2010 Q7 3.0L TDI/CATA replacement wiring harness routing
Thread Starter
AudiWorld Junior Member
Joined: Jan 2023
Posts: 5
Likes: 3
2010 Q7 3.0L TDI/CATA replacement wiring harness routing
This question is regarding the first generation of the 3.0L TDI engine - with code CATA, for vehicles manufactured prior to June 2010. However, it is the updated first generation model, the one with the aluminum upper intake manifold instead of the plastic one.
I needed to do a massive overhaul on this engine. The turbocharger was failing, and as a result, oil had leaked into the entire intake system, likely for years. I have taken apart and cleaned literally everything - upper intake manifold, both lower intake manifolds, EGR cooler, as much of the charge air system as I could get to, etc. I've also pulled the turbocharger off the engine and had it rebuilt.
The unfortunate part of this here is that this is a nearly 16 year old car, with 150,000 miles on it. As a result, the various wiring connectors are brittle, and did not easily slide off. Some of them broke off in pieces, and others still just disintegrated in my fingers. The glow plug boots were particularly problematic, with 5 of the six turning to dust in my hands.
When it became clear that I needed to replace nearly 20 of these connectors, it made sense - cheaper, less frustration - to just replace the entire wiring harness.
Foolishly, I did not take pictures of how the various wiring looms were routed through and around the various engine components. I also broke one of the plastic connectors that is inserted from the plenum chamber, and clips into the wiring harness on the other side of the firewall. I can not, for the life of me, find the part number for this to replace it.
Have any of you actually done this repair? Or, would you be willing to take a picture for me of a 3.0L TDI engine with the cover removed? The part that I'm struggling with is the routing of the wiring around the intake side of the turbocharger. I believe that the wiring bundle goes underneath the cold air intake tube and also in between the charge air output and the engine block. However, this would put the wiring loom pretty close to the exhaust manifold tube that enters the turbo from below, and this concerns me a bit due to the heat.
Any assistance is very much appreciated!!
I needed to do a massive overhaul on this engine. The turbocharger was failing, and as a result, oil had leaked into the entire intake system, likely for years. I have taken apart and cleaned literally everything - upper intake manifold, both lower intake manifolds, EGR cooler, as much of the charge air system as I could get to, etc. I've also pulled the turbocharger off the engine and had it rebuilt.
The unfortunate part of this here is that this is a nearly 16 year old car, with 150,000 miles on it. As a result, the various wiring connectors are brittle, and did not easily slide off. Some of them broke off in pieces, and others still just disintegrated in my fingers. The glow plug boots were particularly problematic, with 5 of the six turning to dust in my hands.
When it became clear that I needed to replace nearly 20 of these connectors, it made sense - cheaper, less frustration - to just replace the entire wiring harness.
Foolishly, I did not take pictures of how the various wiring looms were routed through and around the various engine components. I also broke one of the plastic connectors that is inserted from the plenum chamber, and clips into the wiring harness on the other side of the firewall. I can not, for the life of me, find the part number for this to replace it.
Have any of you actually done this repair? Or, would you be willing to take a picture for me of a 3.0L TDI engine with the cover removed? The part that I'm struggling with is the routing of the wiring around the intake side of the turbocharger. I believe that the wiring bundle goes underneath the cold air intake tube and also in between the charge air output and the engine block. However, this would put the wiring loom pretty close to the exhaust manifold tube that enters the turbo from below, and this concerns me a bit due to the heat.
Any assistance is very much appreciated!!
Thread
Thread Starter
Forum
Replies
Last Post
