse 5 2560 Nidau Switzerland

MB Sprinter, Vehicle Specific Installation Manual

Bozzio AG * joysteer® page 2 of 40

Contents

1 GENERAL .................................................................................................................. 3

2 DISCLAIMER ............................................................................................................. 4

3 INSTALLATION OF VEHICLE SPECIFIC PARTS ..................................................... 5

3.1 Installation of electronics ......................................................................................... 6

3.1.1 Part list ........................................................................................................................ 8

3.2 Installation steering actuator (SAM) ...................................................................... 10

3.2.1 Part list ...................................................................................................................... 12

3.2.2 Installation steps ....................................................................................................... 15


3.3 Installation brake actuator (BAM) .......................................................................... 26

3.3.1 Part list ...................................................................................................................... 27


3.4 Installation brake pressure sensors ...................................................................... 38

3.5 Park Position with CAN Adapter ............................................................................ 39

3.6 Installation Backup-battery .................................................................................... 40



1 General

This document describes the installation of the joysteer® system and to take place by trained personnel exclusively, whereby all points need to be carried out as described.

This document is in addition to the "Universal System Manual".

The electrical connections can be found in the electrical cabling diagram.

This document applies to the joysteer® system generation 2.0.

The main change from generation 1.0 to generation 2.0 is as following:

Display module Alarm module

joysteer® generation 2.0 joysteer® generation 1.0



2 Disclaimer

Bozzio AG refuses their product liability if one or more of the following facts are given:

• Driving the system by users who do not possess an appropriate driving licence Exception: driving accompanied by an authorized driving instructor

• Driving with accompanying driving instructor without installation of an Instructor switch

• Installation/ maintenance/ repairs by companies not trained by Bozzio AG

• Installation/ maintenance/ repairs by personnel not trained by Bozzio AG

• Installation/ maintenance/ repairs not according to the manuals

• Installation/ maintenance/ repairs of components/ modules, which are not mentioned in the part list

• Installation/ maintenance/ repairs of any MMI (Man Machine Interface), which has not been released by Bozzio AG in written form

• Usage of parameter-sets which do not correspond to the “rules” of the Servicemanager

• Any modifications to the cable harness

Important:

• By opening the modules any warranty of the manufacturer is omitted.

(Exception: EnergyAlarm module)



3 Installation of vehicle specific parts

Choose a sensible order to install: The correct order of installing each component of the joysteer® system is depending on which components have to be installed.

Example: If you first install the steering actuator, it is harder to reach the brake pedal and the gear shifter.

Preparation:

• Any floor/B-pillar modification (welding) must be done before installing any electronic equipment.

• Make connections to the steering column module for secondary controls before mounting any joysteer modules.

• Modify or move the ignition switch if necessary.

• Install the mechanical parts of the gear shifter including P-switch before mounting any joysteer modules.

• Check if a newer SW Version is released. The downloads are available in the login domain of www.joysteer.ch.

joysteer modules:

The proposed order of installation for this car type is the following:

1. Mount the electronics (Converter and EAM).

2. Connect the wiring harness to the Electronics and put all the wiring in the desired position.

3. SmartGas 2

4. Steering actuator SAM

5. Brake actuator BAM

6. Brake pressure sensors. To be done while the original pedal is still in place so it’s possible to purge the system immediately after mounting the sensors.

7. P-Switch

8. Backup battery and Pulse Test Box

http://www.joysteer.ch/



3.1 Installation of electronics

The modules and if available the module rack (optional item) have to be grounded well. In case this is done with a cable, the cables cross section must be at least 2.5mm2.

If the module rack is required, all modules are to be connected to it.

The installation order of modules from top to bottom is always:

EAM = EnergyAlarm module

L1 = Steering converter module 1

L2 = Steering converter module 2

B1 = Braking converter module 1

B2 = Braking converter module 2



3.1.1 Part list

(Images not to scale)

Image Description Quantity

Support bracket 1

Mounting bracket 1

Spacer 2

Cylinder head screw M6x16 4

Locknut M6 3

Washer M6 4




Hexagon bolt M8x25 2

Tapping screw 4,8 x 25 2

Washer M8 2



3.2 Installation steering actuator (SAM)

All brackets used in this chapter are blue for a better image visibility

Ensure the following:

• a MB Sprinter specific steering actuator (middle orange disk is turned 90 degrees to the right) has to be delivered. Please contact the producer or distributor if this is not the case.

• In case of an adjustable steering column the steering column needs to be fixed permanently.

• The steering actuator is placed between the steering wheel and the steering column. There is no need to detach the steering column.

• the steering wheel is always in the straight-ahead position during the installation.

• the airbag-ring is in the middle position when installing.

• the catchpins of the airbag-ring needs to be placed in the steering actuator.

If needed they can be extended by using plastic tubes.

• the spacers are placed between the bracket and the steering column.



3.2.1 Part list



Steering wheel adapter (A) 1

Steering wheel bolt 1

Assembly bracket (B) 1

Actuator bracket (C) 1




Mounting bracket left (D) 1

Mounting bracket right (E) 1

90-degree bracket (F) 2



Washer M6 4

Hexagon bolt M6x90 1




Locknut M6 1

Washer M6x25 2

Washer M8 8


Locknut M8 4

Hexagon socket countersunk M6x10

4

Note:

This symbol indicates the usage of Loctite. Always use Loctite 243 unless otherwise mentioned. The required torque is mentioned below the symbol.

..Nm



3.2.2 Installation steps


Steering actuator

Assembly bracket

Mounting bracket Right

Mounting bracket Left

Steering wheel adapter Steering wheel bolt

Hexagon bolt M6x90, 2 washers M6 & locknut M6



1. Remove the negative pole from the battery

2. Remove the steering column covers

3. Remove the steering wheel airbag

4. Remove the steering wheel

5. Remove the steering column switches

6. Remove the adjusting mechanism of the steering column completely and mount:

1x M6x90

2x washers M6x25

1x locknut M6. Do not tighten yet.

7. Mount the left and right mounting bracket to the original mounting points of the steering column. Use the car’s original M8 bolts. First unscrew one side and mount the bracket, then unscrew the other side and mount the bracket. To make it easier to reach, the dashboard covers can be unscrewed and removed partially to make some more working space. Do not fully tighten the Orignal M8 bolts yet

8. Mount the Assembly bracket in between the 2 mounting brackets.

Use: 4x cylinder head screw M6x12

4x washer M6 7.6Nm



9. Unscrew the 4 torx bolts in the back of the steering column switches to remove the steering column switch cover.

10. Adapt the steering column cover as shown on the picture below.

125mm

15mm

20mm



120mm

60mm



11. Mount back the steering column switch covers and mount the steering column switch assembly back to the steering column.

12. Mount the bracket C to the steering actuator

Use:

4 hexagon socket countersunk screws M6x10

13. Mount the 2 brackets F to the bracket C

Use

2x Cylinder head M8x25

4x Washer M8

2x Locknut M8

4.5Nm



14. Mount the steering actuator to the steering wheel adapter.

Use: 6x M5x20

(Make sure the cam on the adapter points downward to the motors to unlock the airbag ring anti rotation lever when mounting)



15. Place the steering actuator with adapter over the original steering axle.

16. Mount the 2 brackets F to the Mounting bracket left (D) and right (E).

Use:

2x Cylinder head M8x25

4x Washer M8

2x Locknut M8

17. Tighten the screws and nuts in the following order:

• Steering wheel bolt

• Screws of the mounting brackets

• Original steering column bolts

• M6x90 of the steering column adjusting mechanism

18. Extend the cable on the steering wheel with approximately 8 cm as shown in the picture.



19. Re connect the connector in the steering wheel and mount back the Airbag

In case there is not enough free play in the slot holes; loosen everything adjust and tighten again.

Important:

Check if the installation is correct by driving the car conventionally after having installed the steering actuator. As the worm wheel and the motors are rotated passively, there is an increase of friction. Whilst the joysteer® system is turned off the friction of the steering actuator should not increase significantly. If this is the case, the steering actuator is misaligned and the screws of the brackets need to be loosened slightly. By sequential tightening of the screws, the alignment of the steering column to the steering actuator is ensured and thus the friction can be minimized.

To finish

1. Reconnect the negative pole to the battery

2. Test full functionality of the system

3. Friction test by conventional driving

Extend



3.3 Installation brake actuator (BAM)

All brackets used in this chapter are blue for a better image visibility

The brake actuator is attached to the brake pedal.

Always ensure that the pin is not under tension and that the locking clip is attached properly.



3.3.1 Part list



Long nut 17x35 4

Excenter round 14 1

Mounting bracket brake actuator 1

Brake pedal hook (assembly) 1

Locking pin with circlip 1

Heat shield 1

Cylinder head M8x16 4




Washer M8 4

Locknut M6 1

Locknut M8 2

Bolt M6x40 1

Washer M6 1

Nut M6 2

Bolt M6x25 2

Bolt M8x40 2

Tapping screw 4.2x13 2

Tapping screw 4.2x50 1

Washer M4x12 1



1. Remove the negative terminal of the battery.

2. Remove the lower, left and middle dashboard cover.

3. Remove the heater outlet tube.

4. Cut the Dashboard support as shown on the picture below.

5. Remove the upper and lower 2 original locknuts from the brake pedal bridge and replace them with the provided long nuts.

6. Cut out the foam to make room for the mounting bracket. See dimensions on the picture below.



7. Mount the nuts and bolts on the pedal hook as shown, before it is mounted to the brake pedal.

Use:

2x bolt M8x40 2x locknut M8 2x bolt M6x25 2x nut M6



8. Mount the pedal hook to the original brake pedal.

9. Mount the round excenter to the back of the pedal hook.

Use:

1x bolt M6x40 1x washer M6 1x locknut M6

10. Adjust the pedal hook so there is no free play. Tighten the locknut on the excenter. Tighten the 2 locknuts M8 until the bolt just protrudes through the lock nut.

Apply Loctite to the 2 adjusting screws. The 2 adjusting screws are tightened after mounting the brake actuator.



11. Mount the brake actuator mounting bracket. (it is not necessary to remove the steering column)

Use:



4x Cylinder head M8x16 1x washer M8

12. Mount the brake actuator to the bracket.

Use:

6x cylinder head M5x6

13. Mount the brake actuator to the pedal hook.

Make sure the actuator is aligned and that the pin can be rotated by hand to make sure it is not under tension or misaligned.

Tighten the 2 adjusting screws and fix them using the 2 nuts M6.

Ensure the circlip is mounted the right way and it is well placed in the groove of the pin.



14. Cut the heater outlet and mount the heat shield as shown on the picture below.

Use two tapping screws 4.2x13.

15. Mount the heater outlet back to the car and fixate it with one tapping screw 4.2x50 and one washer M4x12.



16. Cut the dashboard covering so the brake actuator will fit trough and mount these covers back to the car. See picture below for dimensions.

To finish

1. Reconnect the negative pole to the battery.

2. Test full functionality of the system.

3. Ensure the locking pin can be rotated by hand. This ensures that the brake actuator is not under mechanical tension or misaligned when in its idle position.



3.4 Installation brake pressure sensors

Mount the brake pressure sensors as shown

Use:

1x Bolt M8x75 1x spacer and 1x locknut M8

Purge the brake lines to remove air and connect the sensors to X71 / X72.



3.5 Park Position (CAN Adapter)

The Park Position is safety critical and is detected by the joysteer® system.

On the MB Sprinter 709/910, the Park position is solely detected by the CAN Adapter. There is no way to install P-switches.

The Installation of the CAN Adapter is universal and shown in the System manual.



3.6 Installation Backup-battery

The Backup-battery is placed underneath the passenger-seat.

Ensure the following:

1. The mass cable of the backup-battery should not be connected to the vehicles body. It needs to be connected to the energy alarm module using a cable.

2. All consumers such as ramp door, lift etc. need to be connected to the vehicles primary battery.

3. For safety reasons the backup-battery must always be as specified in the Universal System Manual.

Next installation steps

4. Apply ring cable shoes (10mm2/M6) to the backup-battery.

5. Place fuse near the backup-battery 125A (adapter included).

6. Apply vent hose on the backup-battery. Make sure that the gases are led out of the vehicle (If required; drill a hole and make a tulle.)

7. Connect the EnergyAlarm module to the battery.

8. Place ring cable shoes (10 mm2/M6) to the original battery.

9. Place fuse 125A near the original battery (adapter included).

10. Apply ring cable shoes (10 mm2/M8) to the negative and positive pole of the battery.

11. Mount them to the original battery clamps.

MB Sprinter 907/910 Vehicle Specific Installation Manual · MB Sprinter, Vehicle Specific...

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