Removing and Installing Wire Harness For Engine

Removing And Installing Wire Harness For Engine

Technical values







Preliminary work
1. Place protective covers on the vehicle to avoid damaging the body and passenger compartment.
2. Disconnect the battery.
3. Remove rear wall cover.
4. Remove rear luggage-compartment lining.
5. Remove DME control unit.
6. Remove intake-air distributor.
7. Remove rear wheels.
8. Remove rear cover.

Removing wire harness for engine












1. Release plugs on the six ignition coils -1 bis 6- and pull them off.
2. Release plugs on the six fuel injectors -7 bis 12- and pull them off.
3. Unscrew ground straps on the six ignition coils -13 bis 18-.







3.1. Unscrew and remove ground strap -1-.

4. Release and pull off connectors on the two hall senders -19 and 20-.
5. Release plugs on both solenoid hydraulic valves (valve lift control) -21 and 22- and pull them off.
6. Release plugs on both solenoid hydraulic valves (camshaft timing) -23 and 24- and pull them off.
7. Release connectors on both knock sensors -25 and 26- and pull them off.
8. Release connector on coolant temperature sensor -27- and pull it off.
9. Unscrew fastening nut of starter leads at terminal 30 and terminal 50 -28 and 29- and remove.
10. Loosen junction point for terminal 30 line in the engine compartment.
10.1. Unscrew both fastening screws -1-.







10.2. Remove transfer point at line terminal 30 together with the two spacer sleeves -2- and place to one side with the lines connected.

11. Pull off positive crankcase ventilation hose at the oil filler neck.
11.1. Release plug-in coupling -arrow- and pull off plug.







11.2 Lay positive crankcase ventilation hose aside.

12. Release air-conditioning compressor plug connection -30- and disconnect it.







12.1. Unclip the line fort he air-conditioning compressor at the starter wire harness -arrows-.

13. Disconnect plug connections at generator -32-.
14. Release connector on engine temperature sensor -33- and pull it off.
15. Release tank vent plug connection -34- and remove it.
16. Release connector on air flow sensor -35- and pull it off.
17. Release connector on oil temperature sensor -36- and pull it off.
18. Release and pull off connector on oil pressure regulating valve -37-.







18.1. Release line from water hose -arrow-.

19. Disconnect plug connection on speed sender -38-.







19.1. Remove speed sender plug connection from cable duct -arrow A-.
19.2. Release speed sender plug connection -arrow B- and disconnect -arrows C-.

20. Release connector at oil level sender -39- and pull it off.







20.1. Release connector at oil level sender -arrow A- and pull it off -arrow B-.
20.2. Unclip the line at the two clips on the oil pan -arrows C-.

21. Disconnect plug connections for oxygen sensor ahead of catalytic converter -40 and 41-.







21.1. Open holder and remove lines from holders -arrows-.

22. Disconnect plug connections for oxygen sensor after catalytic converter -42 and 43-.







22.1. Open holder and remove lines from holders -arrows-

23. Release connector on secondary air blower -44- and pull it off.
24. Release sports exhaust system connector -45- and remove it.
25. Release securing clip and pull off connector on intake-manifold flap -46-.
26. Release securing clip and pull off connector on intake-manifold switchover -47-.
27. Release connector on coolant level indicator sensor -48- and pull it off.
28. Release and pull off connector for engine compartment -49-.
29. Release securing clip and pull off connector on coolant change-over valve -50-.







30. Unclip cable duct on left and right fuel collection pipe -arrows-

31. Open connector on PDK transmission -51 and 52- anti-clockwise and pull off.







31.1. Pull line on the four line holders off of the transmission -arrows-.

32. Release and pull off connector on DME control unit -53 bis 55-.







32.1. Unclip wire harness to the DME control unit at the line holder -arrow-.

33. Disconnect plug connections for engine wire harness to main wire harness -56 and 57-.







34. Unscrew ground strap -58-.
34.1. Screw off fastening nut and remove ground strap -arrow-.

35. Release connector at transmission control unit (PDK) -59- and pull it off.







35.1. Unclip wire harness to transmission control unit (PDK) at both line holders -arrows-.

36. Remove grommet -60- and pull through the engine wire harness in direction of engine compartment.







37. Removing wire harness for engine.
37.1. Unscrew fastening screw -1- of cable duct on the left and right.
37.2. Unclip cable duct on the left and right -arrows-.
37.3. Remove wire harness for engine.

Installing wire harness for engine












1. Installing wire harness for engine.
1.1. Lay out wire harness for engine.
1.2. Clip in cable duct at the left and right -arrows-.
1.3. Tighten fastening screw -1- at the cable duct at the left and right. - Tightening torque: 23 Nm

2. Pull through engine wire harness in direction of luggage compartment and fit grommet -60-.
3. Plug on connector at transmission control unit (PDK) -59- until it engages securely.







3.1. Clip in wire harness to transmission control unit (PDK) at both line holders -arrows-.







4. Screw down ground strap -58-.
4.1. Fit ground strap -arrow- and secure with fastening nut. - Tightening torque: 9 Nm (6.5 ftlb.)

5. Connect plug connections for wire harness from engine to main wire harness at rear -56 and 57- until they engage securely.
6. Push on connector of DME control module -53 bis 55- until it engages securely.







6.1. Clip on wire harness to the DME control unit at the line holder -arrow-.

7. Plug connector onto PDK transmission -51 and 52- and lock clockwise.







7.1. Lug line onto the four line holders off of the transmission -arrows-.







8. Clip on cable duct on left and right fuel collection -arrows-
9. Push on connector of intake-manifold change-over switch -50- until the securing clip is felt to engage.
10. Plug on connector on engine compartment fan -49- until it engages securely.
11. Plug on connector for coolant level indicator -48- until it engages securely.
12. Plug in connector on intake-manifold switchover -47- until the securing clip engages securely.
13. Plug in connector on intake-manifold flap -46- until the securing clip engages securely.
14. Plug in sports exhaust system connector -45- until it engages securely.
15. Connect plug on secondary air blower -44- until it engages firmly.

16. Connect plug connections for oxygen sensor behind catalytic converter -42 and 43- until the plug connections engage securely.







16.1. Insert lines into holder and close holder -arrows-.

17. Connect plug connections for oxygen sensor in front of catalytic converter -40 and 41- until the plug connections engage securely.







17.1. Insert lines into holder and close holder -arrows-.

18. Plug on connector at oil level sender -39-.







18.1. Unclip the line with the two clips on the oil pan -arrows A-.
18.2. Plug on the connector at the oil level sender until it is felt to engage -arrow B-.

19. Plug on plug connection on speed sender -38-.







19.1. Push the speed sensor plug connection -arrow A- together until it engages securely.
19.2. Push plug connection for speed sender into the cable duct -arrow B-.

20. Plug in connector on oil pressure regulating valve -37- until the connector engages securely.







20.1. Fix line on water hose -arrow-.

21. Push on connector of oil temperature sensor -36- until it is felt to engage.
22. Plug in connector on mass air flow meter -35- until it engages securely.
23. Plug on the plug connection of the tank vent -34- until it engages securely.
24. Plug on connector of engine temperature sensor -33- until it engages securely.
25. Establish plug connections at generator -32-.

26. Connect the plug connection at the air-conditioing compressor -30- until it engages securely.







26.1. Clip on the line for the air-conditioning compressor at the starter wire harness -arrows-.

27. Fix hose for crankcase ventilation at oil filler neck.
27.1. Plug hose for crankcase ventilation onto the oil filler neck.







27.2. Connect plug-in coupling -arrow- until it clicks into place.

28. Fix transfer point, lead to terminal 30 in engine compartment.
28.1. Position transfer point, lead to terminal 30, in installation position.
28.2. Insert both spacer sleeves -2-.







28.3. Fix both fastening nuts -1-. - Contact force: 10 Nm

29. Position starter lead -28 and 29- for terminal 30 and terminal 50 and secure with fastening nut. - Tightening torque: 18 Nm (13 ftlb.). - Tightening torque: 6.5 Nm (5.0 ftlb.)
30. Plug on connector at coolant temperature sensor -27- until it engages securely.
31. Push on connectors of the two knock sensors -25 and 26- until they are felt to engage.
32. Push on connectors of the two solenoid hydraulic valves (camshaft timing -23 and 24- until they are felt to engage.
33. Push on connectors of the two solenoid hydraulic valves (VHS) -21 and 22- until they are felt to engage.
34. Push on connectors of the two hall senders -19 and 20- until they are felt to engage.
35. Fix ground straps on the six ignition coils -13 bis 18-.







35.1. Position ground straps -1- and screw down with the fastening screw. - Tightening torque: 9 Nm

36. Push on connectors of the six fuel injectors -7 bis 12- until they are felt to engage.
37. Push on connectors of the six injector coils -1 bis 6- until they are felt to engage.

Subsequent work
1. Install rear cover.
2. fit rear wheels.
3. Install intake-air distributor.
4. Install rear wall cover.
5. Install DME control unit.
6. Install rear luggage-compartment lining.
7. Carry out work instructions after disconnecting the battery.