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 engine guard. => 108019 Removing and installing engine guard - section on "Removing"
3. Remove cowl panel cover => 664419 Removing and installing cowl panel cover - section on "Removing".
4. Remove DFI intake-air distributor. => 244619 Removing and installing intake-air distributor on DFI engines - 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 6- and pull them off. => 282020 Removing and installing DFI bar ignition modules - section on "Removing"
2. Release connectors on high-pressure fuel injectors (DFI) -7 to 12- and pull them off. => 244019 Removing and installing high-pressure fuel injector (DFI) - section on "Removing"
3. Screw off fastening nut and detach terminal 50 line -15- from starter. => 276019 Removing and installing starter - section on "Removing"
4. Release connector on right knock sensor on DFI engines -16- and pull it off. => 287220 Removing and installing knock sensors on DFI engines - section on "Removing"
5. Release connector on oil level sensor -17- and pull it off. => 171119 Removing and installing oil level sensor - section on "Removing"
6. Unclip engine wire harness with retaining clips at the front right engine housing -arrows-.
Unclipping engine wire harness at the front right
7. Unclip engine wire harness with retaining clips from the oil pan -arrows-.
Unclipping engine wire harness at the oil pan
8. Unclip engine wire harness with retaining clips at the front left engine housing -arrows A- and detach from the coolant hose together with the support -arrow B-.
Unclipping engine wire harness at the front left
9. Release connector on air-conditioning compressor -18- and pull it off. => 873419 Removing and installing air-conditioning compressor - section on "Removing"
10. Release connector on the generator -19- and pull it off. => 272219 Removing and installing generator - section on "Removing"
11. Release connector on crankshaft pulse sender on DFI engines -20- and pull it off. => 287319 Removing and installing crankshaft pulse sender on DFI engines - section on "Removing"
12. Release connector on oil pressure switch -21- and pull it off. => 170519 Removing and installing oil pressure switch on VR6 DFI engines - section on "Removing"
13. Release connector on left knock sensor on DFI engines -22- and pull it off. => 287220 Removing and installing knock sensors on DFI engines - section on "Removing"
14. Release connector on high-pressure sensor (rail pressure sensor) on DFI engines -23- and pull it off. => 240919 Removing and installing high-pressure sensor (rail pressure sensor) on DFI engines - section on "Removing"
15. Release connector on flow control valve -24- and pull it off. => 246319 Removing and installing DFI high-pressure pump - section on "Removing"
16. Unclip engine wire harness with retaining clips at the rear engine housing -arrows-.
Unclipping engine wire harness at the rear
17. Release connectors on hydraulic valves for camshaft adjustment on VR6 DFI engines -25 and 26- and pull them off. => 153319 Removing and installing timing-case cover on VR6 DFI engines - section on "Removing"
18. Release connector on coolant temperature gauge on DFI engines -27- and pull it off. => 197819 Removing and installing coolant temperature gauge on DFI engines - section on "Removing"
19. Release connector on additional coolant pump -28- ( -arrow A- ) and pull it off -arrow B-. => 194519 Removing and installing additional coolant pump - section on "Removing"
Pulling off connector on additional coolant pump
Information
- Mark hall sender cable plugs according to position of intake and outlet camshafts.
- Have a mirror and lamp to hand in case the installation position is difficult to see.
20. Release connectors on hall senders (camshafts) on DFI engines -29 and 30- and pull them off. => 283919 Removing and installing hall senders (camshafts) on DFI engines - section on "Removing"
21. Release connector on carbon canister valve -31- ( -arrow A- ) and pull it off -arrow B-.
Pulling off connector on carbon canister valve
22. Remove cover for relay carrier in plenum panel E-box.
22.1. Unscrew fastening screws -1- ( -arrows- ) and remove cover.
Removing cover for relay carrier in plenum panel E-box
23. Disconnect plug connection for engine wire harness to main wire harness -33 and 34- in relay carrier for the plenum panel E-box.
23.1. 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
24. Loosen engine wire harness in left plenum panel.
24.1. Unclip engine wire harness with retaining clips from the plenum panel -arrow-.
Loosening engine wire harness in left plenum panel
25. Pull off connector on DME control unit -35-. => 247019 Removing and installing DME control unit - section on "Removing"
26. Loosen ground straps -36-.
26.1. Screw off fastening nut -1- and remove the ground straps together with the twist lock -arrow-.
Loosening ground straps
27. Loosen engine wire harness in right plenum panel and take it out of the plenum panel.
27.1. Pull engine wire harness together with retaining clips off the threaded bolts -arrows A- and remove rubber seal in area -a- ( -arrow B- ).
27.2. Pull rubber sleeve up and out -arrow C-.
27.3. 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
Installing wire harness for engine
Connector overview for engine wire harness
1. Secure engine wire harness in right plenum panel.
1.1. Place engine wire harness in installation position -arrow A- and fit rubber sleeve into the plenum panel -arrow B-.
1.2. Clip in engine wire harness at the plenum panel using the retaining clip -arrow C-.
1.3. Secure engine wire harness on the threaded bolts using the retaining clips -arrows D-.
1.4. Fit rubber seal to the plenum panel in area -a- ( -arrow E- ).
Securing engine wire harness in right plenum panel
2. Fasten ground straps -36-.
2.1. 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
3. Push on connector on DME control unit -35-. => 247019 Removing and installing DME control unit - section on "Installing"
4. Secure engine wire harness in left plenum panel.
4.1. Clip in engine wire harness at the plenum panel using the retaining clips -arrow-.
Securing engine wire harness in left plenum panel
5. Disconnect plug connection for engine wire harness to main wire harness -33 and 34- in relay carrier for the plenum panel E-box.
5.1. Plug in connectors -arrows A-.
5.2. Insert rubber sleeve into the relay carrier -arrow B-.
Plugging in connector for engine wire harness to main wire harness
6. Install cover for relay carrier in the plenum panel E-box.
6.1. Secure cover with the fastening screws -1- ( -arrows- ).
Installing cover for relay carrier in plenum panel E-box
7. Plug in connector on carbon canister valve -arrow- until the connector engages securely.
Plugging in connector on carbon canister valve
8. Plug in connectors on hall senders (camshafts) on DFI engines -29 and 30- until the connectors engage securely. => 283919 Removing and installing hall senders (camshafts) on DFI engines - section on "Installing"
9. Plug in connector on additional coolant pump -28- ( -arrow- ) until the connector engages securely. => 194519 Removing and installing additional coolant pump - section on "Installing"
Plugging in connector on additional coolant pump
10. Plug in connector on coolant temperature gauge on DFI engines -27- until the connector engages securely. => 197819 Removing and installing coolant temperature gauge on DFI engines - section on "Installing"
11. Plug in connectors on hydraulic valves for camshaft adjustment on VR6 DFI engines -25 and 26- until the connectors engage securely. => 153519 Removing and installing timing chain on VR6 DFI engines - section on "Installing"
12. Clip in engine wire harness at the rear engine housing using the retaining clips -arrows-.
Clipping in engine wire harness at the rear
13. Plug in connector on flow control valve -24- until the connector engages securely. => 246319 Removing and installing DFI high-pressure pump - section on "Installing"
14. Plug in connector on high-pressure sensor (rail pressure sensor) on DFI engines -23- until the connector engages securely. => 240919 Removing and installing high-pressure sensor (rail pressure sensor) on DFI engines - section on "Installing"
15. Plug in connector on left knock sensor on DFI engines -22- until the connector engages securely. => 287220 Removing and installing knock sensors on DFI engines - section on "Installing"
16. Plug in connector on oil pressure switch -21- until the connector engages securely. => 170519 Removing and installing oil pressure switch on VR6 DFI engines - section on "Installing"
17. Plug in connector on crankshaft pulse sender on DFI engines -20- until the connector engages securely. => 287319 Removing and installing crankshaft pulse sender on DFI engines - section on "Installing"
18. Plug in connector on generator -19- until the connector engages securely. => 272219 Removing and installing generator - section on "Installing"
19. Plug in connector on air-conditioning compressor -18- until the connector engages securely. => 873419 Removing and installing air-conditioning compressor - section on "Installing"
20. Clip in engine wire harness at the engine housing using the retaining clips at the front left -arrows A- and attach it to the coolant hose together with the support -arrow B-.
Clipping in engine wire harness at the front left
21. Clip in engine wire harness at the oil pan using the retaining clips -arrows-.
Clipping in engine wire harness at the oil pan
22. Clip in engine wire harness at the engine housing using the retaining clips at the front right -arrows-.
Clipping in engine wire harness at the front right
23. Plug in connector on oil level sensor -17- until it engages securely. => 171119 Removing and installing oil level sensor - section on "Installing"
24. Plug in connector on the right knock sensor on DFI engines -16- until the connector engages securely. => 287220 Removing and installing knock sensors on DFI engines - section on "Installing"
25. Connect terminal 50 line -15- to the starter and secure with the fastening nut. => Tightening torque: 8 Nm (6 ftlb.) => 276019 Removing and installing starter - section on "Installing"
26. Plug in connectors on high-pressure fuel injectors (DFI) -7 to 12- until the connectors engage securely. => 244019 Removing and installing high-pressure fuel injector (DFI) - section on "Installing"
27. Plug in connectors on DFI bar ignition modules -1 to 6- until the connectors engage securely. => 282020 Removing and installing DFI bar ignition modules - section on "Installing"
Subsequent work
1. Install DFI intake-air distributor. => 244619 Removing and installing DFI intake-air distributor - section on "Installing"
2. Install cowl panel cover => 664419 Removing and installing cowl panel cover - section on "Installing".
3. Install engine guard. => 108019 Removing and installing engine guard - section on "Installing"
4. Connect the battery and carry out work instructions. => 90 Work instructions after disconnecting the battery