Sub-Part - Replacing Wire Harness In Engine Compartment At the Front Right

Sub-part - replacing wire harness in engine compartment at the front right

Preliminary work
1. Disconnect battery.
2. Remove the carrier for the instrument panel.
3. Remove heater/air-conditioning unit.
4. Remove linings in engine compartment.
5. Remove front right wheel housing liner.
6. Remove main headlight.
7. Remove front apron.
8. Remove air cleaner housing.
9. Remove coolant expansion tank.
10. Remove filler neck on tank for windscreen washer system.
11. Remove DME control unit.
12. Remove cowl panel cover.

Sub-part - removing wire harness in engine compartment at the front right












1. Remove fabric tape and tie-wraps in area -a- (above cut-out for fresh-air intake system for heater/air-conditioning unit) and expose the remaining lines.

INFORMATION: When cutting the front wire harness, make sure there is enough length of cable left to join to the new lines.

2. Cut off front right wire harness in area -b- (left, next to cut-out for fresh-air intake system for heater/air-conditioning unit).
3. Remove support for DME control unit.







3.1. Screw off fastening nut -1- and remove the ground straps together with the twist lock -arrow-.







3.2. Open retaining clip -arrow A- and remove wire harness for DME control unit -arrow B-.
3.3. Unscrew fastening screw -2- and the two fastening nuts -3- and remove support for DME control unit - arrow-.

4. Remove intake manifold for heater/air-conditioning unit.
4.1. Pull out retaining clip on wire harness at the intake manifold -arrow A- and unclip wire harness on the intake manifold -arrow B-.
4.2. Pull out air inlet grille -arrow C-.
4.3. Open retaining clips in the intake manifold -arrow D-.







4.4. Screw off fastening nuts -1- and remove intake manifold -arrow-.







5. Remove right firewall.
5.1. Remove oxygen sensor connector -1- from the support at the firewall and disconnect it.
5.2. Unclip wire harness at the retaining clip -2-.
5.3. Unscrew fastening screws -3- on the firewall.
5.4. Lift the firewall and seal up and off.

6. Release connector on airbag sensor at the right -1- and pull it off.







7. Loosen ground strap for front right cross member -2-.
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 clip -arrow B-.







8. Unclip wire harness at the retaining clips close to the mounting for the right headlight -arrows-.
9. Release connector on TPM transmitter (trigger) at the right -7- and pull it off.







10. Pull off connector on angle sensor for range adjustment -8-.
10.1. Release connector on angle sensor for range adjustment at the right wheel suspension -arrows A- and pull it off -arrow B-.

11. Release plug connection on tank for windscreen washer system -9- and disconnect it.







12. Pull off plug connection for ABS sensor and brake pad wear indicator on the right -10-.
12.1. Release plug connection for ABS sensor and brake pad wear indicator in the right wheel housing - arrow A- and pull it off -arrow B-.
12.2. Unclip connector socket for ABS sensor and brake pad wear indicator -arrow C-.
12.3. Unclip wire harness at the three retaining clips -arrow D-.







13. Pull off connector on right lateral acceleration sensor -11-.
13.1. Release connector on lateral acceleration sensor in the right wheel housing -arrow A- and pull it off - arrow B-.
13.2. Unclip wire harness at the retaining clip -arrow C-.

14. Loosen wire harness on upper right side member.
14.1. Pull wire harness on upper side member down out of the clips -arrows A-.







14.2. Unclip wire harness at the retaining clips -arrows B-.







15. Unclip wire harness with the retaining clip on the upper side member -arrow-.







16. Loosen ground strap for right firewall -13-.
16.1. Screw off fastening nut on the right firewall and remove ground strap together with the twist lock from the threaded bolt -arrow-.







17. Unclip wire harness at the retaining clip -arrow A- and remove rubber sleeve from the bulkhead -arrow B-.







18. Pull off connector on hydraulic unit -14- and remove rubber sleeve -15-.
18.1. Release connector on hydraulic unit -arrow A- and pull it off -arrow B-.
18.2. Unclip wire harness at the three retaining clips -arrows C-.
18.3. Remove rubber sleeve on the right firewall in direction of the engine compartment -arrow D- and remove the front right wire harness.

Subsequent work
1. Install cowl panel cover.
2. Install DME control unit.
3. Install filler neck on tank for windscreen washer system.
4. Install coolant expansion tank.
5. Install air cleaner housing.
6. Install front apron.
7. Install main headlight.
8. Install front right wheel housing liner.
9. Install linings in engine compartment.
10. Install heater/air-conditioning unit.
11. Install the carrier for the instrument panel.
12. Carry out work instructions after disconnecting the battery.