Removing and Installing Wire Harness For Engine

Removing And Installing Wire Harness For Engine







Preliminary work
1. Remove rear wheels.
2. Disconnect battery.
3. Remove rear cover.
4. Remove generator.
5. Remove intake-air distributor.
6. Remove rear luggage-compartment lining.

Removing wire harness for engine












1. Release connectors on the six ignition coils -1 to 6- and pull them off.
2. Release connectors on the six fuel injectors -7 to 12- and pull them off.
3. Release connectors on both knock sensors -15 and 16- and pull them off.
4. Release connectors on both solenoid hydraulic valves (camshaft timing) -17 and 18- and pull them off.
5. Release connectors on both solenoid hydraulic valves (valve lift control) -19 and 20- and pull them off.







6. Unscrew ground straps -22-.
6.1. Unscrew fastening screw and remove ground straps -22-.







7. Disconnect plug connection on speed sensor -23- and unscrew ground straps -21-.
7.1. Pull plug connection -23- out of holder.
7.2. Release plug connection -23- and disconnect it -Arrows a-.
7.3. Unscrew fastening screw and remove ground straps -21-.

8. Release connector on electric fan -24- and pull it off.
9. Release connector on secondary air blower -25- and pull it off.
10. Release securing clip and pull off connector on tank vent -27-.
11. Release connector on oil temperature sensor -29- and pull it off.
12. Unscrew fastening nut of starter leads at terminal 30 and terminal 50 -30 and 31- and remove.
13. Pull off connector on pressure sensor -32-.
14. Release connector on engine temperature sensor -33- and pull it off.







15. Pull off connector on coolant temperature sensor -35-.
15.1. Open holder -Arrow B- and remove line.
15.2. Release connector on coolant temperature sensor -35- -Arrow a- and pull it off.

16. Disconnect plug connections for oxygen sensor ahead of catalytic converter -36 and 37-.
17. Disconnect plug connections for oxygen sensor behind catalytic converter -38 and 39-.
18. Release securing clip and pull off connector on intake-manifold change-over switch -41 -.
19. Release connector on air flow sensor -42- and pull it off.
20. Release securing clip and pull off connector on coolant change-over valve -43-.
21. Release and pull off connector on reversing light switch -44-.
22. Release connector on coolant level indicator -45- and remove it.
23. Release and pull off connector on Tiptronic position switch -46- and Tiptronic control module -47-.
24. Release and disconnect plug connection for engine wire harness to rear wire harness -48-.







25. Disconnect plug connections for engine wire harness to main wire harness rear left and right -49 and 50-.
25.1. Release plug connections for engine wire harness to main wire harness rear left and right -Arrows A-and disconnect -Arrows B-.







26. Unscrew ground strap -51-.
26.1. Screw off fastening nut and remove ground strap.

27. Release and pull off connector on DME control module -52 to 54-.
28. Release and pull off connector on Tiptronic control module -55-.

INFORMATION: Only on the Cayman.







29. Unclip wire harness to Tiptronic control module and DME control module at the two holders in the area of the service flap.
30. Remove grommet -56- and pull through the engine wire harness in direction of engine compartment.
31. Unclip engine wire harness at the tie-wraps -57-.
31.1. Unclip tie-wrap on the secondary pump.
31.2. Unclip tie-wrap at the branch (throttle valve, secondary pump, coolant change-over valve).
31.3. Unclip tie-wrap at cable duct in area of grommet.







32. Remove cable duct on the left and right.
32.1. Unscrew fastening screw of cable duct on the left and right -Arrow A-.
32.2. Unclip cable duct on the left and right -Arrow B-.
32.3. Remove cable duct on the left and right -Arrow C-.







33. Remove centre cable duct.
33.1. Unscrew fastening screws, unclip cable duct -arrow- and remove it.

34. Remove wire harness for engine.

Installing wire harness for engine







1. Lay out wire harness for engine.







2. Install centre cable duct.
2.1. Clip in cable duct -arrow- and secure with the fastening screws. - Tightening torque: 10 Nm (7.5 ftlb.)







3. Install cable duct at left and right.
3.1. Position cable duct left and right -Arrow A- and clip in -Arrow B-.
3.2. Secure cable duct left and right with fastening screw -Arrow C-. - Tightening torque: 10 Nm (7.5 ftlb.)

4. Clip in engine wire harness at the tie-wraps -57-.
4.1. Clip in tie-wrap at cable duct in area of grommet.
4.2. Clip in tie-wrap at the branch (throttle valve, secondary pump, coolant change-over valve).
4.3. Clip in tie-wrap on the secondary pump.

5. Push through engine wire harness in direction of luggage compartment and fit grommet -56-.

INFORMATION: Only on the Cayman.







6. Clip in wire harness to Tiptronic control module and DME control module at the two holders in the area of the service flap.
7. Push on connector of Tiptronic control module -55- until it is felt to engage.
8. Push on connector of DME control module -52 to 54- until it is felt to engage.







9. Screw down ground strap -51-.
9.1. Fit ground strap and secure with fastening nut. - Tightening torque: 9 Nm (6.5 ftlb.)







10. Connect plug connections for engine wire harness to main wire harness left and right -49 and 50-.
10.1. Connect plug connections for engine wire harness to main wire harness left and right until they are felt to engage.

11. Connect plug connection for engine wire harness to rear wire harness -48- until it is felt to engage.
12. Push on connector of Tiptronic position switch -46- and Tiptronic control module -47- until they are felt to engage.
13. Push on connector of coolant level indicator -45- until it is felt to engage.
14. Push on connector for reversing light switch -44- until it is felt to engage.
15. Push on connector of intake-manifold change-over switch -43- until the securing clip is felt to engage.
16. Push on connector of air flow sensor -42- until it is felt to engage.
17. Push on connector of intake-manifold change-over switch -41- until the securing clip is felt to engage.
18. Connect plug connections for oxygen sensor behind catalytic converter -38 and 39-.
19. Connect plug connections for oxygen sensor ahead of catalytic converter -36 and 37-.







20. Push on connector of coolant temperature sensor -35-.
20.1. Push on connector of coolant temperature sensor -35- -Arrow A- until it is felt to engage.
20.2. Insert line into holder and close holder -Arrow B-.

21. Push on connector of engine temperature sensor -33- until it is felt to engage.
22. Push on connector of pressure sensor -32-.
23. Position starter lead for terminal 30 and terminal 50 -30 and 31- and secure with fastening nut. - Tightening torque: 18 Nm (13 ftlb.) - Tightening torque: 6.5 Nm (5.0 ftlb.)
24. Push on connector of oil temperature sensor -29- until it is felt to engage.
25. Push on connector of tank vent -27- until the securing clip is felt to engage.
26. Push on connector of secondary air blower -25- until it is felt to engage.
27. Push on connector of electric fan -24- until it is felt to engage.







28. Screw down ground straps -21- and connect plug connection of speed sensor -23-.
28.1. Position ground straps -21- and screw down with the fastening screw. - Tightening torque: 10 Nm (7.5 ftlb.)
28.2. Push plug connection -23- together until it is felt to engage.
28.3. Push plug connection -23- into holder.







29. Screw down ground straps -22-.
29.1 Position ground straps -22- and screw down with the fastening screw. - Tightening torque: 10 Nm (7.5 ftlb.)

30. Push on connectors of the two solenoid hydraulic valves (valve lift control) -19 to 20- until they are felt to engage.
31. Push on connectors of the two solenoid hydraulic valves (camshaft timing) -17 to 18- until they are felt to engage.
32. Push on connectors of the two knock sensors -15 to 16- until they are felt to engage.
33. Push on connectors of the six fuel injectors -7 to 12- until they are felt to engage.
34. Push on connectors of the six ignition coils -1 to 6- until they are felt to engage.

Subsequent work
1. Install rear luggage-compartment lining.
2. Install intake-air distributor.
3. Install the generator.
4. Install rear cover.
5. Mount rear wheels.
6. Carry out work instruction after disconnecting the battery.