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WC05

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WC05 - Reworking Engine Wire Harness (Workshop Campaign)

Vehicle Type:

Panamera S/Panamera 4S/Panamera Turbo

Model Year:

As of 2010 up to 2011

Equipment:

Vehicles with emissions concept ULEV2 (I-no. 164) or LEV2 (I-no. 162)

Concerns:

Wire harness for engine

Information:

This is to inform you of a voluntary Workshop Campaign on the above-mentioned vehicles. There is the
possibility that moisture can get into the ground splice connections in the wire harness for the engine.
As a result, ground splice connections can become corroded over the service life of the vehicles. This
can cause signal faults in the oil pressure, oil level and oil temperature sensors, and therefore cause the
Check Engine warning light to be activated.

Action
Required:

Replace the ground splice connections in the engine wire harness on the affected vehicles with sealed
ground splice connections.

Affected
Vehicles:

The VIN(s) can be checked by using PIWIS Vehicle Information link to verify if the campaign affects the
vehicle. This Campaign is scope specific to the VIN! Failure to verify in PIWIS may result in an improper
repair.

Parts Info:

DO NOT PLACE ORDER FOR PARTS! PARTS WILL BE AUTOMATICALLY ALLOCATED ON JUNE
11, 2012.
N .906.661.01

⇒ Tie-wrap

1 ea.

000.043.207.84

⇒ Repair kit “Wiring harness for engine, ground strap”

1 ea.

The “Wiring harness for engine” repair kit includes the following individual components:
•
•
•
•
•
•

BDM clips (crimping sleeves) ⇒ Repair kit -1Soldering tin ⇒ Repair kit -2End caps ⇒ Repair kit -3Hot-melt adhesive ⇒ Repair kit -4Long ground strap (one end stripped, one end with a pin crimped on) ⇒ Repair kit -5Short ground strap (both ends stripped) ⇒ Repair kit -6-

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Repair kit

Materials:

...

⇒ Fabric tape, approx. 15 mm wide (commercially available) Length: 1,000
mm*

* The WWS Warranty system will automatically add into the “Miscellaneous item” section (sublet) of the
claim after the claim has been submitted.
Tools:

Cable repair kit Nr.155-1 Pos.1 (NR.155-1 Pos. 1 is found in Cartool Kit supplied as PNA 721 043 003
00)
Press-out tool set Nr.155-3 (NR.155-3 is included in sets with part numbers PNA 721 040 and PNA 721
041)
Heat gun Nr.155-1 Pos.2 (NR.155-1 Pos. 2 is found in Cartool Kit supplied as PNA 721 003 00)
Spoon strainer Nr.155-1 Pos.4 (NR.155-1 Pos. 4 is found in Cartool Kit supplied as PNA 721 043 003
00)
Torque wrench Nr.90 Pos.3 (NR.90 Pos.3 - should be available at your dealership but as an alternative,
may use tool 9768)
Commercially available soldering iron
Commercially available needle-nose pliers

Work
Procedure:

See Attachment “A”.

Administrative
Procedure:

See Attachment “B”

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Attachment "A": Work Procedure
1

Disconnect the battery ⇒ Workshop Manual ’2X00IN Work instructions after disconnecting the
battery’.

2

Ensure that you have easy access to the DME control unit.

3

2.1

Remove cowl panel cover ⇒ Workshop Manual ’508719 Removing and installing cowl panel
cover - section on "Removing"’.

2.2

Release relay carrier in the plenum panel ⇒ Workshop Manual ’978309 Loosening and
securing relay carrier’.

Expose main wire harness.
3.1

Release locking mechanism for the upper
connector on the DME control unit ⇒ Figure
1 -1- (⇒ Figure 1 -arrow-) and pull the
connector off the DME control unit.

3.2

Loosen both retaining clips ⇒ Figure 1 -2- for
the main wire harness ⇒ Figure 1 -3- at the
plenum panel.

3.3

Remove line clip ⇒ Figure 1 -4- underneath
the relay carrier.

Figure 1
4

Disassemble connector housing of the connector for
the DME control unit.
4.1

Remove tie-wrap ⇒ Figure 2 -1- and fabric
tape ⇒ Figure 2 -2- from the three wire
harnesses for the connector.

4.2

Slide the cover of the connector ⇒ Figure 2
-3- forward using a screwdriver ⇒ Figure 2
-arrow- and remove it.

Figure 2

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Use a screwdriver to pull the locking
mechanism on the plug-in contacts ⇒
Figure 3 -1- completely out of the connector
housing ⇒ Figure 3 -2- (⇒ Figure 3 -arrow-).

Figure 3
5

Expose main wire harness lines.
5.1

Pull protective sleeve ⇒ Figure 4 -1- on the
middle wire harness ⇒ Figure 4 -arrow A- on
the connector for the DME control unit back
as far as possible ⇒ Figure 4 -arrow B- and
fix it in place with fabric tape ⇒ Figure 4 -2-.

Figure 4

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Unpin the ground strap (brown/white, pin 42
⇒ Figure 5 -arrow- from the connector for
the DME control unit using the press-out tool
set Nr.155-3 .

Information
There are two ground splice connections in the unpinned
line. These splice connections are referred to below as
“splice connection 1” (⇒ Figure 6 -item 1-) and “splice
connection 2” (⇒ Figure 6 -item 2-).
The splice connection of the red line (5 V sensor line) will
not be reworked.
6

Figure 5

Disconnect lines.
6.1

Cut the lines after splice connection 1 ⇒
Figure 6 -1- as close as possible to the
shrink-fit tubing ⇒ Figure 6 -3-.

6.2

Cut the lines after splice connection 2
⇒ Figure 6 -2- as close as possible to the
shrink-fit tubing ⇒ Figure 6 -3-.

Information
Extra 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 wire harnesses NR.155-1 .

Figure 6

Information
The ground straps in the repair kit have different lengths, are stripped differently and have different
contacts:
Short ground strap ⇒ Line between the first and second splice connection, both ends stripped (referred
to below as “short line”)
Long ground strap ⇒ Line between the second splice connection and the DME control unit (pin 42), one
end stripped, the other end with a pin crimped on (referred to below as “long line”)

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