Unlatch and separate the Engine Oil Pressure (EOP) sensor connector from the main wiring harness. See Figure
Remove Engine Oil Pressure Sensor Connector
Unlatch and separate the Manifold Absolute Pressure (MAP) sensor connector, located on top of the valve cover, from the main wiring harness.
Unlatch and separate Engine Oil Temperature sensor (EOT) connector from the main wiring harness, see Figure
. When the EOT sensor is removed from the front cover, oil will leak out the port.
Remove Engine Oil Temperature Sensor Connector
Unlatch and separate the Engine Coolant Temperature (ECT) sensor connector from the main wiring harness. See Figure
1.Engine Coolant Temperature Sensor
Remove Engine Coolant Temperature Sensor Connector
Unlatch and separate Camshaft Position Sensor (CMP) from the main wiring harness. If necessary, remove CMP mounting bolt and pull CMP sensor from front cover. See Figure
Removing Camshaft Position Sensor
Remove any wiring harness clamps securing the wiring harness to the engine.
Carefully lift entire main wiring harness free from the engine.
To prevent damage to the wiring harness when removing it from the ECM, should any resistance be encountered, do not tug on the wiring harness to free it. Investigate the source of the resistance, and free the connector or clip. Then remove the wiring harness from the engine.
Use the following steps when inspecting the wiring harness:
Be sure to clean any and all Loctite, if present, from the threads of the sensors.
Check all connector pins on sensors. If bent or corroded, replace sensor.
Carefully inspect wiring harness for worn conduit, frayed insulation or heat damage on wires. Refer to the following repair section should repair be necessary.
Inspect each connector for the following conditions. Replace as required.
Corroded connectors - green or gray-white deposits on metal terminals.
Female connector sleeves spread open.
Terminals incorrectly latched into connector body or "pushed back" relative to other terminals in the same connector.
Use service kit 1 830 337 C91 for replacement of ECM harness connectors that show cracks or damage
Inspect the engine wiring harness connectors, connector covers and cover shields for cracks, cuts or worn areas. Replace as required. See Figure
1.Wiring Connector Cover
4.Wiring Harness Connector
2.Connector Cover Shield
Connector Cover Parts
Assembly of Main Wiring Harness
Use the following steps to assemble the main wiring harness. Assembly procedures for engines equipped with separately mounted ECM and IDM units or engines equipped with the engine mounted ECM are the same except where noted.
If removed, install the EOP, ECT, MAP and EOT sensors into their proper locations and tighten.
Place new O-ring onto CMP sensor and lubricate with clean engine oil. Insert into front cover.
Secure CMP sensor to front cover with mounting bolt. Tighten bolt.
Camshaft Position Sensor Installation
Ensure that each connector has its ribbed seal in place before installing onto sensor. In some cases, during disassembly the ribbed seal may pull off the connector and remain in the mating socket of a sensor or actuator. A connector assembled without the appropriate ribbed seal can become contaminated with moisture and corrode the terminals resulting in a poor electrical connection.
Injection Control Pressure Sensor Into Supply Manifold
Install wiring harness onto the engine and carefully align connectors with sensors. Push each connector into its mating socket until locking tabs are fully latched.
Install the two ECM gaskets into the ECM connector receptacles.