Removal Procedure
Engine Wiring Harness Assembly ReplacementRemoval Procedure
1. Disconnect the negative battery cable.
2. Remove the air cleaner.
3. Disconnect the fuel injection control module electrical connectors (1).
4. Loosen the charged air cooler outlet duct clamp (1).
IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
5. Remove the charged air cooler outlet duct.
6. Disconnect the following electrical connectors:
- Water-in-fuel sensor (1)
- Fuel heater (2)
7. Disconnect the right rear fuel injector electrical connector (1).
8. Disconnect the exhaust gas recirculation (EGR) valve solenoid electrical connector (1).
9. Disconnect the EGR valve vent solenoid electrical connector (1).
10. Disconnect the EGR valve vacuum sensor electrical connector (1).
11. Disconnect the EGR throttle valve solenoid electrical connector.
12. Remove the right side glow plug electrical nuts.
13. Remove the right side engine harness from the glow plug (1).
14. Disconnect the right front fuel injector electrical connector (1).
15. Disconnect the turbocharger boost sensor electrical connector (1).
16. Remove the sight shield hold-down bolt and bracket (1).
17. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
18. Reposition the turbocharger water inlet hose clamp.
19. Remove the turbocharger water inlet hose.
20. Remove the turbocharger coolant bypass valve.
21. Remove the glow plug relay.
22. Disconnect the engine harness electrical connectors.
23. Remove the bulk connector bolts from the bracket (1).
24. Loosen the charged air cooler inlet duct to turbocharger clamp (1).
IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
25. Remove the charged air cooler inlet duct from the turbocharger.
26. Reposition the positive crankcase ventilation (PCV) hose clamp.
27. Remove the PCV hose from the left valve cover.
28. Disconnect the left front fuel injector electrical connector (1).
29. Disconnect the left rear fuel injector electrical connector (1).
30. Disconnect the fuel rail temperature sensor electrical connector (1).
31. Disconnect the glow plug controller electrical connectors (1).
32. Remove the fuel pipe retainer nut at the valve cover.
33. Remove the fuel pipe retainer (2).
34. Remove the left front wheelhouse panel.
35. Remove the left side glow plug electrical nuts.
36. Remove the left side engine harness from the glow plugs (1).
37. Disconnect the oil level electrical connector (1).
38. Disconnect the barometric pressure (BARO) sensor electrical connector (1).
39. Disconnect the fuel rail pressure sensor electrical connector (1).
40. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
41. Remove the engine shield bolts and shield.
42. Disconnect the crankshaft position (CKP) sensor electrical connector.
43. Disconnect the camshaft position (CMP) sensor electrical connector (1).
44. Remove the engine harness ground bolts (1).
45. Lower the vehicle.
46. Unroute and lift up the engine wiring harness for access to fuel pressure regulator.
47. Disconnect the fuel pressure regulator electrical connector (1).
48. Remove the engine wiring harness.