Installing Wire Harness For Airbag From The A-Pillar Connection Point To The Head Airbag

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2013 Porsche 911, 2012 Porsche 911, 2011 Porsche 911, 2010 Porsche 911, and 2009 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Incorrect handling of airbag units

Triggering of airbag unit.
System faults can occur.

→ Switch off ignition and remove ignition key or remote control (hand-held transmitter).

→ A power supply (e.g. battery charger) must not be connected to the external power supply/jump-lead starting terminals.

→ Disconnect the battery and insulate the ground strap so that all contact with a ground carrier is avoided.

→ Wait 1 minute after disconnecting the battery.

→ Only pull off connector on the triggering unit after the waiting time has elapsed.

→ Make sure that no foreign objects are located in front of the airbag unit during installation.

→ Replace damaged parts during removal.

→ Always position airbag units so that the blow-out opening is facing upwards, e.g. crest on driver's airbag.

→ Do not position anything on the airbag units.

→ If removed for an extended period, the airbag units must be stored in a safe place.

→ Airbag units must not come into contact with grease, oil, detergents, liquids, or similar substances.

→ Do not expose airbag units to temperatures above 90°.

→ Do not remove the short-circuit spring on the plug-in contacts.

→ Ignition and preparations may only be carried out by skilled staff, supervised by a second responsible person.

→ Before disposal, the airbag unit must be rendered harmless by electrical ignition performed in accordance with all precautionary measures, thereby preventing it from being used incorrectly.

Fig 1: Overview Of Connector Airbag Wire Harness

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3-4 - Plug connections between main wire harness and wire harness for left and right doors

5-6 - Connector for head airbag, left and right

Release and disconnect plug connection for main wire harness to wire harness for door -3 and 4- . → 973219 REMOVING AND INSTALLING WIRE HARNESS FOR DOOR - section on "Removing"
Release and pull off connector on head airbag at the left -5- and right -6- . → Removing Head Airbag Unit - section on "Removing"
Cut off the head airbag connector on the damaged wire harness, insulate it and secure it to the door wire harness with tie-wraps.
Remove rubber sleeve -A- and carefully pull it and the door wire harness out of the A-pillar.

Fig 2: Removing Rubber Sleeve
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Slide the rubber sleeve back slightly -arrow- , remove adhesive tape and pull off the foil hose -A- .

Fig 3: Removing Foil Hose
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Cut and remove tie-wraps for fixing the wire harness to the connector housing.

Fig 4: Removing Cap From Connector Housing
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Release cap on both sides -arrow a- and remove it from the connector housing.
Release the locking mechanism on the connector housing using a small screwdriver -arrow A- and remove it -arrow B- .

Fig 5: Removing Connector From Connector Housing
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Pull the connector out of the connector housing -arrow C- .
Release the connector guide on both sides -arrow a- and push it down off the contact strip.

Fig 6: Pushing Down Connector Guide From Contact Strip
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Information

Allocation of lines - see appropriate wiring diagram.
Release contacts of the damaged lines using the Press-Out Tool 1575-1P of the press-out and unlocking tools for flat and round plug connections of all sizes Nr. 155 (-arrow a- ) and pull out of the contact strip.

Fig 7: Pressing Out Contacts From Contact Strip
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Cut off the contacts of the damaged lines, insulate them and secure them to the main wire harness with tie-wraps.
Insert wire puller -1- with the flexible end on the right side -arrow- into the rubber sleeve -2- . Coat the wire puller -1- with soapy water and slide it through the rubber sleeve -2- (-arrow A- ). → Tools And Materials - section on "Tools and materials"

Fig 8: Inserting Wire Puller
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Information

Two different wire harnesses are available as spare parts, depending on the model year. Up to model year 05, the wire harness -A- comes with insulation as standard. From model year 2006 onwards, the wire harness -B- no longer has this insulation.

Fig 9: Identifying Wire Harness Types
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Information

Observe wrapping direction of adhesive tape! To keep the resistance as low as possible when pulling the new wire harness through, always start wrapping the tape around at the new wire harness and end at the wire puller.
Slide new lines -2- through the eyelet in the rear part of the wire puller -1- (-arrow A- ) wrap them around and secure with adhesive tape -3- (-arrow B- ).

Fig 10: Securing Lines On Wire Puller
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Coat the new wire harness -2- with soapy water and use the wire puller -1- to pull it through the rubber sleeve -3- (-arrow A- ). Carefully push on the new wire harness again at the same time in order to make it easier to slide the wire harness through.

Fig 11: Pulling Wire Harness Through Rubber Sleeve
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove adhesive tape -3- (-arrow A- ) and carefully pull the lines -2- out of the eyelet on the wire puller -1- (-arrow B- ). Make sure not to damage the insulation on the new lines.

Fig 12: Releasing Lines From Wire Puller
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Route new wire harness along the door wire harness and secure at the standard attachment points on the door sub-frame.

Fig 13: Securing New Wire Harness At Door Sub-Frame
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Plug in connector for the new wire harness on the head airbag at the left -5- and right -6- until it engages securely. → Installing Head Airbag Unit - section on "Installing"
Information

Allocation of lines - see appropriate wiring diagram.
Push new lines into the contact strip until the contacts engage securely.

Fig 14: Pressing In Contacts On Contact Strip
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Push connector guide onto the contact strip until it engages securely.

Fig 15: Pushing Connector Guide Onto Contact Strip
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Insert connector into the connector housing -arrow A- .

Fig 16: Inserting Connector Into Connector Housing
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Insert locking mechanism into the connector housing and press it in -arrow B- until it engages securely.
Press cap onto the connector housing until it engages securely.

Fig 17: Pressing Cap Onto Connector Housing
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Secure wire harness to the connector housing using a new tie-wrap -arrow- .
Slide the rubber sleeve back slightly -arrow- , then pull the foil hose (500 mm length) up to the rubber sleeve over the door wire harness and secure at this position with insulating tape.
Pull foil hose tight and wrap it tightly on the entire length from the rubber sleeve up to the connector -A- of the door wire harness with insulating tape.

Fig 18: Attaching Foil Hose
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Information

Route the door wire harness carefully through the A-pillar in the vehicle interior, so that the foil hose and the door wire harness are not damaged!
Carefully slide the door wire harness through the A-pillar and fit the rubber sleeve -A- . Check that the rubber sleeve is installed at the correct position.

Fig 19: Fitting Rubber Sleeve
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