Removing and Installing Wire Harness For Battery Wiring

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.

Preliminary work for B+ line from power distributor to transmission connection point
1. Disconnect battery.
2. Remove current distributor.
3. Unscrew triggering unit.

INFORMATION: For vehicles with manual transmission.

4. Remove shift console.

INFORMATION: For vehicles with automatic transmission.

5. Remove selector support.
6. Remove parking-brake lever.
7. Remove rear underbody cover.
8. Remove cover for centre underbody.

Preliminary work for B+ line from starter to transmission connection point
1. Disconnect battery.
2. Remove throttle housing.
3. Remove generator.
4. Remove rear underbody cover.

Preliminary work for engine ground strap
1. Lift the vehicle.

Removing wire harness for battery wiring

Removing ground strap and B+ line of battery












1. Remove ground strap for battery -1 -.
1.1. Unscrew fastening nut of battery ground strap to body and remove ground strap for battery.







2. Remove B+ line for battery -2-.
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.
2.4. Release and pull off B+ line from power distributor.
2.5. Remove B+ line for battery.

Remove B+ line from power distributor to transmission connection point












1. Unclip B+ line -3- 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.
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.
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.
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.
5.1. Open holder -Arrow A- and remove B+ line -Arrow B-.

INFORMATION: For vehicles with automatic transmission.







6. Remove 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.
7.1. Unscrew fastening screw and fastening nut on guide tube of B+ line.







8. Remove B+ line -3-.
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







1. Screw off fastening nut on starter lead at terminal 30 and remove it.







2. Unclip B+ line -5- at cable duct for engine wire harness.
2.1. Unclip B+ line at cable duct -arrows-.







3. Unscrew B+ line -5- at box for B+ line -4-.
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.

INFORMATION: For vehicles with automatic transmission.

5. Remove cable duct of B+ line -5- at automatic transmission.
6. Remove B+ line -5-.

Removing engine ground strap












1. Remove engine ground strap -6-.
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












1. Install ground strap for battery -1-.
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.
2.2. Screw B+ line tightly to battery. Tightening torque: 5 Nm (3.5 ftlb.)

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.
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-.
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












1. Install B+ line -3-.
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.
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.
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.)

INFORMATION: For vehicles with automatic transmission.







4. Install 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-.
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.
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.
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.
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







1. Lay B+ line -5-.

INFORMATION: For vehicles with manual transmission.

2. Install cable duct of B+ line -5- at manual transmission.

INFORMATION: For vehicles with automatic transmission.

3. Install cable duct of B+ line -5- at automatic transmission.







4. Screw down B+ line -5- at box for B+ line -4-.
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.
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.)

Fitting ground strap to engine












1. Fit engine ground strap -6-.
1.1. Position ground strap and screw down with the fastening screw and fastening nut. 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.

Subsequent work for B+ line from power distributor to transmission connection point
1. Install cover for centre underbody.
2. Install rear underbody cover.
3. Install parking-brake lever.

INFORMATION: For vehicles with automatic transmission.

4. Install selector support.

INFORMATION: For vehicles with manual transmission.

5. Install gearshift bracket.
6. Fasten triggering unit.
7. Install power distributor.
8. Carry out work instructions after disconnecting the battery.

Subsequent work for B+ line from starter to transmission connection point
1. Install the generator.
2. Install throttle housing.
3. Install rear underbody cover.
4. Carry out work instructions after disconnecting the battery.

Subsequent work for engine ground strap
1. Lower the vehicle.