Removing and Installing Wiring Harness In Engine Compartment
Removing And Installing Wiring Harness In Engine Compartment
Tools
Preliminary work
1. Remove insulation for engine compartment lid.
2. Remove cowl panel cover.
3. Remove front right wheel housing liner.
4. Remove tank for windscreen washer system.
Removing bonnet wiring harness
NOTE: The electrical wiring harness in the bonnet is combined with the water line in the windscreen washer system. This means that the water line and the electrical wiring harness can only be removed and installed together.
1. Lever out engine compartment light at the left side with a plastic spatula -arrow A- and remove it.
2. Press the plug lock together -arrows B- and pull off the plug -arrow C-.
3. Unclip wiring harness at the bonnet and bonnet hinge using removal tool, universal NR.21 (-arrows-).
4. Remove rubber sleeve on the bonnet. To do this, pull the wiring harness at the rubber sleeve to the side -arrow A- until the rubber sleeve is released from the bore -arrow B-.
5. Lever out the two covers -arrow A- and remove them from the bonnet.
6. Remove the plug connection for the windscreen washer nozzle heater from the cover -arrow B-.
7. Pull off the plug for the windscreen washer nozzle heater -C-.
8. Pull off the water line from the right angle plug of the windscreen washer nozzle -D-.
9. Pull out the wiring harness with the rubber sleeve -arrow A-. To do this, push the wiring harnesses alternately towards the windscreen washer nozzle and the engine compartment light -arrows B and C-.
10. Press DME control module locks outwards -arrows A-.
11. Remove DME control module to the front -arrow B- and place it on the radiator tank.
12. Release plug connection -arrow A- and remove it to the front -arrow B-.
13. Release plug connection -arrow C- and disconnect -arrow D-.
14. Fold insulating mat forwards -arrow A-.
15. Unclip wiring harness at bonnet hinge -arrows B-.
16. Push the rubber sleeve inwards from the spring strut mount -arrow-, push the water line with the rubber sleeve through the spring strut mount and remove the wiring harness in the engine compartment in an upward direction.
Installing bonnet wiring harness
1. Push the water line of the windscreen washer system together with the rubber sleeve from the engine compartment side outwards through the spring strut mount -arrow A-.
2. Install rubber sleeve from the wheel housing side on the spring strut mount -arrow B-.
NOTE: During removal, replace damaged clips with repair clips.
3. Clip wiring harness to bonnet hinge -arrows A- and fold the insulating mat back into its original position -arrow B-.
4. Push plug connection together -arrows A- until the locking lug -arrow B- is felt to engage.
5. Push plug connection into clip -arrow C- until the locking lug -arrow D- is felt to engage.
6. Push DME control module into the holder -arrow A- and press downwards on the side of the plug until the control unit is felt to engage in the lock -arrows B-.
NOTE:
- During removal, replace damaged clips with repair clips.
- Fasten the plugs of the heatable washer nozzle to the water line with adhesive tape -1- to make it easier to push through to the windscreen washer nozzles. After pushing through, remove the adhesive tape again.
7. Push wiring harness into the bonnet reinforcement -arrow A-.
8. Push water line, together with the electrical wire, through to the windscreen washer nozzles and pull out at the openings -arrow B-
9. Pull the wiring harness to the engine compartment light out of the bonnet reinforcement -arrow C-.
10. Fit rubber sleeve -2-.
11. Push together the cable for the washer nozzle heating and the water line -arrows A and B-.
12. Push the plug connection into the cover -arrow C-.
13. Engage cover in the bonnet and fold it upwards -arrow D- until the cover is felt to engage.
NOTE: During removal, replace damaged clips with repair clips.
14. Clip the wiring harness for the engine compartment light into the bonnet -arrows-.
15. Connect plug to engine compartment light -arrow A- until the lock is felt to engage -arrows B-.
16. Insert engine compartment light into the bonnet -arrow C- and press it in -arrow D- until it is felt to engage.
Subsequent work
1. Remove tank for windscreen washer system.
2. Remove front right wheel housing liner.
3. Install cowl panel cover.
4. Install insulation for engine compartment lid.