97090900 Loosening and securing main wire harness in engine compartment
WM 970909 Loosening and securing main wire harness in engine compartment
Information
The main wire harness is manufactured individually depending on equipment.
- Fastening elements may be different from the parts described.
- The number of plug connections can vary, depending on equipment.
Preliminary work
1. Disconnect the battery. -> 2X00IN Work instructions after disconnecting the battery - section on "Disconnecting" 2X00IN Work instructions after disconnecting the battery
2. Remove plenum panel cover. -> 852219 Removing and installing plenum panel cover - section on "Removing" 852219 Removing and installing plenum panel cover
3. Remove cross panel. -> 508119 Removing and installing cross panel (disassembling plenum panel) - section on "Removing and installing" Service and Repair
Preliminary work for main wire harness in plenum panel
1. Drain refrigerant. -> 870317 Draining and filling in refrigerant Service and Repair
2. Remove heat exchanger return hose. -> 803219 Removing and installing heat exchanger return hose - section on "Removing" 803219 Removing and installing heat exchanger return hose
3. Disconnect refrigerant hoses at the expansion valve. -> 877019 Removing and installing expansion valve - section on "Removing" Service and Repair
4. Remove DME control unit. -> 247019 Removing and installing DME control unit - section on "Removing" 247019 Removing and installing DME control unit
5. Remove directional-control valve. -> 827419 Removing and installing directional-control valve - section on "Removing" Service and Repair
6. Remove heat exchanger supply hose. -> 803019 Removing and installing heat exchanger supply hose - section on "Removing" 803019 Removing and installing heat exchanger supply hose
Preliminary work for main wire harness in left wheel housing
1. Remove main headlight at the left. -> 941519 Removing and installing main headlights - section on "Removing" 941519 Removing and installing main headlights
2. Remove front left wheel.-> 440519 Removing and installing wheel - section on "Removing" Removal and Replacement
3. Remove left front wheel housing liner -> 505619 Removing and installing front wheel housing liner - section on "Removing" Removal and Replacement
Preliminary work for main wire harness in right wheel housing
1. Remove main headlight at the right. -> 941519 Removing and installing main headlights - section on "Removing" 941519 Removing and installing main headlights
2. Remove right front wheel.-> 440519 Removing and installing wheel - section on "Removing" Removal and Replacement
3. Remove right front wheel housing liner -> 505619 Removing and installing front wheel housing liner - section on "Removing" Removal and Replacement
Loosening main wire harness in engine compartment
Main wire harness in engine compartment - installation position
NOTICE
Incorrect handling of main wire harness
- Risk of damage to lines
-> The main wire harness contains all airbag lines, antenna lines and optical waveguides.
-> The main wire harness must not be separated and is always replaced as a complete wire harness when carrying out extensive repairs.
-> If individual lines are damaged, shut off these lines and install new lines. Lay the new lines along the main wire harness and secure them to the main wire harness.
Installation position of main wire harness in engine compartment
Disconnecting main wire harness in plenum panel
1. Release and unplug electric plug connection -1- for the brake fluid reservoir -2-.
Connector for brake fluid reservoir
2. Release and unplug electric plug connection for ignition module for lid at the left and right. -> 696919 Removing and installing ignition module for lid - section on "Removing" 696919 Removing and installing ignition module for lid
3. Loosen fastening nuts for ground points -1- at the bulkhead in the plenum panel and remove supply line.
Ground point in plenum panel
4. Release and unplug electric plug connection for air quality sensor. -> 872219 Removing and installing air quality sensor - section on "Removing" Service and Repair
5. Release and unplug electric plug connection for the bonnet. -> 552219 Removing and installing front lid - section on "Removing" Removal and Replacement
6. Release and unplug electric plug connections -49- and -50- for the engine. -> 975219 Removing and installing wire harness for engine - section on "Disconnecting" 975219 Removing and installing wire harness for engine
Wire harness assignment (Turbo shown)
7. Make sure that all electric plug connections on the engine compartment wire harness in the centre at the plenum panel are released and unplugged.
8. Disconnect wire harness and pull it towards the passenger compartment. -> 97090903 Loosening and securing main wire harness under dashboard - section on "Loosening" 97090903 Loosening and securing main wire harness under dashboard
Loosening main wire harness in left wheel housing
1. Disconnect wire harness for starter and cooling fan at the B+ connection in the engine compartment. -> 974519 Removing and installing battery-starter wire harness - section on "Removing" 97451903 Removing and installing battery-starter wire harness (from external power connection to starter)
2. Release and unplug electric plug connection for oxygen sensor upstream of catalytic converter. -> 246919 Removing and installing oxygen sensor upstream of catalytic converter - section on "Removing" 246919 Removing and installing oxygen sensor upstream of catalytic converter
3. Release and unplug electric plug connection for oxygen sensor downstream of catalytic converter. -> 247319 Removing and installing oxygen sensor downstream of catalytic converter - section on "Removing" 247319 Removing and installing oxygen sensor downstream of catalytic converter
4. Disconnect electric plug connection for front shock absorber (spring damper). -> 408519 Removing and installing front spring strut - section on "Removing" 408519 Removing and installing front spring strut
5. Release and unplug electric plug connection for sensor for body (PASM). -> 433419 Removing and installing sensor for body - section on "Removing"
6. Release and unplug electric plug connection for electric fan for radiator. -> 190819 Removing and installing electric fan - section on "Removing" 190819 Removing and installing electric fan
7. Release and unplug electric plug connection for coolant temperature sensor. -> 197819 Removing and installing coolant temperature sensor - section on "Removing" Service and Repair
8. Release and unplug electric plug connection for air-conditioning pressure switch. -> 878319 Removing and installing pressure switch - section on "Removing" Service and Repair
9. Loosen fastening nut for ground point -1-.
Ground point for main wire harness at the left
10. Release and unplug electric plug connection (connection point for front-end wiring) for front-end wire harness. -> 971619 Removing and installing front-end wire harness - section on "Removing" 971619 Removing and installing wire harness for front-end
11. Release and unplug electric plug connection for airbag sensor on lock support. -> 695119 Removing and installing airbag sensor - section on "Removing" 695119 Removing and Installing Airbag Sensor
12. Release and unplug electric plug connection for level sensor. -> 431855 Replacing front level sensor - section on "Replacing" 431855 Replacing front level sensor
13. Release and unplug electric plug connection for wire harness for front ABS. -> 976519 Removing and installing wire harness for ABS - section on "Removing" 976519 Removing and installing wire harness for ABS (vehicle with PDCC)
14. Release and unplug electric plug connection for Tyre Pressure Monitoring (TPM) transmitter (trigger). -> 443619 Removing and installing TPM transmitter (trigger) - section on "Removing" 443619 Installing and removing TPM transmitter (trigger)
15. Release and unplug electric plug connection for auxiliary heating -1-.
Auxiliary heating connector
16. Release and unplug electric plug connection for circulating pump -1-.
Circulating pump connector
17. Release and unplug electric plug connection for clutch master cylinder. -> 275819 Removing and installing clutch interlock switch - section on "Removing" Service and Repair
18. Release and unplug electric plug connection for Servotronic steering gear -1-.
Steering gear connector
19. Disconnect wire harness in engine compartment at the front left.
Wire harness in engine compartment at the left
19.1. Loosen rubber sleeve -1- for wire harness in engine compartment on the left.
19.2. Make sure that all electric plug connections on the wire harness in the engine compartment on the left are released and unplugged.
19.3. Make sure that all brackets are unclipped and released.
19.4. Pull wire harness in the engine compartment on the left through the bulkhead from the passenger compartment.
-> 97090903 Loosening and securing main wire harness under dashboard - section on "Loosening" 97090903 Loosening and securing main wire harness under dashboard
Loosening main wire harness in right wheel housing
1. Release and unplug electric plug connection for hydraulic unit. -> 453019 Removing and installing hydraulic unit - section on "Removing" 453019 Removing and installing hydraulic unit
2. Release and unplug electric plug connection for oxygen sensor upstream of catalytic converter. -> 246919 Removing and installing oxygen sensor upstream of catalytic converter - section on "Removing" 246919 Removing and installing oxygen sensor upstream of catalytic converter
3. Release and unplug electric plug connection for oxygen sensor downstream of catalytic converter. -> 247319 Removing and installing oxygen sensor downstream of catalytic converter - section on "Removing" 247319 Removing and installing oxygen sensor downstream of catalytic converter
4. Disconnect electric plug connection for front shock absorber (spring damper). -> 408519 Removing and installing front spring strut - section on "Removing" 408519 Removing and installing front spring strut
5. Release and unplug electric plug connection for sensor for body (PASM). -> 433419 Removing and installing sensor for body - section on "Removing"
6. Release and unplug electric plug connection for front-end wire harness. -> 971619 Removing and installing front-end wire harness - section on "Removing" 971619 Removing and installing wire harness for front-end
7. Release and unplug electric plug connection for airbag sensor on lock support. -> 695119 Removing and installing airbag sensor - section on "Removing" 695119 Removing and Installing Airbag Sensor
8. Release and unplug electric plug connection for level sensor. -> 431855 Replacing front level sensor - section on "Replacing" 431855 Replacing front level sensor
9. Release and unplug electric plug connection for wire harness for front ABS. -> 976519 Removing and installing wire harness for ABS - section on "Removing" 976519 Removing and installing wire harness for ABS (vehicle with PDCC)
10. Loosen fastening nut for ground point at the wheel housing -1-.
Ground point at right wheel housing
11. Loosen fastening nut for ground point at the frame carrier -1-.
Ground point at right frame carrier
12. Release and unplug electric plug connection for Tyre Pressure Monitoring (TPM) transmitter (trigger). -> 443619 Removing and installing TPM transmitter (trigger) - section on "Removing" 443619 Installing and removing TPM transmitter (trigger)
13. Release and unplug electric plug connection for alarm system. -> 966519 Removing and installing alarm siren - section on "Removing" Service and Repair
14. Release and unplug electric plug connection for pump for windscreen washer system. -> 925619 Removing and installing pump for windscreen washer system - section on "Removing" Service and Repair
15. Release and unplug electric plug connection for sender for washer fluid-level indicator. -> 926719 Removing and installing sender for washer fluid-level indicator - section on "Removing" Service and Repair
16. Remove reservoir for windscreen washer system. -> 926019 Removing and installing reservoir for windscreen washer system - section on "Removing" Service and Repair
17. Release and unplug electric plug connection for pump for headlight cleaning system. -> 926019 Removing and installing reservoir for windscreen washer system - section on "Removing" Service and Repair
18. Release and unplug electric plug connection for TPM antenna. -> 443819 Removing and installing TPM antenna - section on "Removing" 443819 Removing and installing antenna for tyre pressure monitoring system
19. Loosen wire harness in engine compartment at the front right.
Wire harness in engine compartment at the right
19.1. Loosen rubber sleeve -1- for wire harness in engine compartment on the right.
19.2. Make sure that all electric plug connections on the wire harness in the engine compartment on the right are released and unplugged.
19.3. Make sure that all brackets are unclipped and released.
19.4. Pull wire harness in the engine compartment on the right through the bulkhead from the passenger compartment.
-> 97090903 Loosening and securing main wire harness under dashboard - section on "Loosening" 97090903 Loosening and securing main wire harness under dashboard
Securing main wire harness in engine compartment
1. Installation is performed in reverse order.
2. First lay the main wire harness loosely in the wheel housing and engine compartment, ensuring that it is positioned correctly.
3. Pull wire harnesses in the engine compartment through the relevant cut-outs.
4. Secure main wire harness and wires coming from it.
5. Plug in control units and electric plug connections until they engage securely.
6. Connect ground points.
Subsequent work
Subsequent work for main wire harness in plenum panel
1. Install heat exchanger supply hose. -> 803019 Removing and installing heat exchanger supply hose - section on "Installing" 803019 Removing and installing heat exchanger supply hose
2. Install directional-control valve. -> 827419 Removing and installing directional-control valve - section on "Installing" Service and Repair
3. Install DME control unit. -> 247019 Removing and installing DME control unit - section on "Installing" 247019 Removing and installing DME control unit
4. Fit refrigerant hoses at the expansion valve. -> 877019 Removing and installing expansion valve - section on "Installing" Service and Repair
5. Install heat exchanger return hose. -> 803219 Removing and installing heat exchanger return hose - section on "Installing" 803219 Removing and installing heat exchanger return hose
6. Fill in refrigerant. -> 870317 Draining and filling in refrigerant Service and Repair
Subsequent work for main wire harness in left wheel housing
1. Install left front wheel housing liners. -> 505619 Removing and installing front wheel housing liner - section on "Installing" Removal and Replacement
2. Fit front left wheel.-> 440519 Removing and installing wheel - section on "Installing" Removal and Replacement
3. Install main headlight at the left. -> 941519 Removing and installing main headlights - section on "Installing" 941519 Removing and installing main headlights
Subsequent work for main wire harness in right wheel housing
1. Install right front wheel housing liners. -> 505619 Removing and installing front wheel housing liner - section on "Installing" Removal and Replacement
2. Fit right front wheel. -> 440519 Removing and installing wheel - section on "Installing" Removal and Replacement
3. Install main headlight at the right. -> 941519 Removing and installing main headlights - section on "Installing" 941519 Removing and installing main headlights
Subsequent work
1. Install cross panel. -> 508119 Removing and installing cross panel (disassembling plenum panel) - section on "Installing" Service and Repair
2. Install plenum panel cover. -> 852219 Removing and installing plenum panel cover - section on "Installing" 852219 Removing and installing plenum panel cover
3. Connect the battery. -> 2X00IN Work instructions after disconnecting the battery - section on "Connecting" 2X00IN Work instructions after disconnecting the battery