Wiring Harness: Service and Repair
ENGINE WIRING HARNESS ASSEMBLY REPLACEMENT
REMOVAL PROCEDURE
1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Remove both front wheelhouse panels.
4. Remove the air cleaner outlet duct.
5. Loosen the charged air cooler outlet duct to intake hose clamp.
IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
6. Remove the charged air cooler outlet duct from the intake.
7. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
8. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
9. Disconnect the intake air heater (IAH) electrical connector (1).
10. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (2).
11. Remove the engine harness clip from the side of the air inlet tube.
12. Remove the left glow plug harness bracket bolts.
13. Remove the right glow plug harness bracket bolts.
14. Remove the positive crankcase ventilation (PCV) hose/pipe.
15. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
16. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
17. Disconnect the camshaft position (CMP) sensor electrical connector.
18. Remove the 2 ground bolts.
19. Disconnect the crankshaft position (CKP) sensor electrical connector.
20. Remove the electrical harness bolts.
21. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
22. Open the harness clip (2).
23. Remove the main engine electrical harness connectors.
24. Remove the main engine electrical harness connector bolts.
25. Disconnect the fuel pressure control valve electrical connector.
26. Disconnect the oil level sensor electrical harness connector.
27. Disconnect the fuel temperature sensor electrical connector.
28. Disconnect the glow plug control module electrical connector.
29. Disconnect the glow plug control module battery feed electrical connector (1).
30. Disconnect and remove the turbocharger vane position sensor.
IMPORTANT: Note the wire routing prior to removal.
31. Disconnect the intake air temperature (IAT) sensor electrical connector (1).
32. Disconnect the fuel injector electrical connectors.
NOTE: Label all the injector electrical connectors before the connectors are removed in order to prevent reconnecting to the wrong injector. Failure to properly connect the injectors in the correct sequence will cause severe engine damage.
33. Disconnect the turbocharger vane control solenoid valve.
34. Disconnect the fuel rail pressure sensor electrical connector.
35. Disconnect the oil pressure sensor electrical connector.
36. Remove the oil level sensor harness bolt.
37. Remove the glow plug control module bolts.
38. Remove the glow plug control module.
39. Remove the glow plug electrical connector nuts.
40. Remove the engine wiring harness.
INSTALLATION PROCEDURE
1. Install the engine wiring harness.
2. Install the glow plug electrical connector nuts.
NOTE: Refer to Fastener Notice.
Tighten the nuts to 2 N.m (18 lb in).
3. Install the glow plug control module.
4. Install the glow plug control module bolts.
Tighten the bolts to 10 N.m (89 lb in).
5. Install the oil level sensor harness bolt.
Tighten the bolt to 40 N.m (30 lb ft).
6. Connect the oil pressure sensor electrical connector.
7. Connect the fuel rail pressure sensor electrical connector.
8. Connect the turbocharger vane control solenoid valve.
9. Connect the fuel injector electrical connectors.
10. Connect the IAT sensor electrical connector (1).
11. Install and connect the turbocharger vane position sensor.
12. Connect the glow plug control module battery feed electrical connector (1).
13. Connect the glow plug control module electrical connectors.
14. Connect the fuel temperature sensor electrical connector.
15. Connect the oil level sensor electrical harness connector.
16. Connect the fuel pressure control valve electrical connector.
17. Install the main engine electrical harness connector screws.
Tighten the screws to 10 N.m (89 lb in).
18. Connect the main engine electrical harness connectors.
19. Push down on the latches (1) in order to connect the connectors.
20. Close the harness clip (2).
21. Install electrical harness bolts.
Tighten the screws to 4 N.m (35 lb in).
22. Connect the CKP sensor electrical connector.
23. Install the 2 ground bolts.
Tighten the bolts to 34 N.m (25 lb ft).
24. Connect the CMP sensor electrical connector.
25. Connect the EGR valve electrical connector.
26. Connect the ECT sensor electrical connector.
27. Install the PCV hose/pipe.
28. Install the right glow plug harness bracket bolts.
Tighten the bolts to 10 N.m (89 lb in).
29. Install the right glow plug connectors to the glow plugs.
Tighten the glow plug connector nuts to 2 N.m (18 lb in).
30. Install the left glow plug harness bracket bolts.
Tighten the bolts to 10 N.m (89 lb in).
31. Install the left glow plug connectors to the glow plugs.
Tighten the glow plug connector nuts to 2 N.m (18 lb in).
32. Install the engine harness clip to the side of the air inlet tube.
33. Connect the MAP sensor electrical connector (2).
34. Connect the IAH electrical connector (1).
35. Remove the tape from the turbocharger openings.
IMPORTANT: Lubricate the end of the duct prior to installation.
36. Install the charged air cooler inlet duct connector (4) to the turbocharger.
37. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).
Tighten the clamp to 6 N.m (53 lb in).
38. Install the charged air cooler outlet duct to the intake.
IMPORTANT: Lubricate the end of the duct prior to installation.
39. Tighten the charged air cooler outlet duct to intake hose clamp.
Tighten the clamp to 6 N.m (53 lb in).
40. Install the air cleaner outlet duct.
41. Install both front wheelhouse panels.
42. Install the engine cover.
43. Connect the negative battery cable.