Mechanical Gas Fuel System G5.9, G8.3, G855 – Master Repair Manual 019-043   Engine Wiring Harness

General Information

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Replace a harness if there is an open or short circuit found under the protective covering of the harness body.

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Preparatory Steps

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 WARNING 

Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

Disconnect the batteries. Refer to Procedure 013-009.

Disconnect the starter motor and solenoid connections.

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Remove

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Remove the engine harness clamps.

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Cut the ties on the alternator bracket and front engine cover bracket.

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Cut the ties on the thermostat housing bracket and aftercooler tube.

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Disconnect the engine harness from the fuel control valve.

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Disconnect the engine block ground from the block.

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Disconnect the ignition module.

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Disconnect the engine harness connectors from the CM558.

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Disconnect the ignition harness (2) from the ignition coils.

It is not necessary to disconnect the leads to the ignition coil (1).

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Disconnect the heated oxygen sensor.

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Install

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Connect the heated oxygen sensor.

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Connect the ignition harness (2) to the ignition coils.

If a new ignition coil is used, connect the leads to the coil (1).

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Connect the engine harness connector to the CM558.

Use a 4-mm [5/32-in] hex head wrench to tighten.

Torque Value:  3  n.m  [27 in-lb]

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Connect the ignition module.

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Connect the engine block ground to the engine block.

Torque Value:  20  n.m  [177 in-lb]

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Connect the engine harness to the fuel control valve.

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Fasten the harness to the aftercooler tube and thermostat housing.

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Fasten the harness to the front engine cover bracket and alternator bracket.

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Install the engine harness clamps.

Torque Value:  20  n.m  [177 in-lb]

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Finishing Steps

TOC

 WARNING 

Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

Connect the starter motor and solenoid connections.

Connect the batteries. Refer to Procedure 013-009.

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Last Modified:  10-Jul-2006