Repair Main wire harness (PSM Connector)

Information 

The work described below must only be carried out by experienced technical staff.

1. Release the Porsche Stability Management control unit connector -arrow a-  and pull off.
   Fig 1: Pulling Off Porsche Stability Management Control Unit Connector

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   Information 

   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. → WM 453019 REMOVING AND INSTALLING HYDRAULIC UNIT

   Information 

   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.
   Fig 2: Examining Porsche Stability Management Control Unit For Traces Of Corrosion

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3. Release retaining clips -arrow a-  and slide off the bonnet wire harness plug connection -arrow B-  .
   Fig 3: Disconnecting Bonnet Wire Harness Plug Connection

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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.
   Fig 4: Screwing Down Fastening Nut To Ground Point

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6. Pull out wire harness -1-  under the hydraulic unit. Remove armouring and disconnect ground strap from bonnet wire harness.
   Fig 5: Pulling Out Wire Harness Under Hydraulic Unit

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7. Open the three retaining clips -arrow B-  and take out wire harness.
   Fig 6: Pulling Off Porsche Stability Management Control Unit Connector

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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.
   Fig 7: Pulling Off Cap On Porsche Stability Management Control Unit Connector

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10. Remove tie-wrap -1-  on Porsche Stability Management control unit connector.
11. Open secondary locking on the Porsche Stability Management control unit connector.
    Fig 8: Opening Secondary Locking On Porsche Stability Management Control Unit Connector

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    Information 

    If necessary, mark the electric lines.

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.
    Fig 9: Pressing Out Porsche Stability Management Control Unit Connector Contacts

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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.

    Information 

    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-  .
    Fig 10: Crimping Porsche Stability Management Control Unit Connector Lines

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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.
    Fig 11: Sliding New Ground Straps Into Porsche Stability Management Control Unit Connector

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22. Close secondary locking on the Porsche Stability Management control unit connector.
    Fig 12: Closing Secondary Locking On Porsche Stability Management Control Unit Connector

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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.
    Fig 13: Routing Lines For Porsche Stability Management Control Unit Connector

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24. Attach new tie-wrap -1-  to Porsche Stability Management control unit connector.
    Fig 14: Mounting Cap On Porsche Stability Management Control Unit Connector

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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.
    Fig 15: Mounting Porsche Stability Management Control Unit Connector

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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.
    Fig 16: Routing Wire Harness Under Hydraulic Unit

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30. Mount ground strap together with the twist lock on the stud and screw down with the fastening nut -1-  . → Tightening torque: 9 Nm (6.5 ftlb.) 
    Fig 17: Screwing Down Fastening Nut To Ground Point

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31. Push the bonnet wire harness plug connection together -arrow A-  until it is felt to engage.
    Fig 18: Pushing Together Bonnet Wire Harness Plug Connection

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