Part 2

WM 970955 Replacing wire harness in engine compartment

Installing wire harness in engine compartment





Connector overview for wire harness in engine compartment





1. Install main wire harness - dashboard area and centre console. -> 970919 Removing and installing main wire harness - section on "Installing" 970919 Removing and Installing Main Wiring Harness
2. Fit rubber sleeve -42- on the centre firewall.
2.1. Push wire harness through from the interior towards the engine compartment and fit rubber sleeve on the centre firewall -arrow A-.
2.2. Clip in wire harness on centre firewall with the retaining clip -arrow B-.





Fitting rubber sleeve on centre firewall

3. Secure wire harness on the centre firewall.
3.1. Insert wire harness into the two supports -arrows A- and close the supports -arrows B-.
3.2. Insert line into the two retaining clips -arrows C- and close the retaining clips -arrows D-.





Securing wire harness on the centre firewall

4. Plug in pressure sensor connector (brake assist system) -41-.





Plugging in pressure sensor connector (brake assist system)

4.1. Plug in connector on pressure sensor (brake assist system) -arrow- until it engages securely.
5. Plug in connector on way-sensor (brake assist system) -40-.





Plugging in connector on way-sensor (brake assist system)

5.1. Plug in connector on way-sensor (brake assist system) -arrow- until it engages securely.
6. Plug in connector on brake booster -39-.





Plugging in connector on brake booster

6.1. Plug in connector on brake booster -arrow- until it engages securely.
7. Plug in connector on brake fluid reservoir -38-.





Plugging in connector on brake fluid reservoir

7.1. Plug in connector on brake fluid reservoir -arrow- until it engages securely.
8. Screw on ground strap -35- on centre firewall.





Securing ground strap on centre firewall

8.1. Clip in wire harness on firewall with the retaining clip -arrow A-.
8.2. Connect ground strap together with the twist lock to the threaded bolt on the centre firewall -arrow B- and secure with fastening nut. => Tightening torque: 9 Nm (6.5 ftlb.)
9. Fit rubber sleeve -34- and plug in connector on hydraulic unit -33-.





Plugging in connector on hydraulic unit

9.1. Push front right wire harness through from the interior towards the engine compartment and fit rubber sleeve on the right firewall -arrow A-.
9.2. Route wire harness in plenum panel and clip it in at the retaining clips -arrows B-.
9.3. Plug in connector on hydraulic unit -arrow C- and lock it -arrow D- until the locking mechanism engages securely.
10. Press rubber sleeve into the bulkhead -arrow A- and clip in wire harness with the retaining clips -arrow B-.





Pressing rubber sleeve into bulkhead

11. Screw on ground strap for right firewall -32-.





Securing ground strap

11.1. Connect ground strap together with the twist lock to the threaded bolt on the right firewall -arrow- and secure it with the fastening nut. => Tightening torque: 9 Nm (6.5 ftlb.)
12. Clip in wire harness on the upper side member with the retaining clips -arrow-.





Clipping in wire harness on upper side member

13. Fit rubber sleeve -31- on the left firewall.
13.1. Push front left wire harness through from the interior towards the engine compartment and fit rubber sleeve on the left firewall -arrow-.





Fitting rubber sleeve on the left firewall

14. Route wire harness in plenum panel and clip it in at the retaining clips -arrows-.





Clipping in wire harness in plenum panel

15. Press rubber sleeve into bulkhead -arrow-.





Pressing rubber sleeve into bulkhead

16. Secure wire harness on upper right side member.
16.1. Route wire harness and clip it in at the retaining clips -arrows A-.
16.2. Push wire harness on upper side member onto the clips -arrows B-.





Securing wire harness on upper right side member

17. Secure wire harness on upper left side member.
17.1. Route wire harness and clip it in at the retaining clips -arrows A-.
17.2. Push wire harness on upper side member onto the clips -arrows B-.





Securing wire harness on upper left side member

18. Plug in connector on right lateral acceleration sensor -25-.





Plugging in connector on right lateral acceleration sensor

18.1. Plug in connector on lateral acceleration sensor in right wheel housing -arrow A- until the connector engages securely.
18.2. Route wire harness and clip it in on the wheel housing with the retaining clips -arrow B-.
19. Plug in connector on left lateral acceleration sensor -24- and circulating pump connector -23-.





Plugging in connector on left lateral acceleration sensor

19.1. Plug in connector on lateral acceleration sensor in left wheel housing -arrow A- until the connector engages securely.
19.2. Plug in connector on circulating pump -arrow B- until the connector engages securely.
19.3. Route wire harness and clip it in on the left wheel housing with the three retaining clips -arrows C-.
20. Connect plug connection for ABS sensor and brake pad wear indicator at the left and right -21 and 22-.





Connecting plug connection for ABS sensor and brake pad wear indicator

20.1. Route wire harness and clip it in on the left and right wheel housing with the retaining clips -arrow A-.
20.2. Clip in connector socket for ABS sensor and brake pad wear indicator -arrow B-.
20.3. Connect plug connection for ABS sensor and brake pad wear indicator -arrow C- until the plug connection engages securely.
21. Connect plug connection on tank for windscreen washer system -20- until the plug connection engages securely. -> 92601900 Removing and installing tank for windscreen washer system - section on "Installing" Service and Repair
22. Plug in connector for additional heating -19- until it engages securely. -> 822019 Removing and installing complete heater - section on "Installing" 822019 Removing and installing complete heater
23. Plug in connector on servo valve -18- until it engages securely.





Plugging in connector on servo valve

24. Plug in connector on angle sensor for headlight levelling system at the left and right -16 and 17-.





Plugging in connector on angle sensor for headlight levelling system

24.1. Plug in connectors on angle sensor for headlight levelling system -arrow A- until the connectors engage securely.
24.2. Secure wire harness on the left side to the refrigerant line with a new tie-wrap -arrow B-.
25. Plug in connector on TPM transmitter (trigger) -14 and 15- until it engages securely. -> 44361900 Removing and installing transmitter (trigger) for Tire Pressure Monitoring system (TPM) - section on "Installing" 44361900 Removing and Installing Transmitter (Trigger) For Tire Pressure Monitoring (TPM)
26. Clip in wire harness at the retaining clips close to the mounting for the right headlight -arrows-.





Clipping in wire harness close to mounting for right headlight

27. Clip in wire harness at the retaining clips close to the mounting for the left headlight -arrows-.





Clipping in wire harness close to mounting for left headlight

28. Secure ground strap for front right cross member -7-.





Securing ground strap for front right cross member

28.1. Route wire harness and clip it in on the front side member with the retaining clips -arrow A-.
28.2. Push ground straps together with the twist lock onto the threaded bolt on the front side member -arrow B- and screw on the fastening nut. => Tightening torque: 9 Nm (6.5 ftlb.)
29. Connect plug connection for front wire harness -5- and secure ground strap for front cross member -6-.





Connecting plug connection for front wire harness

29.1. Clip connector socket for front wire harness in at the front of the left cross member -arrow A-.
29.2. Plug in connector -arrow B- until it engages securely.
29.3. Connect ground straps together with the twist lock to the threaded bolt -arrow C- and screw on the fastening nut. => Tightening torque: 9 Nm (6.5 ftlb.)
30. Plug in connectors -3 and 4- on fan.
30.1. Plug in connectors on fan -arrows A- until they engage securely.
30.2. Clip in wire harness at the retaining clips -arrows B-.
30.3. Connect ground straps together with the twist lock to the threaded bolt -arrow C- and screw on the fastening nut. => Tightening torque: 9 Nm (6.5 ftlb.)





Plugging in connectors on fan

31. Plug in connectors on airbag sensor at the left and right -1 and 2- until the connectors engage securely. -> 695119 Removing and installing airbag sensor - section on "Installing" 695119 Removing and installing airbag sensor
32. Install firewall at the left and right.





Installing firewall

32.1. Fit seal on the body and spray with silicon spray.
32.2. Fit firewall and position it correctly.
32.3. Screw in fastening screws -3-.=> Tightening torque: 9 Nm (6.5 ftlb.)
32.4. Clip in wire harness with the retaining clips -2-.
32.5. Connect oxygen sensor connectors -1- until they engage securely and clip oxygen sensor connectors into the support -1-. -> 246919 Removing and installing oxygen sensor ahead of catalytic converter - section on "Installing" 246919 Removing and installing oxygen sensors ahead of catalytic converter on DFI engines-> 247319 Removing and installing oxygen sensor behind catalytic converter - section on "Installing" 247319 Removing and installing oxygen sensor behind catalytic converter on DFI engines
32.6. Secure PDCC reservoir on the plenum panel.
33. Install intake manifold for heating/fresh-air unit.
33.1. Position intake manifold and secure with the fastening nuts -1-. => Tightening torque: 6 Nm (4.5 ftlb.)
33.2. Close retaining clips in the intake manifold -arrow A-.
33.3. Insert air inlet grille -arrow B-.
33.4. Clip in wire harness on the intake manifold -arrow C- and push in retaining clips for wire harness on the intake manifold -arrow D-.





Installing intake manifold on heating/fresh air unit

34. Install support for DME control unit.
34.1. Position support for DME control unit -arrow- and secure with the fastening nuts -3- and fastening screw -2-. => Tightening torque: 8 Nm (6.0 ftlb.) => Tightening torque: 8 Nm (6.0 ftlb.)





Installing support for DME control unit

34.2. Insert wire harness for DME control unit into the retaining clips -arrow A- and close the retaining clips -arrow B-.
34.3. Fit ground straps together with the twist lock to the stud and secure with the fastening nut -1-. => Tightening torque: 9 Nm (6.5 ftlb.)





Securing ground straps

Subsequent work

1. Install relay carrier in plenum chamber E-box. -> 979019 Removing and installing relay carrier in plenum panel E-box - section on "Installing" 979019 Removing and Installing Relay Carrier, Plenum Chamber E-Box
2. Install wiper motor. -> 921519 Removing and installing wiper motor - section on "Installing" 921519 Removing and installing wiper motor
3. Install DME control unit. -> 247019 Removing and installing DME control unit - section on "Installing" Service and Repair
4. Install filler neck on tank for windscreen washer system. -> 926019 Removing and installing tank for windscreen washer system - section on "Installing" Service and Repair
5. Install coolant reservoir. -> 194019 Removing and installing coolant reservoir - section on "Installing" Service and Repair
6. Install air cleaner housing. -> 242519 Removing and installing air cleaner housing - section on "Installing" Service and Repair
7. Install front apron. -> 631519 Removing and installing front apron - section on "Installing"
8. Install main headlight at the left and right. -> 941519 Removing and installing main headlight - section on "Installing" 94151900 Removing and installing main headlights
9. Install front wheel housing liner at the left and right. -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair
10. Install linings in engine compartment. -> 700219 Removing and installing front cover (engine compartment) - section on "Installing" 700219 Removing and installing front trim (engine compartment)
11. Carry out work instructions after disconnecting the battery. -> 2706IN Work instructions after disconnecting the battery Procedures