Replacing Sub-Part of Front Left Wire Harness

Replacing Sub-Part Of Front Left Wire Harness

Tools







Technical values







Information

The main wire harness is manufactured individually depending on equipment.
- Fastening elements may be different from the parts described.
- The number of plug connections can vary, depending on equipment.







Preliminary work
1. Disconnect the battery.
2. Remove main headlight at the left.
3. Remove front left wheel.
4. Remove front wheel housing liner at the left

Removing sub-part of front left wire harness
1. Remove carpet at the front left.
2. Release cable duct at the A-pillar.







2.1. Unscrew fastening nut -1- for cable duct.
2.2. Release cable duct -2- by pulling it -arrow- from the fixing clip.

3. Release cable duct on driver's seat.







3.1. Unscrew fastening nut -1- on driver's seat.
3.2. Release cable duct by pulling it -arrow- from the fixing clip.

4. Unclip and disconnect main wire harness at the front inner sill.







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

5. Cut front left wire harness in area -x-.







6. Make sure that all fastenings on the front left wire harness in the interior are released.
7. Loosen rubber sleeve in the left wheel housing, remove it by pushing it towards the wheel housing and carefully remove the wire harness from the interior by pushing it towards the wheel housing.







8. Loosen sub-part of wire harness in the front left wheel housing at all 13 fastening points -A- and release and pull off all plug connections.







9. Unscrew fastening nut -B- on ground point for left longitudinal member and pull lines off the threaded bolt.







10. Loosen sub-part of wire harness in the front left wheel housing at the bottom at all six fastening points -A- and release and pull off all plug connections.







11. Loosen sub-part of wire harness in the front left wheel housing at all 10 fastening points -A- and release and pull off all plug connections.







12. Loosen sub-part of wire harness in the engine compartment at the left at all 10 fastening points -A- and release and pull off all plug connections.







13. Disconnect connection at the B+ connection point in the engine compartment.







13.1. Unscrew left nut -1- and remove it -arrow A-.
13.2. Remove connection for fan blower -3-.

14. Make sure that all fastenings on the wire harness in the engine compartment at the left are released.
15. Carefully remove sub-part of front left wire harness from the engine compartment through the openings by pulling it towards the wheel housing.
16. Make sure that all fastenings on the wire harness in the front left wheel housing are released.
17. Remove entire sub-part of front left wire harness.

Installing sub-part of front left wire harness
1. Push front left wire harness from the wheel housing towards the interior with the help of another mechanic and fit rubber sleeve at the correct position. The arrow -2- must be pointing to the marking on the rubber sleeve -1-.







2. Route the wire harness through the openings -A- and -B- towards the engine compartment.







3. Secure sub-part of wire harness in the front left wheel housing at all 13 fastening points -A- and plug in and lock all plug connections.







4. Attach lines to the threaded bolt and screw on fastening nut -B- on ground point for left longitudinal member.
- Tightening torque: 9 Nm (6.5 ftlb.)







5. Secure sub-part of wire harness in the front left wheel housing at the bottom at all 6 fastening points -A- and plug in and lock all plug connections.







6. Secure sub-part of wire harness in the front left wheel housing at all 10 fastening points -A- and plug in and lock all plug connections.







7. Secure sub-part of wire harness in the engine compartment at the left at all 10 fastening points -A- and plug in and lock all plug connections.







8. Screw in connection at the B+ connection point in the engine compartment.







8.1. Fit connection for fan blower -3-.
8.2. Screw on nut -arrow B-.

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.

INFORMATION:
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 wire harnesses NR.155-2.

Crimping samples must be prepared before beginning work.

INFORMATION: Allocation of lines - see wiring diagram.

9. Crimp the lines in area -x-.







9.1. Cut off lines in different lengths (due to the shrink-fit connections).
9.2. Slide shrink-fit hoses onto the lines.
9.3. Strip 10 mm of insulation off the wires.
9.4. Crimp lines using crimping sleeves and the hand crimping pliers from the repair kit for wire harnesses Nr.155-1.
9.5. Slide the shrink-fit hoses over the crimp connections and carefully shrink them using the hot-air blower with special nozzle (recommended accessories for repair kit for wire harnesses) so that they are watertight.
9.6. Wrap commercially available PVC tape all around the area of the connection points.
9.7. Secure the repaired area -x- to the main wire harness with tie-wraps.

10. Secure cable duct on driver's seat.
11. Secure cable duct at the A-pillar.
12. Fit carpet at the front left.

Subsequent work
1. Install front wheel housing liner at the left.
2. Install front left wheel.
3. Install main headlight at the left.
4. Connect the battery.