Installing Wiring Harness For Engine
Installing the wiring harness for the engine1. Feed the wiring harness through the opening in the engine compartment to the starter and reversing light switch.
Note!
The terminal 30 cable must be bound with the protective tube with two tie-wraps to the starter. Attach the protective caps to the cable clamp.
2. Screw in the connections on the starter -1 + 2- and tighten. Fasten the two tie-wraps -arrows-.
3. Insert the reversing light switch connector. To do this, press in the two pins and mount the rubber grommet.
4. Fasten the ground cable -arrow- on the starter. Tighten the hexagon socket nut.
Tightening torque hexagon socket nut 46 Nm (34 ftlb.).
5. Install the transmission vent hose and suction hose to the turbocharger. To do so, fasten the upper screw-type hose clamp -arrow- and the lower clamp -arrow-.
6. Install warm air pipe on right -arrow-.
Tightening torque (M6 x 20, M6 x 12) 10 Nm (7.5 ftlb.)
7. Install thermal motor protection.
8. Guide wiring harness under the crankcase vent tube.
9. Lightly lubricate the rubber grommet -arrow- of the wiring harness and press it in. Ensure correct seating.
Note!
Check the sealing rings of the injection valves, replace as necessary and lubricate (e.g. WD 40).
10. Position the screws -arrows- of the right fuel gallery and tighten. Install the tab washers of the injection valves. Ensure that the tab washers are seated correctly.
Tightening torque 10 Nm (7.5 ftlb.)
11. Connectors of the injection valves cyl. 4 - 6 are connected and the wiring harness is fastened to the fuel gallery.
12. Guide the generator connection cable through the air cowl and press in the rubber grommet. Place the cable on the generator, lubricate slightly, and fasten. Press rubber grommet in the air cowl. Position generator cover and tighten.
Tightening torques
D+ cable (blue) 2 Nm (1.5 ftlb.), D- cable (brown) 2 Nm (1.5 ftlb.), and the B+ cable (red) 8 Nm (6 ftlb.)
Fastening screws generator housing 10 Nm (7.5 ftlb.).
13. Install the cooling fan and tighten the restraining strap with a hexagon socket head bolt.
Tightening torque 8 Nm (6 ftlb.)
14. Install the air cowl of the cooling fan. Tighten the screws.
Tightening torque 10 Nm (7.5 ftlb.)
15. Install fan belt monitor and unplug connector.
Tightening torque 10 Nm (7.5 ftlb.)
16. Slide the wiring harness holder on the holder of the ignition coil cable and fasten.
17. Fasten the wiring harness using the two rubberized clamps.
Rubberized clamp
Tightening torque for hexagon-head bolts 10 Nm (7.5 ftlb.)
18. Position and tighten ground cable on the intake pipes.
Tightening torque 10 Nm (7.5 ftlb.)
19. Insert the plug connections from the relay carrier into the engine compartment and mount the cover.
20. Connect the connectors of the injection valves 1.3, distributor ignition, ignition coil (connections are screwed in), oil pressure sensor (connections are screwed in), oil temperature sensor and secondary air pump.
21. Install the complete intake distributor (right, left, and centre). Lightly oil the rubber of the intake pipes. Tighten the hose straps of the intake pipes.
22. Connect all vacuum connections and connectors on the intake distributor.
23. Connect the centre and right vent hose on the throttle body.
Vent hose
24. Place the oil pressure sensor holder and tighten the screws -1-. Fasten the ground strap -arrow-.
25. Engage accelerator cables -arrows-. Lightly oil the rubber of the accelerator cables. Tighten the accelerator cable holder. Connect the hose -1-. Ensure that the accelerator cables are seated correctly and tightly.
Tightening torque 10 Nm (7.5 ftlb.).
26. Fasten the connector on the holder (observe colour code).
Position and tighten the hose from the tank vent.
27. Install air conditioning compressor. Connect connector. Position screws and tighten. Fasten air conditioning lines in the holder.
Tightening torque 28 Nm (21 Ftlb.)
28. Mount the positive crankcase ventilation hose.
29. Install the air cleaner assembly and hot film air flow sensor.
30. Mount the heater blower or the bypass air flap.
31. Install charge air cooler.
32. Mount the air guide bracket from the charge air cooler.
33. Connect the battery.
Note:
After the connector has been disconnected from the control module or if the vehicle battery has been disconnected, the engine must first run 250 seconds before the first adaptation phase begins.
34. Perform a function test.