Front Harness Removal And Installation/Replacement

Mobile Repair Possible: No

Overview:

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WARNING: Electricity hazard
Failure to follow specified procedures may result in death or serious injury from electric shock when working on or near high-voltage components.

Only authorised and appropriately trained persons may carry out work on high-voltage vehicles and components.
Perform High Voltage isolation procedure prior to commencing work
Ensure appropriate Personal Protective Equipment is worn until the system is verified safe

WARNING: Overhead Suspended Load and Falling Parts
Failure to follow specified procedures may result in death or serious injury when elevated load or components are incorrectly secured/supported.

All lifting equipment weight rating must meet or exceed the weight of the vehicle and any contents
The lifting equipment must be in good condition and approved for use
Only lift the vehicle from the identified lift points
Ensure vehicle is stable before performing any work underneath
Ensure there are no loose components which may fall
Always use personal protective equipment (PPE)
Seek assistance when handling larger components

Removal Procedure:

Remove 12V Battery. Refer to 12V BATTERY REMOVAL AND INSTALLATION/REPLACEMENT
Disable HV-System. Refer to HV-SYSTEM DISABLING/ENABLING
Remove front bumper fascia skid plate. Refer to FRONT BUMPER FASCIA SKID PLATE REMOVAL AND INSTALLATION/REPLACEMENT
Remove front bumper fascia. Refer to FRONT BUMPER FASCIA REMOVAL AND INSTALLATION/REPLACEMENT
Remove both front wheelhouse liner. Refer to FRONT WHEELHOUSE LINER REMOVAL AND INSTALLATION/REPLACEMENT
Remove Headlamp. Refer to HEADLAMP REMOVAL AND INSTALLATION/REPLACEMENT
Remove air inlet grille panel and extension. Refer to AIR INLET GRILLE PANEL AND EXTENSION REMOVAL AND INSTALLATION/REPLACEMENT
Remove instrument panel assembly. Refer to INSTRUMENT PANEL ASSEMBLY REMOVAL AND INSTALLATION/REPLACEMENT

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Disconnect all electrical connections along the front harness.
Disconnect all cable connections along the front harness.

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Remove 2 nuts (1) from engine fuse box.
Torque: 5 Nm

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Remove the nut (1) from the left front sub frame.
Torque: 5 Nm

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Remove the bolt (1) on the inside of the right front sub frame.
Torque: 5 Nm

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Remove the front harness from the cable guide (1).

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Disconnect the electrical connector (1) in the front left wheelhouse.
Remove the front harness at the 4 marked points.
Carefully press the grommet (2) inwards with a suitable tool.

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Disconnect the 3 electrical connectors (1) in the front right wheelhouse.
Remove the front harness at the 4 marked points.
Remove the water hose (2).
Carefully press the grommet (3) inwards with a suitable tool.

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Remove nut (1)
Torque: 8 Nm
Disconnect all cable connections along the inside of the front harness.
Carefully press the grommet (2) into the engine compartment using a suitable tool.

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Remove the front harness (1) upwards.
NOTE:
Damage
Risk of damage to vehicle paint work.
- Mask off/protect paint work appropriately to avoid damage.

Installation Procedure:

Installation is the reverse of removal procedure, noting the following.
All fasteners must be tightened to torque specification!
Install instrument panel assembly. Refer to INSTRUMENT PANEL ASSEMBLY REMOVAL AND INSTALLATION/REPLACEMENT
Install air inlet grille panel and extension. Refer to AIR INLET GRILLE PANEL AND EXTENSION REMOVAL AND INSTALLATION/REPLACEMENT
Install headlamp. Refer to HEADLAMP REMOVAL AND INSTALLATION/REPLACEMENT
Install front wheelhouse liner. Refer to FRONT WHEELHOUSE LINER REMOVAL AND INSTALLATION/REPLACEMENT
Install front bumper fascia. Refer to FRONT BUMPER FASCIA REMOVAL AND INSTALLATION/REPLACEMENT
Install front bumper fascia skid plate. Refer to FRONT BUMPER FASCIA SKID PLATE REMOVAL AND INSTALLATION/REPLACEMENT
Enable HV-System. Refer to HV-SYSTEM DISABLING/ENABLING
Install 12V Battery. Refer to 12V BATTERY REMOVAL AND INSTALLATION/REPLACEMENT
Diagnostics, Programming and Setup. Refer to DIAGNOSTICS, PROGRAMMING AND SETUP USING SCAN TOOL IN SERVICE