Sub-Part - Replacing Front Right Wiring Harness

Sub-part - Replacing Front Right Wiring Harness

Tools







Technical values







Preliminary work
1. Disconnect battery.
2. Remove dashboard bracket.
3. Remove heater/air-conditioning unit.
4. Remove cowl panel cover.
5. Remove DME control module.
6. Remove air cleaner housing.
7. Remove filler neck from reservoir for windscreen washer system.
8. Remove coolant reservoir.

Sub-part - removing front right wiring harness

Removing support for DME control module







1. Screw down fastening nut -1- and take off ground strap with the twist lock.







2. Open the retaining clips -arrow A- and take out the DME control module wire harness -arrow B-.
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-.
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.

Sub-part - removing front right wiring harness












1. Remove fabric tape and tie-wrap in area -a- 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-.







3. Pull off connector on sensor for airbag -1-.
3.1. Push in latch -b- on sensor connector for airbag -a- -arrow A-, until this is felt to engage.
3.2. Release locking mechanism on the latch -b- -arrow B- and pull off connector on sensor for airbag -a- -arrow C-.
3.3. Remove line together with lock carrier support -arrow D-.







4. Pull off connector on headlight housing -2-.
4.1. Release connector on headlight housing -arrow A- and pull off -arrow B-.
4.2. Unclip wire harness on the five retaining clips -arrows C-.







5. Pull off front wire harness -4- and loosen front ground strap cross member -3-.
5.1. Release plug connection for front wire harness -arrow A- and disconnect it -arrows B-.
5.2. Unscrew fastening nut on front cross member and remove ground straps together with twist lock from threaded bolt -arrow C-.
5.3. Unclip wire harness on the retaining clips -arrow D-.







6. Pull out bulb holder for the direction indicator light -5- and pull off connector for TPM antenna -6-.
6.1. Slightly turn bulb holder of direction indicator light in right wheel housing and remove -arrow A-.
6.2. Release connector on the antenna for TPM in right wheel housing -arrow B- and pull off -arrow C-.







7. Disconnect plug connection on washer-fluid reservoir -7-.
7.1. Remove plug connection on washer-fluid reservoir from bracket -arrow A-.
7.2. Release plug connection -arrow B- and disconnect it -arrows C-.







8. Pull off connector on angle sensor for HBA -8-.
8.1. Release connector on angle sensor for HBA on the right wheel suspension -arrows A- and pull off -arrow B-.







9. Pull off plug connection for ABS sensor and brake pad wear indicator -9-.
9.1. Release plug connection for ABS sensor and brake pad wear indicator in right wheel housing -arrow A- and pull off -arrow B-.
9.2. Unclip socket for ABS sensor and brake pad wear indicator -arrow C-.
9.3. Unclip wire harness on the three retaining clips -arrows D-.







10. Pull off connector on sensor for lateral acceleration -10-.
10.1. Release connector on sensor for lateral acceleration in right wheel housing -arrow A- and pull off -arrow B-.
10.2. Unclip wire harness on the retaining clips -arrow C-.







11. Remove connector from coolant expansion tank -11-.
11.1. Release connector on coolant reservoir -arrows A- and pull it off -arrow B-.







12. Pull down wire harness on upper side member from the four clips -arrows A-.
13. Unclip wire harness on the two retaining clips -arrows B-.







14. Disconnect bonnet wire harness plug connection -12-.
14.1. Release retaining clips -arrow a- and slide off the bonnet wire harness plug connection -arrow B-.
14.2. Release plug connection for bonnet wire harness -arrow a- and disconnect it -arrow C-.







15. Unclip wire harness on the retaining clips on upper side member.







16. Loosen the ground strap for right firewall -13-.
16.1. Unscrew the fastening nut on the right firewall and remove the ground strap with the twist lock from the threaded bolt.
17. Remove radiator tank at front right.







18. Unclip wire harness on the retaining clips -arrow A-.
19. Remove rubber sleeve from the bulkhead -arrow B-.







20. Remove connector on the hydraulic unit -14- and remove rubber sleeve -15-.
20.1. Release connector on hydraulic unit -arrow A- and pull it off -arrow B-.
20.2. Unclip wire harness on the three retaining clips -arrows C-.
20.3. Remove rubber sleeve on the right firewall in direction of the engine compartment -arrow D- and take out front right wire harness.

Sub-part - installing front right wire harness












1. Mount rubber sleeve -15- and push connector onto the hydraulic unit -14-.
1.1. Push front right wire harness from the engine compartment in direction of passenger compartment and mount the rubber sleeve to the right firewall -arrow A-.
1.2. Route wire harness in plenum panel and clip in on the three retaining clips -arrows B-.
1.3. Push connector onto the hydraulic unit -arrow C- and lock -arrow D-, until the locking mechanism is felt to engage.







2. Press rubber sleeve into bulkhead -arrow A-.
3. Clip in wire harness with the retaining clips -arrow B-.
4. Install radiator tank at front right.







5. Screw down the ground strap for right firewall -13-.
5.1. Connect ground strap together with twist lock on the threaded bolt to the right firewall and screw down with the fastening nut. - Tightening torque: 9 Nm (6.5 ftlb.)







6. Clip in wire harness with the retaining clips to the upper side member.







7. Push together the bonnet wire harness plug connection -12-.
7.1. Push the plug connection for the bonnet wire harness together -arrows A- until it is felt to engage.
7.2. Push the plug connection for the bonnet wire harness onto the retaining clips -arrow B- until it is felt to engage.







8. Route wire harness and clip in both retaining clips -arrows A-.
9. Push on wire harness onto upper side member on the four clips -arrows B-.







10. Push connector onto coolant expansion tank -11-.
10.1. Push connector onto the coolant reservoir until it is felt to engage.







11. Connecting connector on sensor for lateral acceleration -10-.
11.1. Push on connector onto sensor for lateral acceleration in right wheel housing -arrow A- until this is felt to engage.
11.2. Route wire harness and clip in retaining clips to the wheel housing -arrow B-.







12. Push the plug connection for ABS sensor and brake pad wear indicator together -9-.
12.1. Route wire harness and clip in the three retaining clips in the right wheel housing -arrows A-.
12.2. Clip in socket for ABS sensor and brake pad wear indicator -arrows B-.
12.3. Push the plug connection for the ABS sensor and brake pad wear indicator -arrow C-, until this is felt to engage.







13. Push connector on angle sensor for HBA -8-.
13.1. Push connector onto angle sensor for HBA on the right wheel suspension, until this is felt to engage.







14. Connect plug connection to washer-fluid reservoir -7-.
14.1. Press plug connection to washer-fluid reservoir -arrows A- until it is felt to engage.
14.2. Insert the plug connection in the bracket -arrow B-.







15. Connect connector to the antenna for TPM -6- and insert bulb holder into the direction indicator light -5-.
15.1. Push connector onto the antenna for TPM in left wheel housing -arrow A-, until this is felt to engage.
15.2. Insert bulb holder in the direction indicator light in the right wheel housing -arrow B- and turn slightly while doing so.







16. Push plug connection for front wire harness -4- together and tighten ground strap for front cross member -3-.
16.1. Press plug connection for front wire harness -arrows A- together until it is felt to engage.
16.2. Route wire harness and clip in retaining clips to the front side member -arrow B-.
16.3. Push ground straps together with twist lock on threaded bolt to the front side member -arrow C- and screw down with fastening nut. - Tightening torque: 9 Nm (6.5 ftlb.)







17. Push connector onto headlight housing -2-.
17.1. Push connector onto headlight housing -arrow A-, until it is felt to engage.
17.2. Route wire harness and clip in the five retaining clips on the right wheel housing -arrows B-.







18. Push connector on sensor for airbag -1-.
18.1. Push connector onto the sensor for airbag -arrow A-, until it is felt to engage.
18.2. Push line with support onto lock carrier -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.
- 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.
- Allocation of lines - see wiring diagram.







19. Crimp lines at -a-.
19.1. Cut off lines in different lengths (due to the shrink-fit connections).
19.2. Slide shrink-fit hoses onto the lines.
19.3. Strip 10 mm of insulation off the wires.
19.4. Crimp the lines with crimping sleeves and the hand crimping pliers from the repair kit for harnesses NR.155-1.
19.5. 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 harnesses) so that it is watertight.
19.6. Wrap commercially available PVC tape all around the area of the connection points.
19.7. Secure the repaired area -b- to the main wire harness with tie-wraps.

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.
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.
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.

Reworking

Subsequent work
1. Install coolant reservoir.
2. Install filler neck on tank for windscreen washer system.
3. Install air cleaner housing.
4. Install DME control module.
5. Install cowl panel cover.
6. Install heating/air-conditioning unit.
7. Install the bracket for the dashboard.
8. Carry out work instructions after disconnecting the battery.