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974519 Removing and installing wire harness for battery wiring


WM 974519 Removing and installing wire harness for battery wiring

Tools





Technical values






Preliminary work

Preliminary work for ground strap and B+ line of battery

1. Disconnect battery. => 2706IN Working instructions after disconnecting the battery

Preliminary work for B+ line from power distributor to transmission connection point

1. Disconnect battery. => 271000 Work instructions after disconnecting the battery
2. Remove current distributor. => 978919 Removing and installing power distributor - section on "Removing"
3. Unscrew triggering unit. => 695319 Removing and installing triggering unit for airbag - section on "Removing"

Information

For vehicles with manual transmission.

4. Remove shift console. => 340819 Removing and installing gearshift bracket - section on "Removing"

Information

For vehicles with automatic transmission.

5. Remove selector support. => 370819 Removing and installing selector support - section on "Removing"
6. Remove parking-brake lever. => 466119 Removing and installing parking-brake lever - section on "Removing"
7. Remove rear underbody cover. => 519419 Removing and installing rear cover - section on "Removing"
8. Remove cover for centre underbody. => 519319 Removing and installing centre cover - section on "Removing"

Preliminary work for B+ line from starter to transmission connection point

1. Disconnect battery. => 271000 Work instructions after disconnecting the battery
2. Remove throttle housing. => 244219 Removing and installing throttle housing - section on "Removing"
3. Remove generator. => 272219 Removing and installing three-phase generator - section on "Removing"
4. Remove rear underbody cover. => 519419 Removing and installing rear cover - section on "Removing"

Preliminary work for engine ground strap

1. Lift the vehicle. => 401000 Raising the vehicle

Removing wire harness for battery wiring

Removing ground strap and B+ line of battery





Installation position of wire harness for battery wiring





1. Remove ground strap for battery -1-.





Ground strap from battery to body

1.1. Unscrew fastening nut of battery ground strap to body and remove ground strap for battery.
2. Remove B+ line for battery -2-.





Cut through the positive cable.

2.1. Cut through the positive cable of main wire harness -3- at the place indicated -arrows-.
2.2. Remove binding band from main wire harness until the sheathing of the positive cable -3- can be removed -Arrow A-.
2.3. Unscrew B+ line from battery. => 270619 Removing and installing battery - section on "Removing"
2.4. Release and pull off B+ line from power distributor => 978919 Removing and installing power distributor - section on "Removing"
2.5. Remove B+ line for battery.

Remove B+ line from power distributor to transmission connection point





Installation position of wire harness for battery wiring





1. Unclip B+ line -3- from heater/air-conditioning unit.





Unclipping B+ line from heater/air-conditioning unit

1.1. Unclip B+ line at tie-wrap from heater/air-conditioning unit.
1.2. Disconnect B+ line from main wire harness. To do this, remove the tie-wrap and the binding band.
2. Unclip B+ line -3- at unit carrier.





Fastening of B+ line at unit carrier.

2.1. Unclip B+ line at retaining clip -arrow- from unit carrier.
2.2. Pull B+ line through unit carrier.
3. Loosen B+ lead -3- at centre tunnel.





Fastening of B+ line at centre tunnel

3.1. Pull B+ line out of the two holders -arrows-.
3.2. Push B+ line under the carpet away from the direction of travel.
4. Unscrew B+ line -3- at box for B+ line.





Unscrewing B+ line at box for B+ line

4.1. Open box for B+ line at transmission -Arrow A- , unscrew fastening nut -Arrow B- and remove the B+ line.

Information

For vehicles with manual transmission.

5. Unclip B+ line -3- from transmission bracket.





Unclipping B+ line from transmission bracket

5.1. Open holder -Arrow A- and remove B+ line -Arrow B-.

Information

For vehicles with automatic transmission.

6. Remove transmission bracket.





Transmission bracket

6.1. Support automatic transmission with transmission jack WE WE1082.
6.2. Unscrew the four fastening screws and the two fastening nuts.
6.3. Remove transmission bracket.

Information

For vehicles with automatic transmission.

7. Unscrew guide tube of B+ line -3- from body.





Unscrewing guide tube of B+ line

7.1. Unscrew fastening screw and fastening nut on guide tube of B+ line.
8. Remove B+ line -3-.





Removing B+ line

8.1. Remove grommet -Arrow A-.
8.2. Remove B+ line from grommet -Arrow B-.
8.3. Pull B+ line out of the vehicle interior and remove -Arrow C-.

Removing B+ line from starter to transmission connection point





Installation position of wire harness for battery wiring





1. Screw off fastening nut on starter lead at terminal 30 and remove it. => 276019 Removing and installing starter - section on "Removing"
2. Unclip B+ line -5- at cable duct for engine wire harness.





Unclipping B+ line to starter at cable duct

2.1. Unclip B+ line at cable duct -arrows-.
3. Unscrew B+ line -5- at box for B+ line -4-.





Unscrewing B+ line at box for B+ line

3.1. Open box for B+ line at transmission -Arrow A- , unscrew fastening nut -Arrow B- and remove the B+ line.

Information

For vehicles with manual transmission.

4. Remove cable duct of B+ line -5- at manual transmission. => 343519 Removing and installing transmission - section on "Removing"

Information

For vehicles with automatic transmission.

5. Remove cable duct of B+ line -5- at automatic transmission.=> 373527 Removing and mounting automatic transmission - section on "Mounting"
6. Remove B+ line -5-.

Removing engine ground strap





Installation position of wire harness for battery wiring





1. Remove engine ground strap -6-.





Fastening engine ground strap

1.1. Unscrew fastening screws on engine, fastening nut on body, and remove ground strap.

Installing wire harness for battery wiring

Installing ground strap and B+ line of battery





Installation position of wire harness for battery wiring





1. Install ground strap for battery -1-.





Ground strap from battery to body

1.1. Screw down battery ground strap on the body with the fastening nut. => Tightening torque: 5 Nm (3.5 ftlb.)
2. Install B+ line for battery -2-.
2.1. Push the B+ line of the battery onto the mounting point at the power distributor as far as the stop. Check that the B+ line sits firmly. => 978919 Removing and installing power distributor - section on "Installing"
2.2. Screw B+ line tightly to battery. => Tightening torque: 5 Nm (3.5 ftlb.) => 270619 Removing and installing battery - section on "Removing"

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.

3. Crimp the positive cable.





Trimming the positive cable.

3.1. Trim the new positive cable -4- to the -dimension X = approx. 20 cm- and strip the insulation.
3.2. Strip insulation off original positive cable of main wire harness -3- and push on the shrink-fit hose -5-.





Crimping the positive cable

3.3. Crimp crimping sleeve -6- using the hand crimping pliers from the repair kit for harnesses NR.155-1 to the positive cable -3-.
3.4. Crimp crimping sleeve -6- using the hand crimping pliers from the repair kit for harnesses NR.155-1 to the new positive cable -4-. Check the crimp connection carefully.
3.5. Slide the shrink-fit hose over the crimp connection and carefully shrink it using the hot-air blower with special nozzle (recommended accessories for the repair kit for harnesses) so that it is watertight.
3.6. Tie positive cable to the main wire harness with adhesive tape.

Install B+ line from power distributor to transmission connection point





Installation position of wire harness for battery wiring





1. Install B+ line -3-.





Installing B+ line

1.1. Lay B+ line to transmission and push into the vehicle interior -Arrow A-.
1.2. Press B+ line into the grommet -Arrow B-.
1.3. Fit grommet -Arrow C-.

Information

For vehicles with manual transmission.

2. Clip B+ line -3- onto transmission bracket.





Clip B+ line onto transmission bracket.

2.1. Insert B+ line into holder -Arrow A- and close holder -Arrow B-

Information

For vehicles with automatic transmission.

3. Screw down guide tube of B+ line -3- on the body.





Fastening guide tube of B+ line

3.1. Position guide tube of B+ line on the body and screw down with fastening screw and fastening nut. => Tightening torque: 10 Nm (7.5 ftlb.) => Tightening torque: 10 Nm (7.5 ftlb.)

Information

For vehicles with automatic transmission.

4. Install transmission support.





Transmission support

4.1. Position the transmission support and secure with the four fastening screws and the two fastening nuts. => Tightening torque: 65 Nm (48 ftlb.)
4.2. Lower transmission jack WE WE1082 and remove from under the vehicle.
5. Screw down B+ line -3- at box for B+ line -4-.





Screw down B+ line at box for B+ line.

5.1. Insert B+ line into the box and tighten with the fastening nut -Arrow A-.=> Tightening torque: 23 Nm (17 ftlb.)
5.2. Close box for B+ line on transmission -Arrow B-.
6. Fasten B+ lead -3- at centre tunnel.





Fastening of B+ line at centre tunnel

6.1. Push B+ line under the carpet in the direction of travel.
6.2. Insert B+ line into the two holders -arrows-.
7. Clip in B+ line -3- at unit carrier.





Fastening of B+ line at unit carrier.

7.1. Push B+ line through the unit carrier and across the footwell air vent.
7.2. Clip in B+ line -arrow- at unit carrier with the retaining clip.
8. Clip in B+ line -3- at heater/air-conditioning unit.





Fastening B+ line at heater/air-conditioning unit

8.1. Secure the B+ line to the main wire harness with the two new tie-wraps.
8.2. Clip in B+ line at heater/air-conditioning unit with the tie-wraps.

Installing B+ line from starter to transmission connection point





Installation position of wire harness for battery wiring





1. Lay B+ line -5-.

Information

For vehicles with manual transmission.

2. Install cable duct of B+ line -5- at manual transmission. => 343519 Removing and installing transmission - section on "Installing"

Information

For vehicles with automatic transmission.

3. Install cable duct of B+ line -5- at automatic transmission. => 373527 Removing and mounting the automatic transmission - section on "Removing and Mounting"
4. Screw down B+ line -5- at box for B+ line -4-.





Screwing down B+ line at box for B+ line

4.1. Insert B+ line into the box and tighten with the fastening nut -Arrow A-.=> Tightening torque: 23 Nm (17 ftlb.)
4.2. Close box for B+ line on transmission -Arrow B-.
5. Clip in B+ line -5- at cable duct for engine wire harness.





Clipping in starter lead at cable duct

5.1. Clip in B+ line at cable duct -arrows-.
6. Position starter lead for terminal 30 and secure with fastening nut. => Tightening torque: 18 Nm (13.0 ftlb.) => 276019 Removing and installing starter - section on "Installing"

Fitting ground strap to engine





Installation position of wire harness for battery wiring





1. Fit engine ground strap -6-.





Fastening engine ground strap

1.1. Position ground strap and screw down with the fastening screw and fastening nut. => Tightening torque: 23 Nm (17 ftlb.) => Tightening torque: 23 Nm (17 ftlb.)

Subsequent work

Subsequent work for ground strap and B+ line of battery

1. Carry out work instruction after disconnecting the battery. => 2706IN Work instructions after disconnecting the battery

Subsequent work for B+ line from power distributor to transmission connection point

1. Install cover for centre underbody. => 519319 Removing and installing centre cover - section on "Installing"
2. Install rear underbody cover. => 519419 Removing and installing rear cover - section on "Installing"
3. Install parking-brake lever. => 466119 Removing and installing parking-brake lever - section on "Installing"

Information

For vehicles with automatic transmission.

4. Install selector support. => 370819 Removing and installing selector support - section on "Installing"

Information

For vehicles with manual transmission.

5. Install gearshift bracket. => 340819 Removing and installing gearshift bracket - section on "Installing"
6. Fasten triggering unit. => 695319 Removing and installing triggering unit for airbag - section on "Installing"
7. Install power distributor. => 978919 Removing and installing power distributor - section on "Installing"
8. Carry out work instructions after disconnecting the battery. => 271000 Work instructions after disconnecting the battery

Subsequent work for B+ line from starter to transmission connection point

1. Install the generator. => 272219 Removing and installing three-phase generator - section on "Installing"
2. Install throttle housing. => 244219 Removing and installing throttle housing - section on "Installing"
3. Install rear underbody cover. => 519419 Removing and installing rear cover - section on "Installing"
4. Carry out work instructions after disconnecting the battery. => 271000 Work instructions after disconnecting the battery

Subsequent work for engine ground strap

1. Lower the vehicle.