Replacing Sub-Part of Front Right Wire Harness

Replacing Sub-Part Of Front Right 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 lower part of B-pillar trim panel on passenger's side.
3. Remove main headlight at the right.
4. Remove right front wheel.
5. Remove front wheel housing liner at the right.

Removing sub-part of front right wire harness
1. Remove carpet at the front right.
2. Release cable duct on passenger's seat.







2.1. Unscrew fastening nut -1- on passenger's seat.
2.2. Pull cable duct -arrow A- up and release it from the retaining clip.

3. Unclip and disconnect main wire harness at the front inner sill. -arrow A-







4. Loosen fastening nut -1- for ground point at the A-pillar and remove line.







5. Release cable duct at the A-pillar.







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

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

6. Cut front right wire harness in area -x-.







7. Make sure that all fastenings on the front right wire harness in the interior are released.
8. Loosen rubber sleeve -A- in the right 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.







9. Loosen sub-part of wire harness in the front right wheel housing at all 12 fastening points -A- and release and pull off all plug connections.







10. Loosen fastening nut for ground point at the wheel housing -B-.







11. Loosen fastening nut for ground point on the longitudinal member -B-.







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







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







14. Make sure that all fastenings on the wire harness in the engine compartment at the right are released.
15. Carefully remove sub-part of front right 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 right wheel housing are released.
17. Remove entire sub-part of front right wire harness.

Installing sub-part of front right wire harness
1. Push front right 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 -1- on the rubber sleeve.







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 right wheel housing at all 12 fastening points -A- and plug in and lock all plug connections.







4. Fit ground strap at the ground point for the right wheel housing and tighten the fastening nut -B-.
- Tightening torque: 9 Nm (6.5 ftlb.)







5. Fit ground strap at the ground point for the right longitudinal member and tighten the fastening nut -B-.
- Tightening torque: 9 Nm (6.5 ftlb.)







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







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







8. Plug in and lock all connectors.

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 the 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 ducts.
11. Fit carpet at the front right.

Subsequent work
1. Install front wheel housing liner at the right.
2. Fit front right wheel.
3. Install main headlight at the right.
4. Install lower part of B-pillar trim panel on passenger's side.
5. Connect the battery.