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

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

Tools







Technical values







Preliminary Work
1. Disconnect battery.
2. Remove the carrier for the instrument panel.
3. Remove heater/air-conditioning unit.
4. Remove linings in engine compartment.
5. Remove front right wheel housing liner.
6. Remove main headlight.
7. Remove front apron.
8. Remove air cleaner housing.
9. Remove coolant expansion tank.
10. Remove filler neck on tank for windscreen washer system.
11. Remove DME control unit.
12. Remove cowl panel cover.

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












1. Remove fabric tape and tie-wraps in area -a- (above cut-out for fresh-air intake system for heater/air-conditioning unit) and expose the remaining lines.

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 right wire harness in area -b- (left, next to cut-out for fresh-air intake system for heater/air-conditioning unit).
3. Remove support for DME control unit.







3.1. Screw off fastening nut -1- and remove the ground straps together with the twist lock -arrow-.







3.2. Open retaining clip -arrow A- and remove wire harness for DME control unit -arrow B-.
3.3. Unscrew fastening screw -2- and the two fastening nuts -3- and remove support for DME control unit -arrow-.

4. Remove intake manifold for heater/air-conditioning unit.
4.1. Pull out retaining clip on wire harness at the intake manifold -arrow A- and unclip wire harness on the intake manifold -arrow B-.
4.2. Pull out air inlet grille -arrow C-.
4.3. Open retaining clips in the intake manifold -arrow D-.







4.4. Screw off fastening nuts -1- and remove intake manifold -arrow-.







5. Remove right firewall.
5.1. Remove oxygen sensor connector -1- from the support at the firewall and disconnect it.
5.2. Unclip wire harness at the retaining clip -2-.
5.3. Unscrew fastening screws -3- on the firewall.
5.4. Lift the firewall and seal up and off.

6. Release connector on airbag sensor at the right -1- and pull it off.







7. Loosen ground strap for front right cross member -2-.
7.1. Screw off fastening nut on front cross member and remove ground straps together with the twist lock from the threaded bolt -arrow A-.
7.2. Unclip wire harness at the retaining clip -arrow B-.







8. Unclip wire harness at the retaining clips close to the mounting for the right headlight -arrows-.
9. Release connector on TPM transmitter (trigger) at the right -7- and pull it off.







10. Pull off connector on angle sensor for range adjustment -8-.
10.1. Release connector on angle sensor for range adjustment at the right wheel suspension -arrows A- and pull it off -arrow B-.

11. Release plug connection on tank for windscreen washer system -9- and disconnect it.







12. Pull off plug connection for ABS sensor and brake pad wear indicator on the right -10-.
12.1. Release plug connection for ABS sensor and brake pad wear indicator in the right wheel housing -arrow A- and pull it off -arrow B-.
12.2. Unclip connector socket for ABS sensor and brake pad wear indicator -arrow C-.
12.3. Unclip wire harness at the three retaining clips -arrow D-.







13. Pull off connector on right lateral acceleration sensor -11-.
13.1. Release connector on lateral acceleration sensor in the right wheel housing -arrow A- and pull it off -arrow B-.
13.2. Unclip wire harness at the retaining clip -arrow C-.

14. Loosen wire harness on upper right side member.
14.1. Pull wire harness on upper side member down out of the clips -arrows A-.







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







15. Unclip wire harness with the retaining clip on the upper side member -arrow-.







16. Loosen ground strap for right firewall -13-.
16.1. Screw off fastening nut on the right firewall and remove ground strap together with the twist lock from the threaded bolt -arrow-.







17. Unclip wire harness at the retaining clip -arrow A- and remove rubber sleeve from the bulkhead -arrow B-.







18. Pull off connector on hydraulic unit -14- and remove rubber sleeve -15-.
18.1. Release connector on hydraulic unit -arrow A- and pull it off -arrow B-.
18.2. Unclip wire harness at the three retaining clips -arrows C-.
18.3. Remove rubber sleeve on the right firewall in direction of the engine compartment -arrow D- and remove the front right wire harness.

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












1. Fit rubber sleeve -15- and plug in connector on hydraulic unit -14-.
1.1. Push front right wire harness through from the engine compartment towards the interior and fit rubber sleeve on the right firewall -arrow A-.
1.2. Route wire harness in plenum panel and clip it in at the three retaining clips -arrows B-.
1.3. Plug in connector on hydraulic unit -arrow C- and lock it -arrow D- until the locking mechanism engages securely.







2. Press rubber sleeve into the bulkhead -arrow A- and clip in wire harness with the retaining clip -arrow B-.







3. Screw on ground strap for right firewall -13-.
3.1. Connect ground strap together with the twist lock to the threaded bolt on the right firewall -arrow- and secure it with the fastening nut. - Tightening torque: 9 Nm (6.5 ftlb.)







4. Clip in wire harness on the upper side member with the retaining clip -arrow-.
5. Secure wire harness on upper right side member.
5.1. Route wire harness and clip it in at the retaining clips -arrows A-.







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







6. Plug in connector on right lateral acceleration sensor -11-.
6.1. Plug in connector on lateral acceleration sensor in right wheel housing -arrow A- until the connector engages securely.
6.2. Route wire harness and clip it in on the wheel housing with the retaining clip -arrow B-.







7. Connect plug connection for ABS sensor and brake pad wear indicator at the right -10-.
7.1. Route wire harness and clip it in at the right wheel housing with the retaining clips -arrow A-.
7.2. Clip in connector socket for ABS sensor and brake pad wear indicator -arrow B-.
7.3. Connect plug connection for ABS sensor and brake pad wear indicator -arrow C- until the plug connection engages securely.

8. Connect plug connection on tank for windscreen washer system -9- until the plug connection engages securely.







9. Plug in connector on angle sensor for range adjustment -8-.
9.1. Push connector onto angle sensor for range adjustment at the right wheel suspension until the connector engages securely.

10. Plug in connector on TPM transmitter (trigger) at the right -7- until it engages securely.







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







12. Secure ground strap for front right cross member -2-.
12.1. Route wire harness and clip it in on the front side member with the retaining clip -arrow A-.
12.2. Push ground straps together with the twist lock onto the threaded bolt on the front side member -arrow B- and screw on the fastening nut. - Tightening torque: 9 Nm (6.5 ftlb.)

13. Plug in connector on airbag sensor at the right -1- until the connector engages securely.







14. Install right firewall.
14.1. Fit seal on the body and spray with silicon spray.
14.2. Fit firewall and position it correctly.
14.3. Screw in fastening screws -3-. - Tightening torque: 9 Nm (6.5 ftlb.)
14.4. Clip in wire harness with the retaining clip -2-.
14.5. Connect oxygen sensor connectors -1- until they engage securely and clip oxygen sensor connectors into the support -1-.

15. Install intake manifold for heater/air-conditioning unit.
15.1. Position intake manifold -arrow- and secure with the fastening nuts -1-. - Tightening torque: 6 Nm (4.5 ftlb.).
15.2. Close retaining clips in the intake manifold -arrow A-.
15.3. Insert air inlet grille -arrow B-.







15.4. Clip in wire harness on the intake manifold -arrow C- and push in retaining clip for wire harness on the intake manifold -arrow D-.

16. Install support for DME control unit.







16.1. Position support for DME control unit -arrow- and secure with the fastening nuts -3- and fastening screw -2-. - Tightening torque: 8 Nm (6.0 ftlb.) - Tightening torque: 8 Nm (6.0 ftlb.)
16.2. Insert wire harness for DME control unit into the retaining clip -arrow A- and close the retaining clip -arrow B-.






16.3. Fit ground straps together with the twist lock onto the stud -arrow- and secure with the fastening nut -1-. - Tightening torque: 9 Nm (6.5 ftlb.)

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.







17. Crimp the lines in area -a- (above cut-out for fresh-air intake system for heater/air-conditioning unit).
17.1. Cut off lines in different lengths (due to the shrink-fit connections).
17.2. Slide shrink-fit hoses onto the lines.
17.3. Strip 10 mm of insulation off the lines.
17.4. Crimp lines using crimping sleeves and the hand crimping pliers from the repair kit for wire harnesses NR.155-1.
17.5. 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.
17.6. Wrap commercially available PVC tape all around the area of the connection points.
17.7. Secure the repaired area -b- to the main wire harness with tie-wraps.

Subsequent Work
1. Install cowl panel cover.
2. Install DME control unit.
3. Install filler neck on tank for windscreen washer system.
4. Install coolant expansion tank.
5. Install air cleaner housing.
6. Install front apron.
7. Install main headlight.
8. Install front right wheel housing liner.
9. Install linings in engine compartment.
10. Install heater/air-conditioning unit.
11. Install the carrier for the instrument panel.
12. Carry out work instructions after disconnecting the battery.