Remove Wiring Harness For Engine

Note!

^ Since the Motronik has several adaptive systems, terminal 26 of the DME connector is permanently positive.

^ If the connector is disconnected from the control module or if the vehicle battery is disconnected, the engine must first run 250 seconds before the first adaptation phase begins.

^ The DME control module also has a non-volatile fault memory. Therefore, before disconnecting the battery, the fault memory must be read out and the radio code must be found out!

1. Disconnect the battery and cover terminal or battery.

2. Remove the heater blower or bypass air flap, disconnect the ballast resistor on the heating pipe, and clip it in again.





3. Remove the cover from the relay carrier in the engine compartment. Disconnect the plug connections carefully (risk of breakage). Counter when pulling off.





4. Remove the air cleaner assembly and hot film air flow sensor. Disconnect the air flow sensor from the air cleaner housing. lake the air cleaner housing out of the rubber mounts. Unplug the air flow sensor and disconnect from the air cleaner housing by turning.





5. Remove the positive crankcase ventilation hose -arrow-.

Note
The square fastening nuts of the air conditioning compressor holder screws can fall to the floor after they have been unscrewed.

6. Unscrew the four air conditioning compressor holder screws and release the clamp. Disconnect the plug connections and set the air conditioning compressor with a stable base down on the right side section.





7. Release the upper hose clamps (6 pieces / 3 left and 3 right) of the intake pipes.





8. Disconnect the connector from the holder and release the hose from the tank vent -arrow- and remove.





9. Disengage the accelerator cables -arrows- and unscrew the screw of the counter holder. Press the accelerator cables out of the holder. Pull off the hose -1-.





10. Remove the centre and right vent hose on the throttle body.





Vent hose





11. Unscrew the screws -1- of the oil pressure sensor, disconnect I the connector and disconnect the ground strap -arrow-. Lay the oil pressure sensor aside.





12. Pull all vacuum connections and connectors on the intake distributor. Remove the vent hose -1-. Mark the vacuum connections.





1 check valve

Note!
All intake pipes must be sealed (foreign objects).





13. Remove the complete Intake distributor (right, left, and centre)





14. Remove the two rubberized clamps of the wiring harness.





Rubberized clamp





15. Release the ground cable from the intake pipe.





16. Disconnect the connector from the fan belt monitoring and remove the fan belt monitor.

17. Remove the air cowl of the cooling fan. Unscrew the 3 screws and remove the air cowl.





18. Release the cooling fan restraining strap and unscrew the screw. Tilt the cooling fan forward.





19. Unscrew the generator housing screws. Release the cable from the generator. Press the rubber grommet out of the air cowl and pull out the lines.





20. Release the ignition wire retainer and unclip the fastening clip.





21. Unscrew the two screws of the fuel gallery on the right and pull out the tab washers of the injection valve. Then push the fuel gallery lightly toward the rear.

22. Unplug the connectors from the injection valves, distributor ignition, ignition coil (connections are screwed in), oil pressure sensor (connections are screwed in), oil temperature sensor and secondary air pump.

23. Pull the wiring harness approx. 100 mm under the crankcase vent tube toward the passenger compartment.

24. Remove thermal motor protection.





25. Remove the warm air pipe on the right -arrows-. To do this, unscrew the two hexagon socket head bolts and release the hose straps.





26. Remove the transmission vent hose and suction hose to the turbocharger. To do so, release the upper screw4ype hose clamp -arrow- and the lower clamp -arrow-.





27. Unscrew the ground cable -arrow- on the starter. To do this, unscrew the hexagon socket nut.





28. Release the connections from the starter -1 + 2- and cut off the 2 tie-wraps -arrow-.





29. Pull out reversing switch connector. To do this, pull out the rubber grommet and the two pins.





30. Pull out rubber grommet -arrow- from the wiring harness.

Note!
Carefully press the wiring harness past the pipes. Avoid damage.





31. Pull wiring harness up and out. Doing this requires a second person. One person must press the wiring harness from below through the opening in the engine compartment while the other person pulls the wiring harness out.