970941 Repair Main Wire Harness
WM 970941 Repair main wire harness
Tools
Technical values
Preliminary work
1. Disconnect battery. -> 90 Work instructions after disconnecting the battery
2. Remove cowl panel cover. -> 664419 Removing and installing cowl panel cover - section on "removing" Service and Repair
3. Remove DME control module. -> 247019 Removing and installing DME control module - section on "Removing" Service and Repair
Repair main wire harness (PSM connector)
Removing support for DME control module
1. Screw down fastening nut -1- and take off ground strap with the twist lock.
Loosening ground straps
2. Open the retaining clips -arrow A- and take out the DME control module wire harness -arrow B-.
Removing support for DME control module
3. Unscrew the fastening screw -2- and the two fastening nuts -3- and take out the support for the DME control module.
Removing intake pipe on the heating/fresh air unit
1. Pull out wire harness retaining clips on the intake manifold -arrow A- and unclip the wire harness on the intake manifold -arrow B-.
Removing intake pipe on the heating/fresh air unit
2. Pull out air inlet grille -arrow C-.
3. Open both retaining clips in the intake manifold -arrow D-.
4. Unscrew the two fastening nuts -1- and remove the intake manifold.
Repair main wire harness (PSM connector)
WARNING
Risk of damage to the electrical wiring.
- Malfunction of the brake system.
-> The work procedure shown may only be performed by an "experienced" skilled worker.
1. Release the Porsche Stability Management control unit connector -arrow a- and pull off.
Pulling off the Porsche Stability Management control unit connector
Information
The following 3 repair versions for the Porsche Stability Management control unit connector can be selected. The repair version depends on the extent of the damage (number of corroded contacts).
- If only the two contacts of the ground straps are corroded, the ground straps must be replaced.
- If in addition to the ground straps approximately one half of the remaining contacts are corroded, the ground straps and the affected contacts must be replaced.
- If in addition to the ground straps more than one half of the remaining contacts are corroded, the complete connector for the Porsche Stability Management control unit with the ground straps must be replaced.
For all 3 repair variations, the contacts on the Porsche Stability Management control unit must be examined carefully for traces of corrosion. If existing traces of corrosion cannot be removed, the hydraulic unit must be replaced. -> 453019 Removing and installing hydraulic unit Service and Repair
Information
For these repairs, use the prescribed repair kit from the Porsche Spare parts catalogue 9/20/10 (PET).
- Repair kit ground straps for hydraulic unit
- Repair kit wiring harness sub-part for hydraulic unit
2. Examine the contacts in the Porsche Stability Management control unit connector for traces of corrosion and check all seals and lines for processing faults. Check the connector for damage/deformation, if in doubt, replace.
Examining Porsche Stability Management control unit for traces of corrosion
3. Release retaining clips -arrow a- and slide off the bonnet wire harness plug connection -arrow B-.
Disconnecting bonnet wire harness plug connection
4. Release the bonnet wire harness plug connection -arrow a- and disconnect -arrow C-.
5. Screw down fastening nut -1- and take off ground strap with the twist lock.
Screwing down the fastening nut to the ground point
6. Pull out wire harness -1- under the hydraulic unit. Remove armouring and disconnect ground strap from bonnet wire harness.
Pulling out wire harness under the hydraulic unit
7. Open the three retaining clips -arrow B- and take out wire harness.
Pulling off the Porsche Stability Management control unit connector
8. Expose wire harness from Porsche Stability Management control unit connector up to foam grommet -1- in the firewall. To do this, remove the corrugating hoses and the armouring.
9. Release the cap on the Porsche Stability Management control unit connector 4x -arrows a- and take off.
Pulling off cap on Porsche Stability Management control unit connector
10. Remove tie-wrap -1- on Porsche Stability Management control unit connector.
11. Open secondary locking on the Porsche Stability Management control unit connector.
Opening secondary locking on the Porsche Stability Management control unit connector
Information
If necessary, mark the electric lines.
For allocation, see wiring diagram (depending on the model year)
12. Press the contacts for the ground strap -2- using the pressing-out tool 1591 and the remaining corroded contacts -1- using the pressing-out tool 1556-2P from the pressing-out tool set for Cayenne NR.155-3 out of the Porsche Stability Management control unit connector.
Pressing out Porsche Stability Management control unit connector contacts
13. Check contacts using good lighting, with the aid of magnifying glass if necessary to find traces of corrosion. Contacts having uniformly light and shiny surfaces are Ok.
14. Remove corroded ground straps -2- completely from the wire harness.
15. Cut off, strip, and check any remaining corroded lines -1- for traces of corrosion. Shorten original line from vehicle electrical system until bare copper without signs of corrosion appears in the crimping area. The line length should be sufficient in order to position the crimping on the firewall in the area above the foam grommet.
Information
The electric lines are located in the plenum panel and are thus exposed to the highest demands.
The greatest care must be used in the individual work steps for stripping insulation from, crimping, and shrinking/insulating the electric lines.
The procedure for stripping insulation from, crimping, and shrinking/insulating the electric lines must be complied with and observed. The procedures are described in detail in the repair kit for harnesses NR.155-1.
Crimping samples are to be prepared before beginning work.
16. Crimp crimping sleeve -3- using the hand crimping pliers from the repair kit for harnesses NR.155-1 to the original line from the vehicle electrical system -2-.
Crimping the Porsche Stability Management control unit connector lines
17. Push shrink-fit hose -4- onto the new line -1-.
18. Crimp crimping sleeve -3- using the hand crimping pliers from the repair kit for harnesses NR.155-1 to the new line -1-. Check the crimp connection carefully.
19. Slide the shrink-fit hose -4- over the crimp connection and carefully shrink it using the hot-air blower with special nozzle (recommended accessories for the repair kit for harnesses) so that it is watertight.
20. Slide the new line -1- into the Porsche Stability Management control unit connector until the contact is felt to engage.
21. Slide the new ground straps -1- from the repair kit into the Porsche Stability Management control unit connector until the contacts are felt to engage.
Sliding new ground straps into the Porsche Stability Management control unit connector
22. Close secondary locking on the Porsche Stability Management control unit connector.
Closing secondary locking on the Porsche Stability Management control unit connector
23. Tie together the wire harness with insulating tape and route it so that the crimps -1- can be positioned on the firewall in the area above the foam grommet -2- in stages.
Routing new lines for the Porsche Stability Management control unit connector
24. Attach new tie-wrap -1- to Porsche Stability Management control unit connector.
Mounting cap on Porsche Stability Management control unit connector
25. Mount cap on Porsche Stability Management control unit connector until this is felt to engage.
26. Attach armouring to wire harness from Porsche Stability Management control unit connector up to foam grommet -1- in the firewall and fit corrugating hoses.
Mounting the Porsche Stability Management control unit connector
27. Mount the Porsche Stability Management control unit connector and lock -arrow A-.
28. Insert wire harness in the three retaining clips and close -arrow B-.
29. Route wire harness -1- under the hydraulic unit.
Routing wire harness under the hydraulic unit
30. Mount ground strap together with the twist lock on the stud and screw down with the fastening nut -1-. => Tightening torque: 6.5 ftlb.
Screwing down the fastening nut to the ground point
31. Push the plug connection for the bonnet wire harness together -arrow A- until it is felt to engage.
Pushing together the bonnet wire harness plug connection
32. Push the plug connection for the bonnet wire harness onto the retaining clips -arrow B- until it is felt to engage.
Installing intake pipe on the heating/fresh air unit
1. Position intake manifold and secure with both fastening nuts -1-. => Tightening torque : 4.5 ftlb.
Installing intake pipe on the heating/fresh air unit
2. Close both retaining clips in the intake manifold -arrow A-.
3. Insert air inlet grille -arrow B-.
4. Clip in wire harness to intake manifold -arrow C- and insert wire harness retaining clips on intake manifold -arrow D-.
Installing support for DME control module
1. Position support for DME control module and screw down both fastening nuts -3- and the fastening screw -2-. => Tightening torque: 6 ftlb. => Tightening torque: 6 ftlb.
Installing support for DME control module
2. Insert DME control module in the retaining clips -arrow A- and close the retaining clips -arrow B-.
3. Mount ground straps together with the twist lock on the stud and screw down with the fastening nut -1-. => Tightening torque: 6.5 ftlb.
Fastening ground straps
Subsequent work
1. Install DME control module. -> 247019 Removing and installing DME control module - section on "Removing" Service and Repair
2. Install cowl panel cover. -> 664419 Removing and installing cowl panel cover - section on "installing" Service and Repair
3. Connect the battery and carry out work instructions after disconnecting the battery. -> 90 Work instructions after disconnecting the battery