Removing and Installing Wiring Harness For Engine

Removing And Installing Wiring Harness For Engine

Removing wiring harness for engine







1. Disconnect electric plug connection from air conditioning compressor.
1.1. Pull the connector from the support on the air conditioning compressor -arrow A-.
1.2. Release connector -arrow B- and disconnect plug connection -arrows C-.
1.3. Open clip -arrow D-, remove line from clip and bracket -arrows E-.







2. Disconnect connector for camshaft switch-over valve 1-4 and 5-8.
2.1. Pull off cover cap -arrow A-.
2.2. Release -arrow B- and remove -arrow C- connector.







3. Disconnect plugs for bar ignition module 1-8.
3.1. Release connector -arrow a- and pull off in sequence from the bar ignition modules.







4. Disconnect plug connections for the throttle valve, air intake module and tank vent.
4.1. Release connectors from the throttle valve, air intake module, and tank vent -arrows a- and pull off -arrows-.







5. Disconnect positive crankcase ventilation.
5.1. Press the connections of the positive crankcase ventilation -arrows a- together and remove from the camshaft cover -arrow-.







6. Disconnect connectors of secondary air pumps.
6.1. Press the connectors of the two secondary air pumps together -arrows a- and disconnect -arrow-.







7. Disconnect plug connection of hall sender and temperature sensor.
7.1. Release connector of temperature sensor and both hall senders -arrows a- and pull off -arrows-.







8. Open line retaining clips.
8.1. Open the 4 retaining clips on rear of engine by lifting them -arrows- and take out the line.







9. Disconnect front positive crankcase ventilation.
9.1. Press the connections on the front positive crankcase ventilation together -arrows a- and pull off -arrow-.







10. Disconnect plug connection for fuel injectors 1-8.
10.1. Release lock of connectors for fuel injectors -arrows a- and pull off connectors -arrows-.







11. Unclip cable duct.
11.1. Lift cable duct 1-4 and remove carefully from the clips.
11.2. Lift cable duct 5-8 and remove carefully from the clips.







12. Remove intake system.
13. Unscrew ground points.
13.1. Remove the fastening screw -arrow 1-for the ground point cylinders 1-4 and 5-8 on the cylinder head.







14. Remove electric lines on starter.
14.1. Unscrew fastening nut -2- and -3-.
14.2. Remove line from starter.







15. Disconnect plug connection of knock sensors.
15.1. Release connectors of both knock sensors -arrow a- and pull off.







16. Disconnect plug connection to oil level sensor.
16.1. Release connector of oil level sensor -arrow A- and pull off -arrow B-.
16.2. Open clip -arrow C- and remove line -arrow D-.







17. Disconnect plug connection to oil pressure switch.
17.1. Release connector of oil pressure switch -arrow a- and pull it off.







18. Disconnect electrical lines to alternator.
18.1. Pull off the protective cap for the electric plug connection from the mounting on the generator -arrow A-.
18.2. Release the connector on the rear side of the alternator -arrow B- and pull off -arrow C-.
18.3. Undo rear fastening screw -arrow 4- of engine support. 18.4.Unscrew the fastening nut on the B+ line -arrow 5-. Check for damage to nut.
18.5. Remove the electric line from the retaining clips -arrows D-.







19. Loosen cable duct.
19.1. Unscrew fastening screw from oil dipstick -arrow 6-.
19.2. Unscrew fastening screw -7- of cable duct (to alternator).







20. Remove cable duct.
20.1. Remove the harness with retaining clip from the support -arrow A-.
20.2. Use a screwdriver to slide the cable duct from the wide support -arrow B-.







21. Remove harness.
21.1. Lift harness up and out -arrow-.







Installing wiring harness for engine
1. Install harness.
1.1. Lay and position harness on engine.







2. Fix cable duct.
2.1. Slide the cable duct on the support on the engine -arrow A-and check it is securely fixed.
2.2. Clip the harness clip onto the support -arrow B-.







3. Lay cable duct.
3.1. Lay cable duct for generator along the crankcase.
3.2. Secure cable duct to crankcase with fastening screw -7-. Tightening torque: 2 ftlb.
3.3. Secure the oil dipstick with the fastening screw -arrow 6-. Tightening torque: 7.5 ftlb.







4. Connect electric connections to alternator.
4.1. Connect B+ line to alternator and tighten with fastening screw. -arrow 5-. Tightening torque: 11 ftlb.
4.2. Screw in fastening screw for engine support -arrow 4- and tighten. Tightening torque: 44 ftlb.
4.3. Push on electric connector -arrow A-, until the lug -arrow B- is felt to engage.

NOTE: Check condition of protective cap; if it is damaged it must be repaired using body sealant.

4.4. Position protection cap and press it on -arrow C-, ensure that it fits securely and is sealed against moisture.
4.5. Lay the electric lines to the alternator and insert in the retaining clips -arrows D-.







5. Connect plug connection for oil pressure switch.
5.1. Push electric connector onto oil pressure switch until it is felt to engage.







6. Connect plug connection for oil level sensor.
6.1. Push electric connector onto oil level sensor -arrow A- until lug -arrow B- is felt to engage.
6.2. Insert line into clip -arrow C- and close clip -arrow D-.







7. Connect plug connection for knock sensor.
7.1. Push both electric connectors onto the knock sensors until connectors are felt to engage.







8. Connect electric connections to starter.
8.1. Connect lines to the starter.
8.2. Fit fastening nuts -1- and -2- and tighten. Tightening torque: 6 ftlb. Tightening torque: 11 ftlb.







9. Secure ground points.
9.1. Position ground strap at both ends together with fastening screw -arrow 1- and screw the fastening screws into cylinder head. Tightening torque: 7.5 ftlb.







10. Push clips of injection line onto camshaft cover.







11. Connect plug connection for fuel injectors 1-8.
11.1. Push electric connectors onto fuel injectors until connectors are felt to engage.







12. Connect front positive crankcase ventilation.
12.1. Fit positive crankcase ventilation and push on until connections are felt to engage.







13. Fasten wire harness with retaining clips.
13.1. Lay the wiring harness to rear side of engine and insert into fixing clips.
13.2. Close fixing clips.







14. Connect plug connection for hall sender and temperature sensor.
14.1. Push electric connectors onto temperature sensor and the two hall senders until connectors are felt to engage.







15. Connect plug connection for secondary air pumps.
15.1. Push on both electric connectors for the secondary air pumps until they are felt to engage.







16. Connect positive crankcase ventilation.
16.1. Fit crankcase ventilation and insert into the connections of the camshaft cover until the connections are felt to engage.







17. Connect plug connection for the throttle valve, air intake module, and tank vent.
17.1. Push on electrical connectors for the throttle valve, air intake module, and tank vent until the connectors are felt to engage.







18. Connect plug connection for bar ignition modules 1-8.
18.1. Push on electric connectors for bar ignition modules until connectors are felt to engage.







19. Connect plug connection for camshaft switch-over valves 1-4 and 5-8.
19.1. Push on electric connectors for camshaft switch-over valves 1-4 and 5-8, Arrow A, until connectors are felt to engage.
19.2. Push on cap -arrow B- until it is felt to engage.







20. Connect plug connection for air conditioning compressor.
20.1. Push the electric plug connection together -arrow A- until the connector is felt to engage.
20.2. Insert the plug connection in the support on the air conditioning compressor -arrow B-.
20.3. Insert line into the brackets and into the clip -arrows C- and close clip -arrow D- until it is felt to engage.