Installing

WM 970919 Removing and installing main wiring harness

Technical values





Installing main wiring harness

Overview





Information

- The repair instructions document "Removing and installing main wire harness" is divided into several chapters because of its size.

- For body repairs, refer to the specific chapters on installing and removing individual sections of wiring.

Installing main wiring harness - engine compartment on right

Install main wire harness - dashboard area & centre console -> 970919 Removing and installing main wire harness - section on "Installing" 970919 Removing and Installing Main Wiring Harness
1. Push line through from passenger compartment to engine compartment -Arrow A- until rubber sleeve is felt to engage in firewall -B-.





2. Place line in installation position -Arrow C- and close clips -Arrow D-.
3. Push connector onto hydraulic unit -Arrow E- and press in the lock -Arrow F- until it is felt to engage.
4. Clip in line -arrow-.





5. Press line into rubber sleeve -Arrow A-.





6. Place line with rubber sleeve in installation position -Arrow B-.
7. Place line in installation position -Arrow C- and close clip -Arrow D- until locking tabs are felt to engage.
8. Place air intake housing in installation position -Arrow A- and secure with the two fastening nuts -4- => Tightening torque: 4.5 ftlb..





9. Fasten air intake housing from the inside with the holders -Arrow B-.
10. Place support for DME control module in installation position -Arrow A- and screw down with fastening screw -2- and fastening nuts -3- => Tightening torque: 6 ftlb. => Tightening torque: 6 ftlb..





11. Place line in installation position -Arrow B- and close clip -Arrow C- until locking tabs are felt to engage.
12. Place lines with twist locks (to rear of DME control unit) -a- on the threaded bolts -arrow- and tighten with fastening nuts -1- => Tightening torque: 6.5 ftlb..





13. Install DME control module -> 247019 Removing and installing DME control module - section on "Installing" Service and Repair.
14. Install plenum panel at front right.
15. Connect plug connection (right of DME control module) -Arrows A- until locking tab -B- is felt to engage.





16. Push plug connection into clip -Arrow C- until locking tab -D- is felt to engage.
17. Place line (upper side member) in installation position -Arrows A- and close clips -Arrows B- until locking tabs are felt to engage.





18. Fit filler neck of reservoir for windscreen washer system -> 926019 Removing and installing reservoir for windscreen washer system - section on "Installing" Service and Repair.
19. Push connector onto coolant reservoir -Arrow B- until locking tabs -B- are felt to engage.





20. Push connector onto air flow sensor -Arrow A- until locking tab -B- is felt to engage.





21. Place line in installation position -Arrow C- and close clip -Arrow D- until locking tab is felt to engage.
22. Place line (wheel housing) in installation position -Arrow A- and close clips -Arrow B- until locking tabs are felt to engage.





23. Connect plug connection for ABS sensor and brake pad wear indicator -Arrow C- until locking tabs -D- are felt to engage.
24. Push on connector of lateral acceleration sensor (wheel housing) -Arrow A- until locking tab -B- is felt to engage.





25. Place line in installation position -Arrow C- and close clip -Arrow D- until locking tab is felt to engage.

Only for vehicles with automatic headlight levelling system





26. Push connector onto angle sensor (wheel suspension) -Arrow A- until locking tabs -B- are felt to engage.
27. Connect plug to washer-fluid reservoir -Arrows A- until locking lug -B- is felt to engage.





28. Insert line into bracket -Arrow C-.
29. Push connector onto headlight housing -Arrow A- until locking tab -B- is felt to engage.





30. Place lines in installation position -Arrows C- and close clips -Arrows D- until locking tabs are felt to engage.
31. Push connector onto airbag sensor -Arrow A- until the latch is felt to engage.





32. Push line and holder onto lock carrier -Arrow B-.

Fit front apron -> 631519 Removing and installing front apron - section on "Installing" .
33. Connect plug connection to front apron -Arrows A- until locking tab -B- is felt to engage.





34. Place line in installation position -Arrow C- and close clip -Arrow D- until locking tab is felt to engage.
35. Fit ground straps together with twist lock -a- on the threaded bolt (front side member) -Arrow E- and secure with fastening nut -1- => Tightening torque: 6.5 ftlb..

Only for vehicles with tyre pressure monitoring system





36. Push connector onto antenna for tyre pressure monitoring system (wheel housing) -Arrow A- until locking tab -B- is felt to engage.

Install front right main headlight -> 941519 Removing and installing main headlight - section on "Installing" 94151900 Removing and installing main headlights

Install right front wheel housing liner -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair.

Installing main wiring harness - engine compartment in centre

1. Push line through from passenger compartment to engine compartment -Arrow A- until rubber sleeve is felt to engage in firewall -B-.





2. Place line in installation position -Arrow C- and close clip -Arrow D- until locking tabs are felt to engage.

Information

- Before fastening the line to the brake booster, the pressure sensor connector must be connected due to the restricted access.





3. Push connector (brake assist system) onto pressure sensor until locking tab is felt to engage.
4. Turn the line in front of the brake master cylinder to the right and place in the installation position.
5. Place line in the holders -Arrows A- and close them -Arrows B- until locking tabs are felt to engage.





6. Place line in installation position -Arrow C- and close clips -Arrows D- until locking tabs are felt to engage.
7. Push connector onto switch-over valve for run-on pump -Arrow A- until locking tab -B- is felt to engage.





8. Push connector onto distance sensor (brake assist system) -Arrow A- until locking tab -B- is felt to engage.





9. Push connector onto brake assist system -Arrow A- until locking tab -B- is felt to engage.





10. Place line in installation position -Arrow A- and close clip -Arrow B- until locking tab is felt to engage.





11. Fit ground strap together with twist lock -a- on the threaded bolt -Arrow C- and secure with fastening nut -1- => Tightening torque: 6.5 ftlb..

Install front left plenum panel.

Install wiper motor -> 921519 Removing and installing wiper motor - section on "Installing" 921519 Removing and installing wiper motor.

Remove left and rear engine compartment covers -> 700219 Removing and installing front cover (engine compartment) - section on "Installing" .

Installing main wiring harness - engine compartment on left

1. Push line through from passenger compartment to engine compartment -Arrow A- until rubber sleeve is felt to engage in firewall -B-.





2. Fit ground strap (next to relay carrier in plenum panel E-box) together with twist lock -a- on the threaded bolt -Arrow C- and secure with fastening nut -1- => Tightening torque: 6.5 ftlb..
3. Place line (under relay carrier in plenum panel E-box) in installation position -Arrows A- and close clips -Arrows B-.





4. Push connector onto alarm siren -Arrows C- until locking tabs -D- are felt to engage.
5. Push connector onto left air flow sensor -Arrow A- until locking tabs -B- are felt to engage.





6. Connect line to threaded bolt (external power connection) -Arrow A- and tighten with the fastening nut -3- => Tightening torque: 6 ftlb..





7. Close cap -Arrow B-.
8. Connect line to threaded bolt -Arrow C- and tighten with the fastening nut -2- => Tightening torque: 6 ftlb..
9. Close cap -Arrow D-.
10. Place lines (upper side member) in installation position -Arrows A- and close clips -Arrows B- until locking tabs are felt to engage.





11. Fasten line with a new tie-wrap -C-.
12. Place line (under headlight mounting) in installation position -Arrows A- and close clips -Arrows B- until locking tabs are felt to engage.





13. Insert connector -Arrow C- until locking tab -D- is felt to engage.
14. Insert the two connectors (radiator) -Arrows A- until locking tabs -B- are felt to engage.





15. Place line in installation position -Arrows C- and close clips -Arrows D- until locking tabs are felt to engage.
16. Fit ground straps together with twist lock -a- on the threaded bolt (front side member) -Arrow E- and secure with fastening nut -1- => Tightening torque: 6.5 ftlb..
17. Clip in the socket (front cross member) -Arrow A-.





18. Insert connector -Arrow B- until locking tab -C- is felt to engage.
19. Fit ground straps together with twist lock -a- on the threaded bolt -Arrow D- and secure with fastening nut -1- => Tightening torque: 6.5 ftlb.. =>

Only for vehicles with automatic headlight levelling system





20. Push connector onto angle sensor (wheel suspension) -Arrow A- until locking tabs -B- are felt to engage.
21. Place line (wheel housing) in installation position -Arrow A- and close clips -Arrow B- until locking tabs are felt to engage.





22. Insert connector -Arrow C- until locking tab -D- is felt to engage.
23. Push on connector of lateral acceleration sensor (wheel housing) -Arrow A- until locking tab -B- is felt to engage.





24. Place line in installation position -Arrow C- and close clip -Arrow D- until locking tab is felt to engage.

Only in cars with additional heating
25. Push connector onto circulating pump -Arrow E- until locking tab -F- is felt to engage.
26. Place line to circulating pump in installation position -Arrow G- and close clips -Arrows H- until locking tabs are felt to engage.
27. Push connector onto airbag sensor -Arrow A- until the latch is felt to engage.





28. Push line and holder onto lock carrier -Arrow B-.
29. Insert bulb holder into the light (wheel housing) -Arrow A- with a slight turn.





Only for vehicles with tyre pressure monitoring system
30. Push connector onto antenna for tyre pressure monitoring system -Arrow B- until locking tab -C- is felt to engage.

Install front left main headlight -> 941519 Removing and installing main headlight - section on "Installing" 94151900 Removing and installing main headlights

Fit front apron -> 631519 Removing and installing front apron - section on "Installing" .

Install left front wheel housing liner -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair.