Engine Wiring Harness Assembly Replacement
ENGINE WIRING HARNESS ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
1. Disconnect the negative battery cable.
2. Remove the air cleaner assembly.
3. Disconnect fuel injection control module connectors (1).
4. Remove right side charged air cooler outlet duct.
5. Disconnect the fuel filter/heater assembly connectors (1,2).
6. Disconnect the right rear fuel injector harness connector (1).
7. Disconnect the exhaust gas recirculation (EGR) Valve solenoid connector (1).
8. Disconnect the EGR valve vent solenoid connector (1).
9. Disconnect the EGR valve vacuum sensor (1).
10. Disconnect the EGR throttle valve solenoid.
11. Disconnect the electrical from right side glow plugs (1).
12. Disconnect the right front fuel injector harness connector (1).
13. Disconnect the turbo boost sensor connector (1).
14. Remove the sight shield hold-down bracket (1).
15. Disconnect the coolant temperature sensor (1).
16. Remove the turbo water inlet hose.
17. Remove the turbo coolant bypass valve.
18. Remove the glow plug relay assembly.
19. Disconnect the engine harness bulk connectors.
20. Remove the bolts retaining bulk connectors to the bracket (1)
21. Remove the left turbo charged air outlet hose.
22. Remove the positive crankcase ventilation (PCV) hose from the left valve cover.
23. Disconnect left front fuel injector harness connector (1).
24. Disconnect the left rear fuel injector harness connector (1).
25. Disconnect the fuel rail temperature sensor connector (1).
26. Disconnect the glow plug controller connectors (1).
27. Remove the fuel pipe retainer at the valve cover (2).
28. Remove the left front inner fender well.
29. Disconnect the electrical connectors from the left side glow plugs (1).
30. Disconnect the oil level harness connector (1).
31. Disconnect the barometric pressure (BARO) sensor connector (1).
32. Disconnect the fuel rail pressure sensor connector (1).
33. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
34. Remove the front lower skid plate.
35. Disconnect the crankshaft position (CKP) sensor.
36. Disconnect the camshaft position (CMP) sensor (1).
37. Remove the bolts (1) retaining engine harness grounds.
38. Lower the vehicle.
39. Un-route and lift the engine wiring harness assembly for access to fuel rail pressure regulator.
40. Disconnect the fuel rail pressure regulator (1).
41. Remove the engine wiring harness from the vehicle.
INSTALLATION PROCEDURE
1. Install the engine wiring harness to the vehicle.
2. Connect the fuel rail pressure regulator connector (1).
3. Route the engine wiring harness to the engine.
4. Raise the vehicle.
NOTE: Refer to Fastener Notice in Service Precautions.
5. Install the bolts (1) to retain the engine wiring harness grounds.
Tighten
Tighten the bolts to 34 N.m (25 lb ft).
6. Connect the CMP sensor (1).
7. Connect the CKP sensor.
8. Install the front lower skid plate.
9. Lower the vehicle.
10. Connect the fuel rail pressure sensor connector (1).
11. Connect the BARO sensor connector (1).
12. Connect the oil level sensor harness connector (1).
13. Connect the electrical connectors to left side glow plugs (1).
14. Install the left inner fender well.
15. Install the fuel pipe retainer (2).
Tighten
Tighten the nut to 8 N.m (70 lb in).
16. Connect the glow plug controller connectors (1).
17. Connect the fuel rail temperature sensor harness connector (1).
18. Connect the left rear fuel injector harness connector (1).
19. Connect the left front fuel injector harness connector (1).
20. Install the PCV hose to valve cover.
21. Install the left turbo charged air outlet hose.
22. Install the bolts (1) to retain bulk connectors to the bracket.
23. Connect the engine harness bulk connectors.
24. Install the glow plug relay assembly.
25. Install the turbo coolant bypass valve.
26. Install the turbo water inlet hose.
27. Connect the coolant temperature sensor (1).
28. install the engine sight shield hold-down bracket (1).
29. Connect the turbo boost sensor (1).
30. Connect right the front fuel injector harness connector (1).
31. Connect the electrical connectors to the right side glow plugs (1).
32. Connect the EGR throttle valve solenoid connector (1).
33. Connect the EGR vacuum sensor (1)
34. Connect the EGR vent solenoid (1).
35. Connect the EGR valve solenoid (1).
36. Connect the right rear fuel injector harness connector (1).
37. Connect the fuel filter/heater assembly connectors (12).
38. Install the right turbo charged air hose.
39. Connect the fuel injection control module connectors (1).
40. Install the air cleaner assembly.
41. Connect the negative battery cable.