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WH19 - Reworking Routing of Wire Harness for PASM Valve Unit (Workshop Campaign)

Important:

CRITICAL WARNING - This campaign includes steps where control unit(s) in the vehicle will be
programmed. The vehicle voltage must be maintained between 13.5 volts and 14.5 volts during this
programming. Failure to maintain this voltage could result in damaged control unit(s). Damage caused
by inadequate voltage during programming is not a warrantable defect. The technician must verify the
actual vehicle voltage before starting the campaign and also document the actual voltage on the repair
order. Please refer to Equipment Information EQ1401 for a list of suitable battery chargers/power
supplies which should be used to maintain vehicle voltage.

Model Year:

As of 2017 up to 2018

Model Line:

Panamera (971)

Equipment:

Adaptive air suspension with Porsche Active Suspension Management (I-no. 1BK)

Subject:

Wire harness for PASM valve unit

Information:

The wire harness for the PASM valve unit is not routed correctly in the area around the heat
protection panels for the valve unit on the affected vehicles.
Due to relative movements while driving and if significant amounts of dirt get in, this can cause chafing
on the wire harness and as a result, faults can be entered in the fault memory and the warning "Chassis
system fault" may be displayed in the instrument cluster. As a result, the vehicle level can no longer be
set.

Remedial
Action:

•
•

Check wire harness for PASM valve unit and secure with additional tie-wraps.
If the wire harness is already damaged, repair wire harness for PASM valve unit.

Affected
Vehicles:

Only the vehicles assigned to the campaign (see also PIWIS Vehicle information). This campaign affects
1613 vehicles in North America.

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Installation
Position:

Installation position of wire harness for valve unit
1
– Wire harness for PASM valve unit (check and secure again)
2
– Heat protection panel, left
circle – Area of potential chafing

Required parts and materials
Parts Info:

Note: DO NOT ORDER PARTS. PARTS WILL BE AUTOMATICALLY ALLOCATED TO YOUR DEALERSHIP.
Parts required for checking and reworking routing of wire harness:

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Part No.

Designation
– Use

Qty.

N 106 232 01

 Tie-wrap, C2.5 x 95
– For securing wire harness

1 ea.

9A7 971 850 00

 Tie-wrap with expanding clip
– For securing wire harness

1 ea.

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Part No.:

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WH19

9A7 971 838 01

 Tie-wrap with clip
– For securing wire harness

1 ea.

999 049 032 40

 Plastic nut
– Rear underbody panelling

5 ea.

4

Additional parts required for repairing a wire harness that is already damaged:
Information
Ordering repair lines and connector housing
If the required spare parts for the sectional repair of the wire harness are not already available as part of
the Connector Kit 95B (TKR repair case), they must be ordered separately specifically for carrying
out this work.
If necessary, the spare parts for repairing the wire harness can be ordered from the TKR Automotive
GmbH online shop.
To order the spare parts required for repairing the wire harness, the following procedure must be
observed:
•

If only a small section of a line in the wire harness is damaged  Repairing the wire harness -Fig.
A-, the line can be repaired using a crimp connector. To do this, cut the line in question at the chafing
point and join it again using a suitable crimp connector  Repairing the wire harness -1-.

Repairing the wire harness
•

Essentially, all suitable crimp connectors from any vehicle electrical system repair range (e.g. from
Cartool, etc.) can be used provided they have the same line cross-section as the affected line.

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Repair lines  Repairing the wire harness -2- are only required if more extensive chafing is
discovered on a line  Repairing the wire harness -Fig. B- and this damaged area cannot simply be
covered by a crimp connector.
Part No.

Designation
– Use

Qty.

... *

 Repair parts (e.g. from TKR Automotive GmbH)
– Sectional repair of PASM wire harness

1 ea. *

Includes:
...

Repair line, 0.35 - 0.5 mm2

As required

...

Repair line, 1 mm2

As required

...

Repair line, 2.5 mm2

As required

...

Crimp connector, white, 0.5 mm2

As required

...

Crimp connector, red, 0.75 - 1.5 mm2

As required

...

Crimp connector, blue, 1.5 - 2.5 mm2

As required

...

PVC insulating tape, commercially
available

As required

* All parts required for wire harness repairs must be invoiced together under Part
No. WH190000001 for warranty invoicing.
For Part No. WH190000001, enter “expendable items” designation as sublet item & additional
measure, depending on the required repair parts.
You will find information on invoicing the shipping costs for repair parts from TKR Automotive GmbH
under  Technical Information 'WH1900 Warranty processing' at the end of this document.

Required tools
Tools:

•

Torque screwdriver, 1.5 – 3 Nm (1 – 2 ftlb.), e.g. VAS 6494 - Torque screwdriver

Additional tools required for repairing a wire harness that is already damaged:
•
•
•
•

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VAS 1978/1A - Crimping pliers
VAS 1978/3 - Stripping pliers
VAS 1978/14A - Heat Gun
Suitable unlocking tools for electric plug contacts, e.g. VAS 1978/35-20 - Release tool set and
VAS 1978/35-33 - Release tool set

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Preparatory work
Work Procedure: 1

Move the vehicle onto a lifting platform, deactivate the levelling system and then raise the vehicle 
Workshop Manual '4X00IN Lifting the vehicle'.

2

Remove cover for rear underbody  Workshop Manual '519419 Removing and installing cover for
rear underbody'.

3

Loosen left heat protection panel  Loosening left
heat protection panel -1- for PASM module and press
it down carefully.
To do this, loosen the heat protection panel at
the threaded connections  Loosening left heat
protection panel -2- and guide it out.

4

Loosen front heat protection panel for the PASM
module and push it aside.

Loosening left heat protection panel
4.1

Loosen and unscrew fastening screws 
Loosening front heat protection panel -2- on
the heat protection panel  Loosening front
heat protection panel -1-.

Loosening front heat protection panel

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4.2

Carefully move the heat protection panel 
Moving front heat protection panel -1- along
the PASM module as far as the right-hand side
of the vehicle  Moving front heat protection
panel -arrow A- until the line bracket 
Moving front heat protection panel -2- is
accessible.

Moving front heat protection panel
5

Disconnect wire harness  Loosening wire harness
-1- for PASM valve unit.
5.1

Carefully cut tie-wrap  Loosening wire
harness -3- on the expanding clip 
Loosening wire harness -2- for the wire
harness.

5.2

Unclip expanding clip  Loosening wire
harness -2- on the line bracket and remove it
together with the tie-wrap.

Loosening wire harness

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Checking wire harness for PASM valve unit for damage
Work Procedure: 1

2

Perform a visual inspection to see if the wire harness
for the PASM valve unit  Checking wire harness for
damage -1- shows signs of chafing or damage to
the insulation on the line in the area around the heat
protection panel.
•

If there are no chafing marks or damaged areas
visible on the wire harness, re-position the wire
harness and secure it. To do this, continue with
 Technical Information 'WH1900 Reworking
routing of wire harness for PASM valve unit'.

•

If there are visible chafing marks or damaged
areas, the wire harness must be repaired. To do
this, continue with Step 2.

Repair wire harness for PASM valve unit.
Information

2.1

2.2

Checking wire harness for damage

•

Select a place for the joint where there is enough space to join the individual lines.

•

Mark the electric lines if necessary.

•

If the wire harness is damaged to such an extent that it cannot be repaired using a crimp
connector, the individual line in the wire harness must be replaced by a repair line. For
further information, see:  Technical Information '9X0000 Spare parts requirements
for "connectors" - new repair concept: Information, required details and connector