Removing and Installing Wire Harness For Engine

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.
2. Remove cowl panel cover.
3. Remove DFI intake-air distributor.
4. Remove fuel distribution pipe (fuel rail) on DFI engines.
5. Remove the starter.
6. Remove DFI high-pressure pump.
7. Remove generator.

Removing Wire Harness For Engine












1. Release connectors on DFI bar ignition modules -1 to 8- and pull them off.
2. Release connectors on (DFI) high-pressure fuel injectors -9 to 16- and pull them off.
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-.

4. Release connectors on solenoid/hydraulic valves for valve lift switchover -19 and 20- and pull them off.
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-.

6. Pull off connector on crankshaft pulse sender on DFI engines
6.1. Release connector -arrow A- and pull it off -arrow B-.







6.2. Unclip line -arrow C-.

7. Release connectors on the hall senders (camshafts) on DFI engines -26 and 27- and pull them off.
8. Release connectors on the knock sensors on DFI engines -28 to 31- and pull them off.
9. Release connector on tank vent valve -32- and pull it off.
10. Release connector on coolant temperature gauge -36- and pull it off.
11. Release connector on air-conditioning compressor -37- and pull it off.







12. Remove engine wire harness for the air-conditioning compressor from the holder -arrow A- and unclip it at the retaining clip -arrow B-.
13. Release connector on oil pressure control valve -38- and pull it off.
14. Release connector on oil level sensor -39- and pull it off.
15. Release connector on oil pressure sensor -40- and pull it off.







16. Unclip engine wire harness from the oil pan at the retaining clips -arrow-.







17. Unclip vacuum lines at the cable duct -arrows-.
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-.

19. Screw off B+ line -47- at the external power connection.
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.

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-.

25. Loosen engine wire harness in left plenum panel.







25.1. Unclip engine wire harness from the plenum panel at the retaining clips -arrow-.

26. Pull off connector on DME control unit -55-.
27. Loosen ground straps -56-.







27.1. Screw off fastening nuts -1- and remove the ground straps together with the twist lock -arrow-.

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-.

29. Remove vent line.
29.1. Unscrew fastening screws -1-.







29.2. Unclip vent line -2- from the cable duct and remove it -arrow-.

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-.

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-.







32. Unclip engine wire harness at the rear right at the retaining clips -arrow-.







33. Unclip vacuum line from the rubber sleeve -arrow-.
34. Loosen engine wire harness at the engine housing.
34.1. Unscrew fastening screws.







34.2. Lift engine wire harness up and out -arrow-.

Installing Wire Harness For Engine







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.)







2. Clip in vacuum line on the rubber sleeve -arrow-.







3. Clip in engine wire harness at the rear right using the retaining clips -arrow-.
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-.

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-.

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.)

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-).

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.)

9. Push on connector on DME control unit -55-.
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-.

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-.

12. Install cover for relay carrier in the plenum panel E-box.







12.1. Secure cover with the fastening screws -1- (-arrows-).

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.
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.)







18. Clip in vacuum lines at the cable duct -arrows-.







19. Clip in engine wire harness at the oil pan using the retaining clips -arrow-.
20. Plug in connector on oil pressure sensor -40- until it engages securely.
21. Plug in connector on oil level sensor -39- until it engages securely.
22. Plug in connector on oil pressure control valve -38- until it engages securely.







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-.
24. Plug in connector on air-conditioning compressor -37- until it engages securely.
25. Plug in connector on coolant temperature gauge -36- until it engages securely.
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.
28. Plug in connectors on hall senders (camshafts) on DFI engines -26 and 27- until the connectors engage securely.
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.

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.)

31. Plug in connectors on the solenoid/hydraulic valves for valve lift switchover -19 and 20- until the connectors engage securely.
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.

33. Plug in connectors on high-pressure fuel injectors (DFI) -9 to 16- until the connectors engage securely.
34. Plug in connectors on DFI bar ignition modules -1 to 8- until the connectors engage securely.

Subsequent Work
1. Install generator.
2. Install DFI high-pressure pump.
3. Install the starter.
4. Install fuel distribution pipe (fuel rail) on DFI engines.
5. Install DFI intake-air distributor.
6. Fit cowl panel cover.
7. Connect the battery and carry out work instructions.