Removing and Installing Wiring Harness For Battery Wiring

Removing And Installing Wire Harness For Battery Wiring

Tools







Technical Values







Preliminary work

Preliminary work for ground strap and B+ line of battery
1. Disconnect battery.

Preliminary work for B+ line from power distributor to engine connection point
1. Disconnect battery.
2. Remove current distributor.
3. Unscrew triggering unit.

INFORMATION: For vehicles with manual transmission. For vehicles with automatic transmission.

4. Remove shift console.

INFORMATION: For vehicles with automatic transmission.

5. Remove selector frame.
6. Remove parking-brake lever.
7. Remove rear wall cover.
8. Remove engine-compartment lid.

Preliminary work for B+ line from starter to engine connection point
1. Disconnect battery.
2. Remove throttle housing.
3. Remove generator.

Preliminary work for engine ground strap
1. Lift the vehicle.

Removing wire harness for battery wiring

Removing ground strap and B+ line of battery












1. Remove ground strap for battery -1-.
1.1. Unscrew fastening nut of battery ground strap to body and remove ground strap for battery.







2. Remove B+ line for battery -2-.
2.1. Cut through the positive cable of main wire harness -3- at the place indicated -arrows-.
2.2. Remove binding band from main wire harness until the sheathing of the positive cable -3- can be removed -Arrow A-.
2.3. Unscrew B+ line from battery.
2.4. Release and pull off B+ line from power distributor
2.5. Remove B+ line of battery.

Removing B+ line from power distributor to engine connection point












1. Unclip B+ line -3- on heater/air-conditioning unit.
1.1. Unclip B+ line at tie-wrap from heater/air-conditioning unit.
1.2. Disconnect B+ line from main wire harness. To do this, remove the tie-wrap and the binding band.







2. Unclip B+ line -3- at unit carrier.
2.1. Unclip B+ line at retaining clip -arrow- from unit carrier.
2.2. Pull B+ line out through unit carrier.







3. Loosen B+ lead -3- at centre tunnel.
3.1. Pull B+ line out of the two holders -arrows-.
3.2. Push B+ line under the carpet away from the direction of travel.







4. Unscrew B+ line -3- at box for B+ line -4-.
4.1. Open box for B+ line at engine -Arrow A-, unscrew fastening nut -Arrow B- and remove the B+ line.

5. Remove B+ line -3-.

Removing B+ line from starter to engine connection point







1. Unscrew fastening nut of starter lead for terminal 30 and remove starter lead.







2. Unscrew B+ line -5- at box for B+ line -4-.
2.1. Open box for B+ line at engine -Arrow A-, unscrew fastening nut -Arrow B- and remove the B+ line.

3. Remove B+ line -5-.

Removing engine ground strap












1. Remove engine ground strap -6-.
1.1. Unscrew fastening screw on engine and fastening nut on body, and remove ground strap.

Installing wire harness for battery wiring

Installing ground strap and B+ line of battery












1. Install ground strap for battery -1-.
1.1. Screw down battery ground strap on the body with the fastening nut. Tightening torque: 5 Nm (3.5 ftlb.)

2. Install B+ line for battery -2-.
2.1. Push the B+ line of the battery onto the mounting point at the power distributor as far as the stop. Check that the B+ line sits firmly.
2.2. Tighten B+ line to battery. Tightening torque: 5 Nm (3.5 ftlb.)

INFORMATION:
- The electric lines are located in the plenum panel and are thus exposed to the highest demands.
- The greatest care must be used in the individual work steps for stripping insulation from, crimping, and shrinking/insulating the electric lines.
- The procedure for stripping insulation from, crimping, and shrinking/insulating the electric lines must be complied with and observed. The procedures are described in detail in the repair kit for harnesses NR.155-1.
- Crimping samples are to be prepared before beginning work.







3. Crimp the positive cable.
3.1. Trim the new positive cable -4- to the -dimension X = approx. 20 cm- and strip the insulation.







3.2. Strip insulation off original positive cable of main wire harness -3- and push on the shrink-fit hose -5-.
3.3. Crimp crimping sleeve -6- using the hand crimping pliers from the repair kit for harnesses NR.155-1 to the positive cable -3-.
3.4. Crimp crimping sleeve -6- using the hand crimping pliers from the repair kit for harnesses NR.155-1 to the new positive cable -4-. Check the crimp connection carefully.
3.5. Slide the shrink-fit hose over the crimp connection and carefully shrink it using the hot-air blower with special nozzle (recommended accessories for the repair kit for harnesses) so that it is watertight.
3.6. Tie positive cable to the main wire harness with adhesive tape.

Installing B+ line from power distributor to engine connection point







1. Lay B+ line -3-.







2. Screw down B+ line -3- at box for B+ line -4-.
2.1. Insert B+ line into the box -Arrow A- and tighten with the fastening nut. Tightening torque: 23 Nm (17 ftlb.)
2.2. Close box for B+ line on engine -Arrow B-.







3. Fasten B+ line -3- at centre tunnel.
3.1. Push B+ line under the carpet in the direction of travel.
3.2. Insert B+ line into the two holders -arrows-.







4. Clip in B+ line -3- at unit carrier.
4.1. Push B+ line through the unit carrier and across the footwell air vent.
4.2. Clip in B+ line with retaining clip -arrow- at unit carrier.







5. Clip in B+ line -3- at heater/air-conditioning unit.
5.1. Secure B+ line to main wire harness with two new tie-wraps.
5.2. Clip in B+ line at heater/air-conditioning unit with the tie-wraps.

Installing B+ line from starter to engine connection point







1. Lay B+ line -5-.







2. Screw down B+ line -5- at box for B+ line -4-.
2.1. Insert B+ line into the box -Arrow A- and tighten with the fastening nut. Tightening torque: 23 Nm (17 ftlb.)
2.2. Close box for B+ line on engine -Arrow B-.

3. Position starter lead for terminal 30 and secure with fastening nut. Tightening torque: 18 Nm (13 ftlb.)

Fitting ground strap to engine












1. Fit engine ground strap -6-.
1.1. Position ground strap and screw down with the fastening screw and fastening nut. Tightening torque: 23 Nm (17 ftlb.) Tightening torque: 23 Nm (17 ftlb.)

Subsequent work

Subsequent work for ground strap and B+ line of battery
1. Carry out work instructions after disconnecting the battery.

Subsequent work for B+ line from power distributor to engine connection point
1. Install engine-compartment lid.
2. Install rear wall cover.
3. Install parking-brake lever.

INFORMATION: For vehicles with automatic transmission.

4. Install selector support.

INFORMATION: For vehicles with manual transmission.

5. Installing gearshift bracket console.
6. Fasten triggering unit.
7. Install power distributor.
8. Carry out work instructions after disconnecting the battery.

Subsequent work for B+ line from starter to engine connection point
1. Install generator.
2. Install throttle housing.
3. Carry out work instructions after disconnecting the battery.

Subsequent work for engine ground strap
1. Lower vehicle.