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Wiring harness, engine, Z19

Wiring harness, engine, Z19

To remove


1. Remove the battery:

• Detach the negative cable from the battery.

• Detach the positive cable the runs from positive battery terminal to the fuse box.

• Remove the positive battery cable.

• Undo the bolt of the battery lock lug and lift out the battery.

2. Remove the battery tray and components:


• Undo the electrical connection of the bonnet switch (A).

• Remove the glow plug relay (B).

• Remove the fuse holder (C).

• Remove the wiring harness cable tie from the battery tray.

• Remove the battery tray (D).

3. Undo the wiring and detach the fuse box:


• Remove the fuse box cover (A).

• Detach the fuse box (B).

• Remove the front bolt of the fuse box (C).

• Unplug the front connector beneath the fuse box.

• Remove the hose clip (D) and ground connection (D) of the wiring that sits on the structural member.

• Remove the connector (E) on the structural member.

4. Man. gearbox: Remove the connection of the reversing light switch.

5. Remove the clips (A) and connections (B) of the radiator fans and charge air valve.


6. Remove the clips (A) and cable tie (B) that hold the wiring on the left side and rear of the engine.


7. Unplug the connectors (A) of the pressure sensor for the particle trap and temperature sensor and remove the clip (B) from the water hose.


8. Unplug the connectors (A) on the back of the engine.


9. Remove the air filter housing:


• Unplug the connector (A) from the mass air flow sensor.

• Undo the hose from the mass air flow sensor (B).

• Remove the bolts (C) and lift out the air filter housing.

10. Remove the clips (A) on the right rear structural member and the cable tie (B).


11. Remove the connector (A) on the AC pipe and the clip (B) on the right structural member.


12. Remove the clips (A) from the upper radiator member.


13. Raise the vehicle to a suitable work height.

14. Remove the bumper bolts in the wing liner (A).


15. Remove the spoiler shield (A). Unplug the connector (B) and remove the connector (C). Remove the lower engine cover (D).


16. Cars with headlamp washer: Detach the washer hose. Suspend and plug as necessary.

17. Pry the bumper shell corner from the holder bracket and lift off the bumper shell.


18. Remove the right side cover and detach the wiring:


• Remove the right side cover (A).

• Remove the cable tie (B) holding the wiring around the control module.

• Remove the right control module connection (C).

19. Remove the bracket (A) protecting the AC compressor wiring. Release the wiring so that it hangs freely down in the engine bay.


20. Remove the ground connection (A) on the engine.


21. Lower the car.

22. Remove the electrical connections (B) from the starter motor.

23. Remove the electrical connections (A) from the generator.


24. Remove the electrical connections (A) from the power steering pump and the clip holding the wiring.


25. Move up the wiring.


To fit


1. Position the new wiring in the engine bay and bring down the part to be connected to the control module.

2. Route the power steering pump wiring between the engine and power steering hose. Fit the clip and plug in the connectors (A) of the power steering pump.


3. Attach the electrical connections (A) to the generator.


4. Attach the electrical connections (B) to the starter motor.


5. Raise the car.

6. Attach the ground connection (A) on the engine.

7. Fit the bracket (A) protecting the AC compressor wiring.


8. Fit the right side cover and secure the wiring:


• Fit the right side cover (A).

• Fit the cable tie (B) holding the wiring around the control module.

• Attach the right control module connection (C).

9. Fit the bumper shell:


• Check that the cellular block sits correctly in the shell.

• Position the bumper. Press the shell rearward and press the shell clips into the holder.

10. Cars with headlamp washer: Attach the washer hose.

11. Fit the lower engine cover (D), the connector (C) and plug in the connector (B). Fit the spoiler shield (A).


12. Fit the bumper bolts in the wing liner (A).


13. Lower the car.

14. Fit the upper radiator member clips (A).


15. Fit the connector (A) on the AC pipe and the clip (B) on the right structural member.


16. Fit the clips (A) on the right rear structural member and a cable tie (B) to hold the wiring harness together.


17. Fit the air filter housing:


• Fit the air filter housing (C).

• Attach the hose to the mass air flow sensor (B).

• Plug in the mass air flow sensor connector (A).

18. Plug in the connectors (A) on the back of the engine.


19. Plug in the connectors (A) of the pressure sensor for the particle trap and temperature sensor and attach the clip (B) to the water hose.


20. Fit the clips (A) and cable tie (B) that hold the wiring on the left side and rear of the engine.


21. Fit the clips (A) and connections (B) of the radiator fans and charge air valve.


22. Man. gearbox: Attach the connection of the reversing light switch.

23. Connect the wiring and fuse box:


• Attach the connector (E) on the structural member.

• Attach the ground connection (D) and hose clip (D) around the wiring on the structural member.

• Plug in the front connector beneath the detached fuse box.

• Fit the front bolt of the fuse box (C).

• Fit the fuse box (B).

• Fit the fuse box cover (A).

24. Fit the battery tray and components:


• Fit the battery tray (E).

• Fit the wiring harness cable tie (D) to the battery tray.

• Fit the fuse holder (C).

• Fit the glow plug relay (B).

• Attach the electrical connection of the bonnet switch (A).

25. Fit the battery:

• Position the battery and fit the bolt to the battery's lock lug.

• Connect the positive cable of the battery.

• Connect the positive cable that runs between the fuse box and the positive battery terminal.

• Connect the negative cable of the battery.

26. Check the fit of the bumper and adjust as necessary.

27. Carry out Procedure after battery disconnection .