976555 Replacing wire harness for anti-lock brake system (ABS)
WM 976555 Replacing wire harness for anti-lock brake system (ABS)
Tools
Technical values
Preliminary work
Preliminary work on front ABS wire harness
1. Disconnect battery. -> 2706IN Working instructions after disconnecting the battery
2. Remove front wheel housing liner (rear section). -> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair
3. Remove plenum panel cover. -> 852219 Removing and installing cover - section on "Removing" 85221900 Removing and installing cover
Preliminary work on rear ABS wire harness
1. Disconnect battery. -> 2706IN Working instructions after disconnecting the battery
2. Remove rear wheel housing liner. -> 536919 Removing and installing rear wheel housing liner - section on "Removing"
3. Remove oddments tray.
Removing wire harness for anti-lock brake system (ABS)
Removing front ABS wire harness
Installation position for front ABS wire harness
1. Release the cable retainer -arrow A- and pull off the two connectors -arrow B-.
Disconnecting plug connection for front wheel sensor
2. Unscrew the fastening screw and remove the connector socket -arrow C-.
3. Remove the ABS wire harness from the brackets -arrows A-.
Removing the ABS wire harness from the brackets
4. Open the clips -arrows B- and remove the ABS wire harness -arrow C-.
5. Remove the fabric tape -D-.
Information
When cutting the ABS wire harness, make sure that there is enough line length left to join to the new lines.
6. Cut off the ABS wire harness around -E- and remove it.
7. Cut through the fabric tape in the plenum panel, in the area around -a- , and expose the remaining ABS lines.
Exposing ABS wire harness
Removing rear ABS wire harness
Installation position of rear ABS wire harness
1. Release the cable retainer -arrow A- and pull off the two connectors -arrow B-.
Disconnecting plug connection for rear wheel sensor
2. Unscrew the fastening screw and remove the connector socket -arrow C-.
3. Remove the ABS wire harness from the brackets -arrows A-.
Removing ABS wire harness from brackets
4. Open clip -arrow B- and remove ABS wire harness.
Information
When cutting the ABS wire harness make sure there is enough line length left in the interior to join to the new lines.
5. Cut off the ABS wire harness around -d- and press downward with the rubber sleeve -arrow C-.
6. Cut through the fabric tape at -e- and expose remaining ABS lines.
Information
Only for vehicles with TPM.
7. Cut through the rubber sleeve at the side of the TPM line -a- and remove the TPM line -arrow B-.
Cutting off rubber sleeve
Installing wire harness for anti-lock brake system (ABS)
Installing front ABS wire harness
1. Place socket in installation position -arrow A- and screw on the fastening screw. => Tightening torque: 10 Nm (7.5 ftlb.)
Connecting plug connection for front wheel sensor
2. Plug in the two connectors -arrow B-.
3. Fold back the cable retainer -arrow C- until it engages correctly at the connectors.
4. Press the ABS wire harness into the supports by pressing on the rubber sleeves -arrows A-.
Pressing ABS wire harness into supports
5. Secure line for headlight levelling system to the ABS wire harness using fabric tape -B-.
6. Place ABS wire harness in installation position -arrows C- and close clip -arrows D-.
7. Push through ABS wire harness to plenum panel -arrow-.
Routing and connecting ABS wire harness
Information
Select a place for the joint where there is enough space to join all the lines present.
Do not cut the lines too short in case they have to be laid in a different position if there is insufficient space in the area of the joint.
Information
The electric lines are located in the plenum panel and are thus exposed to the highest demands.
The greatest care must be used in the individual work steps for stripping insulation from, crimping, and shrinking/insulating the electric lines.
The procedure for stripping insulation from, crimping, and shrinking/insulating the electric lines must be complied with and observed. The procedures are described in detail in the repair kit for harnesses NR.155-1.
Crimping samples are to be prepared before beginning work.
8. Crimp lines in area around -b-.
8.1. Cut off lines in different lengths (due to the shrink-fit connections).
8.2. Slide shrink-fit hoses onto the lines.
8.3. Strip 10 mm of insulation off the wires.
8.4. Crimp lines using crimping sleeves and the hand crimping pliers from the repair kit for harnesses NR.155-1.
8.5. Slide the shrink-fit hoses over the crimp connections and carefully shrink them using the hot-air blower with special nozzle (recommended accessories for the repair kit for harnesses) so that they are watertight.
8.6. Wrap commercially available PVC tape all around the area of the connection points.
9. Secure the repaired area to the neighbouring wire harnesses using tie-wraps -c-.
Installing rear ABS wire harness
1. Place socket in installation position -arrow A- and screw on the fastening screw. => Tightening torque: 10 Nm (7.5 ftlb.)
Connecting plug connection for rear wheel sensor
2. Plug in the two connectors -arrow B-.
3. Fold back the cable retainer -arrow C- until it engages correctly at the connectors.
4. Press the ABS wire harness into the supports on the spring strut by pressing on the rubber sleeves -arrows A-.
Pressing ABS wire harness into supports
5. Insert ABS wire harness into clip and close clip -arrow B-.
6. Push the ABS wire harness inward -arrow C-.
Information
Only for vehicles with TPM.
7. Cut through the rubber sleeve -a- and insert the TPM line -arrow B-. Stick the rubber sleeve together at the cut edge -a- using a commercially available PUR adhesive and seal.
Sticking rubber sleeve together
8. Fit rubber sleeve -arrow C-
Information
Select a place for the joint where there is enough space to join all the lines present.
Do not cut the lines too short in case they have to be laid in a different position if there is insufficient space in the area of the joint.
Information
The greatest care must be used in the individual work steps for stripping insulation from, crimping, and shrinking/insulating the electric lines.
The procedure for stripping insulation from, crimping, and shrinking/insulating the electric lines must be complied with and observed. The procedures are described in detail in the repair kit for harnesses NR.155-1.
Crimping samples are to be prepared before beginning work.
9. Crimp lines in area around -a-.
Crimping lines
9.1. Cut off lines in different lengths (due to the shrink-fit connections).
9.2. Slide shrink-fit hoses onto the lines.
9.3. Strip 10 mm of insulation off the wires.
9.4. Crimp lines using crimping sleeves and the hand crimping pliers from the repair kit for harnesses NR.155-1.
9.5. Slide the shrink-fit hoses over the crimp connections and carefully shrink them using the hot-air blower with special nozzle (recommended accessories for the repair kit for harnesses) so that they are watertight.
9.6. Wrap commercially available PVC tape all around the area of the connection points.
10. Secure the repaired area -a- to the neighbouring wire harnesses using fabric tape.
Subsequent work
Subsequent work on front ABS wire harness
1. Install plenum panel cover. -> 852219 Removing and installing cover - section on "Installing" 85221900 Removing and installing cover
2. Install front wheel housing liner (rear section). -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair
3. Carry out work instruction after disconnecting the battery. -> 2706IN Work instructions after disconnecting the battery
Subsequent work on rear ABS wire harness
1. Install oddments tray.
2. Install rear wheel housing liner. -> 536919 Removing and installing rear wheel housing liner - section on "Installing"
3. Carry out work instruction after disconnecting the battery. -> 2706IN Work instructions after disconnecting the battery