975219 Removing and installing wire harness for engine
WM 975219 Removing and installing wire harness for engine
Preliminary work
1. Remove bulkhead-> 508119 Removing and installing cross panel (disassembling plenum panel) - section on "Removing" Service and Repair.
2. Remove fuel collection pipe-> 243019 Removing and installing fuel distributor pipe - section on "Removing" Service and Repair.
3. Remove ground strap for battery. -> 9X00IN Work instructions after disconnecting the battery 9X00IN Work instructions after disconnecting the battery
4. Remove front underbody panelling-> 519219 Removing and installing cover for front underbody - section on "Removing" 519219 Removing and installing Cover For Front Underbody.
5. Remove front wheel -> 440519 Removing and installing wheel - section on "Removing" Removal and Replacement.
6. Remove front part of left and right front wheel housing liner -> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair.
7. Remove front-axle support -> 400819 Removing and installing front-axle support - section on "Removing" 400819 Removing and installing front-axle support.
8. Remove radiator frame -> 192019 Removing and installing radiator fan housing (radiator frame) - section on "Removing" 192019 Removing and installing cooling fan housing (radiator frame).
Removing wire harness for engine
Installation position of engine wire harness (illustration as example)
Wire harness assignment (Turbo shown)
Bottom left of engine: => Bottom left wire harness
1. Pull off connector at crankshaft pulse sender on DFI engines (speed sender) -25-.
1.1. Release and pull off connector -arrow-.
1.2. Unclip line and pull it through and up.
Cable plug of crankshaft pulse sender
2. Release and pull off connector at air-conditioning compressor -38-. -> 873419 Removing and installing air conditioning compressor - section on "Removing"
Bottom left wire harness
3. Remove wiring harness for the air conditioning compressor from the line bracket -arrow A- and unclip it at the retaining clip -arrow B-.
Removing engine wire harness for air-conditioning compressor
4. Release and pull off connector at oil level sensor -39-. -> 171119 Removing and installing oil level sensor - section on "Removing" Service and Repair
Bottom right of engine:
5. Release and pull off connector at oil pressure control valve -36-. -> 172619 Removing and installing oil pressure control valve (drive link) on 4.8 l DFI engines - section on "Removing" Service and Repair
Oil pressure controller connector
6. Release and pull off connector at oil pressure sensor -40-. -> 170519 Removing and installing oil pressure sensor on 4.8 l DFI engines - section on "Removing"
7. Release B+ cable from the generator -46-. -> 272219 Removing and installing generator - section on "Removing" Service and Repair
8. Release and pull off excitation current connector -33-.
Front of engine:
9. Unclip engine wire harness from oil guide housing at the retaining clips.
10. Unclip vacuum lines at the cable duct -arrows-.
Unclipping vacuum lines at the cable duct
11. Release and pull off connector for boost pressure sensor -57- (for Turbo only).
12. Unscrew fastening screw -1- at the cable duct -2-.
Releasing cable duct
Rear of engine:
13. Unclip engine wire harness close to the high-pressure pump.
13.1. Unclip engine wire harness at the retaining clips -arrows A-.
13.2. Unscrew screw socket -arrow B-.
Unclipping engine wire harness close to high-pressure pump
14. Unclip engine wire harness close to the vacuum pump.
14.1. Pull engine wire harness out of the holder -arrow A-.
14.2. Unclip engine wire harness at the retaining clip -arrow B-.
Unclipping engine wire harness close to vacuum pump
15. Unclip engine wire harness at the rear right at the retaining clip -arrow-.
Unclipping engine wire harness at the rear right
16. Unclip vacuum line from the rubber sleeve -arrow-.
Unclipping vacuum line from the rubber sleeve
Top of engine:
17. Release and pull off connectors at the DFI bar ignition modules -1 to 4- and -13 to 16-. -> 282020 Removing and installing DFI bar ignition modules - section on "Removing" Service and Repair
18. Release and pull off connectors at the (DFI) high-pressure fuel injectors -5 to 12-. -> 244019 Removing and installing high-pressure fuel injector (DFI) - section on "Removing" Service and Repair
19. Disconnect connectors at the hydraulic valves for camshaft adjustment -17 and 18-.
19.1. Remove cap -arrow A-.
19.2. Release connector -arrow B- and pull it off -arrow C-.
Pulling off connectors for hydraulic valves for camshaft adjustment 1-4 and 5-8
20. Release and pull off connectors at the solenoid/hydraulic valves for valve lift switchover -19 and 20-. -> 155519 Removing and installing solenoid/hydraulic valve for valve lift switchover - section on "Removing" Service and Repair
21. Release and pull off connector for ambient air valve -53- (Turbo only)
22. Release and pull off connector for boost-pressure control valve -56- (Turbo only)
23. Remove protection cap on the starter connections.
24. Unscrew fastening nuts -1 and 2- from starter and remove lines -3 and 4- ( -arrow- ).
Loosening fastening nuts on starter
25. Loosen ground straps -21 to 24- and cable duct at the left and right on camshaft housing cover.
25.1. Unscrew fastening screws on ground straps and remove ground straps.
25.2. Unclip cable duct on camshaft housing cover -arrows-.
Loosening ground straps and unclipping cable duct
26. Remove vent line => Removing vent line.
Removing vent line
26.1. Unscrew fastening screws -1-.
26.2. Unclip vent line -2- from the cable duct and remove it -arrow-.
27. Release and pull off connectors at the hall senders (camshafts) on DFI engines -26 and 27-. -> 283919 Removing and installing hall senders (camshafts) on DFI engines - section on "Removing" Service and Repair
28. Release and pull off connectors at the knock sensors on DFI engines -28 to 31-. -> 287220 Removing and installing knock sensors on DFI engines - section on "Removing" Service and Repair
29. Release and pull off connector at tank vent valve -32-.
30. Release and pull off connector at coolant temperature gauge -37-. -> 197819 Removing and installing coolant temperature gauge - section on "Removing" Service and Repair
31. Screw off B+ line -47- at the external power connection. -> 974519 Removing and installing wire harness for starter battery - section on "Removing" 97451903 Removing and installing battery-starter wire harness (from external power connection to starter)
Remove wire harness:
32. Loosen cable duct.
Engine wire harness, inner V and valve cover
32.1. Unscrew fastening screw at the cable duct.
33. Loosen engine wire harness at the engine housing.
33.1. Unscrew fastening screws.
33.2. Lift engine wire harness up and out -arrow-.
Loosening engine wire harness at the engine housing
Installing wire harness for engine
Installation position of engine wire harness (illustration as example)
1. First lay the wire harness loosely on the engine.
Pay attention to the correct positioning when doing so: The vehicle/engine connection point as well as the plug connection for the DFI control unit are in the rear of the engine compartment, on the right in the direction of travel.
Each cylinder head has an inner and an outer harness.
2. When laying out, make sure that the individual wiring harnesses do not become twisted or entangled.
3. Loosely bolt the cable ducts onto the cylinder heads and on the right control box.
4. Insert the plug connections and clip the individual wiring harnesses in place.
When doing so, proceed in the reverse order to removal:
4.1. Insert plug connections for top of engine.
4.2. Insert plug connections for rear of engine.
4.3. Insert plug connections for front of engine.
4.4. Lift the vehicle.
4.5. Insert plug connections for bottom right of engine.
4.6. Insert plug connections for bottom left of engine.
5. Screw down cable guide ducts.
Subsequent work
1. Install radiator frame -> 192019 Removing and installing radiator fan housing (radiator frame) - section on "Installing" 192019 Removing and installing cooling fan housing (radiator frame).
2. Install front-axle support -> 400819 Removing and installing front-axle support - section on "Installing" 400819 Removing and installing front-axle support.
3. Install front part of left and right front wheel housing liner -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair.
4. Fit front wheels -> 440519 Removing and installing wheel - section on "Installing" Removal and Replacement.
5. Install front underbody panel-> 519219 Removing and installing cover for front underbody - section on "Installing" 519219 Removing and installing Cover For Front Underbody.
6. Secure ground strap to battery. -> 9X00IN Work instructions after disconnecting the battery 9X00IN Work instructions after disconnecting the battery
7. Install fuel collection pipe -> 243019 Removing and installing fuel distributor pipe - section on "Installing" Service and Repair.
8. Install bulkhead -> 508119 Removing and installing cross panel (disassembling plenum panel) - section on "Installing" Service and Repair.