975219 Removing and installing wire harness for engine
WM 975219 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. -> 2X00IN02 Work instructions after disconnecting the battery Work Instructions After Disconnecting the Battery
3. Remove rear wall cover. -> 555919 Removing and installing rear wall cover - section on "Removing" Service and Repair
4. Remove rear luggage-compartment lining.
5. Remove DME control unit. -> 247019 Removing and installing DME control unit - section on "Removing" Service and Repair
6. Remove hood compartment lid and hinges.
7. Remove intake-air distributor. -> 244619 Removing and installing intake-air distributor - section on "Removing" Service and Repair
8. Remove rear wheels. -> 440519 Removing and installing wheel - section on "Removing" Removal and Replacement
9. Remove rear cover. -> 519419 Removing and installing rear cover - section on "Removing" 519419 Removing and Installing Cover for Rear Underbody
Removing wire harness for engine
Installation position of engine wire harness (2.9l)
Connector overview of engine wire harness (2.9l)
1. Release plugs on the six ignition coils -1 bis 6- and pull them off. -> 287020 Removing and installing spark plugs - section on "Removing" Service and Repair
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-.
Ignition coil ground straps
4. Release and pull off connectors on the two hall senders -19 und 20-.
5. Release plugs on both solenoid hydraulic valves (valve lift control) -21 und 22- and pull them off.
6. Release plugs on both solenoid hydraulic valves (camshaft timing) -23 und 24- and pull them off.
7. Release connectors on both knock sensors -25 und 26- and pull them off. -> 287219 Removing and installing knock sensor - section on "Removing" Service and Repair
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 und 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.
Loosening junction point for terminal 30 line in the engine compartment
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.
Pulling off positive crankcase ventilation hose at the oil filler neck
12. Release air-conditioning compressor plug connection -30- and disconnect it. -> 873419 Removing and installing air-conditioning compressor - section on "Removing" Service and Repair
12.1. Unclip the line fort he air-conditioning compressor at the starter wire harness -arrows-.
Release line for air-conditioning compressor
13. Disconnect plug connections at generator -32-. -> 272219 Removing and installing generator - section on "Removing" Service and Repair
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. -> 244519 Removing and installing mass air flow sensor - section on "Removing" Service and Repair
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-.
Release oil pressure control valve line
19. Disconnect plug connection on speed sender -38-.
19.1. Remove speed sender plug connection from cable duct -arrow A-.
Disconnect speed sender plug connection
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-.
Disconnect connector at oil level sender.
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 und 41-. -> 246919 Removing and installing oxygen sensor ahead of catalytic converter - section on "Removing" 246919 Removing and installing oxygen sensors upstream of catalytic converter
21.1. Open holder and remove lines from holders -arrows-.
Remove oxygen sensor ahead of catalytic converter
22. Disconnect plug connections for oxygen sensor after catalytic converter -42 und 43-. -> 247319 Removing and installing oxygen sensor after catalytic converter - section on "Removing" 247319 Removing and installing lambda sensors downstream of catalytic converter
22.1. Open holder and remove lines from holders -arrows-.
Remove oxygen sensor after catalytic converter
23. Release connector on secondary air blower -44- and pull it off. -> 266519 Removing and installing secondary air pump - section on "Removing" Service and Repair
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-.
Unclip cable duct on fuel collection pipe
31. Open connector on PDK transmission -51 und 52- anti-clockwise and pull off.
31.1. Pull line on the four line holders off of the transmission -arrows-.
Release wire harness on PDK transmission
32. Release and pull off connector on DME control unit -53 bis 55-. -> 247019 Removing and installing DME control unit - section on "Removing" Service and Repair
32.1. Unclip wire harness to the DME control unit at the line holder -arrow-.
Release wire harness to DME control unit
33. Disconnect plug connections for engine wire harness to main wire harness -56 and 57-.
34. Unscrew ground strap -58-.
Loosening ground point
34.1. Screw off fastening nut and remove ground strap -arrow-.
35. Release connector at transmission control unit (PDK) -59- and pull it off. -> 373019 Removing and installing transmission control unit (PDK) - section on "Removing" Service and Repair
35.1. Unclip wire harness to transmission control unit (PDK) at both line holders -arrows-.
Release wire harness to transmission control unit (PDK)
36. Remove grommet -60- and pull through the engine wire harness in direction of engine compartment.
37. Removing wire harness for engine.
Removing cable duct
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
Connector overview of engine wire harness (2.9l)
1. Installing wire harness for engine.
Installing cable duct
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. -> 373019 Removing and installing transmission control unit (PDK) - section on "Installing" Service and Repair
3.1. Clip in wire harness to transmission control unit (PDK) at both line holders -arrows-.
Fix wire harness to transmission control unit (PDK)
4. Screw down ground strap -58-.
Securing ground point
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 und 57- until they engage securely.
6. Push on connector of DME control module -53 bis 55- until it engages securely. -> 247019 Removing and installing DME control unit - section on "Installing" Service and Repair
6.1. Clip on wire harness to the DME control unit at the line holder -arrow-.
Fix wire harness to DME control unit
7. Plug connector onto PDK transmission -51 und 52- and lock clockwise.
7.1. Lug line onto the four line holders off of the transmission -arrows-.
Fix wire harness on PDK transmission
8. Clip on cable duct on left and right fuel collection -arrows-.
Clip on cable duct on fuel collection pipe
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. -> 266519 Removing and installing secondary air pump - section on "Installing" Service and Repair
16. Conenct plug connections for oxygen sensor behind catalytic converter -42 und 43- until the plug connections engage securely. -> 247319 Removing and installing oxygen sensor after catalytic converter - section on "Installing" 247319 Removing and installing lambda sensors downstream of catalytic converter
16.1. Insert lines into holder and close holder -arrows-.
Fix oxygen sensor behind catalytic converter
17. Connect plug connections for oxygen sensor in front of catalytic converter -40 und 41- until the plug connections engage securely. -> 246919 Removing and installing oxygen sensor in front of catalytic converter - section on "Installing" 246919 Removing and installing oxygen sensors upstream of catalytic converter
17.1. Insert lines into holder and close holder -arrows-.
Fix oxygen sensor in front of catalytic converter
18. Plug on connector at oil level sender -39-.
18.1. Unclip the line with the two clips on the oil pan -arrows A-.
Plug on connector at oil level sender.
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.
Connect plug connection on speed sender
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-.
Fix line on oil pressure regulating valve
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. -> 244519 Removing and installing mass air flow sensor - section on "Installing" Service and Repair
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-. -> 272219 Removing and installing new three-phase generator - section on "Installing" Service and Repair
26. Connect the plug connection at the air-conditioing compressor -30- until it engages securely. -> 873419 Removing and installing air-conditioning compressor - section on "Installing" Service and Repair
26.1. Clip on the line for the air-conditioning compressor at the starter wire harness -arrows-.
Fix line for air-conditioning compressor
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.
Connecting positive crankcase ventilation hose to the oil filler neck
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
Junction point for terminal 30 line in engine compartment
29. Position starter lead -28 und 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.) -> 276019 Removing and installing starter - section on "Installing"
30. Plug on connector at coolant temperature sensor -27- until it engages securely.
31. Push on connectors of the two knock sensors -25 und 26- until they are felt to engage. -> 287219 Removing and installing knock sensor - section on "Installing" Service and Repair
32. Push on connectors of the two solenoid hydraulic valves (camshaft timing -23 und 24- until they are felt to engage.
33. Push on connectors of the two solenoid hydraulic valves (VHS) -21 und 22- until they are felt to engage.
34. Push on connectors of the two hall senders -19 und 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
Ignition coil ground straps
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. -> 287020 Removing and installing spark plugs - section on "Installing" Service and Repair
Subsequent work
1. Install rear cover. -> 519419 Removing and installing rear cover - section on "Installing" 519419 Removing and Installing Cover for Rear Underbody
2. fit rear wheels. -> 440519 Removing and installing wheel - section on "Installing" Removal and Replacement
3. Install intake-air distributor. -> 244619 Removing and installing intake-air distributor - section on "Installing" Service and Repair
4. Install hood compartment lid and hinges.
5. Install rear wall cover. -> 555919 Removing and installing rear wall cover - section on "Installing" Service and Repair
6. Install DME control unit. -> 247019 Removing and installing DME control unit - section on "Installing" Service and Repair
7. Install rear luggage-compartment lining.
8. Carry out work instructions after disconnecting the battery. -> 2X00IN02 Work instructions after disconnecting the battery Work Instructions After Disconnecting the Battery