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Home >> Porsche >> 2016 >> Cayman GTS, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 74 (97 - Cables) >> WM 970955 Replacing Wire Harness In Engine Compartment (Except Cayenne Diesel) >> Installing Wire Harness In Engine Compartment

Installing Wire Harness In Engine Compartment

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Connector Overview For Wire Harness In Engine Compartment
G09416134Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 1-2 - Airbag sensor connector
  2. 3-4 - Fan connectors
  3. 5 - Plug connection for front left wire harness
  4. 6-7 - Ground strap for front cross member, left and right
  5. 8-9 - Plug connections for front right wire harness
  6. 10-11 - Bulb holder for direction indicator, left and right
  7. 12-13 - Connector for headlight, left and right
  8. 14-15 - Transmitter (trigger) for TPM, left and right
  9. 16-17 - Connector for angle sensor for headlight levelling system, left and right
  10. 18 - Servo valve connector
  11. 19 - Additional heating connector
  12. 20 - Plug connection for tank for windscreen washer system
  13. 21-22 - Plug connection for ABS sensor and brake pad wear indicator, left and right
  14. 23 - Circulating pump connector
  15. 24-25 - Connector for lateral acceleration sensor
  16. 26 - Connector for coolant expansion tank
  17. 27-30 - Connector for plenum panel E-box
  18. 31 - Rubber sleeve
  19. 32 - Ground strap for right firewall
  20. 33 - Connector for hydraulic unit
  21. 34 - Rubber sleeve
  22. 35 - Ground strap
  23. 36 - Connector for wiper motor
  24. 37 - Air quality sensor connector
  25. 38 - Connector for brake fluid reservoir
  26. 39 - Brake booster connector
  27. 40 - Way-sensor connector (brake assist system)
  28. 41 - Pressure sensor connector (brake assist system)
  29. 42 - Rubber sleeve
  1. Install main wire harness - dashboard area and centre console. → Installing Main Wiring Harness 
  2. Fit rubber sleeve -42- on the centre firewall.
    1. 2.1. Push wire harness through from the interior towards the engine compartment and fit rubber sleeve on the centre firewall -arrow A-  .
    2. 2.2. Clip in wire harness on centre firewall with the retaining clip -arrow B-  .
      Fig 2: Fitting Rubber Sleeve On Centre Firewall
      G09416135Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Secure wire harness on the centre firewall.
    1. 3.1. Insert wire harness into the two supports -arrows A-  and close the supports -arrows B-  .
    2. 3.2. Insert line into the two retaining clips -arrows C-  and close the retaining clips -arrows D-  .
      Fig 3: Securing Wire Harness On Centre Firewall
      G09416136Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Plug in pressure sensor connector (brake assist system) -41-  .
    Fig 4: Plugging In Pressure Sensor Connector (Brake Assist System)
    G09416137Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 4.1. Plug in connector on pressure sensor (brake assist system) -arrow-  until it engages securely.
  5. Plug in connector on way-sensor (brake assist system) -40-  .
    Fig 5: Plugging In Connector On Way-Sensor (Brake Assist System)
    G09416138Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 5.1. Plug in connector on way-sensor (brake assist system) -arrow-  until it engages securely.
  6. Plug in connector on brake booster -39-  .
    Fig 6: Plugging In Connector On Brake Booster
    G09416139Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 6.1. Plug in connector on brake booster -arrow-  until it engages securely.
  7. Plug in connector on brake fluid reservoir -38-  .
    Fig 7: Plugging In Connector On Brake Fluid Reservoir
    G09416140Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 7.1. Plug in connector on brake fluid reservoir -arrow-  until it engages securely.
  8. Screw on ground strap -35- on centre firewall.
    Fig 8: Securing Ground Strap On Centre Firewall
    G09416141Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 8.1. Clip in wire harness on firewall with the retaining clip -arrow A-  .
    2. 8.2. Connect ground strap together with the twist lock to the threaded bolt on the centre firewall -arrow B-  and secure with fastening nut. → Tightening torque: 9 Nm (6.5 ftlb.) 
  9. Fit rubber sleeve -34- and plug in connector on hydraulic unit -33-  .
    Fig 9: Plugging In Connector On Hydraulic Unit
    G09416142Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 9.1. Push front right wire harness through from the interior towards the engine compartment and fit rubber sleeve on the right firewall -arrow A-  .
    2. 9.2. Route wire harness in plenum panel and clip it in at the retaining clips -arrows B-  .
    3. 9.3. Plug in connector on hydraulic unit -arrow C-  and lock it -arrow D-  until the locking mechanism engages securely.
  10. Press rubber sleeve into the bulkhead -arrow A-  and clip in wire harness with the retaining clips -arrow B-  .
    Fig 10: Pressing Rubber Sleeve Into Bulkhead
    G09416143Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  11. Screw on ground strap for right firewall -32-  .
    Fig 11: Securing Ground Strap
    G09416144Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 11.1. Connect ground strap together with the twist lock to the threaded bolt on the right firewall -arrow-  and secure it with the fastening nut. → Tightening torque: 9 Nm (6.5 ftlb.) 
  12. Clip in wire harness on the upper side member with the retaining clips -arrow-  .
    Fig 12: Clipping In Wire Harness On Upper Side Member
    G09416145Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  13. Fit rubber sleeve -31-  on the left firewall.
    1. 13.1. Push front left wire harness through from the interior towards the engine compartment and fit rubber sleeve on the left firewall -arrow-  .
      Fig 13: Fitting Rubber Sleeve On Left Firewall
      G09416146Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  14. Route wire harness in plenum panel and clip it in at the retaining clips -arrows-  .
    Fig 14: Clipping In Wire Harness In Plenum Panel
    G09416147Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  15. Press rubber sleeve into bulkhead -arrow-  .
    Fig 15: Pressing Rubber Sleeve Into Bulkhead
    G09416148Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  16. Secure wire harness on upper right side member.
    1. 16.1. Route wire harness and clip it in at the retaining clips -arrows A-  .
    2. 16.2. Push wire harness on upper side member onto the clips -arrows B-  .
      Fig 16: Securing Wire Harness On Upper Right Side Member
      G09416149Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  17. Secure wire harness on upper left side member.
    1. 17.1. Route wire harness and clip it in at the retaining clips -arrows A-  .
    2. 17.2. Push wire harness on upper side member onto the clips -arrows B-  .
      Fig 17: Securing Wire Harness On Upper Left Side Member
      G09416150Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  18. Plug in connector on right lateral acceleration sensor -25-  .
    Fig 18: Plugging In Connector On Right Lateral Acceleration Sensor
    G09416151Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 18.1. Plug in connector on lateral acceleration sensor in right wheel housing -arrow A-  until the connector engages securely.
    2. 18.2. Route wire harness and clip it in on the wheel housing with the retaining clips -arrow B-  .
  19. Plug in connector on left lateral acceleration sensor -24-  and circulating pump connector -23-  .
    Fig 19: Plugging In Connector On Left Lateral Acceleration Sensor
    G09416152Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 19.1. Plug in connector on lateral acceleration sensor in left wheel housing -arrow A-  until the connector engages securely.
    2. 19.2. Plug in connector on circulating pump -arrow B-  until the connector engages securely.
    3. 19.3. Route wire harness and clip it in on the left wheel housing with the three retaining clips -arrows C-  .
  20. Connect plug connection for ABS sensor and brake pad wear indicator at the left and right -21 and 22-  .
    Fig 20: Connecting Plug Connection For ABS Sensor And Brake Pad Wear Indicator
    G09416153Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 20.1. Route wire harness and clip it in on the left and right wheel housing with the retaining clips -arrow A-  .
    2. 20.2. Clip in connector socket for ABS sensor and brake pad wear indicator -arrow B-  .
    3. 20.3. Connect plug connection for ABS sensor and brake pad wear indicator -arrow C-  until the plug connection engages securely.
  21. Connect plug connection on tank for windscreen washer system -20-  until the plug connection engages securely. → Installing Reservoir For Windscreen Washer System
  22. Plug in connector for additional heating -19-  until it engages securely. → Installing Complete Heater
  23. Plug in connector on servo valve -18-  until it engages securely.
    Fig 21: Plugging In Connector On Servo Valve
    G09416154Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  24. Plug in connector on angle sensor for headlight levelling system at the left and right -16 and 17-  .
    Fig 22: Plugging In Connector On Angle Sensor For Headlight Levelling System
    G09416155Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 24.1. Plug in connectors on angle sensor for headlight levelling system -arrow A-  until the connectors engage securely.
    2. 24.2. Secure wire harness on the left side to the refrigerant line with a new tie-wrap -arrow B-  .
  25. Plug in connector on TPM transmitter (trigger) -14 and 15-  until it engages securely. → Installing Transmitter (Trigger) For Tyre Pressure Monitoring (TPM)
  26. Clip in wire harness at the retaining clips close to the mounting for the right headlight -arrows-  .
    Fig 23: Clipping In Wire Harness Close To Mounting For Right Headlight
    G09416156Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  27. Clip in wire harness at the retaining clips close to the mounting for the left headlight -arrows-  .
    Fig 24: Clipping In Wire Harness Close To Mounting For Left Headlight
    G09416157Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  28. Secure ground strap for front right cross member -7-  .
    Fig 25: Securing Ground Strap For Front Right Cross Member
    G09416158Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 28.1. Route wire harness and clip it in on the front side member with the retaining clips -arrow A-  .
    2. 28.2. Push ground straps together with the twist lock onto the threaded bolt on the front side member -arrow B-  and screw on the fastening nut. → Tightening torque: 9 Nm (6.5 ftlb.) 
  29. Connect plug connection for front wire harness -5-  and secure ground strap for front cross member -6-  .
    Fig 26: Connecting Plug Connection For Front Wire Harness
    G09416159Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 29.1. Clip connector socket for front wire harness in at the front of the left cross member -arrow A-  .
    2. 29.2. Plug in connector -arrow B-  until it engages securely.
    3. 29.3. Connect ground straps together with the twist lock to the threaded bolt -arrow C-  and screw on the fastening nut. → Tightening torque: 9 Nm (6.5 ftlb.) 
  30. Plug in connectors -3 and 4-  on fan.
    1. 30.1. Plug in connectors on fan -arrows A-  until they engage securely.
    2. 30.2. Clip in wire harness at the retaining clips -arrows B-  .
    3. 30.3. Connect ground straps together with the twist lock to the threaded bolt -arrow C-  and screw on the fastening nut. → Tightening torque: 9 Nm (6.5 ftlb.) 
      Fig 27: Plugging In Connectors On Fan
      G09416160Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  31. Plug in connectors on airbag sensor at the left and right -1 and 2-  until the connectors engage securely. → Installing Airbag Sensor
  32. Install firewall at the left and right.
    Fig 28: Installing Firewall
    G09416161Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 32.1. Fit seal on the body and spray with silicon spray.
    2. 32.2. Fit firewall and position it correctly.
    3. 32.3. Screw in fastening screws -3-  . → Tightening torque: 9 Nm (6.5 ftlb.) 
    4. 32.4. Clip in wire harness with the retaining clips -2-  .
    5. 32.5. Connect oxygen sensor connectors -1-  until they engage securely and clip oxygen sensor connectors into the support -1-  . → Installing Oxygen Sensor Ahead Of Catalytic Converter → Installing Oxygen Sensor Behind Catalytic Converter
    6. 32.6. Secure PDCC reservoir on the plenum panel.
  33. Install intake manifold for heating/fresh-air unit.
    1. 33.1. Position intake manifold and secure with the fastening nuts -1-  . → Tightening torque: 6 Nm (4.5 ftlb.) 
    2. 33.2. Close retaining clips in the intake manifold -arrow A-  .
    3. 33.3. Insert air inlet grille -arrow B-  .
    4. 33.4. Clip in wire harness on the intake manifold -arrow C-  and push in retaining clips for wire harness on the intake manifold -arrow D-  .
      Fig 29: Installing Intake Manifold On Heating/Fresh Air Unit
      G09416162Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  34. Install support for DME control unit.
    1. 34.1. Position support for DME control unit -arrow-  and secure with the fastening nuts -3-  and fastening screw -2-  . → Tightening torque: 8 Nm (6.0 ftlb.)  → Tightening torque: 8 Nm (6.0 ftlb.) 
      Fig 30: Installing Support For DME Control Unit
      G09416163Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 34.2. Insert wire harness for DME control unit into the retaining clips -arrow A-  and close the retaining clips -arrow B-  .
    3. 34.3. Fit ground straps together with the twist lock to the stud and secure with the fastening nut -1-  . → Tightening torque: 9 Nm (6.5 ftlb.) 
      Fig 31: Securing Ground Straps
      G09416164Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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