Removing and Installing Wiring Harness For Engine
Removing And Installing Wiring Harness For Engine
In order to remove and install the wiring harness according to these instructions, the engine must be removed.
Remove Wiring Harness For Engine
1. Disconnect the electrical plug from the air conditioning compressor.
a. Pull the connector from the holder on the air conditioning compressor "A".
b. Press connectors "a" together and pull apart.
2. Disconnect the plug connections for camshaft switch-over valve 1-4 and 5-8.
a. Press connectors "a" together and pull apart.
3. Disconnect connector for bar ignition module 1-8.
a. Press connector in "a" and disconnect the connectors in sequence from the bar ignition modules.
4. Disconnect the plug connections from the throttle, intake module and the tank bleeding valve.
a. Actuate the plug connections from the throttle, intake module and the tank bleeding valve "a" and disconnect.
5. Disassemble the crankcase ventilation.
a. Press the connectors of the crankcase ventilation "a" together and remove from the camshaft cover.
6. Disconnect the connectors on the secondary air pumps.
a. Press the connectors of the two secondary air pumps together "a" and disconnect.
7. Disconnect the plug connectors from the hall sender and temperature sensor.
a. Actuate the connectors from the hall sender and temperature sensor "a" and disconnect.
8. Open the fastening clips holding the lines.
a. Open the 4 fastening clips on the rear side of the engine by raising them "arrow" and take out the wires.
9. Disassemble the front crankcase ventilation.
a. Press the connectors on the front crankcase ventilation together "a" and disconnect.
10. Disconnect the plug connections to injection valves 1-8.
a. Actuate the retainer on the connector for the injection valves "a" and remove the connector.
11. Unclip the cable duct.
a. Raise cable duct 1-4 and remove carefully from the clips.
b. Raise cable duct 5-8 and remove carefully from the clips.
12. Disassemble the intake system.
13. Unscrew the ground point.
a. Remove the fastening screw for the ground point cylinders 1-4 and 5-8 on the cylinder head.
14. Disassemble the electrical lines on the starter.
a. Unscrew fastening nuts "1" and "2".
b. Remove line from starter.
15. Disconnect the plug connections to the knocking sensors.
a. Actuate the connectors of the two knock sensors "a" and disconnect.
16. Disconnect the plug connector to the oil level sensor.
a. Actuate the connectors of the two knock sensors "a" and disconnect.
17. Disconnect the plug connectors on the oil pressure switch.
a. Actuate the connector of the oil pressure switch "a" and disconnect.
18. Disconnect the electrical lines on the alternator.
a. Unscrew the fastening nut on the B+ wire. Check for damage to the nut.
b. Press the connector "a" on the rear side of the alternator together and unplug.
c. Remove the electrical lines from the fastening clips.
19. Release cable duct.
a. Unscrew the fastening screw "1" from the cable duct (to the alternator).
20. Remove the cable duct.
a. Remove the wiring harness with fastening clips from the holder.
b. Use a screwdriver to slide the cable duct from the wide holder "arrow".
21. Remove the wiring harness.
a. Lift wiring harness up and out.
Installing Wiring Harness For Engine
1. Install the wiring harness.
a. Lay the wiring harness on the engine and position it correctly.
2. Secure the cable duct.
a. Slide the cable duct on the holder on the motor, check it is securely fixed.
b. Clip the wiring harness clip onto the holder.
3. Lay the cable duct.
a. Lay the cable duct for the alternator along the crankcase.
b. Secure the cable duct to the crankcase with the fastening screw "1". Refer to 'Torque'
4. Connect the electrical connections on the alternator.
a. Press in the electric plug until it clicks into place.
b. Connect the B+ wire on the alternator and secure with the fastening screw. Refer to 'Torque'
c. Lay the electrical lines to the alternator and feed to the retaining clips.
5. Connect the oil pressure switch plug connection.
a. Press the electrical plug on the oil pressure switch until it clicks into place.
6. Connect the oil level sensor plug connection.
a. Press the electrical plug on the oil level sensor until it clicks into place.
7. Connect the knock sensor plug connection.
a. Press both electrical connectors on the knock sensors until they perceptibly engage.
8. Connect the electrical connections on the starter.
a. Connect lines on the starter.
b. Insert and tighten fastening nuts "1" and fastening screws "2". Refer to 'Torque'
9. Fix the ground point.
a. Align the ground leads with the fastening screw and screw the fastening screws in the cylinder head. Refer to 'Torque'
10. Connect the clips from the injection wire to the cam shaft cover.
11. Connect the plug connections to injection valves 1-8.
a. Press the electrical connectors on the injection valves until they perceptibly engage.
12. Assemble the front crankcase ventilation.
a. Position the crankcase ventilation and press on until the connections engage.
13. Secure the wiring harness with fastening clips.
a. Lay the wiring harness to the rear side of the motor and in the fastening clips.
b. Close the fastening clips.
14. Connect the plug connectors from the hall sender and temperature sensor.
a. Insert the electrical connectors until they perceptibly engage.
15. Connect the plug connectors for the secondary air pumps.
a. Press both electrical connectors on the secondary air pumps until they perceptibly engage.
16. Connect the crankcase ventilation.
a. Position the crankcase ventilation and press the connectors in the camshaft cover until the connectors perceptibly engage.
17. Connect the plug connections for the throttle, suction module and tank bleeding valve.
a. Connect the electrical connectors for the throttle, suction module and tank bleeding valve, pressing them in until they perceptibly engage.
18. Connect the plug connector for the bar ignition modules 1-8.
a. Press the electrical connectors on the bar ignition modules until they perceptibly engage.
19. Connect the plug connectors for camshaft switch-over valves 1-4 and 5-8.
a. Connect the electrical connectors for the camshaft switch-over valves 1-4 and 5-8, pressing them in until they perceptibly engage.
20. Connect the plug connectors for the air conditioning compressor.
a. "B" Press the electrical plug connectors together until they perceptibly engage.
b. "A" Insert the plug connector in the holder on the air conditioning compressor.
Torque
