Removing and Installing Wire Harness For Engine

Removing And Installing Wire Harness For Engine

Technical values







Preliminary work

1. Remove rear wheels.
2. Disconnect battery.
3. Remove generator.
4. Remove intake-air distributor.

Removing wire harness for engine










1. Release plugs on the six ignition coils -1 to 6- and pull them off.
2. Release plugs on the six fuel injectors -7 to 12- and pull them off.
3. Release connectors on both knock sensors -15 and 16- and pull them off.
4. Release plugs on both solenoid hydraulic valves (camshaft timing) -17 and 18- and pull them off.
5. Release plugs on both solenoid hydraulic valves (valve lift control) -19 and 20- and pull them off.







6. Unscrew ground straps -22-.
6.1. Unscrew fastening screw and remove ground straps -22-.







7. Disconnect plug connection on speed sender -23- and unscrew ground straps -21-.
7.1. Pull plug connection -23- out of holder.
7.2. Release plug connection -23- ( -Arrows a- ) and disconnect it.
7.3. Unscrew fastening screw and remove ground straps -21-.

8. Release securing clip and pull off connector on intake-pipe change-over switch -24-.
9. Release plug on secondary air blower -25- and pull it off.
10. Release securing clip and pull off connector on tank vent -27-.
11. Release connector on oil level sensor -29- and pull it off.
12. Screw off fastening nut on starter lead for terminal 50 -31- and remove it.
13. Pull off plugs on pressure sensor -32 and 33-.
14. Release connector on engine temperature sensor -34- and pull it off.
15. Release and disconnect plug connection to compressor -35-.







16. Pull off connector on water temperature sensor -36-.
16.1. Open holder -Arrow B- and remove lead.
16.2. Release connector on water temperature sensor -36- ( -Arrow a- ) and pull it off.







17. Disconnect plug connection for engine wire harness to rear wire harness -37 and 38-.
17.1. Remove tie-wrap -Arrow-.







17.2. Release engine wire harness at the two plug connections and disconnect it by turning the bayonet locks anti-clockwise.







18. Unclip cable duct on the left and right.
18.1. Unclip cable duct on the left and right at the fuel distributor pipes -Arrows-.







19. Unclip starter lead.
19.1. Unclip starter lead at cable duct -Arrows-.







20. Remove cable duct.
20.1. Unscrew fastening screws, unclip cable duct -Arrow- and remove it.

21. Remove wire harness for engine.

Installing wire harness for engine







1. Lay out wire harness for engine.







2. Install cable duct.
2.1. Clip in cable duct -Arrows- and secure with the fastening screws. - Tightening torque: 10 Nm (7.5 ftlb.)







3. Clip in starter lead.
3.1. Clip in starter lead at cable duct -Arrows-.







4. Clip in cable duct at the left and right.
4.1. Position and clip in cable duct on the left and right at the fuel distributor pipes -Arrows-.







5. Push plug connection for engine wire harness to rear wire harness -37 and 38- together.
5.1. Connect engine wire harness at the two plug connections and lock it by turning the bayonet locks clockwise.







5.2. Fit new tie-wrap -Arrow-.







6. Attach connector on water temperature sensor -36-.
6.1. Plug in connector on water temperature sensor -36- ( -Arrow A- ) until it engages firmly.
6.2. Insert wire into the holder and close holder -Arrow B-.

7. Press plug connection for compressor -35- together until it is felt to engage.
8. Plug in connector on engine temperature sensor -34- until it engages firmly.
9. Connect plugs on pressure sensor -32 and 33-.
10. Position starter lead for terminal 50 -31- and secure with fastening nut. - Tightening torque: 6.5 Nm 5.0 ftlb.)
11. Plug in connector on oil level sensor -29- until it engages securely.
12. Plug in connector on tank vent -27- until the securing clip engages securely.
13. Connect plug on secondary air blower -25- until it engages firmly.
14. Plug in connector on intake-pipe change-over switch -24- until the securing clip engages securely.







15. Screw down ground straps -21- and connect plug connection on speed sender -23-.
15.1. Position ground straps -21- and screw down the fastening screw. - Tightening torque: 10 Nm (7.5 ftlb.)
15.2. Push the plug connection -23- together until it is felt to engage.
15.3. Push plug connection -23- into holder.







16. Screw down ground straps -22-.
16.1. Position ground straps -22- and screw down the fastening screw. - Tightening torque: 10 Nm (7.5 ftlb.)

17. Connect plugs on the two solenoid hydraulic valves (valve lift control) -19 and 20- until they click into place.
18. Connect plugs on the two solenoid hydraulic valves (camshaft timing) -17 and 18- until they click into place.
19. Plug in connectors on the two knock sensors -15 and 16- until they click into place.
20. Connect plugs on the six fuel injectors -7 to 12- until they engage securely.
21. Connect plugs on the six ignition coils -1 to 6- until they engage securely.

Subsequent work
1. Install intake-air distributor.
2. Install the generator.
3. Carry out work instructions after disconnecting the battery.
4. Mount rear wheels.