Replacing Wire Harness In Engine Compartment

Replacing Wire Harness In Engine Compartment


Technical Values







Preliminary Work
1. Disconnect battery.
2. Remove linings in engine compartment.
3. Remove front wheel housing liners on the left and right.
4. Remove main headlight at the left and right.
5. Remove front apron.
6. Remove air cleaner housing.
7. Remove coolant expansion tank.
8. Remove filler neck on tank for windscreen washer system.
9. Remove DME control unit.
10. Remove wiper motor.
11. Remove relay carrier in plenum panel E-box.

Removing 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.







1.2. Open retaining clips -arrow A- and remove wire harness for DME control unit -arrow B-.
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-.







3. Remove firewall at the left and right.
3.1. Remove oxygen sensor connectors -1- from the support at the firewall and disconnect them.
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-.
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-.







6. Pull off plug connection for front left wire harness -5- and loosen ground strap for front left cross member -6-.
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-.
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-.







9. Unclip wire harness at the retaining clips close to the mounting for the right headlight -arrows-.
10. Release connector on TPM transmitter (trigger) -14 and 15- and pull it off.







11. Pull off connector on angle sensor for headlight levelling system at the left and right -16 and 17-.
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-.
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.
14. Release plug connection on tank for windscreen washer system -20- and disconnect it.







15. Pull off plug connection for ABS sensor and brake pad wear indicator at the left and right -21 and 22-.
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-.
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-.
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-.

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-.







20. Remove rubber sleeve from the bulkhead -arrow-.







21. Unclip wire harness in plenum panel at the retaining clips -arrows-.
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.







23. Unclip wire harness with the retaining clips on the upper side member -arrow-.







24. Loosen ground strap for right firewall -32-.
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-.







26. Pull off connector on hydraulic unit -33- and remove rubber sleeve -34-.
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.
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-.
28.1. Release connector on brake fluid reservoir -arrow A- and pull it off -arrow B-.







29. Pull off connector on brake booster -39-.
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-.
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-.
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-.







33. Remove rubber sleeve -42- 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.

Installing Wire Harness In Engine Compartment







1. Install main wire harness - dashboard area and centre console.
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-.

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-.







4. Plug in pressure sensor connector (brake assist system) -41-.
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-.
5.1. Plug in connector on way-sensor (brake assist system) -arrow- until it engages securely.







6. Plug in connector on brake booster -39-.
6.1. Plug in connector on brake booster -arrow- until it engages securely.







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







8. Screw on ground strap -35- 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-.
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-.







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







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







15. Press rubber sleeve into bulkhead -arrow-.
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-.

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-.







18. Plug in connector on right lateral acceleration sensor -25-
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-.
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-.
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.
22. Plug in connector for additional heating -19- until it engages securely.







23. Plug in connector on servo valve -18- until it engages securely.







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







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







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







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

31. Plug in connectors on airbag sensor at the left and right -1 and 2- until the connectors engage securely.







32. Install firewall at the left and right.
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-.
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-.
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-.

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.)
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.)

Subsequent work
1. Install relay carrier in plenum chamber E-box.
2. Install wiper motor.
3. Install DME control unit.
4. Install filler neck on tank for windscreen washer system.
5. Install coolant reservoir.
6. Install air cleaner housing.
7. Install front apron.
8. Install main headlight at the left and right.
9. Install front wheel housing liner at the left and right.
10. Install linings in engine compartment.
11. Carry out work instructions after disconnecting the battery.