Removing Wire Harness For Engine

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NOTE: 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 may 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 .

Fig 1: Overview Of Engine Wire Harness Assignment
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Bar Ignition Module, Cylinder 1
2. Bar Ignition Module, Cylinder 2
3. Bar Ignition Module, Cylinder 3
4. Bar Ignition Module, Cylinder 4
5. Injector, Cylinder 5
6. Injector, Cylinder 6
7. Injector, Cylinder 7
8. Injector, Cylinder 8
9. Injector, Cylinder 1
10. Injector, Cylinder 2
11. Injector, Cylinder 3
12. Injector, Cylinder 4
13. Bar Ignition Module, Cylinder 5
14. Bar Ignition Module, Cylinder 6
15. Bar Ignition Module, Cylinder 7
16. Bar Ignition Module, Cylinder 8
17. Camshaft Adjuster
18. Camshaft Adjuster
19. Solenoid/Hydraulic Valve For Variable Valve-Lift Control
20. Solenoid/Hydraulic Valve For Variable Valve-Lift Control
21. Engine Ground
22. Engine Ground
23. Engine Ground
24. Engine Ground
25. Crankshaft Pulse Sender
26. Hall Sender (Phase Sensor)
27. Hall Sender (Phase Sensor)
28. Knock Sensor
29. Knock Sensor
30. Knock Sensor
31. Knock Sensor
32. Tank Vent
33. Generator
34. Crankcase Heating
35. Flow Control Valve
36. Oil Pressure Regulating Valve
37. Coolant Temperature Sensor
38. Air-Conditioning Compressor
39. Oil Level Sensor
40. Oil-Pressure Sender With Oil Temperature Sensor
41. Electronic Accelerator (Throttle Adjuster)
42. High-Pressure Sensor
43. Starter, Terminal 50
44. Starter, Terminal 30
45. Starter, Terminal 30
46. Generator, B+
47. Transfer Point On Vehicle, B+
48. Intake Manifold Switch-Over Valve
49. Vehicle/Engine Connection Point
50. Vehicle/Engine Connection Point In Relay Box (Three Connectors)
51. DME (DFI) Control Unit
52. Secondary-Air Pump
53. Ambient Air Valve (Not Present On Naturally Aspirated Engine)
54. Pressure Sensor Load Detection
55. Engine Compartment Temperature Sensor
56. Boost-Pressure Control Valve (Not Present On Naturally Aspirated Engine)
57. Boost Pressure Sensor (Not Present On Naturally Aspirated Engine)
58. Map-Controlled Thermostat (Electrically Heated Coolant Regulator)
59. Ground Point

Bottom Left Of Engine:

Disconnect line for air-conditioning compressor -38- .

Fig 2: Identifying Line For Air-Conditioning Compressor
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 1.1. Release and unplug electric plug connection -38- . → REMOVING ELECTRIC AIR-CONDITIONING COMPRESSOR - section on "Removing"
2. 1.2. Unclip the line from the brackets -1- and pull it through in an upward direction.
Bottom right of engine:
Release and disconnect electric plug connection for oil level sensor -39- . → REMOVING OIL LEVEL SENSOR AND OIL TEMPERATURE SENSOR - section on "Removing"
Release and unplug electric plug connection for oil pressure control valve -36- .
1. Fixing clip
2. Connector for oil pressure control valve
  
  Fig 3: Identifying Connector For Oil Pressure Regulator
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Release electric plug connection for oil pressure sensor -40- (-a- ) and disconnect it -A- .

Fig 4: Removing Electric Plug Connection For Oil Pressure Sensor
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove tie-wrap -1- on line for oil pressure sensor.
Front Of Engine:
Open the cable duct and unclip wire harness -arrow- .

Fig 5: Unclipping Wire Harness At Cable Duct
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Release electric plug connection for tank vent valve -32- (-a- ) and disconnect it -A- .

Fig 6: Removing Electric Plug Connection For Tank Vent Valve
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Rear Of Engine:
Disconnect line for crankshaft pulse sender -25- (speed sender).

Fig 7: Disconnecting Line For Crankshaft Pulse Sender
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 8.1. Release and unplug electric plug connection -25- .
2. 8.2. Unclip line -A- and pull it through in an upward direction.
Release and unplug electric plug connection for hall senders (camshafts) at the left and right -26 + 27- . → REMOVING HALL SENDER - section on "Removing"
Release and unplug connectors on the solenoid/hydraulic valve for variable valve-lift control -19 + 20- . → REMOVING HYDRAULIC VALVE FOR VALVE LIFT SWITCHOVER - section on "Removing"
Release and unplug connector on coolant temperature sensor -37- . → REMOVING COOLANT TEMPERATURE SENSOR FOR CONTROLLING ENGINE TEMPERATURE - section on "Removing"
Unclip cable duct for engine at the rear left -1- and remove lines.

Fig 8: Disconnecting Cable Duct For Engine At Rear Left
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Release and unplug electric plug connection for engine compartment temperature sensor -55- .
Release wire harness from the brackets at the rear right -1- .

Fig 9: Identifying Wire Harness At Rear Right
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Release and unplug electric plug connection on engine control unit -51- . → REMOVING DME CONTROL UNIT - section on "Removing"
Screw off fastening nut for ground strap at the firewall -59- .

Fig 10: Identifying Ground Strap On Firewall
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Disconnect line for vehicle/engine connection point in the relay box -50- .

Fig 11: Identifying Line For Vehicle/Engine Connection Point In Relay Box
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 17.1. Open the relay box and remove rubber sleeve -2- by pulling it upwards.
2. 17.2. Release and unplug three electric plug connections for the vehicle/engine connection point in the relay box -50- .
3. 17.3. Unclip bracket -1- on the brake booster.
Top Of Engine:
Release and unplug electric plug connection at the bar ignition modules -1 - 4- and -13 - 16- . → REMOVING BAR IGNITION MODULES - section on "Removing"
Release and unplug electric plug connection at the injectors -5 -12- . → REMOVING FUEL INJECTOR - section on "Removing"
Unplug electric plug connection at the hydraulic valves for camshaft control -17 + 18- .

Fig 12: Disconnecting Connectors For Hydraulic Valves For Camshaft Control 1-4 And 5-8
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 20.1. Pull off cap -A- .
2. 20.2. Release connector -B- and disconnect it -C- .
Disconnect ground straps -21 - 24- and unclip cable duct at the left and right on the camshaft housing cover.

Fig 13: Loosening Ground Straps And Unclipping Cable Duct
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 21.1. Unscrew fastening screws on ground straps and remove ground straps.
2. 21.2. Unclip cable duct on the camshaft housing cover -arrows- .
Remove vent line.

Fig 14: Removing Vent Line
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 22.1. Unscrew and remove fastening screws -1- .
2. 22.2. Unclip vent line -2- from the cable duct and remove it -arrows- .
Release and pull off connectors on the knock sensors -28 - 31- . → 287219 REMOVING AND INSTALLING KNOCK SENSORS - section on "Removing"
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 STARTER - section on "Removing"
Remove wire harness:
Loosen cable duct.

Fig 15: Overview Of Engine Wire Harness, Inner V And Valve Cover
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Wire Harness Fastening Screw, Inner V
2. Wire Harness Fastening Screw, Rear Left (Aluminum Screw)
1. 25.1. Unscrew six fastening screws -1- on wire harness at the inner V.
2. 25.2. Unscrew two fastening screws -2- on the cable duct.
Disconnect wire harness for engine at the engine housing and remove it by pulling it upwards.