Engine Wiring Harness

Engine Wiring Harness - 4.2L

Removal
1. Disconnect the battery ground cable.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

2. Raise and support the vehicle.
3. Remove the cooling fan.
4. Remove the cooling fan belt.
- Note the fitted position.
- Rotate the cooling fan belt tensioner clockwise.
- Loosen the cooling fan belt tensioner bolt to aid the removal of the belt.







NOTE: Restrain the pulley to aid the removal of the bolts.


5. Remove the cooling fan pulley.
- Remove the 3 bolts.

6. Remove the cooling fan drive hub bearing.
- Remove the 5 bolts.







7. Release the accessory drive belt.
- Rotate the accessory drive belt tensioner counter-clockwise, using a 3/8 inch drive wrench.







8. Remove the accessory drive belt tensioner.
- Remove the bolt.







NOTE: Note the fitted position.

9. Remove the accessory drive belt.
10. Remove the accessory drive belt idler pulley.
- Remove the bolt.
- Repeat the above procedure for the remaining idler pulley.







11. Remove the oil level indicator and tube.

CAUTION: Immediately cap all refrigerant lines to prevent ingress of dirt and moisture.

12. Disconnect the refrigerant lines from the air conditioning (A/C) compressor.
- Remove the 2 bolts.
- Remove and discard the 2 O-ring seals.







13. Disconnect the A/C clutch electrical connector.







NOTE: 1 A/C compressor bolt will remain captive until the mounting bracket is removed.

14. Release the A/C compressor.
- Remove the 3 bolts.







15. Remove the A/C compressor mounting bracket.
- Remove the 2 bolts.







16. Remove the A/C compressor.
17. Release the wiring harness from the throttle body intake.
- Remove the 2 bolts.







CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

18. Remove the throttle body intake.
- Disconnect the breather line.
- Release the clip.
- Release the bushing.







19. Remove the engine control module (ECM) cover.
- Remove the 10 Torx screws.







20. Release the engine wiring harness.
- Disconnect the 2 electrical connectors.
- Release the grommet.







21. Disconnect the battery positive cable from the junction box.
- Open the cover.
- Remove the nut.







22. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.







23. Disconnect the throttle body electrical connector.







24. Disconnect the knock sensors (KS) electrical connector.







25. Disconnect the RH mass air flow (MAF) sensor electrical connectors







26. Disconnect the purge control valve (PCV) electrical connector.







27. Remove the ignition coil-on-plug cover.
- Release the 2 clips.
- Repeat the above procedure for the other side.







28. Disconnect the 2 injector harness electrical connectors.







29. Disconnect the 4 LH ignition coil-on-plug connectors.
- Release the 2 clips.
- Repeat the above procedure for the RH side.







30. Disconnect the engine coolant temperature (ECT) sensor electrical connector.







31. Disconnect the fuel temperature sensor electrical connector.







32. Remove the fuel rail pressure sensor (FRP).







33. Disconnect the camshaft position (CMP) sensor electrical connector.
- Repeat the above procedure for the RH side.







34. Disconnect the cylinder head earth connector.
- Remove the bolt.
- Release the 3 clips.







35. Disconnect the cooling fan control electrical connector.







36. Release the 4 A/C harness retaining clips.
37. Disconnect the crankshaft position (CKP) sensor electrical connector.







38. Remove the starter motor heat shield.
- Remove the 2 bolts.







39. Disconnect the starter motor connector.







40. Disconnect the engine oil pressure (EOP) sensor electrical connector.







41. Disconnect the engine oil temperature sensor electrical connector.







42. Disconnect the generator connector.







43. Release the 4 clips securing the generator harness.







44. Disconnect the front LH HO2S and release the clip.







45. Disconnect the RH HO2S and release the clip.







46. Release the 2 HO2S harness brackets.
- Remove the 2 bolts.







47. Remove the engine wiring harness.

Installation
1. Install the engine wiring harness.
2. Attach the HO2S harness brackets.
- Tighten the bolts to 10 Nm (7 lb.ft).

3. Connect the HO2S electrical connectors.
- Carefully secure the clips.

4. Connect the starter motor.
5. Install the starter motor heat shield.
- Tighten the bolts to 45 Nm (33 lb.ft).

6. Connect the oil temperature and oil pressure sensors.
7. Connect the generator electrical connector.
- Secure the clips.

8. Connect the CKP sensor electrical connector.
9. Connect the cooling fan electrical connector.
10. Connect the cylinder head earth ground connector.
- Tighten the bolt to 10 Nm (7 lb.ft).

11. Install both CMP sensors.
12. Connect the FRP sensor electrical connector.
13. Connect the fuel temperature sensor electrical connector.
14. Connect the MAP sensor electrical connector.
15. Connect the KS.
16. Connect the ECT sensor electrical connector.
17. Connect the ignition coil-on-plug electrical connections.
- Install the clips.
- Repeat the above procedure for the other side.

18. Connect the fuel injector harness electrical connectors.
19. Install the ignition coil-on-plug cover.
- Secure the clips.
- Repeat the above procedure for the other side.

20. Connect the purge valve electrical connector.
21. Connect the MAF sensor electrical connector.
22. Connect the throttle body electrical connector.
23. Connect the MAP sensor electrical connector.
24. Connect the battery positive cable to the junction box.
- Tighten the nut to 25 Nm (18 lb.ft).
- Close the cover.

25. Secure the engine wiring harness.
- Install the grommet.
- Connect the electrical connectors.

26. Install the ECM cover.
- Tighten the Torx screws.

27. Install the throttle body intake.
- Clean the component mating faces.
- Align the bushing.
- Secure the clip.
- Connect the breather line.

28. Attach the wiring harness to the throttle body intake.
- Tighten the bolts to 10 Nm (7 lb.ft).

29. Position the A/C compressor to the engine.
- If a new compressor is being installed, the required amount of refrigerant oil must be drained from it.

30. Install the A/C compressor mounting bracket.
- Tighten the bolts to 25 Nm (18 lb.ft).

31. Secure the A/C compressor.
- Tighten the bolts to 25 Nm (18 lb.ft).

32. Connect the A/C clutch electrical connector.

CAUTION: Lubricate the new seals with clean refrigerant oil.

33. Connect the refrigerant lines.
- Clean the component mating faces.
- Install the new O-ring seals.
- Tighten the bolts to 10 Nm (7 lb.ft).

34. Install the oil level indicator and tube.
35. Install the accessory drive belt.
36. Install the accessory drive belt tensioner.
- Tighten the bolt to 40 Nm (30 lb.ft).

37. Install the cooling fan drive hub bearing.
- Tighten the bolts to 10 Nm (7 lb.ft).

38. Install the cooling fan pulley.
- Tighten the bolts evenly to 25 Nm (18 lb.ft).

39. Secure the accessory drive belt.







40. Install the cooling fan belt.
- Tighten the cooling fan belt tensioner bolt to 40 Nm (30 lb.ft)
- Rotate the cooling fan belt tensioner clockwise.

41. Install the cooling fan.
42. Connect the battery ground cable.