Removing and Installing Wire Harness For Engine
Removing And Installing Wire Harness For Engine
Technical values
Preliminary work
Preliminary work for wire harness for engine
1. Disconnect battery.
2. Remove engine.
3. Remove drive belt.
4. Remove the generator.
5. Remove air-conditioning compressor.
6. Remove throttle valve.
7. Remove the two intake pipes at the sides.
7.1. Unscrew the fastening screws -1- on the intake pipe.
7.2. Pull the cable holder out of the intake pipe -2- and unclip the vacuum line -3- on the intake pipe.
7.3. Pull the intake pipe -2- out of the charger.
8. Remove intake-air distributor.
9. Counter the upper fastening nut -1- for the oil line on the oil tank and unscrew it.
10. Unscrew the three fastening screws -2- for the oil tank. Do not remove oil tank
Removing wire harness for engine
1. Open the retaining clip -A- on the engine and take out the exhaust temperature sensor line -28-.
2. Release connectors from engine wire harness on the left side and pull them off.
2.1. Release and disconnect connectors -42, 24, 3, 2, 1, 19, 13, 9, 8, 7- one after the other.
2.2. The plug connection -26- is already disconnected when the intake system is removed.
3. Unclip branch of line -C- to speed sender from the holder.
4. Remove connector, ground strap for cylinder 1 - 3 and the cable duct.
4.1. Release and disconnect connector -18-.
4.2. Unscrew fastening screw -21- for the ground connection.
4.3. Unclip cable duct -X1- from the fuel gallery.
5. Release connectors from engine wire harness on the right side and pull them off.
5.1. Release and disconnect connectors -41, 6, 5, 20, 14, 4, 12, 11, 10, 17, 30- one after the other.
5.2. Unscrew fastening screw -22- for the ground connection.
6. Unclip wire harness at two places on the oil-fill pipe holder and at one place on the intake pipe.
7. Unclip wire harness at two places on the fuel gallery 4 - 6.
7.1. The line on the intake pipe is already unclipped when the intake pipe is removed.
8. Unclip cable duct -X2- from the fuel gallery.
9. Unscrew fastening screw on cable duct, then release and disconnect connectors.
9.1. Release and disconnect connectors -34, 32, 33- one after the other.
9.2. The plug connection for the air-conditioning compressor -35- is already disconnected when the air-conditioning compressor is removed.
9.3. Unscrew fastening screw -Z- for the cable duct.
9.4. Fastening nut for B+ line on the generator -23- is already removed when the generator is removed.
10. Unscrew fastening screw -B- for the water pump and lift the water pump to the side.
10.1. Release and disconnect connector for the knock sensor -16-.
11. Unscrew fastening screw for cable duct (near the heat exchanger), then release and disconnect the connectors.
11.1. Unscrew fastening screw -Z- for the cable duct.
11.2. Release and disconnect connectors -37, 15- one after the other.
11.3. The plug connection -36- for the engine compartment sensor is already disconnected when the air-conditioning compressor is removed.
12. Unclip line for exhaust temperature sensor from the cable duct for the engine wire harness.
13. Pull engine wire harness to the right out of the engine and remove it.
Installing wire harness for engine
1. Slide engine wire harness onto the engine from the right and position it.
2. Lay line for exhaust temperature sensor on the cable duct for the engine wire harness and clip it in.
3. Screw in fastening screw for cable duct and connect connectors.
3.1. Insert connectors -15, 37- one after the other until the connectors engage securely.
3.2. Screw in fastening screw -Z- for the cable duct. - Tightening torque: 10 Nm (7.5 ftlb.)
4. Insert connector for the knock sensor -16- until the connector engages securely.
4.1. Position the water pump and secure it with the fastening screw -B-.
5. Screw in fastening screw for cable duct and connect connectors.
5.1. Insert connectors -33, 32, 34- one after the other until the connectors engage securely.
5.2. Screw in fastening screw -Z- for the cable duct. - Tightening torque: 10 Nm (7.5 ftlb.)
6. Clip in cable duct -X2- on the fuel gallery.
7. Clip wire harness in at two places on the fuel gallery 4 - 6.
8. Clip in wire harness at two places on the oil-fill pipe holder and at one place on the intake pipe.
9. Connect connectors for engine wire harness on the right side until the connectors engage securely.
9.1. Connect connectors -30, 17, 10, 11, 12, 4, 14, 20, 5, 6, 41- one after the other until they engage securely.
9.2. Position ground connection -22- on the engine housing and secure with the fastening screw. - Tightening torque: 10 Nm (7.5 ftlb.)
10. Install connector, ground strap for cylinder 1 - 3 and the cable duct.
10.1. Connect connector -18- until it engages securely.
10.2. Position ground connection -21- on engine housing and secure with the fastening screw. - Tightening torque: 10 Nm (7.5 ftlb.)
10.3. Clip in cable duct -X1- on the fuel gallery 1 - 3.
11. Clip branch of line -C- to speed sender into the holder.
12. Connect connectors for engine wire harness on the left side - cylinder 4 - until they engage securely.
12.1. Connect connectors -7, 8, 9, 13, 19, 1, 2, 3, 24, 42- one after the other until they engage securely.
13. Lay line for exhaust temperature sensor -28- into the retaining clip -A- and close the clip.
Subsequent work
Subsequent work for wire harness for engine
1. Secure the oil tank to the engine with the three fastening screws -2-. - Tightening torque: 23 Nm (17 ftlb.)
2. Position fastening nut -1- for oil line on the oil tank and screw on securely while countering at the same time.
3. Install intake-air distributor.
4. Install the two intake pipes at the sides.
4.1. Slide intake pipe onto the charger.
4.2. Screw in fastening screws -1- for the intake pipe. - Tightening torque: 10 Nm (7.5 ftlb.)
4.3. Clip in the cable clip on the intake pipe -2- and the vacuum line -3- on the intake pipe.
5. Install throttle valve.
6. Install air-conditioning compressor.
7. Install the generator.
8. Install drive belt.
9. Install engine.
10. Connect the battery and carry out work instructions after disconnecting the battery.