975219 Removing and installing wire harness for engine
WM 975219 Removing and installing wire harness for engine
Technical values
Preliminary work
1. Remove rear wheels. -> 440519 Removing and installing wheel - section on "Removing" 44051900 Removing and installing wheel
2. Disconnect battery. -> 2706IN Working instructions after disconnecting the battery 2706IN00 Work instructions after disconnecting the battery
3. Remove rear cover. -> 519419 Removing and installing rear cover - section on "Removing" 519419 Removing and Installing Cover for Rear Underbody
4. Remove generator. -> 272219 Removing and installing generator - section on "Removing" Service and Repair
5. Remove intake-air distributor.
6. Remove rear luggage-compartment lining.
Removing wire harness for engine
Installation position of engine wire harness
Overview of plugs for engine wire harness
1. Release connectors on the six ignition coils -1 to 6- and pull them off. -> 287020 Removing and installing spark plug - section on "Removing" Service and Repair
2. Release connectors on the six fuel injectors -7 to 12- and pull them off. -> 244019 Removing and installing fuel injector - section on "Removing" Service and Repair
3. Release connectors on both knock sensors -15 and 16- and pull them off. -> 287219 Removing and installing knock sensor - section on "Removing" Service and Repair
4. Release connectors on both solenoid hydraulic valves (camshaft timing) -17 and 18- and pull them off. -> 153719 Removing and installing solenoid hydraulic valve (camshaft timing) - section on "Removing" Service and Repair
5. Release connectors on both solenoid hydraulic valves (valve lift control) -19 and 20- and pull them off.
6. Unscrew ground straps -22-.
Unscrewing ground straps on engine
6.1. Unscrew fastening screw and remove ground straps -22-.
7. Disconnect plug connection on speed sensor -23- and unscrew ground straps -21-.
Disconnecting plug connection on speed sensor
7.1. Pull plug connection -23- out of holder.
7.2. Release plug connection -23- and disconnect it -Arrows a-.
7.3. Unscrew fastening screw and remove ground straps -21-.
8. Release connector on electric fan -24- and pull it off. -> 190819 Removing and installing electric fan - section on "Removing"
9. Release connector on secondary air blower -25- and pull it off. -> 266519 Removing and installing secondary air pump - section on "Removing" Service and Repair
10. Release securing clip and pull off connector on tank vent -27-.
11. Release connector on oil temperature sensor -29- and pull it off.
12. Unscrew fastening nut of starter leads at terminal 30 and terminal 50 -30 and 31- and remove. -> 276019 Removing and installing starter - section on "Removing" Service and Repair
13. Pull off connector on pressure sensor -32-.
14. Release connector on engine temperature sensor -33- and pull it off.
15. Pull off connector on coolant temperature sensor -35-.
Removing connector on coolant temperature sensor
15.1. Open holder -Arrow B- and remove line.
15.2. Release connector on coolant temperature sensor -35- -Arrow a- and pull it off.
16. Disconnect plug connections for oxygen sensor ahead of catalytic converter -36 and 37-
17. Disconnect plug connections for oxygen sensor behind catalytic converter -38 and 39-. -> 247319 Removing and installing oxygen sensor behind catalytic converter - section on "Removing" 24732000 Removing and installing oxygen sensor behind catalytic converter
18. Release securing clip and pull off connector on intake-manifold change-over switch -41-.
19. Release connector on air flow sensor -42- and pull it off. -> 244519 Removing and installing air flow sensor - section on "Removing" Service and Repair
20. Release securing clip and pull off connector on coolant change-over valve -43-.
21. Release and pull off connector on reversing light switch -44-. -> 947219 Removing and installing reversing light switch - section on "Removing" Service and Repair
22. Release connector on coolant level indicator -45- and remove it.
23. Release and pull off connector on Tiptronic position switch -46- and Tiptronic control module -47-.
24. Release and disconnect plug connection for engine wire harness to rear wire harness -48-. -> 972519 Removing and installing rear wire harness - section on "Removing" 97251900 Removing and installing rear wire harness
25. Disconnect plug connections for engine wire harness to main wire harness rear left and right -49 and 50-.
Disconnecting plug connection for engine wire harness to rear wire harness
25.1. Release plug connections for engine wire harness to main wire harness rear left and right -Arrows A- and disconnect -Arrows B-.
26. Unscrew ground strap -51-.
Loosening ground point
26.1. Screw off fastening nut and remove ground strap.
27. Release and pull off connector on DME control module -52 to 54-. -> 247019 Removing and installing DME control module - section on "Removing" Service and Repair
28. Release and pull off connector on Tiptronic control module -55-. -> 373019 Removing and installing transmission control module - section on "Removing" 373019 Removing and installing Tiptronic control unit
Information
Only on the Cayman.
29. Unclip wire harness to Tiptronic control module and DME control module at the two holders in the area of the service flap.
Unclipping wire harness to Tiptronic control module and DME control module
30. Remove grommet -56- and pull through the engine wire harness in direction of engine compartment.
31. Unclip engine wire harness at the tie-wraps -57-.
31.1. Unclip tie-wrap on the secondary pump.
31.2. Unclip tie-wrap at the branch (throttle valve, secondary pump, coolant change-over valve).
31.3. Unclip tie-wrap at cable duct in area of grommet.
32. Remove cable duct on the left and right.
Removing cable duct on the left and right
32.1. Unscrew fastening screw of cable duct on the left and right -Arrow A-.
32.2. Unclip cable duct on the left and right -Arrow B-.
32.3. Remove cable duct on the left and right -Arrow C-.
33. Remove centre cable duct.
Removing cable duct
33.1. Unscrew fastening screws, unclip cable duct -arrow- and remove it.
34. Remove wire harness for engine.
Installing wire harness for engine
Overview of plugs for engine wire harness
1. Lay out wire harness for engine.
2. Install centre cable duct.
Installing cable duct
2.1. Clip in cable duct -arrow- and secure with the fastening screws. => Tightening torque: 10 Nm (7.5 ftlb.)
3. Install cable duct at left and right.
Installing cable duct at left and right
3.1. Position cable duct left and right -Arrow A- and clip in -Arrow B-.
3.2. Secure cable duct left and right with fastening screw -Arrow C-. => Tightening torque: 10 Nm (7.5 ftlb.)
4. Clip in engine wire harness at the tie-wraps -57-.
4.1. Clip in tie-wrap at cable duct in area of grommet.
4.2. Clip in tie-wrap at the branch (throttle valve, secondary pump, coolant change-over valve).
4.3. Clip in tie-wrap on the secondary pump.
5. Push through engine wire harness in direction of luggage compartment and fit grommet -56-.
Information
Only on the Cayman.
6. Clip in wire harness to Tiptronic control module and DME control module at the two holders in the area of the service flap.
Clipping in wire harness to Tiptronic control module and DME control module
7. Push on connector of Tiptronic control module -55- until it is felt to engage. -> 373019 Removing and installing transmission control module - section on "Installing" 373019 Removing and installing Tiptronic control unit
8. Push on connector of DME control module -52 to 54- until it is felt to engage. -> 247019 Removing and installing DME control module - section on "Installing" Service and Repair
9. Screw down ground strap -51-.
Securing ground point
9.1. Fit ground strap and secure with fastening nut. => Tightening torque: 9 Nm (6.5 ftlb.)
10. Connect plug connections for engine wire harness to main wire harness left and right -49 und 50-.
Connecting plug connection for engine wire harness to rear wire harness
10.1. Connect plug connections for engine wire harness to main wire harness left and right until they are felt to engage.
11. Connect plug connection for engine wire harness to rear wire harness -48- until it is felt to engage. -> 972519 Removing and installing rear wire harness - section on "Installing" 97251900 Removing and installing rear wire harness
12. Push on connector of Tiptronic position switch -46- and Tiptronic control module -47- until they are felt to engage. -> 373519 Removing and installing automatic transmission - section on "Installing" 37351900 Removing and installing automatic transmission
13. Push on connector of coolant level indicator -45- until it is felt to engage.
14. Push on connector for reversing light switch -44- until it is felt to engage. -> 947219 Removing and installing reversing light switch - section on "Installing" Service and Repair
15. Push on connector of intake-manifold change-over switch -43- until the securing clip is felt to engage.
16. Push on connector of air flow sensor -42- until it is felt to engage. -> 244519 Removing and installing air flow sensor - section on "Installing" Service and Repair
17. Push on connector of intake-manifold change-over switch -41- until the securing clip is felt to engage.
18. Connect plug connections for oxygen sensor behind catalytic converter -38 and 39-. -> 247319 Removing and installing oxygen sensor behind catalytic converter - section on "Installing" 24732000 Removing and installing oxygen sensor behind catalytic converter
19. Connect plug connections for oxygen sensor ahead of catalytic converter -36 and 37-.
20. Push on connector of coolant temperature sensor -35-.
Pushing on connector of coolant temperature sensor.
20.1. Push on connector of coolant temperature sensor -35- -Arrow A- until it is felt to engage.
20.2. Insert line into holder and close holder -Arrow B-.
21. Push on connector of engine temperature sensor -33- until it is felt to engage.
22. Push on connector of pressure sensor -32-.
23. Position starter lead for terminal 30 and terminal 50 -30 and 31- and secure with fastening nut. => Tightening torque: 18 Nm (13 ftlb.) => Tightening torque: 6.5 Nm (5.0 ftlb.) -> 276019 Removing and installing starter - section on "Installing" Service and Repair
24. Push on connector of oil temperature sensor -29- until it is felt to engage.
25. Push on connector of tank vent -27- until the securing clip is felt to engage.
26. Push on connector of secondary air blower -25- until it is felt to engage. -> 266519 Removing and installing secondary air pump - section on "Installing" Service and Repair
27. Push on connector of electric fan -24- until it is felt to engage. -> 190819 Removing and installing electric fan - section on "Installing"
28. Screw down ground straps -21- and connect plug connection of speed sensor -23-.
Connecting plug connection on speed sensor
28.1. Position ground straps -21- and screw down with the fastening screw. => Tightening torque: 10 Nm (7.5 ftlb.)
28.2. Push plug connection -23- together until it is felt to engage.
28.3. Push plug connection -23- into holder.
29. Screw down ground straps -22-.
Screwing down ground straps on engine
29.1. Position ground straps -22- and screw down with the fastening screw. => Tightening torque: 10 Nm (7.5 ftlb.)
30. Push on connectors of the two solenoid hydraulic valves (valve lift control) -19 to 20- until they are felt to engage.
31. Push on connectors of the two solenoid hydraulic valves (camshaft timing) -17 to 18- until they are felt to engage. -> 153719 Removing and installing solenoid hydraulic valve (camshaft timing) - section on "Installing" Service and Repair
32. Push on connectors of the two knock sensors -15 to 16- until they are felt to engage. -> 287219 Removing and installing knock sensor - section on "Installing" Service and Repair
33. Push on connectors of the six fuel injectors -7 to 12- until they are felt to engage. -> 244019 Removing and installing fuel injector - section on "Installing" Service and Repair
34. Push on connectors of the six ignition coils -1 to 6- until they are felt to engage. -> 287020 Removing and installing spark plug - section on "Installing" Service and Repair
Subsequent work
1. Install rear luggage-compartment lining.
2. Install intake-air distributor.
3. Install the generator. -> 272219 Removing and installing three-phase generator - section on "Installing" Service and Repair
4. Install rear cover. -> 519419 Removing and installing rear cover - section on "Installing" 519419 Removing and Installing Cover for Rear Underbody
5. Mount rear wheels. -> 440519 Removing and installing wheel - section on "Installing" 44051900 Removing and installing wheel
6. Carry out work instruction after disconnecting the battery. -> 2706IN Work instructions after disconnecting the battery 2706IN00 Work instructions after disconnecting the battery