Engine bay wiring harness
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Engine bay wiring harness
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1.
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Remove the upper engine cover, insulation and battery cover.
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Detach the negative cable from the battery.
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Detach the positive cable the runs from positive battery terminal to the fuse box.
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Remove the positive battery cable.
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Undo the bolt of the battery lock lug and lift out the battery.
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3.
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Remove the battery tray and components:
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Undo the electrical connection of the bonnet switch (A).
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Remove the glow plug relay (B).
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Remove the fuse holder (C).
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Remove the wiring harness cable tie from the battery tray.
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Remove the battery tray (D).
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4.
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Undo the wiring and detach the fuse box:
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Remove the fuse box cover (A).
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Detach the fuse box (B).
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Remove the front bolt of the fuse box (C).
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Unplug the front connector beneath the fuse box.
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Remove the hose clip (D) and ground connection (D) of the wiring that sits on the structural member.
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Remove the connector (E) on the structural member.
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5.
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Man. gearbox:
Remove the connection of the reversing light switch.
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6.
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Remove the clips (A) and connectors (B) of the radiator fans and charge air valve.
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7.
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Remove the clips (A) holding the wiring on the left side and rear of the engine.
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8.
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Remove the connectors (A) of the pressure sensor for the particle trap and temperature sensor.
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9.
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Undo the connector on the back of the engine.
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10.
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Remove the connectors (A) and clips of the fuel filter.
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11.
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Remove the bracket (B) to access the clips holding the wiring. Remove the clips.
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12.
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Remove the air filter housing:
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Unplug the connector (A) from the mass air flow sensor.
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Undo the hose from the mass air flow sensor (B).
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Remove the bolts (C) and lift out the air filter housing.
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13.
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Remove the clips (A) on the right rear structural member and the cable tie (B).
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14.
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Remove the connector (A) on the AC pipe and the clip (B) on the right structural member.
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15.
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Remove the clips (A) from the upper radiator member.
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16.
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Raise the vehicle to a suitable work height.
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17.
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Remove the bumper bolts in the wing liner (A).
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18.
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Remove the spoiler shield (A). Unplug the connector (B) and remove the connector (C). Remove the lower engine cover (D).
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19.
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Cars with headlamp washer:
Detach the washer hose. Suspend and plug as necessary.
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20.
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Pry the bumper shell corner from the holder bracket and lift off the bumper shell.
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21.
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Remove the right side cover and detach the wiring:
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Remove the right side cover (A).
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Remove the cable tie (B) holding the wiring around the control module.
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Remove the right control module connection (C).
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22.
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Remove the bracket (A) protecting the AC compressor wiring. Release the wiring so that it hangs freely down in the engine bay.
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23.
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Remove the ground connection (A) on the engine.
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25.
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Remove the electrical connections (B) from the starter motor.
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26.
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Remove the electrical connections (A) from the generator.
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27.
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Remove the electrical connections (A) from the power steering pump and the clip holding the wiring.
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1.
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Position the new wiring in the engine bay and bring down the part to be connected to the control module.
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2.
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Route the wiring of the power steering pump between the engine and power steering hose. Plug in the power steering pump connectors (A) and fit the clip.
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3.
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Attach the electrical connections (A) to the generator.
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4.
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Attach the electrical connections (B) to the starter motor.
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6.
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Attach the ground connection (A) on the engine.
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7.
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Fit the bracket (A) protecting the AC compressor wiring.
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8.
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Fit the right side cover and secure the wiring:
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Fit the right side cover (A).
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Fit the cable tie (B) holding the wiring around the control module.
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Attach the right control module connection (C).
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9.
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Fit the bumper shell:
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Check that the cellular block sits correctly in the shell.
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Position the bumper. Press the shell rearward and press the shell clips into the holder.
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10.
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Cars with headlamp washer:
Attach the washer hose.
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11.
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Fit the lower engine cover (D), the connector (C) and plug in the connector (B). Fit the spoiler shield (A).
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12.
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Fit the bumper bolts in the wing liner (A).
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14.
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Fit the upper radiator member clips (A).
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15.
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Fit the connector (A) on the AC pipe and the clip (B) on the right structural member.
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16.
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Fit the clips (A) on the right rear structural member and the cable tie (B).
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17.
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Fit the air filter housing:
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Fit the air filter housing (C).
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Attach the hose to the mass air flow sensor (B).
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Plug in the mass air flow sensor connector (A).
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18.
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Fit the connectors and clips of the fuel filter.
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19.
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Fit the clips (A) and bracket (B).
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20.
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Plug in the connectors (A) on the back of the engine.
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21.
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Plug in the connectors (A) of the pressure sensor for the particle trap and temperature sensor.
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22.
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Fit the clips (A) holding the wiring on the left side and rear of the engine.
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23.
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Fit the clips (A) and connections (B) of the radiator fans and charge air valve.
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24.
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Man. gearbox:
Attach the connection of the reversing light switch.
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25.
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Connect the wiring and fuse box:
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Attach the connector (E) on the structural member.
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Fit the hose clip (D) around the wiring that sits on the structural member.
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Plug in the front connector beneath the detached fuse box.
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Fit the front bolt of the fuse box (C).
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Fit the fuse box cover (A).
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26.
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Fit the battery tray and components:
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Fit the battery tray (D).
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Fit the wiring harness cable tie to the battery tray.
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Fit the fuse holder (C).
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Fit the glow plug relay (B).
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Attach the electrical connection of the bonnet switch (A).
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Position the battery and fit the bolt to the battery's lock lug.
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Connect the positive cable of the battery.
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Connect the positive cable that runs between the fuse box and the positive battery terminal.
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Connect the negative cable of the battery.
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28.
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Fit the insulation, upper engine cover and battery cover.
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29.
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Check the fit of the bumper and adjust as necessary.
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