Replacing Sub-Part For Front Plenum Panel
Replacing Sub-Part For Front Plenum Panel
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 plenum panel cover.
3. Remove cross panel.
4. Drain refrigerant.
5. Remove heat exchanger return hose.
6. Disconnect refrigerant hoses at the expansion valve.
7. Remove directional-control valve.
8. Remove heat exchanger supply hose.
9. Remove dashboard.
Replacing sub-part for front plenum panel
INFORMATION: When cutting the front wire harness, make sure there is enough length of cable left to join to the new lines.
1. Cut wire harness in the interior in area -x-.
2. Loosen all 14 screws -A- on the sleeve in the interior of the vehicle.
3. Loosen all 13 fixing clips -A- in the front left area of the sub-part and release and pull off all plug connections.
4. Detach relay carrier in engine compartment.
4.1. Release retaining clips -1- on the relay carrier in the engine compartment -arrow A-.
4.2. Lift relay carrier in engine compartment up and out -arrow B-.
5. Release all eight fixing clips -A- and release and unplug all plug connections.
6. Loosen fastening nuts -B- at the two ground points on the firewall and remove ground straps.
7. Make sure that all fastenings on the sub-part are released.
8. Remove the sleeve from the firewall and carefully remove the sub-part of the main wire harness for the plenum panel.
Installing sub-part for front plenum panel
1. Installation is performed in reverse order.
2. Connect and lock all plug connections.
3. Secure sub-part at all fastening points.
4. Fit the ground straps at the two ground points on the firewall and tighten the fastening nuts.
- 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.
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 are to be prepared before beginning work.
INFORMATION: Allocation of lines - see wiring diagram.
5. Crimp the lines in area -x-.
5.1. Cut off lines in different lengths (due to the shrink-fit connections).
5.2. Slide shrink-fit hoses onto the lines.
5.3. Strip 10 mm of insulation off the wires.
5.4. Crimp lines using crimping sleeves and the hand crimping pliers from the repair kit for wire harnesses Nr.155-1.
5.5. 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.
5.6. Wrap commercially available PVC tape all around the area of the connection points.
5.7. Secure the repaired area -x- to the main wire harness with tie-wraps.
Subsequent work
1. Install the dashboard.
2. Install heat exchanger supply hose.
3. Install directional-control valve.
4. Secure the refrigerant hoses at the expansion valve.
5. Install heat exchanger return hose.
6. Fill in refrigerant.
7. Install cross panel.
8. Install plenum panel cover.
9. Connect the battery.