Replacing Wiring Harness Section For Engine

REPLACING WIRING HARNESS SECTION FOR ENGINE:

Note instructions on connecting and disconnecting battery. Vehicle Damage Warnings

- Switch off ignition.
- Remove battery negative line.
- Remove complete splash guard.
- Remove fan wheel,

Version 1: (acoustic cover screwed down)
- Remove seal caps (1) and unfasten nuts (2).
- Remove acoustic cover.

Version 2: (acoustic cover with press-stud fastener)
- Open press-studs (1...4) one at a time, at the same time lifting the acoustic cover slightly. Once all four press-studs have been opened, remove the acoustic cover.

Installation Note: Position acoustic cover and press downwards until press-studs (1...4) click into place.

- Unfasten clips (1).
- If fitted, unfasten hose clip (2) on air intake hose for air pump.
- Disconnect plug-in connection (3).
- Unfasten hose clip (4).
- Disconnect plug connection on temperature sensor for intake air.
- Remove upper section of suction filter housing with mass air flow sensor.

- Remove left and right cover from ignition coils.

- Unfasten left and right connections on ignition coils.

Accelerator Cables [(1) Accelerator Pedal, (2) Cruise Control]:

- Remove accelerator cables (1 and 2).
1. Accelerator pedal
2. Cruise control

- Unfasten screw connection on oil filter housing.

- Disconnect plug connection on oil pressure switch.

- Place oil filter housing to one side.

- Cut connections on alternator (Illustration of connections, refer to next figure).

NOTE: Connections here illustrated on removed alternator.

- Unfasten plug connection (1).

- Unfasten nut (2).

Installation Note:
Tightening torque:
KI.D+ (M6) = 7 Nm.
KI.B+ (M8) = 13 Nm.

- Unfasten plug connections to Lambda oxygen sensors on both sides.

Installation Note: Note line routing of Lambda oxygen sensor (1) under the heat shield!

- Disconnect plug connection on reversing light switch.
- Note wire routing!

- Unfasten nuts on starter motor wires.

Installation Note:
Tightening torque:
Terminal 30h (M5) 5 Nm.
Terminal 50 (M6) 6 Nm.
Terminal 30 (M8) 12 Nm.

- Unfasten plug connection on oil level switch.

- Unfasten plug connection on cable duct (1 to 3).
1. Knock sensor cylinders (3 and 4)
2. Knock sensor cylinders (1 and 2)
3. Impulse sensor for TDC on vibration damper on the crankshaft.

- Press down retaining bracket.
- Pull off connectors.

- Unfasten plug connection on cable duct (1 to 3).
1. Knock sensor cylinders (7 and 8)
2. Knock sensor cylinders (5 and 6)
3. Sensor for cylinder recognition (camshaft sensor)

- Disconnect plug connection (1) on tank vent valve.

- Unclip wire from brackets on protective tube (1) of positive battery lead.

- Disconnect plug connection (1) on idle speed adjuster and plug connection (2) on throttle valve potentiometer.

- Disconnect plug connection on throttle valve potentiometer for ASC+T.

- Unclip lines on guide tube (1) for dipstick.

- Unclip wire on front of upper section of oil pan.

- Disconnect plug connection on rear of water box (1 to 3).
1. Temperature sensor for coolant for DME (white)
2. Temperature sensor for remote thermometer (black)
3. Ground connection of ignition coils (terminal 4a)

- Ground connections (1), unfasten nuts.
- Unclip diagnosis connector (2) from bracket.
- Unfasten ignition coil connections (3).

- Unfasten screws on cable ducts.
- Remove cable ducts from brackets.

- Unfasten screws in cover on electronics box.

Tightening Torque: 4.4 Nm.

- Remove relays (1 and 2) with bracket.
1. Relay for Lambda oxygen sensor heating.
2. Relay for Digital Motor Electronics (DME) (can be recognized because cross section of feed lines is greater than 2.5 mm.square).

- Disconnect plug connection on temperature sensor for electronics box.

- Disconnect plug connection (1 to 3).
1. Control unit for automatic transmission
2. Control unit for cruise control
3. Control unit for Digital Motor Electronics (DME)

- Disconnect plug connections (1 to 4).