Wiring Harness: Service and Repair
Replacing the cable harness for the control system
Special tools:
999 5475 GAUGE 999 5475 Gauge
Removal
Preparations
Note! When removing the battery lead, see Note when disconnecting and connecting the battery lead Battery Disconnecting.
Remove:
- the air cleaner (ACL) housing, the intake manifold and the battery according to Replacing the air cleaner (ACL) Service and Repair
- the battery shelf.
Remove:
- separate the 6--pin connector and the 8-pin connector for the cable harness
- slacken off the cap nut for the oil pipe on the control system cover.
Preparations, continued
- Raise the car
- Position a container underneath the transmission
- Drain the oil. Measure and note the volume of oil
- Install the oil drain plug. Use a new sealing ring. Tighten to: 40 Nm.
- Detach the oil pipes. Push them to one side
- Seal all openings using plastic plugs.
Removing the lever on the gear shift linkage rod
Remove:
- the retaining clip from the lever
- the cable from the lever
- the lever from the gear shift linkage rod
- the screw for the gear selector sensor and cable harness.
Twist out the tab on the cable harness holder.
Note! The following only applies when replacing the control system.
Set the transmission lever to the neutral position. Move the lever as far forward as possible to position P and then back two steps to neutral.
Opening the control system
Remove the Torx TX40 screws for the control system cover.
Clean the sealing compound from the threads. Use tap M8 * 1.25.
Remove the cover.
Use tool 999 5477 JOINT WEDGE 999 5477 Joint Wedge. Tap the tool carefully into the joint between the cover and the transmission to ensure that the cover sealing flange is not distorted. Take care not to damage the oil temperature sensor cables.
Clean the gasket residue from the cover and the transmission. Use a scraper.
Note! Ensure that no debris enters the transmission. Wash the cover thoroughly.
Removing the cable harness
Note the position of the connectors.
Remove:
- the connectors for the solenoid valves
- the screw for the oil temperature sensor holder. Remove the oil temperature sensor from the control system
- the cable harness from the holders on the control system.
Remove the cable harness.
Installation
Installing the cable harness
Lubricate the O-rings for the cable harness grommet and the oil temperature sensor with automatic transmission fluid.
Install the cable harness. Connect the connectors to the solenoids according to the notes.
Install the oil temperature sensor with the holder and the screw. Tighten to 10 Nm.
Install the cable harness on the holder. Check that the cable harness is correctly positioned.
Sealing the cover
Check that the mating surface for the cover is level.
Wipe the cleaned mating surfaces on the cover and transmission. Use denatured alcohol.
Note! Ensure that no dirt gets into the transmission.
Apply a bead of sealing compound, approximately 3 mm thick, to the cover. P/N 1161409-6. Apply the compound around the screw holes.
Installing the cover
Install:
- the control system cover on the transmission.
Tighten the screws (Torx TX40) alternately.
Tighten to: 12 Nm
- the oil pipe on the transmission with a new O-ring. Apply a little petroleum jelly to the O-ring.
Tighten to: 10 Nm
- the oil return line on the control system cover. Tighten the cap nut from above
- the screw for the pipe holder on the cover.
Tighten to: 10 Nm
- the splash guards under the engine
- the splash guard under the left wheel arch.
Lower the car.
Installing the cable harness
Install and connect the cable harness connector to the bracket.
Ensure that the cable harness is correctly positioned.
Attach the cable harness using tie straps.
Installing components
Install:
- the lever on the gear shift linkage rod.
Tighten to: 16 Nm
- the transmission cable on the lever using a retaining clip. Apply a small amount of grease (P/N 1161241- 3) to the lever shaft journal.
If the transmission cable has been removed it must be adjusted. See Adjusting the mechanical cable for the transmission, AW55-50/51SN Adjustments.
Installing other components
Tighten the oil pipe cap nut on the control system cover.
Install:
- the air cleaner (ACL) housing assembly, see Replacing the air cleaner (ACL) Service and Repair
- the battery shelf
- the battery.
Note! When installing the battery lead, see Note when disconnecting and connecting the battery lead Battery Disconnecting.
Filling and checking oil
Fill with oil, P/N 1161540-8 to the volume previously noted when the transmission was drained.
Top up and check the oil level. See Checking and adjusting the oil, AW55-50/51SN Checking Oil Level.
Note! After replacing the transmission oil, the "Transmission oil change" counter must be reset. Use VIDA vehicle communication to reset the counter.
Checking diagnostic trouble codes (DTCs)
Check and erase any diagnostic trouble codes (DTCs).