Repair of Main Wiring Harness
Repair of main wiring harness
INFORMATION
- The combination wires for ABS and BVA are integrated in the wiring harness. In the event of damage, the integrated wires can be disconnected and replaced by repair wires. The disconnection points are located at the front left and front right above the radiator tank. After repair, the following function tests must be performed:
- ABS: Test with the Porsche System Tester 2.
- BVA: The indicator light must go out with the engine running and the brake linings intact.
- Disconnection point, front left: Join wires between the -arrows- with crimp connectors.
- Disconnection point, front right: Join wires between the -arrows- with crimp connectors.
Removal
1. Take off cover of battery and radiator tank.
2. Disconnect the battery and cover terminal or battery.
3. Remove front wheel housing liner. Undo cable ties in the area of the wheel housing, and remove combination wire.
4. Carefully remove insulating tape from the combination wire in the area of the disconnection point and cut the old combination wire before the exit to the wheel housing (do not damage any other wires).
Installing main wiring harness
1. Install repair wire in the wheel housing. Join wires as specified in the table using a crimp connector and crimping tool.
2. Colour coding of left and right hand sides of wires:
- Wire 1 - br/gn
- Wire 2 - br/bk
- Wire 3 - br
- Wire 4 - br/bl
- Wire 5 - br/wt
- Gbr - brown
- bk - black
- bl - blue
- wt - white
- gn - green
3. Cut wires to the correct length in the disconnection point area.
4. Exercise caution when stripping insulation from wiring. Other wires must not be damaged.
5. Push on the supplied heat-shrinking tubes.
6. Push the large heat-shrinking tube over all wires.
7. Strip 10 mm of insulation off the wires.
8. Join wires using crimp connector.
9. Shrink shrink-fit hoses with a hot-air gun.
10. It is essential that all wires are watertight.
11. Wrap commercially available PVC tape all around the area of the connection points.