Engine Wiring Harness, 2.0L TDI/CR, Engine Code CBEA
Engine Wiring Harness, 2.0L TDI/CR, Engine Code CBEA
Special tools, testers and auxiliary items required
• Hose clamps up to 25 mm dia. (3094)
• Torque Wrench (V.A.G 1331)
• Drip tray (VAS 6208)
• Spring-type clip pliers (VAS 6362)
Conditions
• The ignition is switched off.
• The engine must be cold.
Procedure
- Check the DTC memory for all control modules before removal. Refer to "Vehicle OBD".
- Remove the engine cover.
CAUTION!
Electrical components could be damaged when disconnecting the battery:
• Follow the instructions for disconnecting the battery.
- Disconnect the battery. Refer to --> [ Battery, Disconnecting and Connecting ] .
- Remove air filter housing.
- Remove the battery and the battery carrier - arrows -.
- Remove the windshield wiper arm and the plenum chamber cover. Refer to --> [ Windshield Wiper System ] Removal and Replacement.
- Remove the plenum chamber bulkhead.
The following illustration shows the wiring harness as viewed from the windshield with the hood open.
1. Plenum Chamber Bulkhead
2. Wiring harness
3. Front window
- Unclip the wiring harness - 2 - from the retainers - arrows -.
- Remove the mounting bolt - 1 - and nut - 2 - of plenum chamber bulkhead - 3 -.
- Remove plenum chamber bulkhead - 3 - upward and out of vehicle.
- Remove the engine control module.
- Remove the connector - arrow B - on the engine control module - arrow A -.
- Release the wiring harness guide - A - at the retaining tab - arrow -.
- Pull the wiring harness guide - A - upward.
- Remove the wiring harness from the bracket - arrow A -.
- Unclip the wiring guide near the transmission mount - arrows B through D -.
- Disconnect the cable tie on the black 14-pin connector at coupling 1 in the left of the engine compartment - arrow B - and remove the connector from the bracket.
- Disconnect the black 14-pin connector at coupling 1 in the left of the engine compartment - arrow A -.
- Unclip the wiring guide - arrow C -.
- Remove the 10-pin connector near the left headlamp - arrow A - from the bracket - arrow B - and disconnect the connector.
- Release the wiring harness connecting base at the starter bracket - arrow B -.
- Release the wiring harness connecting base on the bracket for the oil filter bracket - arrow A -.
Component location, refer to --> [ 3 Connecting Base ] 2.0L TDI/CR, Engine Code CBEA, Intake Side.
- Carefully remove the wiring harness from the brackets.
- Release the wiring harness clip and remove it from the bracket on the oil filter bracket - arrow -.
- Remove the connector from the EGR vacuum regulator solenoid valve (N18) - 1 - and from the throttle valve control module (J338) - 2 -.
Throttle valve control module installation location, refer to --> [ 2 Connector, 50-Pin ] 2.0L TDI/CR, Engine Code CBEA, Intake Side
- Loosen the clip near the oil filter bracket - arrow -.
- Release the connector from the camshaft position sensor (G40) and disconnect it - arrow -.
Component location, refer to --> [ 7 Connector,
3-Pin ] 2.0L TDI/CR, Engine Code CBEA, Intake Side.
- Remove the connector from the fuel temperature sensor (G81) - 1 - and from the fuel metering valve (N290) on the high pressure fuel pump - 2 -.
Fuel metering valve installation location, refer to --> [ 7 Connector,
2-pin ] 2.0L TDI/CR, Engine Code CBEA, Top View.
- Be careful of the wiring guide.
- Guide the wiring harness out.
- Release the connector from the oil pressure switch (F1) and disconnect it - arrow A -.
Component location, refer to --> [ 4 Connector, 1-Pin ] 2.0L TDI/CR, Engine Code CBEA, Intake Side.
• The oil filter bracket must be removed and installed when releasing and disconnecting the connector from the engine speed (RPM) sensor (G28).
- Oil filter bracket.
- Release and disconnect the connector from the engine speed (RPM) sensor - arrow -.
- Release and disconnect the connector from the intake flap motor (V157) - arrow A -.
Intake flap motor installation location, refer to --> [ 1 Connector,
5-Pin ] 2.0L TDI/CR, Engine Code CBEA, Intake Side.
- Remove the wiring harness from the bracket - arrow B -.
- Remove the connector from the fuel pressure sensor - arrow A -.
- Unclip the wire from the bracket - arrow B -.
- Remove the fuel line nut - arrow D -.
- Remove the wiring guide from the rail element (high pressure accumulator) - arrow C -.
- Remove the connector from the fuel pressure regulator valve (N276) - arrow A -.
Component location, refer to --> [ 5 Connector, 2-Pin ] 2.0L TDI/CR, Engine Code CBEA, Top View.
- Remove the connectors from all injection units - A -.
Injection unit installation locations, refer to --> [ 1 Injection Unit Connectors, 2-Pin ] 2.0L TDI/CR, Engine Code CBEA, Top View
- Loosen the spring clamp - arrow B - with the (VAS 6362) and remove the wire on the rail element (high pressure accumulator).
- Remove the wire - arrow C -.
- Clean the return line connection on the injection units with a commercially available degreaser before removal.
- Dry the return line connections.
- Remove the connectors from all glow plugs.
CAUTION!
Follow the procedure Glow Plug Connectors, Removing and Installing exactly. Refer to --> [ Glow Plug Connectors ] Glow Plug Connectors.
Glow plug connector installation locations, refer to --> [ 8 Glow Plug Connectors ] 2.0L TDI/CR, Engine Code CBEA, Top View.
- Remove the wiring harness with the wiring guide from the rail element and guide the wiring harness out.
- Remove the connector - arrow - from the coolant temperature sensor (G62).
Component location, refer to--> [ 7 , 2-Pin ] 2.0L TDI/CR, Engine Code CBEA, Exhaust Side.
- Guide the wire out - arrows -.
The illustration shows the coolant temperature sensor wiring harness. - arrow -.
- Arrow C - shows the wiring harness to the following components:
• Exhaust pressure sensor 2 (G451)
• Charge pressure actuator position sensor (G581)
• EGR valve 2 (N213)
• EGR temperature sensor (G98)
- Guide the wiring harness out of the bracket - arrow B -.
- Arrow D - Wiring harness from the "bracket on the cylinder head cover".
- Arrow A - Wiring harness to the EGR temperature sensor (G98).
- Arrow B - Wiring harness to the EGR valve 2 (N213).
- Arrow C - Bracket for the EGR valve 2 (N213) wire.
- Disconnect the heat shield - arrows - and remove the connector from the exhaust pressure sensor 2 (G451) - 1 -.
Installation location, refer to --> [ 2 Connector, 3-Pin ] 2.0L TDI/CR, Engine Code CBEA, Exhaust Side.
- Disconnect the heat shield - arrow -.
Installation location, refer to --> [ 3 Connector, 3-Pin ] 2.0L TDI/CR, Engine Code CBEA, Top View.
- Remove the connector from the charge pressure actuator position sensor (G581) - arrow - on the turbocharger vacuum diaphragm and guide the wire out of the retainers.
- Remove the connector from the EGR temperature sensor - arrow A - and guide the wire out.
EGR temperature sensor connector installation location, refer to --> [ 1 Connector ] 2.0L TDI/CR, Engine Code CBEA, Exhaust Side.
- Remove the insulation pan..
• Assembly Overview, Vehicle from Below:
• Check the wiring routing and the heat shield location.
Installation position of EGR valve 2, refer to --> [ 4 Connector ] 2.0L TDI/CR, Engine Code CBEA, Exhaust Side
- Disconnect the heat shield - arrow B - and slide it off the connector.
- Remove the connector from the EGR valve 2.
- Disconnect the cable tie - arrow A -.
• Engine compartment assembly overview:
- Remove the intake hose.
• Check the wiring routing before guiding the wire out.
- Carefully guide the wire - 1 - out between the turbocharger intake scoop - 2 - and the pre-heating hose - 3 - - arrow A -.
- Carefully remove the engine wiring harness from the engine compartment.
Install in reverse order of removal. Note the following:
CAUTION!
Follow the procedure Glow Plug Connectors, Removing and Installing exactly. Refer to --> [ Glow Plug Connectors ] Glow Plug Connectors.
Make sure all of the connectors are seated securely.
Return the heat insulation to the original locations. Refer to --> [ ECM Connector Heat Shield ] ECM Connector Heat Shield.
Replace all self-locking nuts, seals, gaskets and clamps.
Secure hose connections with spring clamp.
Install spring clamps with (VAS 6362) or (VAS 6340).
Follow the instructions. Refer to --> [ ECM Connector Installation Information ] [1][2]Diagrams.