Sub-Part - Replacing Wire Harness In Engine Compartment At the Front Left

Sub-Part - Replacing Wire Harness In Engine Compartment At The Front Left

Tools







Technical values







Preliminary Work
1. Disconnect battery.
2. Remove the carrier for the instrument panel.
3. Remove linings in engine compartment.
4. Remove front left wheel housing liner.
5. Remove main headlight.
6. Remove front apron.
7. Remove air cleaner housing.
8. Remove wiper motor.
9. Remove relay carrier in plenum panel E-box.

Sub-part - Removing Wire Harness In Engine Compartment At The Front Left












1. Remove cover on cable duct (above the pedals) -arrow-.

INFORMATION: When cutting the front wire harness, make sure there is enough length of cable left to join to the new lines.







2. Cut off front left wire harness in areas -a- (top left, next to the pedals).
3. Remove fabric tape and tie-wraps in area -b- and expose the remaining lines.







4. Remove left firewall.
4.1. Remove oxygen sensor connector -1- from the support at the firewall and disconnect it.
4.2. Unclip wire harness at the retaining clip -2-.
4.3. Loosen PDCC reservoir at the firewall and set it aside.
4.4. Unscrew fastening screws -3- on the firewall.
4.5. Lift the firewall and seal up and off.

5. Release connector on airbag sensor at the left -1- and pull it off.

6. Pull off connectors -2 and 3- on fan.
6.1. Unclip wire harness at the retaining clips -arrows A-.
6.2. Release connectors on fan -arrows B- and pull them off -arrows C-.







6.3. Screw off fastening nut and pull the ground straps together with the twist lock off the threaded bolt -arrow D-.







7. Pull off plug connection for front left wire harness -4- and loosen ground strap for front left cross member -5-.
7.1. Release plug connection for front wire harness on the front left cross member -arrow A- and pull off connector -arrow B-.
7.2. Unclip connector socket -arrow C-.
7.3. Screw off fastening nut and pull the ground straps together with the twist lock off the threaded bolt -arrow D-.







8. Unclip wire harness at the retaining clips close to the mounting for the left headlight -arrows-.
9. Release connector on TPM transmitter (trigger) -8- and pull it off.







10. Pull off connector on angle sensor for range adjustment at the left -9-.
10.1. Release connector on angle sensor for range adjustment at the left -arrows A- and pull it off -arrow B-.
10.2. Remove tie-wrap used to fix the wire harness in place on the refrigerant line -arrow C-.







11. Pull off connector on servo valve -10-
11.1. Release connector on servo valve -arrow A- and pull it off -arrow B-.

12. Release connector for additional heating -11- and pull it off.







13. Pull off plug connection for ABS sensor and brake pad wear indicator on the left -12-.
13.1. Release plug connection for ABS sensor and brake pad wear indicator in the left wheel housing -arrow A- and pull it off -arrow B-.
13.2. Unclip connector socket for ABS sensor and brake pad wear indicator -arrow C-.
13.3. Unclip wire harness at the three retaining clips -arrow D-.







14. Pull off connector on left lateral acceleration sensor -14- and circulating pump connector -13-.
14.1. Release connector on lateral acceleration sensor in the left wheel housing -arrow A- and pull it off -arrow B-.
14.2. Release connector on circulating pump -arrow C- and pull it off -arrow D-.
14.3. Unclip wire harness at the retaining clips -arrows E-.

15. Loosen wire harness on upper left side member.
15.1. Pull wire harness on upper side member down out of the clips -arrows A-.







15.2. Unclip wire harness at the retaining clips -arrows B-.







16. Remove rubber sleeve from the bulkhead -arrow-.







17. Unclip wire harness in plenum panel at the retaining clips -arrows-.
18. Remove rubber sleeve -19- on the left firewall.







18.1. Remove rubber sleeve on the left firewall in direction of the engine compartment -arrow- and remove the front left wire harness.

Sub-part - Installing Wire Harness In Engine Compartment At The Front Left












1. Fit rubber sleeve -19- on the left firewall -arrow-.
1.1. Push front left wire harness through from the engine compartment towards the interior and fit rubber sleeve on the left firewall.







2. Route wire harness in plenum panel and clip it in at the retaining clips -arrows-.







3. Press rubber sleeve into the bulkhead -arrow-.
4. Secure wire harness on upper left side member.
4.1. Route wire harness and clip it in at the retaining clips -arrows A-.







4.2. Push wire harness on upper side member onto the clips -arrows B-.







5. Plug in connector on left lateral acceleration sensor -14- and circulating pump connector -13-.
5.1. Plug in connector on lateral acceleration sensor in left wheel housing -arrow A- until the connector engages securely.
5.2. Plug in connector on circulating pump -arrow B- until the connector engages securely.
5.3. Route wire harness and clip it in on the left wheel housing with the three retaining clips -arrows C-.







6. Connect plug connection for ABS sensor and brake pad wear indicator on the left -12-.
6.1. Route wire harness and clip it in at the left wheel housing with the retaining clips -arrow A-.
6.2. Clip in connector socket for ABS sensor and brake pad wear indicator -arrow B-.
6.3. Connect plug connection for ABS sensor and brake pad wear indicator -arrow C- until the plug connection engages securely.

7. Plug in connector for additional heating -11- until it engages securely.







8. Plug in connector on servo valve -10- until it engages securely.







9. Plug in connector on angle sensor for range adjustment at the left -9-.
9.1. Plug in connectors on angle sensor for range adjustment at the left -arrow A- until the connectors engage securely.
9.2. Secure wire harness on the refrigerant line with a new tie-wrap -arrow B-.

10. Plug in connector on TPM transmitter (trigger) -8- until it engages securely.







11. Clip in wire harness at the retaining clips close to the mounting for the left headlight -arrows-.







12. Connect plug connection for front wire harness -4- and secure ground strap for front cross member -5-.
12.1. Clip connector socket for front wire harness in at the front of the left cross member -arrow A-.
12.2. Plug in connector -arrow B- until it engages securely.
12.3. Connect ground straps together with the twist lock to the threaded bolt -arrow C- and screw on the fastening nut. - Tightening torque: 9 Nm (6.5 ftlb.)

13. Plug in connectors -2 and 3- on fan.
13.1. Plug in connectors on fan -arrows A- until they engage securely.
13.2. Clip in wire harness at the retaining clips -arrows B-.







13.3. Connect ground straps together with the twist lock to the threaded bolt -arrow C- and screw on the fastening nut. - Tightening torque: 9 Nm (6.5 ftlb.)

14. Plug in connectors on airbag sensor at the left -1- until the connectors engage securely.







15. Install left firewall.
15.1. Fit seal on the body and spray with silicon spray.
15.2. Fit firewall and position it correctly.
15.3. Screw in fastening screws -3-. - Tightening torque: 9 Nm (6.5 ftlb.)
15.4. Clip in wire harness with the retaining clip -2-.
15.5. Connect oxygen sensor connectors -1- until they engage securely and clip oxygen sensor connectors into the support -1-.
15.6. Secure PDCC reservoir on the plenum panel.

INFORMATION:
- Select a place for the joint where there is enough space to join all the lines present.
- Do not cut the lines too short in case they have to be laid in a different position if there is insufficient space in the area of the joint.
- 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 Cayenne harnesses NR.155-2.
- Crimping samples are to be prepared before beginning work.







16. Crimp the lines in area -a- (in cable duct above the pedals).
16.1. Cut off lines in different lengths (due to shrink-fit connections).
16.2. Slide shrink-fit hoses onto the lines.
16.3. Strip 10 mm of insulation off the lines.
16.4. Crimp lines using crimping sleeves and the hand crimping pliers from the repair kit for wire harnesses NR.155-1.
16.5. Slide the shrink-fit hoses over the crimp connections and carefully shrink them using the hot-air blower with special nozzle (recommended accessories for the repair kit for wire harnesses) so that they are watertight.
16.6. Wrap commercially available PVC tape all around the area of the connection points.
16.7. Secure the repaired area -b- to the main wire harness with tie-wraps.







17. Fit cover on cable duct (above the pedals) -arrow-.


Subsequent Work
1. Install relay carrier in plenum panel E-box.
2. Install wiper motor.
3. Install air cleaner housing.
4. Install front apron.
5. Install main headlight.
6. Install front left wheel housing liner.
7. Install linings in engine compartment.
8. Install the carrier for the instrument panel.
9. Carry out work instructions after disconnecting the battery.