975219 Removing and installing wire harness for engine
WM 975219 Removing and installing wire harness for engine
Technical values
Information
The main wire harness is manufactured individually depending on equipment.
- Fastening elements may be different from the parts described.
- The number of plug connections can vary, depending on equipment.
Preliminary work
1. Disconnect ground strap for battery. -> 2X00IN Work instructions after disconnecting the battery 2X00IN Work instructions after disconnecting the battery
2. Remove left and right cross panel. -> 508119 Removing and installing cross panel - section on "Removing" Service and Repair
3. Remove cooling fan housing (radiator frame). -> 19201901 Removing and installing cooling fan housing (radiator frame) - section on "Removing" Service and Repair
4. Remove high-pressure pump. -> 246319 Removing and installing high-pressure pump - section on "Removing" 246319 Removing and installing high-pressure pump
5. Remove air cleaner housing at the left and right. -> 242519 Removing and installing air cleaner housing - section on "Removing" Service and Repair
6. Remove the generator. -> 272219 Removing and installing generator - section on "Removing" Service and Repair
7. Remove the starter. -> 276019 Removing and installing starter - section on "Removing" Service and Repair
Removing wire harness for engine
NOTICE
Voltage peaks
- Risk of damage to load or to the control unit
-> Switch off ignition and remove remote control before disconnecting or removing load.
Information
Always comply with the regulations for handling ESD-sensitive components!
- Assembly work must only be carried out if the mechanic is wearing the working clothes and shoes approved by Porsche.
- The new part must only be removed from the ESD (electrostatic discharge) protective packaging just before installation and at the position at which the part is to be installed.
- Never touch the electric pins and plug contacts.
Engine wire harness assignment (Turbo shown)
Bottom left of engine:
1. Release line for air-conditioning compressor -38-.
Line for air-conditioning compressor
1.1. Release and unplug electric plug connection -38-. -> 873419 Removing and installing air-conditioning compressor - section on "Removing" Service and Repair
1.2. Unclip the line from the brackets -1- and pull it through in an upward direction.
Bottom right of engine:
2. Release and unplug electric plug connection for oil level sensor -39-. -> 171119 Removing and installing oil level sensor - section on "Removing" Service and Repair
3. Release and unplug electric plug connection for oil pressure control valve -36-.
Oil pressure controller connector
4. Release and unplug electric plug connection for oil pressure sensor -40-.
Line for oil pressure sensor
5. Remove tie-wrap -1- on line for oil pressure sensor.
Front of engine:
6. Open the cable duct and unclip wire harness -arrows-.
Unclipping wire harness at the cable duct
7. Release electric plug connection for tank vent valve -32- ( -a- ) and unplug it -A-.
Line for tank vent valve
Rear of engine:
8. Disconnect line for crankshaft pulse sender -25- (speed sender).
Line for crankshaft pulse sender
8.1. Release and unplug electric plug connection -25-.
8.2. Unclip line -A- and pull it through in an upward direction.
9. Release and unplug electric plug connection for hall senders (camshafts) at the left and right -26 + 27-. -> 283919 Removing and installing hall sender (camshaft) - section on "Removing" Service and Repair
10. Release and unplug connectors on the solenoid/hydraulic valve for variable valve-lift control -19 + 20-. -> 155519 Removing and installing solenoid/hydraulic valve for valve lift switchover - section on "Removing" Service and Repair
11. Release and unplug connector on coolant temperature sensor -37-. -> 197819 Removing and installing coolant temperature sensor - section on "Removing"
12. Unclip cable duct for engine at the rear left -1- and remove lines.
Cable duct for engine at the rear left
13. Release and unplug electric plug connection for engine compartment temperature sensor -55-.
14. Release wire harness from the brackets at the rear right -1-.
Releasing wire harness at the rear right
15. Release and unplug electric plug connection on engine control unit -51-. -> 247019 Removing and installing DME control unit - section on "Removing" 247019 Removing and installing DME control unit
16. Screw off fastening nut for ground strap on the firewall -59-.
Ground strap on firewall
17. Disconnect line for vehicle/engine connection point in the relay box -50-.
Line for vehicle/engine connection point in relay box
17.1. Open the relay box and remove rubber sleeve -2- by pulling it upwards.
17.2. Release and unplug three electric plug connections for the vehicle/engine connection point in the relay box -50-.
17.3. Unclip bracket -1- on the brake booster.
Top of engine:
18. Release and unplug electric plug connection at the bar ignition modules -1 - 4- and -13 - 16-. -> 282020 Removing and installing bar ignition modules - section on "Removing" Service and Repair
19. Release and unplug electric plug connection at the injectors -5 -12-. -> 244020 Removing and installing fuel injectors - section on "Removing" Service and Repair
20. Unplug electric plug connection at the hydraulic valves for camshaft control -17 + 18-.
Unplugging connector for the hydraulic valves for camshaft control 1-4 and 5-8
20.1. Remove cap -A-.
20.2. Release connector -B- and pull it off -C-.
21. Disconnect ground straps -21 - 24- and unclip cable duct at the left and right on the camshaft housing cover.
Disconnecting ground straps and unclipping cable duct
21.1. Unscrew fastening screws on ground straps and remove ground straps.
21.2. Unclip cable duct on the camshaft housing cover -arrows-.
22. Remove vent line => Removing vent line.
Removing vent line
22.1. Unscrew fastening screws -1-.
22.2. Unclip vent line -2- from the cable duct and remove it -arrow-.
23. Release and pull off connectors on the knock sensors -28 - 31-. -> 287219 Removing and installing knock sensors - section on "Removing" Service and Repair
24. Screw off B+ line -47- at the external power connection. -> 974519 Removing and installing wire harness for battery starter - section on "Removing" 974519 Removing and installing wire harness for battery-> 974519 Removing and installing wire harness for battery starter - section on "Removing" 974519 Removing and installing wire harness for battery
Remove wire harness:
25. Loosen cable duct.
Engine wire harness, inner V and valve cover
25.1. Unscrew six fastening screws -1- on wire harness inner V.
25.2. Unscrew two fastening screws -2- on the cable duct.
26. Disconnect wire harness for engine at the engine housing and remove it by pulling it upwards.
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. Insert plug connections for bottom right of engine.
4.5. Insert plug connections for bottom left of engine.
5. Screw down cable guide ducts.
6. Tighten fastening nut on ground point to => Tightening torque: 9 Nm (6.5 ftlb.).
7. Tighten fastening screws on ground points to => Tightening torque: 10 Nm (7.5 ftlb.).
Subsequent work
1. Install the generator. -> 272219 Removing and installing generator - section on "Installing" Service and Repair
2. Install the starter. -> 276019 Removing and installing starter - section on "Installing" Service and Repair
3. Install high-pressure pump. -> 246319 Removing and installing high-pressure pump - section on "Installing" 246319 Removing and installing high-pressure pump
4. Install cooling fan housing (radiator frame). -> 19201901 Removing and installing cooling fan housing (radiator frame) - section on "Installing" Service and Repair
5. Install air cleaner housing at the left and right. -> 242519 Removing and installing air cleaner housing - section on "Installing" Service and Repair
6. Install cross panel at the left and right. -> 508119 Removing and installing cross panel - section on "Installing" Service and Repair
7. Secure ground strap for battery. -> 2X00IN Work instructions after disconnecting the battery 2X00IN Work instructions after disconnecting the battery