Part 1
WM 970955 Replacing wire harness in engine compartment
Technical values
Preliminary work
1. Disconnect battery. -> 2706IN Work instructions after disconnecting the battery Procedures
2. Remove linings in engine compartment. -> 700219 Removing and installing front cover (engine compartment) - section on "Removing" 700219 Removing and installing front trim (engine compartment)
3. Remove front wheel housing liners on the left and right. -> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair
4. Remove main headlight at the left and right. -> 941519 Removing and installing main headlight - section on "Removing" 94151900 Removing and installing main headlights
5. Remove front apron. -> 631519 Removing and installing front apron - section on "Removing"
6. Remove air cleaner housing. -> 242519 Removing and installing air cleaner housing - section on "Removing" Service and Repair
7. Remove coolant expansion tank. -> 194019 Removing and installing coolant expansion tank - section on "Removing" Service and Repair
8. Remove filler neck on tank for windscreen washer system. -> 926019 Removing and installing tank for windscreen washer system - section on "Removing" Service and Repair
9. Remove DME control unit. -> 247019 Removing and installing DME control unit - section on "Removing" Service and Repair
10. Remove wiper motor. -> 921519 Removing and installing wiper motor - section on "Removing" 921519 Removing and installing wiper motor
11. Remove relay carrier in plenum panel E-box. -> 979019 Removing and installing relay carrier in plenum panel E-box - section on "Removing" 979019 Removing and Installing Relay Carrier, Plenum Chamber E-Box
Removing wire harness in engine compartment
Installation position of wire harness in engine compartment
Connector overview for wire harness in engine compartment
Information
- The wire harness contains the airbag lines, antenna lines and optical waveguides.
- If individual lines are damaged, these must be "shut down" (disconnect wires, remove plug-in contacts from plug connections, etc.) and replaced by installing new lines along the original wire harness.
1. Remove support for DME control unit.
1.1. Screw off fastening nut -1- and remove the ground straps together with the twist lock.
Loosening ground straps
1.2. Open retaining clips -arrow A- and remove wire harness for DME control unit -arrow B-.
Removing support for DME control unit
1.3. Unscrew fastening screw -2- and the two fastening nuts -3- and remove support for DME control unit -arrow-.
2. Remove intake manifold for heating/fresh-air unit.
2.1. Pull out retaining clips on wire harness at the intake manifold -arrow A- and unclip wire harness on the intake manifold -arrow B-.
2.2. Pull out air inlet grille -arrow C-.
2.3. Open retaining clips in the intake manifold -arrow D-.
2.4. Screw off fastening nuts -1- and remove intake manifold -arrow-.
Removing intake manifold on heating/fresh air unit
3. Remove firewall at the left and right.
Removing firewall
3.1. Remove oxygen sensor connectors -1- from the support at the firewall and disconnect them. -> 246919 Removing and installing oxygen sensor ahead of catalytic converter - section on "Removing" 246919 Removing and installing oxygen sensors ahead of catalytic converter on DFI engines-> 247319 Removing and installing oxygen sensor behind catalytic converter - section on "Removing" 247319 Removing and installing oxygen sensor behind catalytic converter on DFI engines
3.2. Unclip wire harness at the retaining clips -2-.
3.3. Loosen PDCC reservoir at the firewall and set it aside.
3.4. Unscrew fastening screws -3- on the firewall.
3.5. Lift the firewall and seal up and off.
4. Release and pull off connector for airbag sensor at the left and right -1 and 2-. -> 695119 Removing and installing airbag sensor - section on "Removing" 695119 Removing and installing airbag sensor
5. Pull off connectors -3 and 4- on fan.
5.1. Unclip wire harness at the retaining clips -arrows A-.
5.2. Release connectors on fan -arrows B- and pull them off -arrows C-.
5.3. Screw off fastening nut and pull the ground straps together with the twist lock off the threaded bolt -arrow D-.
Pulling off connectors on fan
6. Pull off plug connection for front left wire harness -5- and loosen ground strap for front left cross member -6-.
Disconnecting plug connection for front wire harness
6.1. Release plug connection for front wire harness on the left cross member at the front -arrow A- and pull off connector -arrow B-.
6.2. Unclip connector socket -arrow C-.
6.3. Screw off fastening nut and pull the ground straps together with the twist lock off the threaded bolt -arrow D-.
7. Loosen ground strap for front right cross member -7-.
Loosening ground strap for front right cross member
7.1. Screw off fastening nut on front cross member and remove ground straps together with the twist lock from the threaded bolt -arrow A-.
7.2. Unclip wire harness at the retaining clips -arrow B-.
8. Unclip wire harness at the retaining clips close to the mounting for the left headlight -arrows-.
Unclipping wire harness close to mounting for left headlight
9. Unclip wire harness at the retaining clips close to the mounting for the right headlight -arrows-.
Unclipping wire harness close to mounting for right headlight
10. Release connector on TPM transmitter (trigger) -14 and 15- and pull it off. -> 44361900 Removing and installing transmitter (trigger) for Tire Pressure Monitoring system (TPM) - section on "Removing" 44361900 Removing and Installing Transmitter (Trigger) For Tire Pressure Monitoring (TPM)
11. Pull off connector on angle sensor for headlight levelling system at the left and right -16 and 17-.
Pulling off connector on angle sensor for headlight levelling system
11.1. Release connector on angle sensor for headlight levelling system at the left and right -arrows A- and pull it off -arrow B-.
11.2. Remove tie-wrap on the left side for fixing the wire harness in place on the refrigerant line -arrow C-.
12. Pull off connector on servo valve -18-.
Pulling off connector on servo valve
12.1. Release connector on servo valve -arrow A- and pull it off -arrow B-.
13. Release connector for additional heating -19- and pull it off. -> 822019 Removing and installing complete heater - section on "Removing" 822019 Removing and installing complete heater
14. Release plug connection on tank for windscreen washer system -20- and disconnect it. -> 92601900 Removing and installing tank for windscreen washer system - section on "Removing" Service and Repair
15. Pull off plug connection for ABS sensor and brake pad wear indicator at the left and right -21 and 22-.
Pulling off plug connection for ABS sensor and brake pad wear indicator
15.1. Release plug connection for ABS sensor and brake pad wear indicator in the left and right wheel housing -arrow A- and pull it off -arrow B-.
15.2. Unclip connector socket for ABS sensor and brake pad wear indicator -arrow C-.
15.3. Unclip wire harness at the three retaining clips on the left and right -arrow D-.
16. Pull off connector on left lateral acceleration sensor -24- and circulating pump connector -23-.
Pulling off connector on lateral acceleration sensor
16.1. Release connector on lateral acceleration sensor in the left wheel housing -arrow A- and pull it off -arrow B-.
16.2. Release connector on circulating pump -arrow C- and pull it off -arrow D-.
16.3. Unclip wire harness at the retaining clips -arrows E-.
17. Pull off connector on right lateral acceleration sensor -25-.
Pulling off connector on lateral acceleration sensor
17.1. Release connector on lateral acceleration sensor in the right wheel housing -arrow A- and pull it off -arrow B-.
17.2. Unclip wire harness at the retaining clips -arrow C-.
18. Loosen wire harness on upper left side member.
18.1. Pull wire harness on upper side member down out of the clips -arrows A-.
18.2. Unclip wire harness at the retaining clips -arrows B-.
Loosening wire harness on upper left side member
19. Loosen wire harness on upper right side member.
19.1. Pull wire harness on upper side member down out of the clips -arrows A-.
19.2. Unclip wire harness at the retaining clips -arrows B-.
Loosening wire harness on upper right side member
20. Remove rubber sleeve from the bulkhead -arrow-.
Removing rubber sleeve from the bulkhead
21. Unclip wire harness in plenum panel at the retaining clips -arrows-.
Unclipping wire harness in plenum panel
22. Remove rubber sleeve -31- on the left firewall.
22.1. Remove rubber sleeve on the left firewall in direction of the interior -arrow- and remove the front left wire harness.
Removing rubber sleeve on the left firewall
23. Unclip wire harness with the retaining clips on the upper side member -arrow-.
Unclipping wire harness on upper side member
24. Loosen ground strap for right firewall -32-.
Loosening ground strap
24.1. Screw off fastening nut on the right firewall and remove ground strap together with the twist lock from the threaded bolt -arrow-.
25. Unclip wire harness at the retaining clips -arrow A- and remove rubber sleeve from the bulkhead -arrow B-.
Removing rubber sleeve from the bulkhead
26. Pull off connector on hydraulic unit -33- and remove rubber sleeve -34-.
Pulling off connector on hydraulic unit
26.1. Release connector on hydraulic unit -arrow A- and pull it off -arrow B-.
26.2. Unclip wire harness at the retaining clips -arrows C-.
26.3. Remove rubber sleeve on the right firewall in direction of the interior -arrow D- and remove front right wire harness.
27. Screw off ground strap -35- on the centre firewall.
Removing ground strap on the centre firewall
27.1. Screw off the fastening nut on the centre firewall and remove the ground strap with the twist lock -arrow A-.
27.2. Unclip wire harness at the retaining clips -arrow B-.
28. Pull off connector on brake fluid reservoir -38-.
Pulling off connector on brake fluid reservoir
28.1. Release connector on brake fluid reservoir -arrow A- and pull it off -arrow B-.
29. Pull off connector on brake booster -39-.
Pulling off connector on brake booster
29.1. Release connector on brake booster using a suitable aid (e.g. angled piece of wire) -a- ( -arrow A- ) and pull it off -arrow B-.
30. Pull off way-sensor connector (brake assist system) -40-.
Pulling off way-sensor connector (brake assist system)
30.1. Release way-sensor connector (brake assist system) using a suitable aid (e.g. angled piece of wire) -a- ( -arrow A- ) and pull it off -arrow B-.
31. Pull off pressure sensor connector (brake assist system) -41-.
Pulling off pressure sensor connector (brake assist system)
31.1. Release pressure sensor connector (brake assist system) using a suitable aid (e.g. angled piece of wire) -a- ( -arrow A- ) and pull it off -arrow B-.
32. Loosen wire harness on the centre firewall.
32.1. Open retaining clips -arrows A- and remove the line -arrow B-.
32.2. Open both supports (brake assist system) -arrows C- and remove wire harness -arrow D-.
Removing wire harness on the centre firewall
33. Remove rubber sleeve -42- on the centre firewall.
Removing rubber sleeve on the centre firewall
33.1. Unclip wire harness from the centre firewall at the retaining clips -arrow A-.
33.2. Remove rubber sleeve on the centre firewall in direction of the interior -arrow B- and remove wire harness.
34. Remove main wire harness - dashboard area and centre console. -> 970919 Removing and installing main wire harness - section on "Removing" 970919 Removing and Installing Main Wiring Harness.