This document describes the ALEX ORIGINAL (ESD) Electric Sliding Door system, designed for Mercedes Sprinter (2006-2017) and Volkswagen Crafter (2006-2016) models (Euro 4, 5, 6). The system allows for automatic operation of the vehicle's sliding door, enhancing convenience and accessibility.
Function Description
The ESD Electric Sliding Door system automates the opening and closing of the vehicle's sliding door. It can be operated via the vehicle's original remote key or the original sliding door handle. The system integrates with the vehicle's existing electrical and mechanical components to provide seamless operation.
The core of the system involves a main drive assembly, a motor, an actuator assembly, and an electronic control box. These components work in conjunction with various sensors and switches to control the door's movement, detect obstacles, and ensure safe operation.
The system includes features such as:
- Remote Operation: Control the sliding door using the vehicle's original remote key.
- Handle Operation: Use the original sliding door handle to initiate door movement.
- Obstacle Detection: The system is designed to detect obstacles during closing and will reopen the door to prevent damage or injury.
- Adjustable Sensitivity: The sensitivity of the obstacle detection can be adjusted via a potentiometer on the electronic control box.
- Door Position Programming: The system allows for programming the door to open to a "half-way" position, useful in situations where a seat or other obstruction is near the door.
- Integration with Vehicle Systems: The system connects to the vehicle's ignition, battery, door switch, and vehicle speed sensor (VSS) for intelligent operation.
- Safety Features: Includes microswitches to prevent operation when door handles are not being pulled, and a preventing door from closing input.
Important Technical Specifications
Main Components and Part Numbers:
- Main Drive Assy. Template: P.N. 2032-325
- Front Wheel: P.N. 2032-321
- Template for Lock: P.N. 2032-275
- Motor (Actuator Assembly): P.N. 5110-2182
- Actuator Assy.: P.N. 2032-2761
- New Cable (Actuator Assembly): P.N. 2032-251
- Door Conveyor Template: P.N. 2032-328
- 2 Pins for Belt Clip: P.N. 2471-574
- Conveyor Bracket: P.N. 2032-323
- Belt Clamp A: P.N. 2032-331
- Rear Wheel Template: P.N. 2032-327
- Rear Wheel (Long/Extra Long Body): P.N. 2032-324
- Rear Wheel Cover (Long/Extra Long Body): P.N. 3801-855
- Rear Wheel Template (Short Body): P.N. 2032-327
- Belt 335cm: P.N. 3119-350
- Rear Belt Clamp: P.N. 2032-332
- Electronic Control Box: P.N. 1740-298S
- Switch Bracket: P.N. 2032-305
- Door Switch: P.N. 1050-8261
- Shoulder Spacer: P.N. 2471-557
- Guide for Drill: P.N. 2032-329
- Flap Motor with Gear: P.N. 5110-650
- Upper Lock Assy.: P.N. 2032-258
- Lock Assy. Small Plastic Cover: P.N. 3801-811
- Lock Assy.: P.N. 2032-274
- Locking Latch: P.N. 2901-007
- Sockethead Bolt: M6x65
Required Tools:
- Calipers
- Black Marker
- Screwdrivers (Phillips and Flathead)
- Pliers
- Hex Keys (4mm, 5mm, 6mm)
- Socket Wrenches (8mm, 10mm, 15mm)
- Ratchet Wrenches (1/4", 3/8")
- Drill bits: Ø3mm (1/8"), Ø6mm (1/4"), Ø8mm (5/16"), Ø10mm (3/8"), Ø12mm (1/2"), Ø14mm (9/16"), Ø27mm (1.1/16")
- Grinding tool (Ø10mm (3/8"))
- Measuring tape (CR-MV M10, 30, 45)
- Wrenches (5.5mm, 8mm, 10mm, 15mm)
Electrical Connections:
- Power Supply: Connected to the vehicle's battery and after ignition.
- Signal to Open Original Lock: Connected to the original lock mechanism (refer to Fig. 21).
- VSS (Vehicle Speed Sensor): Connected to pin 9 of the original black plug in the instrument panel (refer to Fig. 45).
- Electronic Control Box Relocation: Under the co-driver seat.
- Fuse Box Connection: Original Yellow/Black wire in Grey Plug C1 Pin No 3 in fuse box for after ignition signal.
- Optional Connections:
- Electric Step Connection Output: (-) signal for operating an ALEX ORIGINAL electric step (pin 7 at white 10 pin connector).
- Wheel Chair Lift Extract Output: (+) signal when the door is in full opening position (pin 9 at white 10 pin connector).
- Wheel Chair Lift Insert Door Operation Input: (-) signal to close the door when the wheel chair lift is at close position.
- Preventing Door from Closing: (-) signal on pin 2, plug 3 will prevent the door from closing.
Usage Features
Operation Modes:
- Remote Key: The door can be opened and closed using the vehicle's original remote key.
- Original Handle: The door can be operated by pulling the original sliding door handle.
- Driver's Switch: A dedicated driver's switch allows for continuous operation of the door. A continuous press on the driver's switch allows the door to operate even if there is an obstacle.
Programming Features:
- Basic Programming (Close/Open Cycle):
- Turn off ignition key.
- Disconnect and reconnect the black connector.
- Turn on ignition key.
- Press driver's switch: first press closes the door (continuous beep), second press opens the door (continuous beep).
- The door is ready for use once it stops in the open position.
- Door Position Programming (Half-Way Mode):
- To set the door to open half-way, move the jumper out of the J3 socket on the electronic control box. No programming is needed when using the original driver key (FOB).
- Remote Control Programming (Inside Sliding Door):
- For original driver key (FOB) usage, no programming is needed.
- For other remote controls: Remove jumper, insert into J1 socket on the electronic control box, and press the remote for 3 seconds. The LED will blink for confirmation. Repeat for additional remotes.
- Remote Control Programming (Door Handle Operation):
- Remove jumper, insert into J2 socket on the electronic control box, and hold the sliding door handle in the open position for 3 seconds. The LED will blink for confirmation.
- When ignition is on, door handle operates like the driver switch.
- When ignition is off, door handle operates like the driver switch until the close position.
- When the door is in the closed position and ignition key is off, door handle operation is disabled.
BEEPING SOUNDS:
- Learning Mode: Continuous beeping during the first learning cycle.
- Opening Mode: Fragmented beeping when the door is opening.
- Closing Mode: Fragmented beeping when the door is closing.
- Obstacle Detection: Continuous beeping when an obstacle is detected during closing. The door will reopen fully.
Maintenance Features
Installation and Preparation:
- Templates: Use provided templates (e.g., Main Drive Assy. Template P.N. 2032-325, Template for Lock P.N. 2032-275, Door Conveyor Template P.N. 2032-328, Rear Wheel Template P.N. 2032-327) for accurate drilling and component placement.
- Corrosion Prevention: After cutting or grinding, file the opening and cover with paint to prevent corrosion.
- Cable Routing: Route wires through the original chain and ensure proper connection to the actuator microswitch and assembly.
- Door Support: When removing the lower door arm, ensure the door is protected from damage and supported to prevent falling.
- Silicone Application: For long and extra-long body models, apply a silicone layer for insulation around the rear wheel cover.
Troubleshooting (Opening Mode):
- Door Opens Half Way: Verify the jumper is in J3 position on the electronic control box. Check for obstacles or dirt in the belt track. Reprogram the electronic control box.
- Door Not Moving at Constant Speed: Verify the encoder cable is properly connected and undamaged. Check drive belt length and adjust. Check original rollers for smooth operation. Reprogram the electronic control box if needed.
- Long Beep Sound While Opening: Check encoder connection to the electronic control box. Reprogram the door's system if needed.
- Door Starts to Open and Stops: Check drive belt length and adjust. Check the cable connecting the actuator to the original door lock. Ensure the microswitch is not pressed when the door handle isn't pulled. Check for obstacles or dirt in the belt track.
- Door Stays Locked: Check the actuator assembly and motor. Check and adjust actuator assembly cables. Check contacts on the door and B pillar. Verify the children's lock is unlocked.
- Door Not Opening/Closing by Handle: Check microswitches and wire connections according to the electric diagram. Reprogram the door's system and remote controls to the door PCB using Jumper J2.
Troubleshooting (Closing Mode):
- Long Beep Sound While Closing: Verify the encoder cable is properly connected and undamaged. Reprogram the electronic control box.
- Door Closes But Not Lock: Check main and upper latch operation and adjust. Check contacts on the door and B pillar. Check the cable connecting the actuator to the original door lock.
- Door Opens by Itself with Long Beeping: Check for obstacles or dirt in the belt track. Check drive belt length and adjust. Adjust the potentiometer clockwise if the problem persists.
- Door Not Moving at Constant Speed: Verify the encoder cable is properly connected and undamaged. Close and open the door and check if the problem is solved. Reprogram the electronic control box if needed. Adjust the potentiometer clockwise if the problem persists.
Troubleshooting (Remote Control and Buttons):
- Remote Control Doesn't Operate: Remote control operates only when the ignition key is off. Check remote control batteries. Verify the remote is programmed to the electric control box. For vehicles with original remote control, check if the central locking signal wire is connected to electronic control box pin 4 plug 3.
- Dash Button Doesn't Operate: Driver button operates only when the ignition key is on. Check connections after ignition. Check if the LED in the driver button is on when the door is closed and flashing when the door is open. Check output signal on the button white wire to the electronic control box.
- Door Handle Operation: Door handle operates only when the ignition key is on. Microswitch installed in the door should not be pressed when the door handle isn't pulled. Check microswitch remote control batteries. Reprogram door handle remote control to electronic control box (J2).
- Door Not Working at All (Dash Switch & Remote Control): Check the fuse of the door system. Check the battery voltage on the electronic control box main supply plug.
- VSS Signal (Door Not Closing Automatically When Vehicle Moves): Check if the VSS signal option is connected correctly to the original cantus/wires of the vehicle. If no connection, use ALEX ORIGINAL VSS print P.N. 1740-001.
- Others: Check the belt for damage and length. Readjust the belt for 6-7 teeth if needed.
Belt Length Adjustment:
- Close the door.
- Release the belt from the rear belt clamp.
- Stretch the belt and cut according to the drawing, leaving 8 teeth.
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