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Body Wiring Harness Replacement

Body Wiring Harness Replacement


Special Tools

BO-569-A Plug Lifter

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Note

For a better description the following graphic shows the vehicle without attaching parts.



Note

For a better description the following graphic shows the vehicle without attaching parts.



Note

Arrange a place to embed the removed parts.



1. Install the MDI, turn on the ignition and read out the trouble codes.

Delete them and read out the trouble codes again. If there are any trouble codes notice them.

2. Lift up the vehicle. Refer to Lifting and Jacking the Vehicle .

3. Open the hood and remove the battery and the battery tray. Refer to Battery Replacement and Battery Tray Replacement (Diesel) Battery Tray Replacement (LHU/A20NFT) .

4. Remove the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement

5. Remove the front compartment fuse block housing. Refer to Front Compartment Fuse Block Housing Replacement .

6. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement (Diesel) Radiator Surge Tank Replacement (LAU/A28NER) Radiator Surge Tank Replacement (LLU/A16LET) .

7. Remove the power vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement (Left Hand Drive) Power Vacuum Brake Booster Replacement (Right Hand Drive)

8. Remove the electronic brake control module. Refer to Electronic Brake Control Module Replacement .

9. Raise the vehicle half its high.

10. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .

11. Remove the rear bumper. Refer to Rear Bumper Fascia Replacement .

12. Remove all of the wheelhouse covers. Refer to Front Wheelhouse Front Liner Replacement and Rear Wheelhouse Panel Liner Replacement .

13. Disconnect all of the electrical connectors in all wheelhouses.

14. Lower the vehicle and remove the headlamp left side. Refer to Headlamp Replacement .

15. Remove both rear lamps. Refer to Tail Lamp Replacement .

16. Release the body wiring harness from the cross car beam. Make pictures for the correct routing.

17. Remove the driver and passenger seat. Refer to Driver or Passenger Seat Replacement (8-Way Power) Driver or Passenger Seat Replacement (2/4/6-Way Hybrid, 6-Way Hybrid Sport) .

18. Remove the rear seat and rear seat back. Refer to Rear Seat Replacement (Back 40 Percent) Rear Seat Replacement (Back 60 Percent) .

19. Remove the rear window trim finish panel. Refer to Rear Window Trim Finish Panel Replacement .

20. Remove the roof headliner. Refer to Headlining Trim Panel Replacement (Without Sunroof) Headlining Trim Panel Replacement (With Sunroof) .

21. Remove the front floor console. Refer to Front Floor Console Replacement .

22. Release the 4 shift control lever fasteners.

23. Remove the front and rear carpet. Refer to Front Floor Panel Carpet Replacement and Rear Floor Panel Carpet Replacement .

24. Remove the rear compartment carpet. Refer to Rear Compartment Floor Panel Carpet Replacement .

25. Remove the steering column. Refer to Steering Column Replacement .

26. Remove the instrument panel. Refer to Instrument Panel Assembly Replacement .

27. Release all mass connectors of the instrument panel wiring harness and then disconnect the X1 connector between the instrument and body wiring harness.

• Make pictures for correct orientation.

• Remove the instrument panel wiring harness.

28. Remove the instrument panel tie bar. Refer to Instrument Panel Tie Bar Replacement .

Secure the HVAC module at the body.

29. Remove the pedal module. Refer to Brake, Accelerator, and Clutch Pedal Replacement (Left Hand Drive) Brake, Accelerator, and Clutch Pedal Replacement (Right Hand Drive) .

30. Make pictures from the routing and fixing points of the body wiring harness for the orientation.

31. Disconnect all electrical connectors and unscrew the ground cables.

32. Release the X1 plug connector (1) from the a-pillar using the BO-569-A plug lifter.


33. Release all fixations.

34. Take care about destroyed cable straps and harness guidance regarding noises and rattle.

35. Remove the body wiring harness guidance in the firewall and draw-out the body wiring harness from the engine compartment through the passenger compartment.

36. Remove the old body wiring harness and lay it on the floor.


37. Unpack the new body wiring harness and compare the old with the new harness concerning quantity of fixing points, cable straps, guides, part numbers and pin assignments.


Installation Procedure


1. After compare the new with the old harness lay the new body wiring harness into the passenger compartment and carry the new harness through the firewall into the engine compartment.

2.
Note

Take care for the leak tightness.


Then install the wiring harness guidance in the firewall.

3. Now check that there is no rotation and fix the new body wiring harness.

4.
Note

Take care for the correct counterpart and the pin assignment. Use the pictures for orientation.


Connect all electrical connectors.

5. Refer to Fastener Caution .

Tighten all ground cables on the grounding studs to 9 Nm (80 lb in) .

6. Install the pedal module. Refer to Brake, Accelerator, and Clutch Pedal Replacement (Left Hand Drive) Brake, Accelerator, and Clutch Pedal Replacement (Right Hand Drive) .

7.
Note

Tighten the pedal module fastener after the installation of the instrument tie bar due to have more clearance.


Install the instrument panel tie bar. Refer to Instrument Panel Tie Bar Replacement .

8.
Note

Take care about rotations. Use the pictures for correct orientation and use new cable straps.


Install the instrument panel wiring harness.

9. Install the instrument panel. Refer to Instrument Panel Assembly Replacement .

10. Install the steering column. Refer to Steering Column Replacement .

11. Previous to the installation of the front and rear carpet, clean the car inside and remove all used tools.

12. Install the rear compartment carpet. Refer to Rear Compartment Floor Panel Carpet Replacement .

13. Install the front and rear carpet. Refer to Front Floor Panel Carpet Replacement and Rear Floor Panel Carpet Replacement .

14. Tighten the 4 shift control lever fasteners to 15 Nm (11 lb ft) .

15. Install the front floor console. Refer to Front Floor Console Replacement .

16. Install the headlining. Refer to Headlining Trim Panel Replacement (Without Sunroof) Headlining Trim Panel Replacement (With Sunroof) .

17. Install the rear window trim finish panel. Refer to Rear Window Trim Finish Panel Replacement .

18. Install the rear seat and rear seat back. Refer to Rear Seat Replacement (Back 40 Percent) Rear Seat Replacement (Back 60 Percent) .

19. Install the driver and passenger seat. Refer to Driver or Passenger Seat Replacement (8-Way Power) Driver or Passenger Seat Replacement (2/4/6-Way Hybrid, 6-Way Hybrid Sport) .

20. Lift up the vehicle. Refer to Lifting and Jacking the Vehicle .

21.
Note

Use the pictures for the correct routing. Use new cable straps.


Install the body wiring harness on the cross car beam.

22. Install both rear lamps. Refer to Tail Lamp Replacement .

23. Install the headlamp left side. Refer to Headlamp Replacement .

24.
Note

Take care for the correct counterpart and the pin assignment.


Raise the vehicle half its high and connect all the electrical connectors in all wheelhouses.

25. Install all wheelhouse covers. Refer to Front Wheelhouse Front Liner Replacement and Rear Wheelhouse Panel Liner Replacement .

26. Install the rear bumper. Refer to Rear Bumper Fascia Replacement .

27. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .

28. Lower the vehicle and install the electronic brake control module. Refer to Electronic Brake Control Module Replacement .

29.
Note

Tighten the antilock brake system control module fastener after the installation of the brake pipes and the vacuum brake booster due to have more clearance.


Install the power vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement (Left Hand Drive) Power Vacuum Brake Booster Replacement (Right Hand Drive)

30. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement (Diesel) Radiator Surge Tank Replacement (LAU/A28NER) Radiator Surge Tank Replacement (LLU/A16LET) .

31. Install the front compartment fuse block housing. Refer to Front Compartment Fuse Block Housing Replacement .

32. Install the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement

33. Install the battery tray and the battery. Refer to Battery Tray Replacement (Diesel) Battery Tray Replacement (LHU/A20NFT) and Battery Replacement .

34. Install the MDI, turn on the ignition and read out the trouble codes.

If there are any stored DTC s delete them and read out the trouble codes again.

35. Aim the headlamps. Refer to Headlamp Aiming (Base) Headlamp Aiming (Check and Adjust) .

36. Program the volatile memory and then check all electrical functions and make a test run.

37. Clean the car outside and inside.