Remove/install engine wiring harness

AR01.00-P-2411CD

Remove/install engine wiring harness

14.2.12

 

Remove/install

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Danger!

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.

Deburr repair panels.

AS00.00-Z-0017-01A

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect ground cable at battery

AR54.10-P-0003CW



Notes on battery

AH54.10-P-0001-01A

2

Disconnect electrical connector from DPF differential pressure sensor

AR07.04-P-0012CD

3

Separate connector (1)

4.1

Remove catalytic converter diesel particulate filter unit

204.0/ 2/ 3 except 4MATIC

AR49.10-P-5501CD

4.2

Remove diesel particulate filter

204.0/ 2 with 4MATIC

AR14.40-P-1000OMD

4.3

Remove catalytic converter

Model 204.9

AR49.10-P-5500OMD

5

Detach high-pressure line bracket for power steering on oil pan

If installed.



*BA46.30-P-1006-01R

6

Disconnect electrical connection on alternator (G2) and remove alternator (G2)

 For vehicles with 4MATIC unscrew the nut for the circuit 30 electrical line to alternator (G2).

AR15.40-P-5032CD

 The alternator (G2) remains in engine compartment. The fan unit must not be removed. Secure alternator (G2) against falling down, if necessary.

7

Remove shield for starter (M1)



*BA15.30-P-1004-01P

8

Remove shield for the turbocharger

Vehicles with 4MATIC

9

Detach circuit 50 electrical line (M1) from starter

 Installation: Ensure lines are installed correctly.

 Attach a pulling-in aid (e.g. a cord) on the end of the electrical line in order to simplify routing during assembly.



*BA15.30-P-1003-01P

10

Remove impact plate

 The impact plate is installed in front of the belt drive.

11

Disconnect rear engine compartment electrical connection (X26/7)

Vehicles without 4MATIC

 The rear engine compartment electrical connection (X26/7) is attached to the right rear engine suspension lug.

12

Detach ground line at ground point for the fuel filter with heating element (W12) and at the internal combustion engine ground point (W11)



*BA15.18-P-1004-01C



*BA15.18-P-1006-01C

13

Disconnect engine wiring harness (2) from wiring harness on the body side (3)

 Installation: Replace cable ties.

14

Detach cover (4)

 Installation: For model 204.0/9 as of 06/2009 and on model 204 2/3, install fuel pressure sensor (B4/7).

15

Disconnect glow plug electrical connection (X214)

16

Disconnect electrical connection on coolant temperature sensor (B11/4) and create access to electrical feed line from the thermostat housing bracket

17

Unclip engine wiring harness (2) on mounting brackets and rail (arrows)

18

Remove screw (13)

19

Remove cable ties from fuel lines on fuel filter

 Installation: Replace cable ties.

20

Disconnect electrical connections and connectors

 Disconnect at the following sensors or actuators and expose their electrical feed lines by unclipping from the clamps:

 Rail pressure sensor ()B4/6

 Fuel filter condensation sensor with heating element (B76/1)

 Fuel injectors (Y76)

 Camshaft Hall sensor (B6/1)

 Pressure regulator valve (Y74)

 Exhaust back pressure sensor (B60)

 Intake port shutoff actuator motor (M55)

 Fuel pressure sensor (B4/7), for model 204.0/9 as of 06/2009 and for model 204.2/3

 Coolant thermostat heating element (R48)

 Glow output stage (N14/3)

 Temperature sensor upstream of turbocharger (B19/11)

 Vent line heater element (R39/1)

Only with single-stage charging:

 Boost pressure positioner (Y77/1)

Only with two-stage charging:

 Low-pressure turbocharger boost pressure sensor (B5/4)

 Boost pressure control transducer (Y31/5)

 Charge air bypass flap switchover valve (Y132)

21

Disconnect electrical connector at pressure sensor downstream of air filter (B28/5)

 Installation: Observe the colored marking of the electrical connection.

22

Pull out exposed wiring harness of the engine wiring harness (2) out of the engine compartment upwards

 Installation: Observe installation of lines between the engine and turbocharger compressor housing.

 Expose electrical feed lines of the already separated electrical connections; to do this unclip clamps from right oil pan top section, cylinder crankcase, major assembly carrier for the alternator (G2) and belt drive as well as from the glow output stage (N14/3) bracket.

23

Remove fuel filter

 Fasten fuel filter with attached fuel hoses free of tension on the engine using a cable tie.

AP47.20-P-0780CWD

24

Remove exhaust gas recirculation cooler

 Tie up exhaust gas recirculation cooler to engine with coolant hoses attached.

AR14.20-P-7665CD

25

Unhook filter for boost pressure control with attached hoses from the fastening and lay outside the working area

26

Disconnect electrical connector on boost pressure sensor (B5/1)

27

Disconnect connector (7) from cylinder 1+2 (A16/4) knock sensor

28

Disconnect electrical connector on quantity control valve of the power steering pump (Y10/1)

29

Disconnect electrical connection at the coolant pump switchover valve (Y133)

 Installation: Observe the colored marking of the electrical connection.

 Detach coolant pump switchover valve (Y133) from fastening if necessary.

30

Remove electrical connector on exhaust gas recirculation cooler bypass switchover valve (Y85)

 Installation: Observe the colored marking of the electrical connection.

 Detach exhaust gas recirculation cooler bypass switchover valve (Y85) with attached hoses from fastening if necessary.

31

Remove bracket (8)

32

Remove bracket (9)



*BA46.30-P-1011-01R



*BA46.30-P-1012-01R

33

Disconnect electrical connector on oil spray nozzles shutoff valve (Y131)

34

Disconnect connector (10) from A/C compressor (A9)

35

Disconnect electrical connector at charge air temperature sensor (B17/8)

36

Pull out exposed wiring harness of the engine wiring harness (2) out of the engine compartment upwards

 Installation: Ensure lines are installed correctly.

 Expose electrical feed lines to all already separated electrical connections; to do this unclip clamps for the exhaust gas recirculation cooler support brace (6) on the oil filter housing, from the oil filter housing major assembly carrier and from the engine charge air duct.

37

Detach engine wiring harness (2) from the mixing chamber and from the exhaust gas recirculation valve bracket on the cylinder crankcase

38

Disconnect connector (11) from the exhaust gas recirculation actuator (Y27/9)

39

Disconnect electrical connectors

 Disconnect at the following sensors or actuators and expose their electrical feed lines by unclipping from the clamps:

 Quantity control valve (Y94)

 Throttle valve actuator (M16/6)

 Oil level check switch on oil pan bottom section

 Oil temperature sensor (B1)

 Engine oil pump valve (Y130), vehicles as of 06/2010

 Crankshaft position sensor (L5), vehicles without code (B03) ECO start/stop function

 Fuel temperature sensor (B50)

Only with two-stage charging:

 Boost pressure control flap pressure transducer (Y93)

40

Disconnect connector (12) from cylinder 3+4 (A16/1) knock sensor

41

Remove engine wiring harness (2) completely from engine compartment

 Installation: Ensure lines are installed correctly.

 Expose electrical feed lines for all already separated electrical connections and connectors; to do this unclip clamps from oil pan bottom section, oil pan top section and cylinder crankcase.

42

Install in the reverse order



Checking

43

Check routing of all electrical feed lines for tight seating as well as positive latching of the electrical connections or connectors

Number

Designation

Engine 651

BA15.30-P-1003-01P

Nut, connection for circuit 50

Nm

6

BA15.30-P-1004-01P

Shield on starter

Nm

9

Number

Designation

Model
204 with engine 651

BA46.30-P-1006-01R

Bracket from high-pressure line/low-pressure line to oil pan

Nm

10

BA46.30-P-1011-01R

Bolt, power steering pump bracket to engine support

Nm

20

BA46.30-P-1012-01R

Bolt, power steering pump bracket to power steering pump

Nm

14

Number

Designation

Engine 651

BA15.18-P-1004-01C

Bolt, engine wiring harness ground connection (W11) for glow time output stage (GZE) to cylinder head

Nm

9

BA15.18-P-1006-01C

Bolt, engine wiring harness ground connection (W12) for fuel heater

Nm

9