975219 Removing and installing wire harness for engine
WM 975219 Removing and installing wire harness for engine
Technical values
Preliminary work
1. Before the engine wire harness can be removed, the battery must be disconnected and the terminal covered. => 90 Work instructions after disconnecting the battery
2. Remove cowl panel cover => 664419 Removing and installing cowl panel cover - section on "Removing".
3. Remove DFI intake-air distributor. => 244619 Removing and installing intake-air distributor on DFI engines - section on "Removing"
4. Remove fuel distribution pipe (fuel rail) on DFI engines. => 243019 Removing and installing fuel distribution pipe (fuel rail) on DFI engines - section on "Removing"
5. Remove the starter. => 276019 Removing and installing starter - section on "Removing"
6. Remove DFI high-pressure pump. => 246319 Removing and installing DFI high-pressure pump - section on "Removing"
7. Remove generator. => 272219 Removing and installing generator - section on "Removing"
Removing wire harness for engine
Installation position of engine wire harness
Connector overview for engine wire harness
1. Release connectors on DFI bar ignition modules -1 to 8- and pull them off. => 282020 Removing and installing DFI bar ignition modules - section on "Removing"
2. Release connectors on (DFI) high-pressure fuel injectors -9 to 16- and pull them off. => 244019 Removing and installing high-pressure fuel injector (DFI) - section on "Removing"
3. Pull off connectors on hydraulic valves for camshaft adjustment -17 and 18-.
3.1. Remove cap -arrow A-.
3.2. Release connector -arrow B- and pull it off -arrow C-.
Pulling off connectors for hydraulic valves for camshaft adjustment 1-4 and 5-8
4. Release connectors on solenoid/hydraulic valves for valve lift switchover -19 and 20- and pull them off. => 155519 Removing and installing solenoid/hydraulic valve for valve lift switchover - section on "Removing"
5. Loosen ground straps -21 to 24- and cable duct at the left and right on camshaft housing cover.
5.1. Unscrew fastening screws on ground straps and remove ground straps.
5.2. Unclip cable duct on camshaft housing cover -arrows-.
Loosening ground straps and unclipping cable duct
6. Pull off connector on crankshaft pulse sender on DFI engines -25-.
6.1. Release connector -arrow A- and pull it off -arrow B-.
6.2. Unclip line -arrow C-.
Pulling off connector on crankshaft pulse sender on DFI engines
7. Release connectors on the hall senders (camshafts) on DFI engines -26 and 27- and pull them off. => 283919 Removing and installing hall senders (camshafts) on DFI engines - section on "Removing"
8. Release connectors on the knock sensors on DFI engines -28 to 31- and pull them off. => 287220 Removing and installing knock sensors on DFI engines - section on "Removing"
9. Release connector on tank vent valve -32- and pull it off.
10. Release connector on coolant temperature gauge -36- and pull it off. => 197819 Removing and installing coolant temperature gauge - section on "Removing"
11. Release connector on air-conditioning compressor -37- and pull it off. => 873419 Removing and installing air-conditioning compressor - section on "Removing"
12. Remove engine wire harness for the air-conditioning compressor from the holder -arrow A- and unclip it at the retaining clip -arrow B-.
Removing engine wire harness for air-conditioning compressor
13. Release connector on oil pressure control valve -38- and pull it off. => 172619 Removing and installing oil pressure control valve (drive link) on 4.8 l DFI engines - section on "Removing"
14. Release connector on oil level sensor -39- and pull it off. => 171119 Removing and installing oil level sensor - section on "Removing"
15. Release connector on oil pressure sensor -40- and pull it off. => 170519 Removing and installing oil pressure sensor on 4.8 l DFI engines - section on "Removing"
16. Unclip engine wire harness from the oil pan at the retaining clips -arrow-.
Unclipping line at the oil pan
17. Unclip vacuum lines at the cable duct -arrows-.
Unclipping vacuum lines at the cable duct
18. Release cable duct at the front right.
18.1. Unscrew fastening screw on oil dipstick -11- ( -arrow- ).
18.2. Unscrew fastening screw -12- on the cable duct -arrow-.
Releasing cable duct at the front right
19. Screw off B+ line -47- at the external power connection. => 974519 Removing and installing wire harness for starter battery - section on "Removing"
20. Release and disconnect plug connection for clutch protection -49-.
21. Release connector on boost pressure valve -51- and pull it off.
22. Release connector on ambient air valve -52- and pull it off.
23. Remove cover for relay carrier in plenum panel E-box.
23.1. Unscrew fastening screws -1- ( -arrows- ) and remove cover.
Removing cover for relay carrier in plenum panel E-box
24. Disconnect plug connection for engine wire harness to main wire harness -53 and 54- in the relay carrier for the plenum panel E-box.
24.1. Pull off connectors (white, red) -arrows A- and remove engine wire harness -arrow B-.
Pulling off connector for engine wire harness to main wire harness
25. Loosen engine wire harness in left plenum panel.
25.1. Unclip engine wire harness from the plenum panel at the retaining clips -arrow-.
Loosening engine wire harness in left plenum panel
26. Pull off connector on DME control unit -55-. => 247019 Removing and installing DME control unit - section on "Removing"
27. Loosen ground straps -56-.
27.1. Screw off fastening nuts -1- and remove the ground straps together with the twist lock -arrow-.
Loosening ground straps
28. Loosen engine wire harness in right plenum panel and take it out of the plenum panel.
28.1. Pull engine wire harness together with retaining clips off the threaded bolts -arrows A- and remove rubber seal in area -a- ( -arrow B- ).
28.2. Pull rubber sleeve up and out -arrow C-.
28.3. Unclip engine wire harness at the retaining clip -arrow D- and remove engine wire harness -arrow E-.
Loosening engine wire harness in right plenum panel
29. Remove vent line.
29.1. Unscrew fastening screws -1-.
29.2. Unclip vent line -2- from the cable duct and remove it -arrow-.
Removing vent line
30. Unclip engine wire harness close to the high-pressure pump.
30.1. Unclip engine wire harness at the retaining clips -arrows A-.
30.2. Unscrew screw socket -arrow B-.
Unclipping engine wire harness close to high-pressure pump
31. Unclip engine wire harness close to the vacuum pump.
31.1. Pull engine wire harness out of the holder -arrow A-.
31.2. Unclip engine wire harness at the retaining clip -arrow B-.
Unclipping engine wire harness close to vacuum pump
32. Unclip engine wire harness at the rear right at the retaining clips -arrow-.
Unclipping engine wire harness at the rear right
33. Unclip vacuum line from the rubber sleeve -arrow-.
Unclipping vacuum line from the rubber sleeve
34. Loosen engine wire harness at the engine housing.
34.1. Unscrew fastening screws.
34.2. Lift engine wire harness up and out -arrow-.
Loosening engine wire harness at the engine housing
Installing wire harness for engine
Connector overview for engine wire harness
1. Secure engine wire harness at the engine housing.
1.1. Position and lay engine wire harness at the engine housing -arrow-.
1.2. Tighten fastening screws. => Tightening torque: 10 Nm (7.5 ftlb.)
Securing engine wire harness at the engine housing
2. Clip in vacuum line on the rubber sleeve -arrow-.
Clipping in vacuum line on the rubber sleeve
3. Clip in engine wire harness at the rear right using the retaining clips -arrow-.
Clipping in engine wire harness at the rear right
4. Clip in engine wire harness close to the vacuum pump.
4.1. Clip in engine wire harness using the retaining clips -arrow A-.
4.2. Slide engine wire harness onto the holder -arrow B-.
Clipping in engine wire harness close to the vacuum pump
5. Clip in engine wire harness close to the high-pressure pump.
5.1. Screw in and tighten the screw socket -arrow A-. => Tightening torque: 23 Nm (17 ftlb.)
5.2. Clip in engine wire harness using the retaining clips -arrows B-.
Clipping in engine wire harness close to the high-pressure pump
6. Install vent line.
6.1. Position vent line -1- and clip it into the cable duct -arrow-.
6.2. Tighten fastening screws -2-. => Tightening torque: 10 Nm (7.5 ftlb.)
Installing vent line
7. Secure engine wire harness in right plenum panel.
7.1. Place engine wire harness in installation position -arrow A- and fit rubber sleeve into the plenum panel -arrow B-.
7.2. Clip in engine wire harness at the plenum panel using the retaining clip -arrow C-.
7.3. Secure engine wire harness on the threaded bolts using the retaining clips -arrows D-.
7.4. Fit rubber seal to the plenum panel in area -a- ( -arrow E- ).
Securing engine wire harness in right plenum panel
8. Fasten ground straps -56-.
8.1. Fit ground straps together with the twist lock onto the stud -arrow- and secure with the fastening nut -1-. => Tightening torque: 9 Nm (6.5 ftlb.)
Securing ground straps
9. Push on connector on DME control unit -55-. => 247019 Removing and installing DME control unit - section on "Installing"
10. Secure engine wire harness in left plenum panel.
10.1. Clip in engine wire harness at the plenum panel using the retaining clips -arrow-.
Securing engine wire harness in left plenum panel
11. Connect plug connection for engine wire harness to main wire harness -53 and 54- in the relay carrier for the plenum panel E-box.
11.1. Plug in connectors -arrows A-.
11.2. Insert rubber sleeve into the relay carrier -arrow B-.
Plugging in connector for engine wire harness to main wire harness
12. Install cover for relay carrier in the plenum panel E-box.
12.1. Secure cover with the fastening screws -1- ( -arrows- ).
Installing cover for relay carrier in plenum panel E-box
13. Plug in connector on ambient air valve -52- until it engages securely.
14. Plug in connector on boost pressure valve -51- until it engages securely.
15. Push plug connection for clutch protection -49- together until it engages securely.
16. Screw on B+ line -47- at the external power connection. => 974519 Removing and installing wire harness for starter battery - section on "Installing"
17. Secure cable duct at the front right.
17.1. Route cable duct on the crankcase.
17.2. Secure cable duct on the crankcase with the fastening screw -12- ( -arrow- ). => Tightening torque: 3 Nm (2.0 ftlb.)
17.3. Secure oil dipstick with the fastening screw -11- ( -arrow- ). => Tightening torque: 10 Nm (7.5 ftlb.)
Securing cable duct at the front right
18. Clip in vacuum lines at the cable duct -arrows-.
Clipping in vacuum lines at the cable duct
19. Clip in engine wire harness at the oil pan using the retaining clips -arrow-.
Clipping in engine wire harness at the oil pan
20. Plug in connector on oil pressure sensor -40- until it engages securely. => 170519 Removing and installing oil pressure sensor on 4.8 l DFI engines - section on "Installing"
21. Plug in connector on oil level sensor -39- until it engages securely. => 171119 Removing and installing oil level sensor - section on "Installing"
22. Plug in connector on oil pressure control valve -38- until it engages securely. => 172619 Removing and installing oil pressure control valve (drive link) on 4.8 l DFI engines - section on "Installing"
23. Clip in engine wire harness for the air-conditioning compressor using the retaining clips -arrow A- and place it in the holder -arrow B-.
Securing engine wire harness for air-conditioning compressor
24. Plug in connector on air-conditioning compressor -37- until it engages securely. => 873419 Removing and installing air-conditioning compressor - section on "Installing"
25. Plug in connector on coolant temperature gauge -36- until it engages securely. => 197819 Removing and installing coolant temperature gauge - section on "Installing"
26. Plug in connector on tank vent valve -32- until it engages securely.
27. Plug in connectors on knock sensors on DFI engines -28 to 31- until the connectors engage securely. => 287220 Removing and installing knock sensors on DFI engines - section on "Installing"
28. Plug in connectors on hall senders (camshafts) on DFI engines -26 and 27- until the connectors engage securely. => 283919 Removing and installing hall senders (camshafts) on DFI engines - section on "Installing"
29. Plug in connector on crankshaft pulse sender on DFI engines -25-.
29.1. Clip in line -arrow A-
29.2. Plug in connector on crankshaft pulse sender on DFI engines -arrow B- until the connector engages securely.
Plugging in connector on crankshaft pulse sender on DFI engines
30. Clip in cable duct and fasten ground straps -21 to 24- at the left and right to the camshaft housing cover.
30.1. Clip in cable duct on camshaft housing cover -arrows-.
30.2. Position ground straps and secure with the fastening screws. => Tightening torque: 10 Nm (7.5 ftlb.)
Clipping in cable duct and securing ground straps
31. Plug in connectors on the solenoid/hydraulic valves for valve lift switchover -19 and 20- until the connectors engage securely. => 155519 Removing and installing solenoid/hydraulic valve for valve lift switchover - section on "Installing"
32. Plug in connectors on hydraulic valves for camshaft adjustment -17 and 18-.
32.1. Plug in connector -arrow A- until it engages securely.
32.2. Fit cap -arrow B- until it engages securely.
Plugging in connectors on hydraulic valves for camshaft adjustment
33. Plug in connectors on high-pressure fuel injectors (DFI) -9 to 16- until the connectors engage securely. => 244019 Removing and installing high-pressure fuel injector (DFI) - section on "Installing"
34. Plug in connectors on DFI bar ignition modules -1 to 8- until the connectors engage securely. => 282020 Removing and installing DFI bar ignition modules - section on "Installing"
Subsequent work
1. Install generator. => 272219 Removing and installing generator - section on "Installing"
2. Install DFI high-pressure pump. => 246319 Removing and installing DFI high-pressure pump - section on "Installing"
3. Install the starter. => 276019 Removing and installing starter - section on "Installing"
4. Install fuel distribution pipe (fuel rail) on DFI engines. => 243019 Removing and installing fuel distribution pipe (fuel rail) on DFI engines - section on "Installing"
5. Install DFI intake-air distributor. => 244619 Removing and installing DFI intake-air distributor - section on "Installing"
6. Fit cowl panel cover => 664419 Removing and installing cowl panel cover - section on "Installing".
7. Connect the battery and carry out work instructions. => 90 Work instructions after disconnecting the battery