Removing and installing/replacing wiring harness section for engine sensor system module 2 (S55 engine)

CAUTION: Read and comply with notes on PROTECTION AGAINST ELECTROSTATIC DISCHARGE (ESD PROTECTION) !

Necessary preliminary work:

Read out the fault memory of the DME control unit.
Switch off ignition.
Remove left INTAKE FILTER HOUSING .
Remove right-hand INTAKE SILENCER HOUSING .
Remove CORROSION PROTECTION COVER .
Remove FRONT AIR DUCT .

Removal:

Unfasten hose clamp (2).

Unlock and disconnect the plug connection (1).

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Do not detach coolant hoses (2) from charge air cooler (1).

Detach the coolant hose from the clamp (3).

Do not detach coolant hose (4) from charge air cooler (1).

Do not drain coolant!

Release charge air cooler (1) upwards from the rubber mounts and place to one side, do not remove.

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Disconnect all plug connections (1) on engine control unit.

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Release screws (1).

Release holder (2) and lay to one side.

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Unlock connector (1) and unlock and detach from the tank ventilation line.

Unlock connector (2) and unlock and detach from the tank vent valve.

Remove connector (3) from DME control unit.

Unlock connector (4) to the wiring harness section of sensor system 1 and detach.

Unlock connector (5) from the rail pressure sensor and detach.

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Unlock and detach connector (1) from hot film air mass meter of cylinder bank 2.

Unlock connector (2) and unlock and detach from the tank vent valve.

Unlock connector (3) from oil pressure sensor and detach.

Unlock and detach connector (4) from the hot film air mass meter of cylinder bank 1.

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Release screws (1).

Unlock and detach connector (2) from electrical wastegate valve controller, cylinder bank 1.

Unlock connector (3) vent hose and detach.

Unlock connector (4) from the exhaust camshaft sensor and detach.

Unlock connector (5) from VANOS solenoid valve and detach.

Unlock connector (6) from VANOS solenoid valve and detach.

Unlock connector (7) from the exhaust camshaft sensor and detach.

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Unlock and detach connector (1) from electrical wastegate valve controller, cylinder bank 2.

Unlock and detach connector (2) from hydraulic valve connector.

Unlock and detach connector (3) from the auxiliary coolant pump.

Unlock and detach connector (4) from coolant thermostat.

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Release wiring harness if necessary from existing clips and clamps.

Feed out wiring harness and remove.

Installation:

Attach connector (1) to the fuel tank ventilation line and lock audibly.

Connect the connector (2) to the tank vent valve and lock audibly.

Route the connector (3) to the DME control unit.

Attach connector (4) to the wiring harness section of sensor system 1 and lock audibly.

Attach connector (5) to the rail pressure sensor and lock audibly.

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Attach connector (1) to the hot film air mass meter of cylinder bank 2 and lock audibly.

Connect the connector (2) to the tank vent valve and lock audibly.

Connect the connector (3) to the oil pressure sensor and lock it audibly.

Attach connector (4) to the hot film air mass meter of cylinder bank 1 and lock audibly.

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Tighten screws (1).

Tightening torque 12 90 1AZ .

Attach connector (2) to the electrical wastegate valve controller of cylinder bank 1 and lock audibly.

Attach connector (3) to vent hose and lock audibly.

Attach connector (4) to the exhaust camshaft sensor and lock audibly.

Attach connector (5) to the VANOS solenoid valve and lock audibly.

Attach connector (6) to the VANOS solenoid valve and lock audibly.

Attach connector (7) to the exhaust camshaft sensor and lock audibly.

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Attach connector (1) to the electrical wastegate valve controller of cylinder bank 2 and lock audibly.

Attach connector (2) to the hydraulic valve and lock audibly.

Attach connector (3) to the auxiliary coolant pump and lock audibly.

Attach connector (4) to the coolant thermostat and lock audibly.

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Mount holder (2).

Tighten screws (1).

Tightening torque 12 90 6AZ .

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Attach and audibly lock all plug connections (1) on the engine control unit.

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Feed the charge air cooler (1) into the rubber mounts and latch.

Check coolant hoses (2) for a correct fit on the charge air cooler.

Secure coolant hoses (3) with clamp (3).

Check coolant hose (4) for a correct fit on the charge air cooler.

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Tighten hose clamp (2).

Tightening torque 17 10 9AZ .

Connect and lock the connector (1).

Connector (1) must snap audibly into place.

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Installation note:

Check wiring harness installation arrangement.

Check plug connections for correct fit.

Check stored fault message.

Delete the fault memory.

Required follow-up work:

Install left INTAKE FILTER HOUSING .
Install right INTAKE FILTER HOUSING .
Install CORROSION PROTECTION COVER .
Install FRONT AIR DUCT .
Read out the fault memory of the DME control unit.