Installing Wire Harness In Engine Compartment

Fig 1: Connector Overview For Wire Harness In Engine Compartment

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1. 1-2 - Airbag sensor connector
2. 3-4 - Fan connectors
3. 5 - Plug connection for front left wire harness
4. 6-7 - Ground strap for front cross member, left and right
5. 8-9 - Plug connections for front right wire harness
6. 10-11 - Bulb holder for direction indicator, left and right
7. 12-13 - Connector for headlight, left and right
8. 14-15 - Transmitter (trigger) for TPM, left and right
9. 16-17 - Connector for angle sensor for headlight levelling system, left and right
10. 18 - Servo valve connector
11. 19 - Additional heating connector
12. 20 - Plug connection for tank for windscreen washer system
13. 21-22 - Plug connection for ABS sensor and brake pad wear indicator, left and right
14. 23 - Circulating pump connector
15. 24-25 - Connector for lateral acceleration sensor
16. 26 - Connector for coolant expansion tank
17. 27-30 - Connector for plenum panel E-box
18. 31 - Rubber sleeve
19. 32 - Ground strap for right firewall
20. 33 - Connector for hydraulic unit
21. 34 - Rubber sleeve
22. 35 - Ground strap
23. 36 - Connector for wiper motor
24. 37 - Air quality sensor connector
25. 38 - Connector for brake fluid reservoir
26. 39 - Brake booster connector
27. 40 - Way-sensor connector (brake assist system)
28. 41 - Pressure sensor connector (brake assist system)
29. 42 - Rubber sleeve

1. Install main wire harness - dashboard area and centre console. → Installing Main Wiring Harness 
2. Fit rubber sleeve -42- on the centre firewall.
   1. 2.1. Push wire harness through from the interior towards the engine compartment and fit rubber sleeve on the centre firewall -arrow A-  .
   2. 2.2. Clip in wire harness on centre firewall with the retaining clip -arrow B-  .
      Fig 2: Fitting Rubber Sleeve On Centre Firewall

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3. Secure wire harness on the centre firewall.
   1. 3.1. Insert wire harness into the two supports -arrows A-  and close the supports -arrows B-  .
   2. 3.2. Insert line into the two retaining clips -arrows C-  and close the retaining clips -arrows D-  .
      Fig 3: Securing Wire Harness On Centre Firewall

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4. Plug in pressure sensor connector (brake assist system) -41-  .
   Fig 4: Plugging In Pressure Sensor Connector (Brake Assist System)

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   1. 4.1. Plug in connector on pressure sensor (brake assist system) -arrow-  until it engages securely.
5. Plug in connector on way-sensor (brake assist system) -40-  .
   Fig 5: Plugging In Connector On Way-Sensor (Brake Assist System)

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   1. 5.1. Plug in connector on way-sensor (brake assist system) -arrow-  until it engages securely.
6. Plug in connector on brake booster -39-  .
   Fig 6: Plugging In Connector On Brake Booster

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   1. 6.1. Plug in connector on brake booster -arrow-  until it engages securely.
7. Plug in connector on brake fluid reservoir -38-  .
   Fig 7: Plugging In Connector On Brake Fluid Reservoir

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   1. 7.1. Plug in connector on brake fluid reservoir -arrow-  until it engages securely.
8. Screw on ground strap -35- on centre firewall.
   Fig 8: Securing Ground Strap On Centre Firewall

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   1. 8.1. Clip in wire harness on firewall with the retaining clip -arrow A-  .
   2. 8.2. Connect ground strap together with the twist lock to the threaded bolt on the centre firewall -arrow B-  and secure with fastening nut. → Tightening torque: 9 Nm (6.5 ftlb.) 
9. Fit rubber sleeve -34- and plug in connector on hydraulic unit -33-  .
   Fig 9: Plugging In Connector On Hydraulic Unit

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   1. 9.1. Push front right wire harness through from the interior towards the engine compartment and fit rubber sleeve on the right firewall -arrow A-  .
   2. 9.2. Route wire harness in plenum panel and clip it in at the retaining clips -arrows B-  .
   3. 9.3. Plug in connector on hydraulic unit -arrow C-  and lock it -arrow D-  until the locking mechanism engages securely.
10. Press rubber sleeve into the bulkhead -arrow A-  and clip in wire harness with the retaining clips -arrow B-  .
    Fig 10: Pressing Rubber Sleeve Into Bulkhead

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11. Screw on ground strap for right firewall -32-  .
    Fig 11: Securing Ground Strap

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    1. 11.1. Connect ground strap together with the twist lock to the threaded bolt on the right firewall -arrow-  and secure it with the fastening nut. → Tightening torque: 9 Nm (6.5 ftlb.) 
12. Clip in wire harness on the upper side member with the retaining clips -arrow-  .
    Fig 12: Clipping In Wire Harness On Upper Side Member

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13. Fit rubber sleeve -31-  on the left firewall.
    1. 13.1. Push front left wire harness through from the interior towards the engine compartment and fit rubber sleeve on the left firewall -arrow-  .
       Fig 13: Fitting Rubber Sleeve On Left Firewall

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14. Route wire harness in plenum panel and clip it in at the retaining clips -arrows-  .
    Fig 14: Clipping In Wire Harness In Plenum Panel

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15. Press rubber sleeve into bulkhead -arrow-  .
    Fig 15: Pressing Rubber Sleeve Into Bulkhead

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16. Secure wire harness on upper right side member.
    1. 16.1. Route wire harness and clip it in at the retaining clips -arrows A-  .
    2. 16.2. Push wire harness on upper side member onto the clips -arrows B-  .
       Fig 16: Securing Wire Harness On Upper Right Side Member

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17. Secure wire harness on upper left side member.
    1. 17.1. Route wire harness and clip it in at the retaining clips -arrows A-  .
    2. 17.2. Push wire harness on upper side member onto the clips -arrows B-  .
       Fig 17: Securing Wire Harness On Upper Left Side Member

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18. Plug in connector on right lateral acceleration sensor -25-  .
    Fig 18: Plugging In Connector On Right Lateral Acceleration Sensor

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    1. 18.1. Plug in connector on lateral acceleration sensor in right wheel housing -arrow A-  until the connector engages securely.
    2. 18.2. Route wire harness and clip it in on the wheel housing with the retaining clips -arrow B-  .
19. Plug in connector on left lateral acceleration sensor -24-  and circulating pump connector -23-  .
    Fig 19: Plugging In Connector On Left Lateral Acceleration Sensor

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    1. 19.1. Plug in connector on lateral acceleration sensor in left wheel housing -arrow A-  until the connector engages securely.
    2. 19.2. Plug in connector on circulating pump -arrow B-  until the connector engages securely.
    3. 19.3. Route wire harness and clip it in on the left wheel housing with the three retaining clips -arrows C-  .
20. Connect plug connection for ABS sensor and brake pad wear indicator at the left and right -21 and 22-  .
    Fig 20: Connecting Plug Connection For ABS Sensor And Brake Pad Wear Indicator

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    1. 20.1. Route wire harness and clip it in on the left and right wheel housing with the retaining clips -arrow A-  .
    2. 20.2. Clip in connector socket for ABS sensor and brake pad wear indicator -arrow B-  .
    3. 20.3. Connect plug connection for ABS sensor and brake pad wear indicator -arrow C-  until the plug connection engages securely.
21. Connect plug connection on tank for windscreen washer system -20-  until the plug connection engages securely. → Installing Reservoir For Windscreen Washer System
22. Plug in connector for additional heating -19-  until it engages securely. → Installing Complete Heater
23. Plug in connector on servo valve -18-  until it engages securely.
    Fig 21: Plugging In Connector On Servo Valve

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24. Plug in connector on angle sensor for headlight levelling system at the left and right -16 and 17-  .
    Fig 22: Plugging In Connector On Angle Sensor For Headlight Levelling System

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    1. 24.1. Plug in connectors on angle sensor for headlight levelling system -arrow A-  until the connectors engage securely.
    2. 24.2. Secure wire harness on the left side to the refrigerant line with a new tie-wrap -arrow B-  .
25. Plug in connector on TPM transmitter (trigger) -14 and 15-  until it engages securely. → Installing Transmitter (Trigger) For Tyre Pressure Monitoring (TPM)
26. Clip in wire harness at the retaining clips close to the mounting for the right headlight -arrows-  .
    Fig 23: Clipping In Wire Harness Close To Mounting For Right Headlight

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27. Clip in wire harness at the retaining clips close to the mounting for the left headlight -arrows-  .
    Fig 24: Clipping In Wire Harness Close To Mounting For Left Headlight

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28. Secure ground strap for front right cross member -7-  .
    Fig 25: Securing Ground Strap For Front Right Cross Member

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    1. 28.1. Route wire harness and clip it in on the front side member with the retaining clips -arrow A-  .
    2. 28.2. Push ground straps together with the twist lock onto the threaded bolt on the front side member -arrow B-  and screw on the fastening nut. → Tightening torque: 9 Nm (6.5 ftlb.) 
29. Connect plug connection for front wire harness -5-  and secure ground strap for front cross member -6-  .
    Fig 26: Connecting Plug Connection For Front Wire Harness

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    1. 29.1. Clip connector socket for front wire harness in at the front of the left cross member -arrow A-  .
    2. 29.2. Plug in connector -arrow B-  until it engages securely.
    3. 29.3. Connect ground straps together with the twist lock to the threaded bolt -arrow C-  and screw on the fastening nut. → Tightening torque: 9 Nm (6.5 ftlb.) 
30. Plug in connectors -3 and 4-  on fan.
    1. 30.1. Plug in connectors on fan -arrows A-  until they engage securely.
    2. 30.2. Clip in wire harness at the retaining clips -arrows B-  .
    3. 30.3. Connect ground straps together with the twist lock to the threaded bolt -arrow C-  and screw on the fastening nut. → Tightening torque: 9 Nm (6.5 ftlb.) 
       Fig 27: Plugging In Connectors On Fan

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31. Plug in connectors on airbag sensor at the left and right -1 and 2-  until the connectors engage securely. → Installing Airbag Sensor
32. Install firewall at the left and right.
    Fig 28: Installing Firewall

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    1. 32.1. Fit seal on the body and spray with silicon spray.
    2. 32.2. Fit firewall and position it correctly.
    3. 32.3. Screw in fastening screws -3-  . → Tightening torque: 9 Nm (6.5 ftlb.) 
    4. 32.4. Clip in wire harness with the retaining clips -2-  .
    5. 32.5. Connect oxygen sensor connectors -1-  until they engage securely and clip oxygen sensor connectors into the support -1-  . → Installing Oxygen Sensor Ahead Of Catalytic Converter → Installing Oxygen Sensor Behind Catalytic Converter
    6. 32.6. Secure PDCC reservoir on the plenum panel.
33. Install intake manifold for heating/fresh-air unit.
    1. 33.1. Position intake manifold and secure with the fastening nuts -1-  . → Tightening torque: 6 Nm (4.5 ftlb.) 
    2. 33.2. Close retaining clips in the intake manifold -arrow A-  .
    3. 33.3. Insert air inlet grille -arrow B-  .
    4. 33.4. Clip in wire harness on the intake manifold -arrow C-  and push in retaining clips for wire harness on the intake manifold -arrow D-  .
       Fig 29: Installing Intake Manifold On Heating/Fresh Air Unit

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34. Install support for DME control unit.
    1. 34.1. Position support for DME control unit -arrow-  and secure with the fastening nuts -3-  and fastening screw -2-  . → Tightening torque: 8 Nm (6.0 ftlb.)  → Tightening torque: 8 Nm (6.0 ftlb.) 
       Fig 30: Installing Support For DME Control Unit

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    2. 34.2. Insert wire harness for DME control unit into the retaining clips -arrow A-  and close the retaining clips -arrow B-  .
    3. 34.3. Fit ground straps together with the twist lock to the stud and secure with the fastening nut -1-  . → Tightening torque: 9 Nm (6.5 ftlb.) 
       Fig 31: Securing Ground Straps

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