Installation Procedure

Engine Wiring Harness Assembly Replacement

Installation Procedure




1. Install the engine wiring harness.




2. Connect the fuel pressure regulator electrical 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 engine wiring harness ground bolts (1).

Tighten
Tighten the bolts to 34 N.m (25 lb ft).




6. Connect the CMP sensor electrical connector (1).




7. Connect the CKP sensor electrical connector.




8. Install the engine shield and bolts.

Tighten
Tighten the bolts to 20 N.m (15 lb ft).

9. Lower the vehicle.




10. Connect the fuel rail pressure sensor electrical connector (1).




11. Connect the BARO sensor electrical connector (1).




12. Connect the oil level sensor electrical connector (1).




13. Install the left side engine harness to the glow plugs (1).
14. Install the glow plug electrical nuts.

Tighten
Tighten the nuts to 2 N.m (18 lb in).

15. Install the left inner wheelhouse panel.




16. Install the fuel pipe retainer (2).
17. Install the fuel pipe retainer nut at the valve cover.

Tighten
Tighten the nut to 8 N.m (70 lb in).




18. Connect the glow plug controller electrical connectors (1).




19. Connect the fuel rail temperature sensor electrical connector (1).




20. Connect the left rear fuel injector electrical connector (1).




21. Connect the left front fuel injector electrical connector (1).




22. Install the PCV hose to valve cover.
23. Position the PCV hose clamp.




24. Install the charged air cooler inlet duct to the turbocharger.
25. Align the mark on the duct (2) with the mark on the turbocharger.
26. Position the clamp (1) as shown for proper clearance.

Tighten
Tighten the clamp to 6 N.m (53 lb in).




27. Install the bulk connector bolts (1) to the bracket.

Tighten
Tighten the bolts to 21 N.m (15 lb ft).




28. Connect the engine harness electrical connectors.
29. Install the glow plug relay.




30. Install the turbocharger coolant bypass valve.

Tighten
Tighten the valve to 60 N.m (44 lb ft).




31. Install the turbocharger water inlet hose.
32. Position the turbocharger water inlet hose clamp.




33. Connect the ECT sensor electrical connector (1).




34. Install the engine sight shield hold-down bracket (1) and bolt.

Tighten
Tighten the bolt to 10 N.m (89 lb in).




35. Connect the turbocharger boost sensor electrical connector (1).




36. Connect the right front fuel injector electrical connector (1).




37. Install the right side engine harness to the glow plugs (1).
38. Install the right side glow plug electrical nuts.

Tighten
Tighten the nuts to 2 N.m (18 lb in).




39. Connect the EGR throttle valve solenoid electrical connector (1).




40. Connect the EGR vacuum sensor electrical connector (1).




41. Connect the EGR vent solenoid electrical connector (1).




42. Connect the EGR valve solenoid electrical connector (1).




43. Connect the right rear fuel injector electrical connector (1).




44. Connect the following electrical connectors:
- Water-in-fuel sensor (1)
- Fuel heater (2)




45. Install the charged air cooler outlet duct to the intake.
46. Tighten the charged air cooler outlet duct clamp (1).

Tighten
Tighten the clamp to 6 N.m (53 lb in).




47. Connect the fuel injection control module electrical connectors (1).
48. Install the air cleaner.
49. Connect the negative battery cable.