Repair Main Wire Harness

Repair Main Wire Harness

Tools







Preliminary work

1. Disconnect battery.
2. Remove cowl panel cover.
3. Remove DME control module.

Repair main wire harness (PSM connector)

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.

Repair main wire harness (PSM connector)

WARNING: Risk of damage to the electrical wiring.

- Malfunction of the brake system.
- The work procedure shown may only be performed by an "experienced" skilled worker.







1. Release the Porsche Stability Management control unit connector -arrow a- and pull off.

NOTE: The following 3 repair versions for the Porsche Stability Management control unit connector can be selected. The repair version depends on the extent of the damage (number of corroded contacts).

- If only the two contacts of the ground straps are corroded, the ground straps must be replaced.
- If in addition to the ground straps approximately one half of the remaining contacts are corroded, the ground straps and the affected contacts must be replaced.
- If in addition to the ground straps more than one half of the remaining contacts are corroded, the complete connector for the Porsche Stability Management control unit with the ground straps must be replaced.

For all 3 repair variations, the contacts on the Porsche Stability Management control unit must be examined carefully for traces of corrosion. If existing traces of corrosion cannot be removed, the hydraulic unit must be replaced.

For these repairs, use the prescribed repair kit from the Porsche Spare parts catalogue 9/20/10 (PET).
- Repair kit ground straps for hydraulic unit
- Repair kit wiring harness sub-part for hydraulic unit







2. Examine the contacts in the Porsche Stability Management control unit connector for traces of corrosion and check all seals and lines for processing faults. Check the connector for damage/deformation, if in doubt, replace.







3. Release retaining clips -arrow a- and slide off the bonnet wire harness plug connection -arrow B-.
4. Release the bonnet wire harness plug connection -arrow a- and disconnect -arrow C-.







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







6. Pull out wire harness -1- under the hydraulic unit. Remove armouring and disconnect ground strap from bonnet wire harness.







7. Open the three retaining clips -arrow B- and take out wire harness.
8. Expose wire harness from Porsche Stability Management control unit connector up to foam grommet -1- in the firewall. To do this, remove the corrugating hoses and the armouring.







9. Release the cap on the Porsche Stability Management control unit connector 4x -arrows a- and take off.
10. Remove tie-wrap -1- on Porsche Stability Management control unit connector.







11. Open secondary locking on the Porsche Stability Management control unit connector.

NOTE: If necessary, mark the electric lines.

For allocation, see wiring diagram (depending on the model year)







12. Press the contacts for the ground strap -2- using the pressing-out tool 1591 and the remaining corroded contacts -1- using the pressing-out tool 1556-2P from the pressing-out tool set for Cayenne NR.155-3 out of the Porsche Stability Management control unit connector.
13. Check contacts using good lighting, with the aid of magnifying glass if necessary to find traces of corrosion. Contacts having uniformly light and shiny surfaces are Ok.
14. Remove corroded ground straps -2- completely from the wire harness.
15. Cut off, strip, and check any remaining corroded lines -1- for traces of corrosion. Shorten original line from vehicle electrical system until bare copper without signs of corrosion appears in the crimping area. The line length should be sufficient in order to position the crimping on the firewall in the area above the foam grommet.

NOTE: 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 harnesses NR.155-1.

Crimping samples are to be prepared before beginning work.







16. Crimp crimping sleeve -3- using the hand crimping pliers from the repair kit for harnesses NR.155-1 to the original line from the vehicle electrical system -2-.
17. Push shrink-fit hose -4- onto the new line -1-.
18. Crimp crimping sleeve -3- using the hand crimping pliers from the repair kit for harnesses NR.155-1 to the new line -1-. Check the crimp connection carefully.
19. Slide the shrink-fit hose -4- over the crimp connection and carefully shrink it using the hot-air blower with special nozzle (recommended accessories for the repair kit for harnesses) so that it is watertight.
20. Slide the new line -1- into the Porsche Stability Management control unit connector until the contact is felt to engage.







21. Slide the new ground straps -1- from the repair kit into the Porsche Stability Management control unit connector until the contacts are felt to engage.







22. Close secondary locking on the Porsche Stability Management control unit connector.







23. Tie together the wire harness with insulating tape and route it so that the crimps -1- can be positioned on the firewall in the area above the foam grommet -2- in stages.







24. Attach new tie-wrap -1- to Porsche Stability Management control unit connector.
25. Mount cap on Porsche Stability Management control unit connector until this is felt to engage.







26. Attach armouring to wire harness from Porsche Stability Management control unit connector up to foam grommet -1- in the firewall and fit corrugating hoses.
27. Mount the Porsche Stability Management control unit connector and lock -arrow A-.
28. Insert wire harness in the three retaining clips and close -arrow B-.







29. Route wire harness -1- under the hydraulic unit.







30. Mount ground strap together with the twist lock on the stud and screw down with the fastening nut -1-. Tightening torque 6.5 ftlb.







31. Push the plug connection for the bonnet wire harness together -arrow A- until it is felt to engage.
32. Push the plug connection for the bonnet wire harness onto the retaining clips -arrow B- until it is felt to engage.

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. 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.

Subsequent work

1. Install DME control module.
2. Install cowl panel cover.
3. Connect the battery and carry out work instructions after disconnecting the battery.