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Home >> Porsche >> 2011 >> Boxster S, Automatic DCT >> Repair and Diagnosis >> Accessories & Equipment >> Wiring System (Data Link Connectors, Pwr Dist., Grnd Dist.) >> 97 - Cables -- 987-BOXSTER-CAYMAN >> WM 975219 Removing And Installing Wire Harness For Engine (CAYMAN, CAYMAN S, CAYMAN Black Edition, CAYMAN Black Edition) >> Installing Wire Harness For Engine

Installing Wire Harness For Engine

Fig 1: Identifying Engine Wire Harness (2.9L; 1 Of 2)
G09606216Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fig 2: Identifying Engine Wire Harness (2.9L; 2 Of 2)
G09606217Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Installing wire harness for engine.
    1. 1.1. Lay out wire harness for engine.
    2. 1.2. Clip in cable duct at the left and right -arrows-  .
    3. 1.3. Tighten fastening screw -1-  at the cable duct at the left and right. → Tightening torque: 23 Nm 
    Fig 3: Installing Wire Harness For Engine
    G09593929Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Pull through engine wire harness in direction of luggage compartment and fit grommet -60-  .
  3. Plug on connector at transmission control unit (PDK) -59-  until it engages securely. → Installing Tiptronic Control Unit
    1. 3.1. Clip in wire harness to transmission control unit (PDK) at both line holders -arrows-  .
      Fig 4: Locating Wire Harness To Transmission Control Unit Clip (PDK)
      G09593930Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Screw down ground strap -58-  .
    1. 4.1. Fit ground strap -arrow-  and secure with fastening nut. → Tightening torque: 9 Nm (6.5 ftlb.) 
    Fig 5: Securing Ground Point
    G09593931Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Connect plug connections for wire harness from engine to main wire harness at rear -56 and 57-  until they engage securely.
  6. Push on connector of DME control module -53 to 55-  until it engages securely. → Installing DME Control Unit
    1. 6.1. Clip on wire harness to the DME control unit at the line holder -arrow-  .
      Fig 6: Locating Wire Harness To DME Control Unit Clip
      G09593932Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Plug connector onto PDK transmission -51 and 52-  and lock clockwise.
    1. 7.1. Lug line onto the four line holders off of the transmission -arrows-  .
      Fig 7: Installing Wire Harness On PDK Transmission
      G09593933Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Clip on cable duct on left and right fuel collection -arrows-  .
    Fig 8: Clipping Cable Duct On Fuel Collection Pipe
    G09593934Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  9. Push on connector of intake-manifold change-over switch -50-  until the securing clip is felt to engage.
  10. Plug on connector on engine compartment fan -49-  until it engages securely.
  11. Plug on connector for coolant level indicator -48-  until it engages securely. → Installing Engine Coolant Level Sensor
  12. Plug in connector on intake-manifold switchover -47-  until the securing clip engages securely.
  13. Plug in connector on intake-manifold flap -46-  until the securing clip engages securely.
  14. Plug in sports exhaust system connector -45-  until it engages securely.
  15. Connect plug on secondary air blower -44-  until it engages firmly. → Installing Secondary Air Pump
  16. Connect plug connections for oxygen sensor behind catalytic converter -42 and 43-  until the plug connections engage securely. → Installing Lambda Sensor Downstream Of Catalytic Converter
    1. 16.1. Insert lines into holder and close holder -arrows-  .
      Fig 9: Connecting Oxygen Sensor Behind Catalytic Converter
      G09593935Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  17. Connect plug connections for oxygen sensor in front of catalytic converter -40 and 41-  until the plug connections engage securely. → Installing Oxygen Sensor Upstream Of Catalytic Converter
    1. 17.1. Insert lines into holder and close holder -arrows-  .
      Fig 10: Connecting Oxygen Sensor In Front Of Catalytic Converter
      G09593936Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  18. Plug on connector at oil level sender -39-  .
    1. 18.1. Unclip the line with the two clips on the oil pan -arrows A-  .
    2. 18.2. Plug on the connector at the oil level sender until it is felt to engage -arrow B-  .
    Fig 11: Locating Connector At Oil Level Sender
    G09593937Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  19. Plug on plug connection on speed sender -38-  .
    1. 19.1. Push the speed sensor plug connection -arrow A-  together until it engages securely.
    2. 19.2. Push plug connection for speed sender into the cable duct -arrow B-  .
    Fig 12: Connecting Plug Connection On Speed Sender
    G09593938Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  20. Plug in connector on oil pressure regulating valve -37-  until the connector engages securely.
    1. 20.1. Fix line on water hose -arrow-  .
      Fig 13: Fixing Line On Oil Pressure Regulating Valve
      G09593939Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  21. Push on connector of oil temperature sensor -36-  until it is felt to engage.
  22. Plug in connector on mass air flow meter -35-  until it engages securely. → Installing Mass Air Flow Sensor
  23. Plug on the plug connection of the tank vent -34-  until it engages securely.
  24. Plug on connector of engine temperature sensor -33-  until it engages securely.
  25. Establish plug connections at generator -32-  . → Installing Three-Phase Generator
  26. Connect the plug connection at the air-conditioing compressor -30-  until it engages securely. → Installing Air Conditioning Compressor
    1. 26.1. Clip on the line for the air-conditioning compressor at the starter wire harness -arrows-  .
      Fig 14: Fixing Line For Air-Conditioning Compressor
      G09593940Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  27. Fix hose for crankcase ventilation at oil filler neck.
    1. 27.1. Plug hose for crankcase ventilation onto the oil filler neck.
    2. 27.2. Connect plug-in coupling -arrow-  until it clicks into place.
      Fig 15: Locating Positive Crankcase Ventilation Hose To Oil Filler Neck
      G09593941Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  28. Fix transfer point, lead to terminal 30 in engine compartment.
    1. 28.1. Position transfer point, lead to terminal 30, in installation position.
    2. 28.2. Insert both spacer sleeves -2-  .
    3. 28.3. Fix both fastening nuts -1-  . → Contact force: 10 Nm
      Fig 16: Identifying Transfer Point Terminal Spacer Sleeves And Fastening Nuts
      G09593942Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  29. Position starter lead -28 and 29-  for terminal 30 and terminal 50 and secure with fastening nut. → Tightening torque: 18 Nm (13 ftlb.)  → Tightening torque: 6.5 Nm (5.0 ftlb.)  → Installing Starter
  30. Plug on connector at coolant temperature sensor -27-  until it engages securely. → Installing Coolant Temperature Sensor
  31. Push on connectors of the two knock sensors -25 and 26-  until they are felt to engage. → Installing Knock Sensor
  32. Push on connectors of the two solenoid hydraulic valves (camshaft timing -23 and 24-  until they are felt to engage. → Installing Hydraulic Valve For Camshaft Timing
  33. Push on connectors of the two solenoid hydraulic valves (VHS) -21 and 22-  until they are felt to engage.
  34. Push on connectors of the two hall senders -19 and 20-  until they are felt to engage. → Installing Hall Sender
  35. Fix ground straps on the six ignition coils -13 to 18-  .
    1. 35.1. Position ground straps -1-  and screw down with the fastening screw. → Tightening torque: 9 Nm 
      Fig 17: Identifying Ignition Coil Ground Straps
      G09593943Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  36. Push on connectors of the six fuel injectors -7 to 12-  until they are felt to engage. → Installing Fuel Injector
  37. Push on connectors of the six injector coils -1 to 6-  until they are felt to engage. → 287020 REMOVING AND INSTALLING SPARK PLUGS
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