Removing and Installing Wire Harness For Engine
Removing And Installing Wire Harness For Engine
Preliminary work
1. Remove bulkhead
2. Remove fuel collection pipe
3. Remove ground strap for battery.
4. Remove front underbody panelling
5. Remove front wheel
6. Remove front part of left and right front wheel housing liner
7. Remove front-axle support
8. Remove radiator frame
Removing wire harness for engine
Installation position of engine wire harness (illustration as example)
Wire harness assignment (Turbo shown)
1.- Bar ignition module, cylinder 1
2.- Bar ignition module, cylinder 2
3.- Bar ignition module, cylinder 3
4.- Bar ignition module, cylinder 4
5.- Injector, cylinder 5
6.- Injector, cylinder 6
7.- Injector, cylinder 7
8.- Injector, cylinder 8
9.- Injector, cylinder 1
10.- Injector, cylinder 2
11.- Injector, cylinder 3
12.- Injector, cylinder 4
13.- Bar ignition module, cylinder 5
14.- Bar ignition module, cylinder 6
15.- Bar ignition module, cylinder 7
16.- Bar ignition module, cylinder 8
17.- Camshaft Adjuster
18.- Camshaft Adjuster
19.- Hydraulic valve for variable valve-lift control
20.- Hydraulic valve for variable valve-lift control
21.- Engine ground
22.- Engine ground
23.- Engine ground
24.- Engine ground
25.- Speed sensor
26.- Hall sender (phase sensor)
27.- Hall sender (phase sensor)
28.- Knock sensor
29.- Knock sensor
30.- Knock sensor
31.- Knock sensor
32.- Tank vent
33.- Generator
34.- Crankcase heating
35.- Flow control valve
36.- Oil pressure regulating valve
37.- Water temperature sensor
38.- Air conditioning compressor
39.- Oil level sensor
40.- Oil-pressure sender with oil temperature sensor
41.- Electronic accelerator (throttle adjuster)
42.- High-pressure sensor
43.- Starter, terminal 50
44.- Starter, terminal 30
45.- Starter, terminal 30
46.- Generator, B+
47.- Transfer point on vehicle B+
48.- Intake manifold switch-over valve
49.- Vehicle/engine connection point
50.- Vehicle/engine connection point
51.- DME (DFI) control unit
52.- Secondary-air pump
53.- Ambient air valve (not present on naturally aspirated engine)
54.- Pressure sensor load detection
55.- Engine compartment temperature sensor
56.- Boost-pressure control valve (not present on naturally aspirated engine)
57.- Boost pressure sensor (not present on naturally aspirated engine)
58.- Map-controlled thermostat (electrically heated coolant regulator)
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.
2. Release and pull off connector at air-conditioning compressor -38-.
3. Remove wiring harness for the air conditioning compressor from the line bracket -arrow A- and unclip it at the retaining clip -arrow B-.
4. Release and pull off connector at oil level sensor -39-.
Bottom right of engine:
5. Release and pull off connector at oil pressure control valve -36-.
6. Release and pull off connector at oil pressure sensor -40-.
7. Release B+ cable from the generator -46-.
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-.
11. Release and pull off connector for boost pressure sensor -57- (for Turbo only).
12. Unscrew fastening screw -1- at the cable duct -2-.
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-.
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-.
15. Unclip engine wire harness at the rear right at the retaining clip -arrow-.
16. Unclip vacuum line from the rubber sleeve -arrow-.
Top of engine:
17. Release and pull off connectors at the DFI bar ignition modules -1 to 4- and -13 to 16-.
18. Release and pull off connectors at the (DFI) high-pressure fuel injectors -5 to 12-.
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-.
20. Release and pull off connectors at the solenoid/hydraulic valves for valve lift switchover -19 and 20-.
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- ).
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-.
26. Remove 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-.
28. Release and pull off connectors at the knock sensors on DFI engines -28 to 31-.
29. Release and pull off connector at tank vent valve -32-.
30. Release and pull off connector at coolant temperature gauge -37-.
31. Screw off B+ line -47- at the external power connection.
Remove wire harness:
32. Loosen cable duct.
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-.
Installing wire harness for engine
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.
2. Install front-axle support.
3. Install front part of left and right front wheel housing liner.
4. Fit front wheels
5. Install front underbody panel.
6. Secure ground strap to battery.
7. Install fuel collection pipe
8. Install bulkhead