Service Manual: 2X - ENGINE-ELECTRIC - GENERAL -- 92A CAYENNE

WM 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY

(CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) >
TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Ground line for Tightening 20 Nm (15

battery to body torque ftlb.)

WM 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY

(CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) >
DISCONNECTING THE BATTERY

WARNING: Static battery charge

Battery can explode

Electrical discharges

→ Do not rub the battery with a dry cloth.

Information

Switch off all loads and remove the ignition key.

Do not disconnect the battery while the engine is running .

Disconnect and reconnect battery with extreme caution .

Do not rub the battery with a dry cloth .

Information

The battery is located under the driver's seat.

1. Detach and fold over carpet in front of the driver's seat. → 704119 REMOVING AND
INSTALLING CARPET

2. Screw off ground strap at the ground point in front of the driver's seat:

3. Risk of short circuit! Screw off the ground strap -2- at the ground point -1- under the driver's
seat in front of the battery box.
 Fig 1: Identifying Ground Strap Point

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Route or insulate the ground strap -2- so that all contact with a ground carrier (e.g. body,
battery terminal) is avoided.

WM 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY

(CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) >
CONNECTING THE BATTERY

1. Connect the battery

1. 1.1. Connect the ground strap -2- to the ground point -1- on the body in front of the
driver's seat and secure with the fastening nut. Tightening torque 20 Nm (15 ftlb.)
 Fig 1: Identifying Ground Strap Point

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Re-lay the carpet.

WM 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY

(CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > EFFECT
OF DISCONNECTION OR TOTAL DISCHARGE OF BATTERY ON ELECTRICAL
SYSTEMS IN THE VEHICLE AND THE PRECAUTIONS TO BE TAKEN

Information

WM 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY

(CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > EFFECT
OF DISCONNECTION OR TOTAL DISCHARGE OF BATTERY ON ELECTRICAL
SYSTEMS IN THE VEHICLE AND THE PRECAUTIONS TO BE TAKEN > CONTROL
UNIT MEMORIES

Values and faults stored in the control units can be deleted if the battery is disconnected or completely
discharged.

If possible, all fault memories should be checked and, if necessary, printed out before the battery is
disconnected .

Information
Supply voltage fault entry

The entry "supply voltage" may be stored in various control units if the battery has been completely
discharged.

Delete the "supply voltage" entry from the control units in question .

Information

Ready status

In some countries (presently the U.S.A. and Canada), after disconnecting the battery, it is necessary to
reach the Ready status by a test drive and/or by using the Porsche System Tester DME control module
menu). If in doubt about this, contact the relevant importer.

Information

2470 DME control module

With all DME systems, the engine must run for several minutes before the engine control module can
relearn the idle speed and mixture adaptation values!

After disconnection of the power supply, the idle speed might change or fluctuate briefly until the throttle
valve adjusting unit has been readapted.

The mixture adaptation is also lost.

After the battery is connected:

With the DME, it is necessary to carry out a learning and adaptation routine as described below:

Switch ignition on for 30 seconds without starting the engine .

Do not actuate accelerator pedal .

This completes the adaptation of the throttle valve adjusting unit.

Information

Tyre pressure monitoring system

When the battery is disconnected and connected, the tire pressure is first displayed as "- - - ".

Once the battery has been disconnected and work is complete, the vehicle must be driven for a
short distance .

The actual pressures will then be displayed again.

Information

4560 Steering angle sensor

The steering angle sensor must be re-initialised when the battery is disconnected and connected.

Turn wheels to straight-ahead position .

Switch ignition off and then on again twice .

Start engine .
 From the straight-ahead position, turn steering wheel approx. 20° to the right, past the
straight-ahead position .

Drive the vehicle straight ahead for at least one second at a speed above 4 km/h (2.5 mph) .

The steering angle sensor segment is recognized again in this process.

Once the sensor has been successfully initialized, the fault code that is stored in the fault memory is
documented using the fault deletion counter.

The fault memory erases itself automatically.

The PSM indicator light in the instrument cluster goes out.

Information

6014 Motor for sunroof

The limit positions of the sunroof are deleted from the control unit when the battery is disconnected and
connected.

Switch on ignition .

Press the sunroof button for several seconds in direction of travel .

After approx. 10 seconds, the sunroof performs an automatic standardization process and resets
all positions .

Keep the button pressed during the standardization process .

Afterwards, the sunroof is standardized correctly.

Information

6452 Power windows

The limit positions of the power windows are deleted from the control unit when the battery is
disconnected and connected.

Perform the following procedure for all power windows:

Pull rocker switch and fully close window once .

Pull rocker switch once more .

The upper end position of the window is stored.

Press rocker switch and fully open window once .

Press rocker switch once more .

The lower end position of the window is stored.

Information

4815 Electrical steering column adjustment (ELVS)

The electrical steering column adjustment end positions (ELVS) are deleted when the battery is
disconnected and connected.
The following buttons must be pressed in sequence in order to reinitializes electrical steering column
adjustment.

Press the extend button three times (extend towards the driver) .

Press the retract button once .

Press the extend button once (towards the driver) .

Press the up button once .

Press the down button once .

Once the buttons have been pressed correctly, the steering column automatically moves all axles and
stops at the center position (only works when the vehicle is stationary).

1. Carry out a test drive after connecting the battery.

WM 2X00IN ADAPTATIONS - CONTI DME (CAYENNE S, CAYENNE TURBO, CAYENNE

GTS, CAYENNE TURBO S) > INFORMATION

The following adaptations will be deleted automatically when you erase the fault memory (see
INFORMATION )

Mixture adaptation

Lambda adaptation

Camshaft adaptation

Knock adaptation

Map-controlled thermostat adaptation

WM 2X00IN ADAPTATIONS - CONTI DME (CAYENNE S, CAYENNE TURBO, CAYENNE

GTS, CAYENNE TURBO S) > DELETING ADAPTATIONS > ALL ADAPTATIONS

Necessary after:

Replacing engine

How?

PIWIS Tester:

1. Preconditions:

1. 1.1. Engine off

2. 1.2. Ignition on

3. 1.3. Engine cold if possible

2. Select menu:

1. 2.1. DME
 2. 2.2. Programming

3. 2.3. Automatic programming

3. Start function: [F8]

4. Adapt throttle valve (see below)

1)
The RBM data is also deleted here .

WM 2X00IN ADAPTATIONS - CONTI DME (CAYENNE S, CAYENNE TURBO, CAYENNE

GTS, CAYENNE TURBO S) > DELETING ADAPTATIONS > DELETING ADAPTATIONS
SELECTIVELY (AFFECTED AREAS)

Fuel high-pressure adaptation

Necessary after:

Replacing high-pressure pump

All work that must be carried out as a result of high-pressure faults, e.g. electric fuel pump, control
unit for electric fuel pump...

Fuel high-pressure adaptation

Necessary after:

Replacing oil pump

Replacing oil pressure control valve

Mixture adaptation

Lambda adaptation

Necessary after:

Replacing high-pressure injectors

Correcting faults during load detection, mixture control, emissions measurement

Pressure sensors, intake manifold

Necessary after:

Replacing intake manifold pressure sensor

Replacing boost pressure sensor (Turbo only)

Boost pressure control (Turbo only)

Necessary after:

Replacing turbocharger

Correcting faults in boost pressure control system

How?
PIWIS Tester:

1. Preconditions:

1. 1.1. Engine off

2. 1.2. Ignition on

3. 1.3. Engine cold if possible

2. Select menu:

1. 2.1. DME

2. 2.2. Maintenance/repairs

3. 2.3. Delete adaptation values

3. Information on deleting adaptation values

4. Confirm with [F8]

5. Submenu of adaptation ranges

6. Select adaptation range and continue with [F12]

7. Switch off ignition (see also INFORMATION )

WM 2X00IN ADAPTATIONS - CONTI DME (CAYENNE S, CAYENNE TURBO, CAYENNE

GTS, CAYENNE TURBO S) > OVERWRITING ADAPTATION VALUES > INFORMATION

Consequences of Tester adaptation if conditions for automatic adaptation are not met (violated boundary
condition):

For a fault entry in the load detection range (P0068 + P1069... P1077), the limits are extended in
order to prevent incorrect detections.

This extension is cancelled if an adaptation is performed when the conditions for automatic
adaptation are met, or after 15 warm-up cycles at the latest

(Warm-up cycle = coolant temperature increases by more than 23 °C (73 °F) after start-up and
reaches at least 73 °C (163 °F))

Following manual throttle valve adaptation when ambient conditions are not met, throttle valve
adaptation is carried out again automatically as soon as the ambient conditions are met.

There is NO 30-second waiting time here, but a slightly delayed engine start is possible once.

The ambient conditions for automatic adaptation are as follows:

Engine off and ignition on for > 30 seconds.

Accelerator pedal is not pressed.

Vehicle is stationary.

Power supply for throttle valve adjusting unit is OK.

Coolant temperature 5 °C... 100 °C (41 °F... 212 °F)

Intake air temperature 5 °C... 40 °C (41 °F... 104 °F)

WM 2X00IN ADAPTATIONS - CONTI DME (CAYENNE S, CAYENNE TURBO, CAYENNE

GTS, CAYENNE TURBO S) > OVERWRITING ADAPTATION VALUES > THROTTLE
VALVE

after deletion or without deletion

Necessary after:

Re-programming DME control unit

Replacing DME control unit

Replacing throttle valve

How?

Ignition on > 30 seconds if the preconditions are met

or

PIWIS Tester:

1. Preconditions:

1. 1.1. Engine off

2. 1.2. Ignition on

2. Select menu:

1. 2.1. DME

2. 2.2. Maintenance/repairs

3. 2.3. Adaptations

4. 2.4. Throttle valve adaptation

3. Go to Note: [F12]

4. Start function: [F12]

5. Switch off ignition (see INFORMATION )

WM 2X00IN ADAPTATIONS - CONTI DME (CAYENNE S, CAYENNE TURBO, CAYENNE

GTS, CAYENNE TURBO S) > OVERWRITING ADAPTATION VALUES > KICKDOWN
ACCELERATOR PEDAL MODULE (CAYENNE (92A) TIPTRONIC ONLY)

Necessary after:

Re-programming DME control unit

Replacing DME control unit

 Replacing accelerator pedal module

How?

PIWIS Tester:

1. Preconditions:

1. 1.1. Engine off

2. 1.2. Ignition on

2. Select menu:

1. 2.1. DME

2. 2.2. Maintenance/repairs

3. 2.3. Adaptations

4. 2.4. Kickdown adaptation

3. Start function: [F8]

4. Press accelerator pedal fully and release it again after 30 seconds

5. Switch off ignition (see also INFORMATION )

WM 2X00IN ADAPTATIONS - CONTI DME (CAYENNE S, CAYENNE TURBO, CAYENNE

GTS, CAYENNE TURBO S) > OVERWRITING ADAPTATION VALUES > INFORMATION

The accelerator pedal must always be pressed after approx. 1.5 minutes since each adaptation step is
limited to 5 Nm.

WM 2X00IN ADAPTATIONS - CONTI DME (CAYENNE S, CAYENNE TURBO, CAYENNE

GTS, CAYENNE TURBO S) > OVERWRITING ADAPTATION VALUES > TORQUE LOSS

Necessary after:

Re-programming DME control unit

Replacing DME control unit

Re-programming PDK control unit

Necessary before:

Re-calibrating PDK

How?

Engine idling

1. Preconditions:

1. 1.1. Engine at operating temperature

2. Engine idling for 3 minutes without activating loads, press accelerator pedal once after approx.
 1.5 minutes during this time

3. Engine idling for 3 minutes with air conditioning switched on, press accelerator pedal once
after approx. 1.5 minutes during this time

4. Engine idling for 3 minutes with air conditioning switched on and transmission range engaged,
press accelerator pedal once after approx. 1.5 minutes during this time

5. Switch off ignition (see also INFORMATION )

WM 2X00IN BASIC SAFETY INSTRUCTIONS FOR WORKING WITH LEAD-ACID

BATTERIES (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > DANGERS CAUSED BY
ELECTROLYTE WHEN FILLING LEAD-ACID BATTERIES > DANGERS FOR PERSONS

Electrolyte is extremely caustic.

Avoid contact with caustic fluid.

Wear personal protective gear.

Rinse acid splashes in the eyes immediately with clean water. Then consult a doctor immediately

Neutralize acid splashes on the skin or clothing immediately with acid neutralizer or soap suds and
rinse again with plenty of water. Contact a doctor if necessary.

In the event of extensive skin contact with electrolyte, remove soaked clothing immediately and
wash the skin thoroughly in a shower. Then consult a doctor immediately.

If you drink electrolyte, rinse your mouth immediately with water. Drink water in small sips, do not
induce vomiting. Then consult a doctor immediately.

If you inhale acid mist, breathe in fresh air immediately. Contact a doctor if necessary.

Do not tilt the battery. Electrolyte can emerge from the vent openings.

WM 2X00IN BASIC SAFETY INSTRUCTIONS FOR WORKING WITH LEAD-ACID

BATTERIES (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > DANGERS CAUSED BY
ELECTROLYTE WHEN FILLING LEAD-ACID BATTERIES > DANGERS FOR THE
ENVIRONMENT

Electrolyte reacts with alkalis and water and generates a considerable amount of heat. Electrolyte
destroys paper, wood and textiles and has a corrosive reaction to metals. Electrolyte is a fluid that is
hazardous to water and causes ecological damage as a result of pH changes.

Absorb spilt electrolyte using binding material.

Neutralize spilt electrolyte with acid neutralizer.

Dilute small quantities and residual quantities with water and rinse it away.

Store electrolyte only in acid-resistant containers in the area reserved for pollutants and hazardous
substances.
 Transport electrolyte only in securely locked containers.

WM 2X00IN BASIC SAFETY INSTRUCTIONS FOR WORKING WITH LEAD-ACID

BATTERIES (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > DANGERS WHEN
CHARGING LEAD-ACID BATTERIES > DANGERS FOR PERSONS

Highly inflammable hydrogen can be produced if batteries are overcharged or if the charge voltage is too
high. Danger of production of hydrogen gas (highly inflammable mixture).

Only charge lead-acid batteries in special battery rooms.

Fit forced ventilation systems in the room for excellent ventilation.

Keep ventilation openings free.

Keep clear of ignition sources.

Connect and disconnect the battery terminals only with the charger switched off in order to prevent
sparks.

Do not hold a naked flame or lit cigarette near a battery.

Only illuminate the inside of a battery with a torch.

WM 2X00IN BASIC SAFETY INSTRUCTIONS FOR WORKING WITH LEAD-ACID

BATTERIES (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > DANGERS CAUSED BY
SHORT CIRCUIT > DANGERS FOR PERSONS

A short circuit between the battery terminals as a result of conductive objects can cause a fire. Danger
due to arc, cable fire, terminal meltdown and electrostatic discharge.

Cover the battery terminals.

Disconnect the negative cable from the battery before working on the battery.

Keep electrically conductive objects clear of the battery terminals.

Only use work clothing and shoes approved by Porsche.

WM 2X00IN BASIC SAFETY INSTRUCTIONS FOR WORKING WITH LEAD-ACID

BATTERIES (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > PERSONAL
PROTECTIVE EQUIPMENT

The protective equipment required for workshop activities is compulsory. The following specific
protective equipment is also required for working with lead-acid batteries.

Protective goggles with side protection.

Acid/chemical-resistant protective gloves.

 Acid-resistant rubber apron.

Industrial footwear with acid-resistant soles.

WM 2X00IN BATTERY TRICKLE CHARGING (CAYENNE, CAYENNE GTS, CAYENNE

TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) >
INFORMATION > BATTERY TRICKLE CHARGING

Information

When working or carrying out tests on the vehicle or when the vehicle is in the workshop, a battery
charger with a rated current of at least 40 A must be connected .

As soon as the vehicle is unlocked, e.g. the vehicle is in the workshop or salesroom, it must be
trickle charged with a battery charging device .

NOTE: Using charging cables/jump leads directly on the vehicle battery.

Risk of damage to battery sensors.

→ Always connect charging cables/jump leads to the external power supply for jump-lead starting.

1. Open protective cover on positive terminal for jump-lead starting -+- (-arrow- ).
 Fig 1: Opening Protective Cover On Positive Terminal

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. First, connect the positive cable from the charger to the positive terminal -+- .

3. Then connect the negative cable from the charger to the ground point for jump-lead starting - .

4. Read and follow the operating instructions for the charger.

5. Switch off all electrical loads.

 6. Switch on the charger.

WM 2X00IN CLASSIFICATION OF HIGH-VOLTAGE BATTERY (CAYENNE S E-HYBRID)

> TOOLS

Designation Type Number Description

Workshop Workshop WE 1188

crane equipment

Diagnosis box Workshop WE 1587

equipment

High-voltage Workshop WE 1589

cordon equipment

wire mesh crate Workshop WE 1590

equipment

temperature Workshop WE 1591

gauge equipment

Warning sign Workshop WE 1594

(No equipment
unauthorized
access)

Warning sign Workshop WE 1595

(No fire, naked equipment
flames or
smoking)

Warning sign Workshop WE 1596

(Warning of equipment
dangerous
electrical
voltage)

Warning sign Workshop WE 1597

(Warning of equipment
dangers
associated with
batteries)

Lifting tackle VW tool 3033

 PIWIS Tester II Special tool 9818

Adapter plate Special tool 9860

WM 2X00IN CLASSIFICATION OF HIGH-VOLTAGE BATTERY (CAYENNE S E-HYBRID)

> INFORMATION > INSTALLATION POSITION OF HIGH-VOLTAGE BATTERY

Fig 1: Identifying High-Voltage Battery Installation Position

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

WM 2X00IN CLASSIFICATION OF HIGH-VOLTAGE BATTERY (CAYENNE S E-HYBRID)
> INFORMATION > GENERAL WARNING NOTES

WARNING: Lithium-ion high-voltage battery in dangerous state

Risk of fire

Risk of explosion

→ Cancel classification immediately

→ Alert the fire services

→ Take steps to deal with the danger from fire/gas leaks

WARNING: Lithium-ion high-voltage battery in critical state

Danger of poisoning from emerging gases/fluids

→ If battery is in the vehicle: Move the vehicle to the quarantine location.

→ If battery is not in the vehicle: Place battery in wire mesh crate at quarantine location.

WARNING: High voltage at the high-voltage system on hybrid vehicles

Danger of electric shock from live parts

Risk of serious burns or death

Health risks for persons with life-support systems.

→ Before working on the high-voltage electrical system and carrying out any repair work to the body, a
high-voltage technician must switch off the power to the system.

→ All work on vehicles with a high-voltage vehicle electrical system must only be carried out by
electrically instructed persons (eip). The work must be done under the instruction of a high-voltage
technician (HVT).

→ Observe general warning notes for working on the high-voltage electrical system. → 2X00IN
GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE ELECTRICAL SYSTEM

WM 2X00IN CLASSIFICATION OF HIGH-VOLTAGE BATTERY (CAYENNE S E-HYBRID)

> CLASSIFICATION OF HIGH-VOLTAGE BATTERY > HIGH-VOLTAGE BATTERY WITH
CLASSIFICATION IN VEHICLE

WARNING: Lithium-ion high-voltage battery in dangerous state

 Risk of fire

Risk of explosion

→ Cancel classification immediately

→ Alert the fire services

→ Take steps to deal with the danger from fire/gas leaks

WARNING: Lithium-ion high-voltage battery in critical state

Danger of poisoning from emerging gases/fluids

→ If battery is in the vehicle: Move the vehicle to the quarantine location.

→ If battery is not in the vehicle: Place battery in wire mesh crate at quarantine location.

1. Complete the test log for classification of lithium-ion high-voltage batteries with general
information.

2. Perform an initial visual assessment as described in the test log.

1. 2.1. Work through and document the criteria as described in the test log.

3. Perform a functional and thermal assessment as described in the test log.

Information

The PIWIS Tester II 9818 instructions take precedence since the description may be different
with later Tester releases.

The procedure described here has been structured in general terms; different text or additions
may appear in PIWIS Tester II 9818 .

Information

1. If communication between the PIWIS Tester and HV battery control unit cannot be
established even after several attempts, contact Technical Support to find out how to
proceed .

1. 3.1. PIWIS Tester must be connected to the vehicle before starting the Tester. Switch
on ignition.

2. 3.2. Select "Vehicle" on the Tester --> Vehicle data is read out.

3. 3.3. Select "Control unit for high-voltage battery" on the "Overview" tab, press
[F12] and continue without creating a VAL.

4. 3.4. Switch to the "Maintenance and repairs" tab.

5. 3.5. Select "Battery classification" and press [F12] --> Follow instructions on the
Tester.
 6. 3.6. Document the result shown on the Tester in the test log.

4. If the battery was not assessed as dangerous or critical , the battery can be removed.

Information

If fluid is leaking out, electrolyte can easily be distinguished from normal coolant by its pungent
smell. To check the vent line, first remove the protection cap and re-fit it after you have
checked the line.

5. After removing the battery, perform a detailed visual assessment as described in the test log.

1. 5.1. Work through and document the criteria as described in the test log.

Information

1. If the answer "Yes" was not given for any of the test criteria, the battery condition is not
critical .

6. Document the overall result in the test log and sign the test log.

WM 2X00IN CLASSIFICATION OF HIGH-VOLTAGE BATTERY (CAYENNE S E-HYBRID)

> CLASSIFICATION OF HIGH-VOLTAGE BATTERY > HIGH-VOLTAGE BATTERY WITH
CLASSIFICATION OUTSIDE OF VEHICLE

WARNING: Lithium-ion high-voltage battery in dangerous state

Risk of fire

Risk of explosion

→ Cancel classification immediately

→ Alert the fire services

→ Take steps to deal with the danger from fire/gas leaks

WARNING: Lithium-ion high-voltage battery in critical state

Danger of poisoning from emerging gases/fluids

→ If battery is in the vehicle: Move vehicle to the quarantine location.

→ If battery is not in the vehicle: Place battery in wire mesh crate at quarantine location.

Information

When setting down a removed high-voltage battery, make sure to use suitable supports to prevent
damage to any water drains on the underside of the battery .

1. Complete the test log for classification of lithium-ion high-voltage batteries with general
 information.

2. Perform an initial visual assessment as described in the test log.

1. 2.1. Work through and document the criteria as described in the test log.

3. Perform a thermal assessment as described in the test log.

1. 3.1. Stick adhesive strips -4- at the three measuring points -1- , -2- , -3- .

2. 3.2. Perform thermal measurement using temperature gauge WE 1591 -5- .

3. 3.3. Document the measurement result in the test log.

Fig 1: Measuring Points Of Thermal Measurement

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

If fluid is leaking out, electrolyte can easily be distinguished from normal coolant by its pungent
smell. To check the vent line, first remove the protection cap and re-fit it after you have
checked the line.

4. Perform a detailed visual assessment as described in the test log.

1. 4.1. Work through and document the criteria as described in the test log.

5. Perform a detailed functional and thermal assessment as described in the test log.

1. 5.1. Diagnosis box WE 1587 must be connected to the battery.

 Information

The PIWIS Tester II 9818 instructions take precedence since the description may be
different with later Tester releases.

The procedure described here has been structured in general terms; different text or
additions may appear in PIWIS Tester II 9818 .

Information

1. If communication between the PIWIS Tester and HV battery control unit cannot
be established even after several attempts, contact Technical Support to find
out how to proceed .

2. 5.2. PIWIS Tester II 9818 must then be connected to the diagnosis box WE 1587 .

3. 5.3. Diagnosis box WE 1587 must be connected to the power supply.

4. 5.4. Diagnosis box WE 1587 must then be switched on before pressing [F1] to
activate terminal 15 and [F2] to activate terminal 30. If not pre-set, press [F3] to
select a resistance value of 120 Ohm. PIWIS Tester must now be started.

5. 5.5. Select "Vehicle" on the Tester --> Vehicle data is read out.

6. 5.6. Select "Control unit for high-voltage battery" on the "Overview" tab, press
[F12] and continue without creating a VAL.

7. 5.7. Switch to the "Maintenance and repairs" tab.

8. 5.8. Select "Battery classification" and press [F12] --> Follow instructions on the
Tester.

9. 5.9. Document the result in the test log.

Information

1. If the answer "Yes" was not given for any of the test criteria, the battery condition is not
critical .

6. Document the overall result in the test log and sign the test log.

WM 2X00IN CLASSIFICATION OF HIGH-VOLTAGE BATTERY (CAYENNE S E-HYBRID)

> QUARANTINE OF A HIGH-VOLTAGE BATTERY > QUARANTINE OF A
HIGH-VOLTAGE BATTERY IN THE VEHICLE

1. Move vehicle to the quarantine location and cordon it off in accordance with instructions using
high-voltage cordon High-voltage cordon WE 1589 and warning signs Warning sign (No
unauthorized access) WE 1594 , Warning sign (No fire, naked flames or smoking) WE
1595 , Warning sign (Warning of dangerous electrical voltage) WE 1596 , Warning sign
(Warning of dangers associated with batteries) WE 1597 .

WM 2X00IN CLASSIFICATION OF HIGH-VOLTAGE BATTERY (CAYENNE S E-HYBRID)

> QUARANTINE OF A HIGH-VOLTAGE BATTERY > QUARANTINE OF A REMOVED
HIGH-VOLTAGE BATTERY
 WARNING: Danger of objects or loads falling down

Risk of squashing or crushing

→ Secure components to prevent them from falling down.

Information

A cross member can also be fitted on the battery. For quick handling, the adapter plate can also be fitted
on the battery with a cross member.

1. Adapter plate 9860 -1- must be positioned on the high-voltage battery and fitted to the
high-voltage battery using fastening screws -2- .
Fig 1: Securing Adapter Plates

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Lifting tackle 3033 -1- can then be fitted to the adapter plates -2- .
 Fig 2: Fitting Lift Tackle

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Set the workshop crane Workshop crane WE 1188 to the fourth detent (500 kg).

3. Workshop crane WE 1188 must be engaged in the lifting tackle 3033 . Then lift it carefully
at the center.

4. Using the workshop crane WE 1188 , slowly lower the suspended high-voltage battery into
the wire mesh crate WE 1590 -1- . When doing so, make sure that the high-voltage battery
-2- is sitting on the correct brackets -3- .
 Fig 3: Positioning Wire Mesh Crate

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Close the wire mesh crate and mark it according to instructions using high-voltage cordon
WE 1589 , warning signs Warning sign (No unauthorized access) WE 1594 , Warning
sign (No fire, naked flames or smoking) WE 1595 , Warning sign (Warning of dangerous
electrical voltage) WE 1596 , Warning sign (Warning of dangers associated with
batteries) WE 1597 .

WM 2X00IN FUNCTION TEST ON HIGH-VOLTAGE TEST ADAPTER (CAYENNE S

E-HYBRID) > TOOLS

Designation Type Number Description

high-voltage test Workshop WE 1585

adapter HVA 280 equipment

high-voltage test Workshop WE 1586

adapter HVR 40 equipment

WM 2X00IN FUNCTION TEST ON HIGH-VOLTAGE TEST ADAPTER (CAYENNE S

E-HYBRID) > FUNCTION TEST ON HIGH-VOLTAGE TEST ADAPTER > FUNCTION
TEST ON HIGH-VOLTAGE TEST ADAPTER VAS 6558/9-6
Information

When checking the system using high-voltage test adapter HVA 280 WE 1585 , make sure not to
damage the pins in the socket of the test adapter.

Information

When taking measurements on the connectors, it is not clear which is the positive and which is the
negative terminal. For this reason, both pins on the connector must always be measured against the
respective socket on the test adapter. One of the pins must correspond to the value specified in the test
log. Follow the procedure shown in the graphics when taking measurements. The pins on the
connectors are shown correctly here.

1. Perform function test on the high-voltage test adapter High-voltage test adapter HVA 280 WE
1585 in accordance with the test log for verifying isolation from the power supply using a
multimeter. Set the multimeter to resistance (Ohm).

1. 1.1. Measure negative terminal for line A on negative socket.

 Fig 1: Measuring Negative Terminal For Line On Negative Socket (Line A)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. 1.2. Measure positive terminal for line A on positive socket.

 Fig 2: Measuring Positive Terminal For Line On Positive Socket (Line A)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. 1.3. Measure shielding for line A on shielded socket.

 Fig 3: Measuring Shielding For Line On Shielded Socket (Line A)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. 1.4. Measure negative terminal for line B on negative socket.

 Fig 4: Measuring Negative Terminal For Line On Negative Socket (Line B)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. 1.5. Measure positive terminal for line B on positive socket.

 Fig 5: Measuring Positive Terminal For Line On Positive Socket (Line B)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. 1.6. Measure shielding for line B on shielded socket.

 Fig 6: Measuring Shielding For Line On Shielded Socket (Line B)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

WM 2X00IN FUNCTION TEST ON HIGH-VOLTAGE TEST ADAPTER (CAYENNE S

E-HYBRID) > FUNCTION TEST ON HIGH-VOLTAGE TEST ADAPTER > FUNCTION
TEST ON HIGH-VOLTAGE TEST ADAPTER VAS 6558/9-7

Information

When checking the system using high-voltage test adapter HVR 40 WE 1586 , make sure not to
damage the pins in the socket of the test adapter.

Information

When taking measurements on the connectors, it is not clear which is the positive and which is the
negative terminal. For this reason, both pins on the connector must always be measured against the
respective socket on the test adapter. One of the pins must correspond to the value specified in the test
log. Follow the procedure shown in the graphics when taking measurements. The pins on the
connectors are shown correctly here.

1. Perform function test on the high-voltage test adapter High-voltage test adapter HVR 40 WE
1586 in accordance with the test log for verifying isolation from the power supply using a
multimeter. Set the multimeter to resistance (Ohm).

1. 1.1. Measure negative terminal for line A on negative socket.

Fig 1: Measuring Negative Terminal For Line On Negative Socket (Line A)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. 1.2. Measure positive terminal for line A on positive socket.

 Fig 2: Measuring Positive Terminal For Line On Positive Socket (Line A)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. 1.3. Measure shielding for line A on shielded socket.

 Fig 3: Measuring Shielding For Line On Shielded Socket (Line A)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. 1.4. Measure negative terminal for line B on negative socket.

 Fig 4: Measuring Negative Terminal For Line On Negative Socket (Line B)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. 1.5. Measure positive terminal for line B on positive socket.

 Fig 5: Measuring Positive Terminal For Line On Positive Socket (Line B)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. 1.6. Measure shielding for line B on shielded socket.

 Fig 6: Measuring Shielding For Line On Shielded Socket (Line B)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

WM 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE

VEHICLE ELECTRICAL SYSTEM (CAYENNE S E-HYBRID) > TOOLS

Designation Type Number Description

Insulated tool set Workshop WE 1593

equipment

WM 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE

VEHICLE ELECTRICAL SYSTEM (CAYENNE S E-HYBRID) > GENERAL WARNING
NOTES > GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE
VEHICLE ELECTRICAL SYSTEM

WARNING: High voltage

Danger of electric shock from live parts

Risk of serious burns or death

→ Work on the high-voltage battery may only be carried out by a high-voltage technician.

→ Always use insulated tools Insulated tool set WE 1593 when working on the high-voltage battery.

→ Observe general warning notes for working on the high-voltage vehicle electrical system.

→ 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE ELECTRICAL

SYSTEM

Information

The workshop flow chart (see Standard documents) must be observed when working on high-voltage
vehicles.

Information

In the event of queries or uncertainty regarding the terms "Electrically instructed person (Eip)", "high-
voltage technician (HVT)", "high-voltage expert" or the hybrid system, please contact the relevant
importer before starting any work.

Information

Before starting to work on the high-voltage system or close to high-voltage components, a high-voltage
technician must isolate the high-voltage system from the power supply.

The document → 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON HYBRID VEHICLES describes the various types of work for which the high-voltage system
must be isolated from the power supply.

The test log Verifying absence of electric charge and Restarting high-voltage system can be found
under Standard forms in the PPN.

Information

Please note the following when de-energising the high-voltage system:

The high-voltage system must only be isolated from the power supply by a correspondingly
qualified person (High Voltage Technician - HVT) .

The high voltage technician ascertains that the system is de-energized and secures it to prevent
reactivation .

The system is secured to prevent reactivation by disconnecting the 12-volt service connector and
securing the system with a padlock. The high voltage technician must store the key for the padlock
in a safe place .
 The high voltage technician identifies the vehicle as de-energized by attaching a corresponding
sign .

All work (e.g. maintenance, changing tires, convenience electronics) on vehicles with a
high-voltage system must only be carried out by an electrically instructed person (eip). The work
must be done under the instruction of a high-voltage technician .

Before working on the high-voltage system and carrying out any repair work to the body, a high
voltage technician must switch off the power to the system .

If the high-voltage system cannot be isolated from the power supply, further repairs must only be
carried out by a high voltage expert .

Persons with medical devices must not carry out any work on vehicles with a high-voltage system.
Medical devices include internal analgesic pumps, implanted defibrillators, pacemakers, insulin
pumps and hearing aids .

Information

Handling high-voltage lines:

Do not support yourself or your tools on high-voltage lines and their components .

Work involving metal-removing, deforming and sharp-edged tools in the vicinity of high-voltage
components and lines is prohibited .

Work involving heat sources such as welding, soldering, hot air and thermal bonding in the vicinity
of high-voltage components and lines is prohibited .

High-voltage lines must not be extensively bent or kinked .

In the event of queries or uncertainties, consult the relevant high voltage technician .

WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (CAYENNE S HYBRID) >
TOOLS

Designation Type Number Description

Hybrid test Workshop WE 1378

adapter VAS equipment
6558/1
 voltage tester Workshop WE 1380
equipment

PIWIS Tester II Special tool 9818

WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (CAYENNE S HYBRID) >
TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Crash panel to Fastening screw Tightening 9 Nm (6.5 ftlb.)

power - 4- torque
electronics

Crash panel to Fastening screw Tightening 9 Nm (6.5 ftlb.)

power - 5- torque
electronics

WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (CAYENNE S HYBRID) >
GENERAL WARNING NOTES > GENERAL WARNING NOTES FOR WORKING ON THE
HIGH-VOLTAGE SYSTEM

Information

In the event of queries or uncertainty regarding the terms "Electrically instructed person (Eip)", "high-
voltage technician (HVT)", "high-voltage expert" or the hybrid system, please contact the relevant
importer before starting any work.

Information
Before starting to work on the high-voltage system or close to high-voltage components, a high-voltage
technician must isolate the high-voltage system from the power supply.

The document → 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON HYBRID VEHICLES describes the various types of work for which the high-voltage system
must be isolated from the power supply.

The test log Verifying absence of electric charge and Restarting high-voltage system can be found
under Standard forms in the PPN.

Information

Please note the following when de-energising the high-voltage system:

The high-voltage system must only be isolated from the power supply by a correspondingly
qualified person (high-voltage technician (HVT)) .

The high-voltage technician ascertains that the system is de-energized and secures it to prevent
reactivation .

The system is secured to prevent reactivation by getting the high-voltage technician to lock the
service disconnector .

The high-voltage technician identifies the vehicle as de-energized by attaching a corresponding

sign .

All work (e.g. maintenance, changing tires, comfort electrics) on vehicles with a high-voltage
system must only be carried out by an electrically instructed person (eip). The work must be done
under the instruction of a high-voltage technician (HVT) .

Before working on the high-voltage system and carrying out any repair work to the body, a
high-voltage technician must switch off the power to the system .

If the high-voltage system cannot be isolated from the power supply, do not continue working on
the system and contact Technical Support .

Persons with medical devices must not carry out any work on vehicles with a high-voltage system.
Medical devices include internal analgesic pumps, implanted defibrillators, pacemakers, insulin
pumps and hearing aids .

Information

Handling high-voltage cables:

Do not support yourself or your tools on high-voltage cables and their components .

Work involving metal-removing, deforming and sharp-edged tools in the vicinity of high-voltage
components and cables is prohibited .

Work involving heat sources such as welding, soldering, hot air and thermal bonding in the vicinity
of high-voltage components and cables is prohibited .

High-voltage cables must not be extensively bent or kinked .

In the event of queries or uncertainties, consult the relevant high-voltage technician .

WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (CAYENNE S HYBRID) >
INFORMATION > ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER
SUPPLY

Information

Work for which the high-voltage system has to be isolated from the power supply:

All work on a hybrid vehicle must only be carried out by persons who are at least qualified as an
Eip (Electrically instructed person) .

When carrying out any work on a hybrid vehicle, the hybrid-specific components in the
activity/work area must be visually inspected .

The high-voltage cables must not be extensively bent or kinked .

Anything anomalous or unclear must be reported to the HVT (high-voltage technician) or HVE
(high-voltage expert) .

Working close to high-voltage components and high-voltage lines using cutting, deforming and
sharp-edged tools or heat sources, such as welding, soldering, hot air and thermal bonding, is
prohibited .

→ 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE TASKS ON

HYBRID VEHICLES

WARNING: High voltage at the high-voltage system on hybrid vehicles

Danger of electric shock from live parts

Risk of serious burns or death

Health risks for persons with medical devices/life-support systems.

→ Before working on the high-voltage electrical system and carrying out any repair work to the body, a
high-voltage technician must switch off the power to the system.

→ All work on vehicles with a high-voltage electrical system may only be carried out by electrically
instructed persons. The work must be done under the instruction of a high-voltage technician.

→ Observe general warning notes for working on the high-voltage electrical system. → 2X00IN
GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE ELECTRICAL SYSTEM

Information

In the event of queries or uncertainty regarding the terms "Electrically instructed person (Eip)", "high-
voltage technician (HVT)", "high-voltage expert" or the hybrid system, please contact the relevant
importer before starting any work.

1. Read out the fault memory using PIWIS Tester II 9818 .

2. The following work must only be carried out by a person who is at least trained and qualified as
a recognized high-voltage technician .
3. Switch off the ignition (term. 15) and make sure that it cannot be switched back on again. Then
remove the remote control from the ignition lock. On vehicles with "Keyless Entry and Go",
release the operating lever and pull it out of the ignition lock. Store the remote control and
operating lever in a safe place.

4. Remove service disconnector cover on the high-voltage battery.

Fig 1: Removing Service Disconnector Cover On High-Voltage Battery

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Release the service disconnector by moving it to the right -1- and lift up the securing clip -2- .
 Fig 2: Removing Service Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Remove the service disconnector from the high-voltage battery.

 Fig 3: Removing Service Disconnector From High-Voltage Battery

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Release and unplug the pilot line connector.

 Fig 4: Removing Pilot Line Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. The lock -1- for the two high-voltage lines -2- opens.
 Fig 5: Removing High-Voltage Lines From High Volage Battery

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

The test log Verifying absence of electric charge and Restarting high-voltage system
can be found under Standard forms in the PPN.

9. Release high-voltage lines -HV-- and -HV+- one after the other (rapid-action coupling) and
disconnect them from the battery.

10. Use the Hybrid test adapter VAS 6558/1 WE 1378 and the voltage tester WE 1380 to verify
the absence of electric charge at the two high-voltage contacts on the high-voltage battery.

1. 10.1. Carry out measurements in accordance with the test log.

11. Remove engine compartment cover at the left. → 700219 REMOVING AND INSTALLING
FRONT COVER (ENGINE COMPARTMENT) .

12. Remove crash panel from the power electronics.

1. 12.1. Unscrew the three fastening screws -4- .

2. 12.2. Unscrew fastening nut -5- .

3. 12.3. Remove crash panel.

 Fig 6: Identifying Crash Panel For Power Electronics With Fastening Nut And Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

13. Release the high-voltage line -1- at the power electronics (rapid-action coupling) and unplug it
from the power electronics.
 Fig 7: Removing High-Voltage Lines From Power Electronics

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

14. Open the securing clip for the high-voltage line -2- .
 Fig 8: Opening Clip For High-Voltage Line

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

15. Release the high-voltage lines -2, 3- at the power electronics (rapid-action coupling) and
unplug them from the power electronics.

16. Plug in the high-voltage line -1- for the air-conditioning compressor at the power electronics
(rapid action coupling) until the connector engages securely.
 Fig 9: Plugging High-Voltage Line For Air-Conditioning Compressor At Power Electronics

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

17. Use the Hybrid test adapter VAS 6558/1 WE 1378 and the voltage tester WE 1380 to verify
the absence of electric charge at the power electronics.

1. 17.1. Set the tester to volts and carry out measurements in accordance with the test
log.

18. Document the measurements and values in the test log stored under Standard forms in the
PPN "Verifying absence of electric charge" and place it in the vehicle documents folder.

WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (CAYENNE S HYBRID) >
INFORMATION > STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM
 WARNING: High voltage at the high-voltage system on hybrid vehicles

Danger of electric shock from live parts

Risk of serious burns or death

Health risks for persons with medical devices/life-support systems.

→ Before working on the high-voltage electrical system and carrying out any repair work to the body, a
high-voltage technician must switch off the power to the system.

→ All work on vehicles with a high-voltage electrical system may only be carried out by electrically
instructed persons. The work must be done under the instruction of a high-voltage technician.

→ Observe general warning notes for working on the high-voltage electrical system. → 2X00IN
GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE ELECTRICAL SYSTEM

Information

The contact surfaces of the equipotential bonding lines must be checked prior to installation.

The contact surfaces must be clean and free of rust and grease.

Clean the contact surfaces using the contact surface cleaning set VAS 6410 if necessary.

1. A visual inspection must be carried out on all threaded connections on the high-voltage
components (battery, power electronics, electric motor and air-conditioning compressor).

Information

Always check the connections for the high-voltage lines and the connector holders before
plugging in the high-voltage lines.

1. If the plug contacts are deformed or damaged, stop working on the system and contact
Technical Support .

2. If the plug connections are deformed or damaged, stop working on the system and
contact Technical Support .

3. If the lines are deformed or damaged, stop working on the system and contact Technical
Support .

2. Check the outside of all high-voltage and electric potential lines for damage and check that the
connections are correct and that the lines are locked securely.

3. Release the high-voltage line -1- for the air-conditioning compressor at the power electronics
(rapid-action coupling) and unplug it.
 Fig 1: Removing High-Voltage Line For Air-Conditioning Compressor

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Plug the high-voltage lines -3, 2, 1- into the power electronics one after the other until the
connectors engage securely.
 Fig 2: Connecting High-Voltage Lines To Power Electronics

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Install crash panel on the power electronics.

1. 5.1. Fit the crash panel.

2. 5.2. Secure the crash panel with the three fastening screws -4- . → Tightening
torque: 9 Nm (6.5 ftlb.)

3. 5.3. Secure the crash panel with the fastening nut -5- . → Tightening torque: 9 Nm
(6.5 ftlb.)
 Fig 3: Identifying Crash Panel For Power Electronics Fastening Nut And Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Install engine compartment cover at the left. → 700219 REMOVING AND INSTALLING
FRONT COVER (ENGINE COMPARTMENT)

Information

Always check the connections for the high-voltage lines and the connector holders before
plugging in the high-voltage lines.

1. If the plug contacts are deformed or damaged, stop working on the system and contact
Technical Support .

2. If the plug connections are deformed or damaged, stop working on the system and
contact Technical Support .

3. If the lines are deformed or damaged, stop working on the system and contact Technical
Support .

7. At the high-voltage battery, plug in the high-voltage lines -1- until the connectors engage
securely.
 Fig 4: Installing High-Voltage Lines On Power Electronics

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Fit the lock for the two high-voltage lines -2- and secure them to the pilot line connector.

1. 8.1. Plug in the pilot line connector until it engages securely.

 Fig 5: Plugging Pilot Line Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9. Insert the service disconnector in the high-voltage battery.

 Fig 6: Installing Service Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10. Lock the service disconnector -1- and close it -2-

 Fig 7: Locking Service Disconnector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

11. Fit service disconnector cover on the high-voltage battery.

 Fig 8: Fitting Service Connector Cover

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

12. Read out the fault memory using PIWIS Tester II 9818 . If faults are present in the
high-voltage system, correct them according to the fault-finding strategy.

13. Create the test log under Standard forms in the PPN "Restarting high-voltage system" and
place it in the vehicle documents folder.

14. Proceed according to the current specifications in "Guided Fault Finding" and in the latest
Technical Information releases for special tasks to be performed after servicing and repairing
the Cayenne Hybrid.

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > TOOLS

Designation Type Number Description

Hybrid test adapter Workshop WE 1378

set equipment

Insulation tester Workshop WE 1379

equipment

High-voltage test Workshop WE 1585

adapter HVA 280 equipment
 High-voltage test Workshop WE 1586
adapter HVR 40 equipment

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > INFORMATION

ON INSULATION FAULT FINDING

The measurements must be performed using the insulation tester Insulation tester WE 1379 .

A measuring voltage of 500 V must be selected.

To obtain the required measuring resistance, the measuring voltage must be present on the
insulation tester for at least 1 second .

The tolerance range is +/- 10% .

Two measurements must always be performed for each measuring point. Positive terminal on
shielding and negative terminal on shielding.

A measurement is only regarded as being within the tolerance range if both measured values are
within the tolerance range.

The direction of measurement of the insulation tester does not affect the test result.

The measured values must be documented in the "Insulation fault finding test log". The test log is
stored under Standard forms in the PIWIS information system.

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > INFORMATION

ON INSULATION FAULT FINDING > OVERVIEW OF FAULT FINDING PROCEDURE
(FAULT SEARCH TREE)

Fault search tree

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > PRELIMINARY

WORK

1. Observe warning notes. → 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE
HIGH-VOLTAGE VEHICLE ELECTRICAL SYSTEM

2. Isolate the high-voltage system from the power supply and complete the relevant
documentation. → 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM
POWER SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM

3. Perform function test on test adapter. → 2X00IN FUNCTION TEST ON TEST ADAPTER

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > TAKING

MEASUREMENTS > PERFORMING MEASUREMENT 1

Preliminary work for measurement 1:

1. Remove luggage compartment cover. → 700619 REMOVING AND INSTALLING TRIM PANEL
FOR LUGGAGE COMPARTMENT (LUGGAGE COMPARTMENT COVER)

2. Release high-voltage connector HVR 40 from the high-voltage battery and disconnect it.
 Measurement 1.1:

Fig 1: Overview Of Luggage Compartment Cover (Measurement 1.1)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Connect high-voltage test adapter High-voltage test adapter HVR 40 WE 1586 to

high-voltage connector for the high-voltage charger -1- . Leave the second connection on the
test adapter open.
 Fig 2: Identifying High-Voltage Test Adapter Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Perform measurement 1.1.

1. 4.1. Setpoint value: > 550 MOhm

Measurement 1.2:
 Fig 3: Overview Of Luggage Compartment Cover (Measurement 1.2)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Connect high-voltage test adapter High-voltage test adapter HVR 40 WE 1586 to the
high-voltage battery -1- . Leave the second connection on the test adapter open.
 Fig 4: Identifying High-Voltage Test Adapter Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Perform measurement 1.2.

1. 6.1. Setpoint value: > 2.4 MOhm

7. Evaluate the test results .

1. 7.1. If the specified measured values from measurement 1.1 are not within the
tolerance range and the specified measured values from measurement 1.2 are within
the tolerance range, continue with measurement 2 .

2. 7.2. If the specified measured values from measurement 1.2 are not within the
tolerance range and the specified measured values from measurement 1.1 are within
the tolerance range, continue with measurement 6 .

3. 7.3. The measured values from both measurements are not within the tolerance
range.

1. 7.3.1. Repeat the measurements.

2. 7.3.2. Check measuring equipment and repeat the measurements.

3. 7.3.3. Follow both paths for measurement 1.1 and measurement 1.2.
 4. 7.3.4. Contact Technical Support.

4. 7.4. The measured values from both measurements are within the tolerance range.

1. 7.4.1. Insulation fault in high-voltage battery.

2. 7.4.2. Check the VAL again to determine whether an insulation fault is

present. If an insulation fault is indicated, carry out classification of the HV
battery and contact Technical Support.

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > TAKING

MEASUREMENTS > PERFORMING MEASUREMENTS 2

Preliminary work for measurement 2:

1. Remove side trim panel for rear luggage compartment at the left. → 700319 REMOVING AND
INSTALLING SIDE TRIM PANEL FOR REAR LUGGAGE COMPARTMENT

2. Release high-voltage connector for rear PTC from the high-voltage charger and disconnect it.

3. Release high-voltage connector for front PTC from the high-voltage charger and disconnect it.
Fig 1: Overview Of High-Voltage Connections On High-Voltage Charger

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. -1- = HV connection for rear PTC

2. -2- = HV connection for front PTC

3. -3- = HV connection for HV battery

4. -4- = HV connection for charging socket (3-phase)

Measurement 2.1:
 Fig 2: Overview Of Side Trim Panel For Rear Luggage Compartment (Measurement 2.1)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Connect high-voltage test adapter High-voltage test adapter HVR 40 WE 1586 to

high-voltage connector for the high-voltage charger -1- . Leave the second connection on the
test adapter open.
 Fig 3: Identifying High-Voltage Test Adapter Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Perform measurement 2.1.

1. 5.1. Setpoint value: > 550 MOhm

Measurement 2.2:
 Fig 4: Overview Of Side Trim Panel For Rear Luggage Compartment (Measurement 2.2)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to
high-voltage connector for rear PTC -1- . Leave the second connection on the test adapter
open.
 Fig 5: Identifying High-Voltage Test Adapter Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Perform measurement 2.2.

1. 7.1. Setpoint value: > 550 MOhm

 Fig 6: Overview Of Side Trim Panel For Rear Luggage Compartment (Measurement
2.3)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Measurement 2.3:

8. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to
high-voltage connector for front PTC -1- . Leave the second connection on the test adapter
open.
 Fig 7: Identifying High-Voltage Test Adapter Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9. Perform measurement 2.3.

1. 9.1. Setpoint value: > 550 MOhm

10. Evaluate the test results .

1. 10.1. If the specified measured values from measurement 2.1 are not within the
tolerance range and the specified measured values from measurement 2.2 and 2.3
are within the tolerance range, continue with measurement 3 .

2. 10.2. If the specified measured values from measurement 2.2 are not within the
tolerance range and the specified measured values from measurement 2.1 and 2.3
are within the tolerance range, continue with measurement 4 .

3. 10.3. If the specified measured values from measurement 2.3 are not within the
tolerance range and the specified measured values from measurement 2.1 and 2.2
are within the tolerance range, continue with measurement 5 .

4. 10.4. The measured values from two or all measurements are not within the
tolerance range.

1. 10.4.1. Repeat the measurements.

 2. 10.4.2. Check measuring equipment and repeat the measurements.

3. 10.4.3. Follow both paths for measurement 2.1, 2.2 and measurement 2.3.

4. 10.4.4. Contact Technical Support.

5. 10.5. The measured values from two or all measurements are within the tolerance
range.

1. 10.5.1. Repeat the measurements.

2. 10.5.2. Check measuring equipment and repeat the measurements.

3. 10.5.3. Contact Technical Support.

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > TAKING

MEASUREMENTS > PERFORMING MEASUREMENTS 3

Preliminary work for measurement 3:

1. Release high-voltage connector from high-voltage battery to high-voltage charger and

disconnect it
Fig 1: Overview Of High-Voltage Connections On High-Voltage Charger

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. -1- = HV connection for rear PTC

2. -2- = HV connection for front PTC

3. -3- = HV connection for HV battery

4. -4- = HV connection for charging socket (3-phase)

Measurement 3.1:
 Fig 2: Overview Of Side Trim Panel For Rear Luggage Compartment (Measurement 3.1)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Connect high-voltage test adapter High-voltage test adapter HVR 40 WE 1586 to

high-voltage connector for the high-voltage charger -1- . Leave the second connection on the
test adapter open.
 Fig 3: Identifying High-Voltage Test Adapter Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Perform measurement 3.1.

1. 3.1. Setpoint value: > 550 MOhm

Measurement 3.2:
 Fig 4: Overview Of Side Trim Panel For Rear Luggage Compartment (Measurement 3.2)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to
high-voltage charger for rear PTC -1- . Leave the second connection on the test adapter open.
 Fig 5: Identifying High-Voltage Test Adapter

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Perform measurement 3.2.

1. 5.1. Setpoint value: > 550 MOhm

6. Evaluate the test results .

1. 6.1. If the specified measured values from measurement 3.1 are not within the
tolerance range and the specified measured values from measurement 3.2 are within
the tolerance range:

1. 6.1.1. Insulation fault in high-voltage line from high-voltage charger to

high-voltage battery.

2. 6.1.2. Replace high-voltage line from high-voltage charger to high-voltage

battery following consultation with Technical Support. → 279319
REMOVING AND INSTALLING HIGH-VOLTAGE LINE BETWEEN
HIGH-VOLTAGE CHARGER AND HIGH-VOLTAGE BATTERY

2. 6.2. If the specified measured values from measurement 3.2 are not within the
tolerance range and the specified measured values from measurement 3.1 are within
the tolerance range:

1. 6.2.1. Insulation fault in high-voltage charger.

 2. 6.2.2. Replace high-voltage charger following consultation with Technical
Support. → Installing High-Voltage Charger

3. 6.3. The measured values from both measurements are not within the tolerance
range.

1. 6.3.1. Repeat the measurements.

2. 6.3.2. Check measuring equipment and repeat the measurements.

3. 6.3.3. Contact Technical Support.

4. 6.4. The measured values from both measurements are within the tolerance range.

1. 6.4.1. Repeat the measurements.

2. 6.4.2. Check measuring equipment and repeat the measurements.

3. 6.4.3. Contact Technical Support.

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > TAKING

MEASUREMENTS > PERFORMING MEASUREMENT 4

Preliminary work for measurement 4:

1. Release and disconnect high-voltage connector on rear PTC.

Measurement 4.1:

Fig 1: Performing Measurement Overview

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to
high-voltage connector for high-voltage line for rear PTC -1- . Leave the second connection on
 the test adapter open.
Fig 2: Identifying High-Voltage Test Adapter Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Perform measurement 4.1.

1. 3.1. Setpoint value: > 550 MOhm

Measurement 4.2:
 Fig 3: Overview Of Side Trim Panel For Rear Luggage Compartment (Measurement 4.2)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to the rear
PTC -1- . Leave the second connection on the test adapter open.
 Fig 4: Identifying High-Voltage Test Adapter Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Perform measurement 4.2.

1. 5.1. Setpoint value: > 550 MOhm

6. Evaluate the test results .

1. 6.1. If the specified measured values from measurement 4.1 are not within the
tolerance range and the specified measured values from measurement 4.2 are within
the tolerance range:

1. 6.1.1. Insulation fault in high-voltage line from high-voltage charger to rear

PTC.

2. 6.1.2. Replace high-voltage line from high-voltage charger to rear PTC

following consultation with Technical Support. → 279319 REMOVING AND
INSTALLING HIGH-VOLTAGE LINE FROM HIGH-VOLTAGE CHARGER
TO ELECTRIC HEATER FOR HIGH-VOLTAGE BATTERY (REAR PTC)

2. 6.2. If the specified measured values from measurement 4.2 are not within the
tolerance range and the specified measured values from measurement 4.1 are within
the tolerance range:

1. 6.2.1. Insulation fault in rear PTC.

 2. 6.2.2. Replace rear PTC following consultation with Technical Support. →
Installing Electric High-Voltage Battery Heater

3. 6.3. The measured values from both measurements are not within the tolerance
range.

1. 6.3.1. Repeat the measurements.

2. 6.3.2. Check measuring equipment and repeat the measurements.

3. 6.3.3. Contact Technical Support.

4. 6.4. The measured values from both measurements are within the tolerance range.

1. 6.4.1. Repeat the measurements.

2. 6.4.2. Check measuring equipment and repeat the measurements.

3. 6.4.3. Contact Technical Support.

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > TAKING

MEASUREMENTS > PERFORMING MEASUREMENT 5

Preliminary work for measurement 5:

1. Remove front wheel housing liner trim panel at the left. → 505619 REMOVING AND
INSTALLING FRONT WHEEL HOUSING LINER

2. Release and disconnect high-voltage connector on front PTC.

Measurement 5.1:

Fig 1: Overview Of Front Wheel Housing Liner Trim Panel - Left (Measurement 5.1)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to
high-voltage connector for high-voltage line for front PTC -1- . Leave the second connection
on the test adapter open.
Fig 2: Identifying High-Voltage Test Adapter Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Perform measurement 5.1.

1. 4.1. Setpoint value: > 550 MOhm

Measurement 5.2:
 Fig 3: Overview Of Front Wheel Housing Liner Trim Panel - Left (Measurement 5.2)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to the front
PTC -1- . Leave the second connection on the test adapter open.
 Fig 4: Identifying High-Voltage Test Adapter HVA 280 WE 1585 Second Connection

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Perform measurement 5.2.

1. 6.1. Setpoint value: > 550 MOhm

7. Evaluate the test results .

1. 7.1. If the specified measured values from measurement 5.1 are not within the
tolerance range and the specified measured values from measurement 5.2 are within
the tolerance range:

1. 7.1.1. Insulation fault in high-voltage line from high-voltage charger to front

PTC.

2. 7.1.2. Replace high-voltage line from high-voltage charger to front PTC

following consultation with Technical Support. → Installing High-Voltage
Line From Battery To Power Electronics

2. 7.2. If the specified measured values from measurement 5.2 are not within the
tolerance range and the specified measured values from measurement 5.1 are within
the tolerance range:

1. 7.2.1. Insulation fault in front PTC.

 2. 7.2.2. Replace front PTC following consultation with Technical Support. →
Installing Electric Passenger Compartment Heater

3. 7.3. The measured values from both measurements are not within the tolerance
range.

1. 7.3.1. Repeat the measurements.

2. 7.3.2. Check measuring equipment and repeat the measurements.

3. 7.3.3. Contact Technical Support.

4. 7.4. The measured values from both measurements are within the tolerance range.

1. 7.4.1. Repeat the measurements.

2. 7.4.2. Check measuring equipment and repeat the measurements.

3. 7.4.3. Contact Technical Support.

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > TAKING

MEASUREMENTS > PERFORMING MEASUREMENT 6

Preliminary work for measurement 6:

Fig 1: Overview Of High-Voltage Connections For Power Electronics

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

-1- = cable shoe on high-voltage line from PE to HV battery

-2- = 2 = HV connection from PE to air-conditioning compressor

-3- = 3-phase wiring to electric machine

1. Unscrew both high-voltage connectors for high-voltage line to power electronics from the
high-voltage battery and disconnect them. → 270819 REMOVING AND INSTALLING
HIGH-VOLTAGE BATTERY

2. Unscrew media shield from the power electronics unit. → 279119 REMOVING AND
INSTALLING POWER ELECTRONICS FOR HIGH-VOLTAGE SYSTEM

3. Release high-voltage connector from high-voltage air-conditioning compressor and disconnect

it. → 279119 REMOVING AND INSTALLING POWER ELECTRONICS FOR HIGH-VOLTAGE
SYSTEM

Measurement 6.1:

Fig 2: Overview Of Media Shield From Power Electronics Unit (Measurement 6.1)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to
high-voltage connector for high-voltage line for high-voltage air-conditioning compressor -1- .
Leave the second connection on the test adapter open.
 Fig 3: Identifying High-Voltage Test Adapter Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Perform measurement 6.1.

1. 5.1. Setpoint value: > 550 MOhm

Measurement 6.2:
 Fig 4: Overview Of Media Shield From Power Electronics Unit (Measurement 6.2)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to the power
electronics unit (high-voltage connection for air-conditioning compressor) -1- . Leave the
second connection on the test adapter open.
 Fig 5: Identifying High-Voltage Test Adapter Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Perform measurement 6.2.

1. 7.1. Setpoint value: 2.9 MOhm

8. Evaluate the test results .

1. 8.1. If the specified measured values from measurement 6.1 are not within the
tolerance range and the specified measured values from measurement 6.2 and 6.3
are within the tolerance range:

1. 8.1.1. Insulation fault in high-voltage battery.

2. 8.1.2. Replace high-voltage battery following consultation with Technical

Support. → 270855 REPLACING HIGH-VOLTAGE BATTERY

2. 8.2. If the specified measured values from measurement 6.2 are not within the
tolerance range and the specified measured values from measurement 6.1 and 6.3
are within the tolerance range, continue with measurement 7 .

3. 8.3. If the specified measured values from measurement 6.3 are not within the
tolerance range and the specified measured values from measurement 6.1 and 6.2
are within the tolerance range, continue with measurement 8 .
 4. 8.4. The measured values from two or all measurements are not within the
tolerance range.

1. 8.4.1. Repeat the measurements.

2. 8.4.2. Check measuring equipment and repeat the measurements.

3. 8.4.3. Follow both paths for measurement 6.2 and measurement 6.3.

4. 8.4.4. Contact Technical Support.

5. 8.5. The measured values from two or all measurements are within the tolerance
range.

1. 8.5.1. Repeat the measurements.

2. 8.5.2. Check measuring equipment and repeat the measurements.

3. 8.5.3. Contact Technical Support.

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > TAKING

MEASUREMENTS > PERFORMING MEASUREMENT 7

Preliminary work for measurement 7:

Fig 1: Overview Of High-Voltage Connections For Power Electronics

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

-1- = cable shoe on high-voltage line from PE to HV battery

-2- = 2 = HV connection from PE to air-conditioning compressor

-3- = 3-phase wiring to electric machine

1. Disconnect high-voltage line from high-voltage air-conditioning compressor. → 279319
REMOVING AND INSTALLING HIGH-VOLTAGE LINE FROM POWER ELECTRONICS TO
AIR-CONDITIONING COMPRESSOR

2. Remove front wheel housing liner trim panel at the left. → 505619 REMOVING AND
INSTALLING FRONT WHEEL HOUSING LINER

3. Remove front underbody panelling. → 108019 REMOVING AND INSTALLING ENGINE

GUARD

Measurement 7.1:

Fig 2: Overview Front Wheel Housing Liner Trim Panel (Measurement 7.1)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to
high-voltage connector for high-voltage line for high-voltage air-conditioning compressor.
Leave the second connection on the test adapter open.
 Fig 3: Identifying High-Voltage Test Adapter

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Perform measurement 6.2.

1. 5.1. Setpoint value: > 550 MOhm

Measurement 7.2:
 Fig 4: Overview Front Wheel Housing Liner Trim Panel (Measurement 7.2)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Connect high-voltage test adapter VAS 6558/1-3 from Hybrid test adapter set WE 1378 to
the high-voltage air-conditioning compressor.
 Fig 5: Identifying High-Voltage Test Adapter VAS 6558/1-3 Connector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Perform measurement 6.2.

1. 7.1. Setpoint value: > 550 MOhm

8. Evaluate the test results .

1. 8.1. If the specified measured values from measurement 7.1 are not within the
tolerance range and the specified measured values from measurement 7.2 are within
the tolerance range:

1. 8.1.1. Insulation fault in high-voltage line from power electronics to

air-conditioning compressor.

2. 8.1.2. Replace high-voltage line from power electronics to air-conditioning

compressor following consultation with Technical Support. → 279319
REMOVING AND INSTALLING HIGH-VOLTAGE LINE FROM POWER
ELECTRONICS TO AIR-CONDITIONING COMPRESSOR

2. 8.2. If the specified measured values from measurement 7.2 are not within the
tolerance range and the specified measured values from measurement 7.1 are within
the tolerance range:

1. 8.2.1. Insulation fault in high-voltage air-conditioning compressor.

 2. 8.2.2. Replace high-voltage air-conditioning compressor following
consultation with Technical Support. → Installing Electric Air-Conditioning
Compressor

3. 8.3. The measured values from both measurements are not within the tolerance
range.

1. 8.3.1. Repeat the measurements.

2. 8.3.2. Check measuring equipment and repeat the measurements.

3. 8.3.3. Contact Technical Support.

4. 8.4. The measured values from both measurements are within the tolerance range.

1. 8.4.1. Repeat the measurements.

2. 8.4.2. Check measuring equipment and repeat the measurements.

3. 8.4.3. Contact Technical Support.

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > TAKING

MEASUREMENTS > PERFORMING MEASUREMENT 8

Preliminary work for measurement 8:

Fig 1: Overview Of High-Voltage Connections For Power Electronics

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

-1- = cable shoe on high-voltage line from PE to HV battery

-2- = 2 = HV connection from PE to air-conditioning compressor

 -3- = 3-phase wiring to electric machine

1. Unscrew and remove both cable shoes for high-voltage line to the high-voltage battery from
the power electronics unit. → 279119 REMOVING AND INSTALLING POWER
ELECTRONICS FOR HIGH-VOLTAGE SYSTEM

Measurement 8.1:

Fig 2: Overview Front Wheel Housing Liner Trim Panel (Measurement 8.1)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Hold both measuring tips of the insulation tester WE 1379 at each terminal shoe -1- and at
the insulation -2- on both high-voltage lines from the power electronics to the high-voltage
battery.
 Fig 3: Measuring Insulation Resistance At Cable Shoes

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Perform measurement 8.1.

1. 3.1. Setpoint value of both lines: > 550 MOhm

Measurement 8.2:
 Fig 4: Overview Front Wheel Housing Liner Trim Panel (Measurement 8.2)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to the power
electronics unit (high-voltage connection for air-conditioning compressor). Leave the second
connection on the test adapter open.
 Fig 5: Identifying High-Voltage Test Adapter

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Perform measurement 8.2.

1. 5.1. Setpoint value: > 2.4 MOhm

6. Evaluate the test results .

1. 6.1. If the specified measured values from measurement 8.1 are not within the
tolerance range and the specified measured values from measurement 8.2 are within
the tolerance range:

1. 6.1.1. Insulation fault in high-voltage line from power electronics to

high-voltage battery.

2. 6.1.2. Replace high-voltage line from power electronics to high-voltage

battery following consultation with Technical Support. → Installing
High-Voltage Line From Battery To Power Electronics

2. 6.2. If the specified measured values from measurement 8.2 are not within the
tolerance range and the specified measured values from measurement 8.1 are within
the tolerance range, continue with measurement 8 .

3. 6.3. The measured values from both measurements are not within the tolerance
range.
 1. 6.3.1. Repeat the measurements.

2. 6.3.2. Check measuring equipment and repeat the measurements.

3. 6.3.3. Contact Technical Support.

4. 6.4. The measured values from both measurements are within the tolerance range.

1. 6.4.1. Repeat the measurements.

2. 6.4.2. Check measuring equipment and repeat the measurements.

3. 6.4.3. Contact Technical Support.

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > TAKING

MEASUREMENTS > PERFORMING MEASUREMENT 9

Preliminary work for measurement 9:

Fig 1: Overview Of High-Voltage Connections For Power Electronics

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

-1- = cable shoe on high-voltage line from PE to HV battery

-2- = 2 = HV connection from PE to air-conditioning compressor

-3- = 3-phase wiring to electric machine

1. Unscrew and remove 3-phase high-voltage line from power electronics unit. → 279119
REMOVING AND INSTALLING POWER ELECTRONICS FOR HIGH-VOLTAGE SYSTEM

Measurement 9.1:
 Fig 2: Overview Of Power Electronics Unit

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to the power
electronics unit. Leave the second connection on the test adapter open.
 Fig 3: Connecting High-Voltage Test Adapter HVA 280 WE 1585 To Power Electronics Unit

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Perform measurement 8.2.

1. 3.1. Setpoint value: > 2.4 MOhm

Measurement 9.2:
 Fig 4: Overview Of Power Electronics Unit (Measurement 9.2)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Hold both measuring tips of the insulation tester WE 1379 at one of the three terminal shoes
-1- and at the insulation -2- on the 3-phase high-voltage line.
 Fig 5: Measuring Insulation Resistance At Cable Shoes

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Perform measurement 9.2.

1. 5.1. Setpoint value: > 550 MOhm

6. Evaluate the test results .

1. 6.1. If the specified measured values from measurement 9.1 are not within the
tolerance range and the specified measured values from measurement 9.2 are within
the tolerance range:

1. 6.1.1. Insulation fault in power electronics.

2. 6.1.2. Replace power electronics following consultation with Technical

Support. → Installing Fuse For Power Electronics Unit

2. 6.2. If the specified measured values from measurement 9.2 are not within the
tolerance range and the specified measured values from measurement 9.1 are within
the tolerance range, continue with measurement 10 .

3. 6.3. The measured values from both measurements are not within the tolerance
range.

1. 6.3.1. Repeat the measurements.

 2. 6.3.2. Check measuring equipment and repeat the measurements.

3. 6.3.3. Contact Technical Support.

4. 6.4. The measured values from both measurements are within the tolerance range.

1. 6.4.1. Repeat the measurements.

2. 6.4.2. Check measuring equipment and repeat the measurements.

3. 6.4.3. Contact Technical Support.

WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > TAKING

MEASUREMENTS > PERFORMING MEASUREMENT 10

Preliminary work for measurement 10:

1. Remove engine and electric machine. → 100127 REMOVING ENGINE FROM

TRANSMISSION AND MOUNTING ENGINE ON TRANSMISSION

2. Disconnect 3-phase wiring from electric machine. → 279319 REMOVING AND INSTALLING
HIGH-VOLTAGE LINE FROM POWER ELECTRONICS TO ELECTRIC MOTOR

Measurement 10.1:

Fig 1: Overview Of Power Electronics To Electric Motor (Measurement 10.1)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Use insulation tester Insulation tester WE 1379 to test the insulation resistance at the
contacts of the electric machine (measurement 10.1).

1. 3.1. Setpoint value: >550 MOhm

Measurement 10.2:
 Fig 2: Overview Of Power Electronics To Electric Motor (Measurement 10.2)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Hold both measuring tips of the insulation tester WE 1379 at all three terminal shoes -1- and
at the insulation -2- on the 3-phase high-voltage line.
 Fig 3: Measuring Insulation Resistance At Cable Shoes

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Perform measurement 10.2.

1. 5.1. Setpoint value: > 550 MOhm

6. Evaluate the test results .

1. 6.1. If the specified measured values from measurement 10.1 are not within the
tolerance range and the specified measured values from measurement 10.2 are
within the tolerance range:

1. 6.1.1. Insulation fault in electric machine.

2. 6.1.2. Replace electric machine following consultation with Technical

Support. → 279019 REMOVING AND INSTALLING ELECTRIC MOTOR
WITH DECOUPLER (HYBRID MODULE)

2. 6.2. If the specified measured values from measurement 10.2 are not within the
tolerance range and the specified measured values from measurement 10.1 are
within the tolerance range:

1. 6.2.1. Insulation fault in 3-phase wiring from power electronics to electric

machine.
 2. 6.2.2. Replace 3-phase wiring from power electronics to electric machine
following consultation with Technical Support. → Installing High-Voltage
Line From Power Electronics To Electric Motor

3. 6.3. The measured values from both measurements are not within the tolerance
range.

1. 6.3.1. Repeat the measurements.

2. 6.3.2. Check measuring equipment and repeat the measurements.

3. 6.3.3. Contact Technical Support.

4. 6.4. The measured values from both measurements are within the tolerance range.

1. 6.4.1. Repeat the measurements.

2. 6.4.2. Check measuring equipment and repeat the measurements.

3. 6.4.3. Contact Technical Support.

WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (DIAGNOSTICS)
(CAYENNE S E-HYBRID) > TOOLS

Designation Type Number Description

PIWIS Tester II Special tool 9818

Locking device VW tool T40262

WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (DIAGNOSTICS)
(CAYENNE S E-HYBRID) > GENERAL WARNING NOTES

WARNING: High voltage at the high-voltage system on hybrid vehicles

Danger of electric shock from live parts

Risk of serious burns or death

Health risks for persons with life-support systems.

→ Before working on the high-voltage electrical system and carrying out any repair work to the body, a
high-voltage technician must switch off the power to the system.

→ All work on vehicles with a high-voltage vehicle electrical system must only be carried out by
electrically instructed persons (eip). The work must be done under the instruction of a high-voltage
technician (HVT).

→ Observe general warning notes for working on the high-voltage electrical system. → 2X00IN
GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE ELECTRICAL SYSTEM

Information

The procedure shown in the Workshop flow chart must be followed at all times. The Workshop flow
chart document is stored under Standard forms in the PPN.

Information

In the event of queries or uncertainty regarding the terms "Electrically instructed person (Eip)", "high-
voltage technician (HVT)", "high-voltage expert" or the hybrid system, please contact the relevant
importer before starting any work.

Information

Before starting to work on the high-voltage system, a high-voltage technician must isolate the
high-voltage system from the power supply.

The document → 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON HYBRID VEHICLES describes the various types of work for which the high-voltage system
must be isolated from the power supply.

The test log Verifying absence of electric charge and Restarting high-voltage system can be found
under Standard forms in the PPN.

Information

Please note the following when de-energising the high-voltage system:

The high-voltage system must only be isolated from the power supply by a correspondingly
qualified person (high-voltage technician (HVT)) .

The high-voltage technician ascertains that the system is de-energized and secures it to prevent
reactivation .
 The system is secured to prevent reactivation by getting the high-voltage technician to lock the
service disconnector .

The high-voltage technician identifies the vehicle as de-energized by attaching a corresponding

sign .

All work (e.g. maintenance, changing tires, comfort electrics) on vehicles with a high-voltage
system must only be carried out by an electrically instructed person (eip). The work must be done
under the instruction of a high-voltage technician (HVT) .

Before working on the high-voltage system and carrying out any repair work to the body, a
high-voltage technician must switch off the power to the system .

If the high-voltage system cannot be isolated from the power supply, do not continue working on
the system and contact Technical Support .

Persons with medical devices must not carry out any work on vehicles with a high-voltage system.
Medical devices include internal analgesic pumps, implanted defibrillators, pacemakers, insulin
pumps and hearing aids .

Information

Handling high-voltage cables:

Do not support yourself or your tools on high-voltage cables and their components .

Work involving metal-removing, deforming and sharp-edged tools in the vicinity of high-voltage
components and cables is prohibited .

Work involving heat sources such as welding, soldering, hot air and thermal bonding in the vicinity
of high-voltage components and cables is prohibited .

High-voltage cables must not be extensively bent or kinked .

In the event of queries or uncertainties, consult the relevant high-voltage technician .

WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (DIAGNOSTICS)
(CAYENNE S E-HYBRID) > ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM
POWER SUPPLY (DIAGNOSTICS)

Information

Having successfully verified that the system is isolated from the power supply, attach green HV warning
signs to the vehicle.

Information

The test logs Verifying absence of electric charge (e-hybrid) and Restarting high-voltage system
(e-hybrid) can be found under Standard forms in the PPN.

Information

If absence of electric charge could not be verified automatically or if the function could not be run (see
display in PIWIS Tester II 9818 ), the voltage must be measured manually. See 'ISOLATING
HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER SUPPLY (MANUAL) '.
1. PIWIS Tester II 9818 must be connected to the vehicle before starting the System Tester.

2. Select the vehicle type and start the diagnostic application.

3. Select Additional menu [F7].

4. Select High-voltage system in the Additional menu and press [F12].

5. Select the Isolate from power supply function and press [F12] to continue.

6. As soon as the relevant instruction appears on the Porsche System Tester, switch off ignition
(term. 15).

7. Follow the instructions on the Tester and read the information displayed.

8. When you are prompted to disconnect the 12 V service disconnector, open and secure the
connector as described below.

1. 8.1. Open luggage compartment lid and then open and remove the cover on the
luggage compartment trim at the right of the luggage compartment.
Fig 1: Removing Luggage Compartment Cover

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. 8.2. Release service disconnector -1- , press the locking hook back slightly and
open the service disconnector.
 Fig 2: Disconnecting Service Disconnector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. 8.3. Lock the service disconnector with a padlock Locking device T40262 and store
the key in a safe place until the system is restarted.
 Fig 3: Locking Service Disconnector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9. Continue to follow the instructions on the Tester and read the information displayed.

10. Document the results in the test log Verifying absence of electric charge in accordance with
the display on the Porsche System Tester:

1. 10.1. Voltage values of the high-voltage components

2. 10.2. Symbols displayed in the instrument cluster and on the Porsche System Tester

3. 10.3. Code displayed on the Tester

11. Once you have isolated the system from the power supply, place the signed test log Verifying
absence of electric charge in the vehicle documents folder and attach green high-voltage
warning signs to the vehicle.

Information

If absence of electric charge could not be verified automatically or if the function could not be
run (see display in PIWIS Tester II 9818 ), the voltage must be measured manually. See
'ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER SUPPLY (MANUAL) '.

WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (DIAGNOSTICS)
(CAYENNE S E-HYBRID) > STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM
 WARNING: High voltage at the high-voltage system on hybrid vehicles

Danger of electric shock from live parts

Risk of serious burns or death

Health risks for persons with life-support systems.

→ Before working on the high-voltage electrical system and carrying out any repair work to the body, a
high-voltage technician must switch off the power to the system.

→ All work on vehicles with a high-voltage electrical system may only be carried out by electrically
instructed persons. The work must be done under the instruction of a high-voltage technician.

→ Observe general warning notes for working on the high-voltage electrical system. → 2X00IN
GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE ELECTRICAL SYSTEM

Information

The test logs Verifying absence of electric charge (e-hybrid) and Restarting high-voltage system
(e-hybrid) can be found under Standard forms in the PPN.

Information

Always check the connections for the high-voltage lines and the connector holders before plugging in the
high-voltage lines.

If the plug contacts are deformed or damaged, stop working on the system and contact Technical
Support .

If the plug connections are deformed or damaged, stop working on the system and contact
Technical Support .

If the lines are deformed or damaged, stop working on the system and contact Technical Support
.

Information

The contact surfaces of the equipotential bonding lines must be checked prior to installation.

The contact surfaces must be clean and free of rust and grease.

Clean the contact surfaces using the contact surface cleaning set VAS 6410 if necessary.

1. Attach red HV warning sign to the vehicle

2. A visual inspection must be carried out on all threaded connections on the high-voltage
components (battery, power electronics, electric motor and air-conditioning compressor).
Always observe specified tightening torques.

3. Open and remove the padlock Locking device T40262 .

4. Release the service disconnector using a small screwdriver -a- , press the hook down slightly
and push it in -b- . Push service disconnector together -B- .
 Fig 1: Closing Service Disconnector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Close the cover on the luggage compartment trim at the right of the luggage compartment.

6. Park the locked vehicle and wait 10 minutes .

7. Read out the fault memory using PIWIS Tester II 9818 . If faults are present in the
high-voltage system, correct them according to the fault-finding strategy and then erase the
fault memory.

8. Create the test log Restarting high-voltage system (e-hybrid) and place it in the vehicle
documents folder.

WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (MANUAL) (CAYENNE S
E-HYBRID) > TOOLS

Designation Type Number Description

High-voltage Workshop WE 1585

test adapter equipment
HVA 280
 high-voltage Workshop WE 1586
test adapter equipment
HVR 40

PIWIS Tester II Special tool 9818

Locking device VW tool T40262

WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (MANUAL) (CAYENNE S
E-HYBRID) > GENERAL WARNING NOTES

WARNING: High voltage at the high-voltage system on hybrid vehicles

Danger of electric shock from live parts

Risk of serious burns or death

Health risks for persons with life-support systems.

→ Before working on the high-voltage electrical system and carrying out any repair work to the body, a
high-voltage technician must switch off the power to the system.

→ All work on vehicles with a high-voltage vehicle electrical system must only be carried out by
electrically instructed persons (eip). The work must be done under the instruction of a high-voltage
technician (HVT).

→ Observe general warning notes for working on the high-voltage electrical system. → 2X00IN
GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE ELECTRICAL SYSTEM
Information

The procedure shown in the Workshop flow chart must be followed at all times. The Workshop flow
chart document is stored under Standard forms in the PPN.

Information

In the event of queries or uncertainty regarding the terms "Electrically instructed person (Eip)", "high-
voltage technician (HVT)", "high-voltage expert" or the hybrid system, please contact the relevant
importer before starting any work.

Information

Before starting to work on the high-voltage system, a high-voltage technician must isolate the
high-voltage system from the power supply.

The document → 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON HYBRID VEHICLES describes the various types of work for which the high-voltage system
must be isolated from the power supply.

The test log Verifying absence of electric charge and Restarting high-voltage system can be found
under Standard forms in the PPN.

Information

Please note the following when de-energising the high-voltage system:

The high-voltage system must only be isolated from the power supply by a correspondingly
qualified person (high-voltage technician (HVT)) .

The high-voltage technician ascertains that the system is de-energized and secures it to prevent
reactivation .

The system is secured to prevent reactivation by getting the high-voltage technician to lock the
service disconnector .

The high-voltage technician identifies the vehicle as de-energized by attaching a corresponding

sign .

All work (e.g. maintenance, changing tires, comfort electrics) on vehicles with a high-voltage
system must only be carried out by an electrically instructed person (eip). The work must be done
under the instruction of a high-voltage technician (HVT) .

Before working on the high-voltage system and carrying out any repair work to the body, a
high-voltage technician must switch off the power to the system .

If the high-voltage system cannot be isolated from the power supply, do not continue working on
the system and contact Technical Support .

Persons with medical devices must not carry out any work on vehicles with a high-voltage system.
Medical devices include internal analgesic pumps, implanted defibrillators, pacemakers, insulin
pumps and hearing aids .

Information

Handling high-voltage cables:

 Do not support yourself or your tools on high-voltage cables and their components .

Work involving metal-removing, deforming and sharp-edged tools in the vicinity of high-voltage
components and cables is prohibited .

Work involving heat sources such as welding, soldering, hot air and thermal bonding in the vicinity
of high-voltage components and cables is prohibited .

High-voltage cables must not be extensively bent or kinked .

In the event of queries or uncertainties, consult the relevant high-voltage technician .

WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (MANUAL) (CAYENNE S
E-HYBRID) > ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER
SUPPLY (MANUAL)

Information

Isolation from power supply is only verified manually if isolation from power supply cannot be verified
automatically (see display in PIWIS Tester II 9818 ).

Information

Work for which the high-voltage system has to be isolated from the power supply:

All work on a hybrid vehicle must only be carried out by persons who are at least qualified as an
Eip (Electrically instructed person) .

When carrying out any work on a hybrid vehicle, the hybrid-specific components in the
activity/work area must be visually inspected .

The high-voltage cables must not be extensively bent or kinked .

Anything anomalous or unclear must be reported to the HVT (high-voltage technician) or HVE
(high-voltage expert) .

Working close to high-voltage components and high-voltage lines using cutting, deforming and
sharp-edged tools or heat sources, such as welding, soldering, hot air and thermal bonding, is
prohibited .

Information

The dummy connection on the high-voltage charger can be used as an alternative measuring point for
the high-voltage battery.

Information

Having successfully verified that the system is isolated from the power supply, attach green HV warning
signs to the vehicle.

→ 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE TASKS ON

HYBRID VEHICLES

1. Read out the fault memory using PIWIS Tester II 9818 .

2. The following work must only be carried out by a person who is at least trained and qualified as
a recognized high-voltage technician .

3. Switch off ignition (term. 15).

4. Open luggage compartment lid and then open and remove the cover on the luggage
compartment trim at the right of the luggage compartment.
Fig 1: Removing Luggage Compartment Cover

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Release service disconnector, press release hook back slightly and open service disconnector.
 Fig 2: Disconnecting Service Disconnector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Lock the service disconnector with a padlock Locking device T40262 and store the key in a
safe place until the system is restarted.
 Fig 3: Locking Service Disconnector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

When checking the system using high-voltage test adapter HVR 40 WE 1586 , make sure
not to damage the pins in the socket of the test adapter.

7. Perform function test on the high-voltage test adapter High-voltage test adapter HVA 280 WE
1585 or High-voltage test adapter HVR 40 WE 1586 in accordance with the test log for
verifying isolation from the power supply.→ 2X00IN FUNCTION TEST ON TEST ADAPTER

8. Use high-voltage test adapter HVR 40 WE 1586 and the voltage tester to measure the
voltage at the high-voltage battery.

1. 8.1. Release and disconnect high-voltage connector for high-voltage line to the
high-voltage charger at the high-voltage battery.

2. 8.2. High-voltage test adapter HVR 40 WE 1586 must be connected between the
high-voltage battery and high-voltage line to the high-voltage charger.

3. 8.3. Carry out measurements in accordance with the test log.

 Fig 4: Measuring Voltage At High-Voltage Battery

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9. High-voltage test adapter HVA 280 WE 1585 or high-voltage test adapter HVR 40 WE
1586 can now be disconnected.

10. Create test log Verifying absence of electric charge (e-hybrid) and place it in the vehicle
documents folder.

11. Attach green HV warning sign to the vehicle.

Information

The test logs Verifying absence of electric charge (e-hybrid) and Restarting high-voltage
system (e-hybrid) can be found under Standard forms in the PPN.
 Information

If the system could not be isolated from the power supply, do not continue working on the
system and contact Technical Support.

WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (MANUAL) (CAYENNE S
E-HYBRID) > STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM

WARNING: High voltage at the high-voltage system on hybrid vehicles

Danger of electric shock from live parts

Risk of serious burns or death

Health risks for persons with life-support systems.

→ Before working on the high-voltage electrical system and carrying out any repair work to the body, a
high-voltage technician must switch off the power to the system.

→ All work on vehicles with a high-voltage electrical system may only be carried out by electrically
instructed persons. The work must be done under the instruction of a high-voltage technician.

→ Observe general warning notes for working on the high-voltage electrical system. → 2X00IN
GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE ELECTRICAL SYSTEM

Information

Always check the connections for the high-voltage lines and the connector holders before plugging in the
high-voltage lines.

If the plug contacts are deformed or damaged, stop working on the system and contact Technical
Support .

If the plug connections are deformed or damaged, stop working on the system and contact
Technical Support .

If the lines are deformed or damaged, stop working on the system and contact Technical Support
.

Information

The contact surfaces of the equipotential bonding lines must be checked prior to installation.

The contact surfaces must be clean and free of rust and grease.

Clean the contact surfaces using the contact surface cleaning set VAS 6410 if necessary.

1. Attach red HV warning sign to the vehicle.

2. A visual inspection must be carried out on all threaded connections on the high-voltage
components (battery, power electronics, electric motor and air-conditioning compressor).
Always observe specified tightening torques.
3. At the high-voltage battery, connect HV line -1- and lock it.
Fig 1: Connecting HV Line To HV Charger

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Open and remove the padlock Locking device T40262 .

5. Release the service disconnector using a small screwdriver -a- , press the hook down slightly
and push it in -b- . Push service disconnector together -B- .
 Fig 2: Closing Service Disconnector

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Close the cover on the luggage compartment trim at the right of the luggage compartment.

7. Read out the fault memory using PIWIS Tester II 9818 . If faults are present in the
high-voltage system, correct them according to the fault-finding strategy.

8. Create the test log Restarting high-voltage system (e-hybrid) and place it in the vehicle
documents folder.

Information

The test logs Verifying absence of electric charge (e-hybrid) and Restarting high-voltage
system (e-hybrid) can be found under Standard forms in the PPN.

WM 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON E-HYBRID VEHICLES (CAYENNE S E-HYBRID) > TOOLS

Designation Type Number Description

Insulated tool set Workshop WE 1593

equipment

WM 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON E-HYBRID VEHICLES (CAYENNE S E-HYBRID) > ISOLATION FROM
SUPPLY PRIOR TO PERFORMING MAINTENANCE TASKS ON E-HYBRID VEHICLES

WARNING: High voltage

Danger of electric shock from live parts

Risk of serious burns or death

→ Work on the high-voltage battery may only be carried out by a high-voltage technician.

→ Always use insulated tools Insulated tool set WE 1593 when working on the high-voltage battery.

→ Observe general warning notes for working on the high-voltage vehicle electrical system.

→ 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE ELECTRICAL

SYSTEM

Information

Specific qualifications are required for carrying out the maintenance tasks listed here.

The minimum qualification of the person performing the task is shown in the table.

The table also shows whether or not the vehicle must be isolated from the power supply in order to
perform the task.

Only HVTs are permitted to isolate the high-voltage system from the power supply .

The eip is permitted to perform defined tasks according to instructions and under the supervision of
the HVT .

Work on high-voltage system components must only be performed following isolation of the
high-voltage system from the power supply by the HVT .

All work on high-voltage vehicles must only be performed by persons who are at least qualified as
an eip .

When performing each task on a high-voltage vehicle, the high-voltage components in the
task/work area must be inspected visually .

The high-voltage cables must not be extensively bent or kinked .

Anything anomalous or unclear must be reported to the HVT or the high voltage expert (HVE) .

All work specified here refers to the removal and installation or replacement of the individual
components .

For regular maintenance work, the high-voltage system does not need to be isolated from the
power supply .

Information

Definition of isolating HV system from power supply:

 Isolate system from power supply

Ensure that system cannot be switched back on again

Verify safe isolation from power supply

Information

Definition of minimum qualification:

Eip = Electrically instructed person

The eip may perform general work and maintenance tasks on a high-voltage vehicle as well as
mechanical work on the de-energized high-voltage system on instruction from the HVT .

HVT = High Voltage Technician

The high voltage technician's qualifications authorize him to do the same as an eip. The HVT is
additionally authorized to perform certified measurements to verify isolation of the high-voltage
system from the power supply. The HVT is authorized to do the following work on the isolated
high-voltage system .

Isolate system from power supply

Ensure that system cannot be switched back on again

Verify and document safe isolation from power supply

Delegate work on the isolated high-voltage system to the eip

Start the vehicle and complete the relevant documentation

HVE = High Voltage Expert

The HVE has additional knowledge to that of the HVT and is solely authorized to isolate the
high-voltage system in the vehicle from the power supply, in the event that the HVT is not able to
do this using the conventional tools and measurements .

If the authorization of the HVT to perform work on the high-voltage system is terminated, the HVE
must continue the work .

The task of the HVE is exclusively to deactivate the high-voltage system if this cannot be
performed using the conventional equipment or methods of the HVT .

→ 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE VEHICLE

ELECTRICAL SYSTEM

→ 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER SUPPLY/STARTING

HIGH-VOLTAGE ELECTRICAL SYSTEM

WM 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON E-HYBRID VEHICLES (CAYENNE S E-HYBRID) > ISOLATION FROM
SUPPLY PRIOR TO PERFORMING MAINTENANCE TASKS ON E-HYBRID VEHICLES >
WORKING ON THE HIGH-VOLTAGE SYSTEM
 When working on the following components: Minimum qualification:

Isolate high-voltage system from power supply HVT

Get the HVT to isolate the high-voltage system

When working on the following from the power supply before starting work? Minimum
components qualification:
Yes No

Electric machine with decoupler X (1)

Power electronics X HVT

12 V service disconnector X HVT

Removing and installing HV

X HVT
battery

Removing and installing control

X HVT
unit for HV battery

Cooling line inside HV battery X HVT

Cooling line outside of HV battery X Eip

Fuse for HV battery X HVT

Removing and installing E-box X HVT

(1)
High-voltage lines X

Charging socket X (1)

(1)
High-voltage charger X

Electric passenger compartment (1)

X
heater
(1)
Evaporator, HV valve block X

Electric HV battery heater X (1)

Front-axle carrier reinforcement X Eip

Electric air-conditioning (1)

X
compressor

Pressure regulator for decoupler X Eip

(1)
Decoupler (separating clutch) X

Pressure line for decoupler X Eip

Brake fluid for decoupler X Eip

Equipotential bonding lines X HVT

Work on the coolant system of the

X Eip
high-voltage components
Measurement at insulation
X HVT
resistors

Measurement at pilot line X HVT

Control unit for acoustic simulator X Eip

Acoustic simulator X Eip

(1) Eip1 A HVT must connect and disconnect the HV lines on the affected components.

WM 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON E-HYBRID VEHICLES (CAYENNE S E-HYBRID) > ISOLATION FROM
SUPPLY PRIOR TO PERFORMING MAINTENANCE TASKS ON E-HYBRID VEHICLES >
CONVENTIONAL WORK CLOSE TO HIGH-VOLTAGE COMPONENTS

Get the HVT to isolate the

high-voltage system from the
power supply before starting Minimum
When working on the following components
work? qualification

Yes No

Removing and installing design cover X Eip

Spark plugs X Eip

Left catalytic converter X Eip

Right catalytic converter X Eip

Exhaust system X Eip

Cardan shaft X Eip

Removing and installing engine with transmission X (1)

(1)
Removing and installing engine X

Removing and installing transmission X (1)

Additional pressure pump for transmission oil (12 V) X Eip

Fuel tank X Eip

Front unit carrier X Eip

Rear axle housing X Eip

Underbody panelling X Eip

Welding work (covering high-voltage components and

X Eip
then carrying out visual inspection)

Body repair work (using straightening bench) X Eip

Body repair work (assembly work and dent removal) X Eip

Working close to high-voltage components and
high-voltage lines using cutting, deforming and
X Eip
sharp-edged tools or heat sources, such as welding,
soldering, hot air and thermal bonding

Removing and installing left headlight X Eip

Removing and installing right headlight X Eip

Removing and installing headlight bulbs X Eip

(1) Eip1 A HVT must connect and disconnect the HV lines on the affected components.

WM 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON E-HYBRID VEHICLES (CAYENNE S E-HYBRID) > ISOLATION FROM
SUPPLY PRIOR TO PERFORMING MAINTENANCE TASKS ON E-HYBRID VEHICLES >
GENERAL WORK

Get the HVT to isolate the

high-voltage system from the
power supply before starting Minimum
When working on the following components:
work? qualification:

Yes No

Removing and installing 12 V battery X Eip

Removing and installing general control units and

X Eip
electric components (12 V)

Draining and filling fluids (coolant and oils) X Eip

Removing refrigerant by suction, evacuating and filling X Eip

A/C lines directly on the air-conditioning compressor X Eip

A/C lines in peripheral vehicle equipment (work that is

not carried out directly on the air-conditioning
X Eip
compressor, without opening the refrigerant circuit, e.g.
loosening and securing refrigerant lines).

Air conditioning performance test (for checking the

X Eip
pressure transmitter, using air conditioning service unit)

Work in the engine area for which the lines at the (1)
X
power electronics must be disconnected.

Work for which the engine must be raised (e.g.

X Eip
removing and installing engine mount).

Hydraulic pump for steering (12 V) X Eip

Electric vacuum pump (12 V) X Eip

Emissions inspection X Eip

(1) Eip1 A HVT must connect and disconnect the HV lines on the affected components.

WM 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON HYBRID VEHICLES (CAYENNE S HYBRID) > TOOLS

Designation Type Number Description

Hybrid test Workshop WE 1378

adapter VAS equipment
6558/1

Hybrid test Workshop WE 1446

adapter VAS equipment
6558/8

WM 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON HYBRID VEHICLES (CAYENNE S HYBRID) > ISOLATION FROM SUPPLY
PRIOR TO PERFORMING MAINTENANCE TASKS ON HYBRID VEHICLES

Information

Specific qualifications are required for carrying out the maintenance tasks listed here.

The qualification of the person performing the task is shown in the table.

The table also shows whether or not the vehicle must be isolated from the power supply in order to
perform the task.

Only HVTs are permitted to isolate the high-voltage system from the power supply .

The Eip is permitted to perform defined items of work according to instructions and under the
supervision of the HVT .
 Work on high-voltage components must only be performed following isolation of the high-voltage
system from the power supply by the HVT .

All work on high-voltage vehicles must only be performed by persons who are at least qualified as
Eips .

When performing each task on a high-voltage vehicle, the high-voltage components in the
task/work area must be inspected visually .

The high-voltage cables must not be extensively bent or kinked .

Anything anomalous or unclear must be reported to the HVT or the high-voltage expert (HVE) .

All work specified here refers to the removal and installation or replacement of the individual
components .

For regular maintenance work, the high-voltage system does not need to be isolated from the
power supply .

Information

Definition of isolating the HV system from the power supply applies to isolating the system from
the power supply at the high-voltage battery (rear) and power electronics (front)

Isolate from power supply

Ensure that system cannot be switched back on again

Verify safe isolation from power supply

Information

Definition of minimum qualification:

Eip = Electrically instructed person

The Eip may perform general work and maintenance tasks on a high-voltage vehicle as well as
mechanical work on the isolated high-voltage system on instruction from the HVT .

HVT = High-voltage technician

The high-voltage technician's qualifications authorise him to do the same as an Eip. The HVT is
additionally authorized to perform certified measurements to verify isolation of the high-voltage
system from the power supply. The HVT is authorized to do the following work on the isolated
high-voltage system .

Isolate from power supply

Ensure that system cannot be switched back on again

Verify and document safe isolation from power supply

Delegate work on the isolated high-voltage system to the Eip

Start the vehicle and complete the relevant documentation

HVE = High-voltage expert

 The HVE has additional knowledge to that of the HVT and is solely authorized to isolate the
high-voltage system in the vehicle from the power supply, in the event that the HVT is not able to
do this using the conventional tools and measurements .

If the authorization of the HVT to perform work on the high-voltage system is terminated, the HVE
must continue the work .

The task of the HVE is exclusively to isolate the high-voltage system from the power supply, if this
cannot be performed using the conventional equipment or methods of the HVT .

→ 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE ELECTRICAL

SYSTEM

→ 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER SUPPLY/STARTING

HIGH-VOLTAGE ELECTRICAL SYSTEM

WM 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON HYBRID VEHICLES (CAYENNE S HYBRID) > ISOLATION FROM SUPPLY
PRIOR TO PERFORMING MAINTENANCE TASKS ON HYBRID VEHICLES > WORK ON
THE HIGH-VOLTAGE SYSTEM

When working on the following components: Minimum qualification:

Isolate the high-voltage system from the power HVT

supply

Is the high-voltage system isolated from the

power supply by the HVT before starting
When working on the following Minimum
work?
components qualification:
Yes No

Electric machine with decoupler (2) Eip

(2)
Power electronics Eip

Service disconnector X HVT

Rear pilot line connector X HVT

Front pilot line connector X HVT

High-voltage line from power

(2)
electronics to air-conditioning Eip
compressor

High-voltage line from power (2)

Eip
electronics to electric machine

High-voltage line from hybrid battery (2) Eip

to power electronics

Removing and installing high-voltage (1)

Eip
battery

Charging high-voltage battery X HVT

 (1)
High-voltage battery control unit HVT

Fan on high-voltage battery (1) Eip

Air extraction duct on high-voltage (1) Eip

battery

Air supply for the high-voltage battery

X Eip
fans
(2)
Electric air-conditioner compressor Eip

Pressure regulator for decoupler X Eip

(2)
Decoupler Eip

Pressure line for decoupler X Eip

Brake fluid for decoupler X Eip

Equipotential bonding lines X Eip

Work on the coolant system of the

X Eip
high-voltage components

Measurement at insulation resistors (2) HVT

(1) X1 Use measuring box Hybrid test adapter VAS 6558/1 WE 1378 to take measurements at the
high-voltage battery and measuring box Hybrid test adapter VAS 6558/8 WE 1446 to take
measurements on the high-voltage lines with power electronics.
(2)
X2 Use measuring box Hybrid test adapter VAS 6558/1 WE 1378 to take measurements at the
high-voltage battery and then at the front at the power electronics.

WM 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON HYBRID VEHICLES (CAYENNE S HYBRID) > ISOLATION FROM SUPPLY
PRIOR TO PERFORMING MAINTENANCE TASKS ON HYBRID VEHICLES >
CONVENTIONAL WORK IN THE VICINITY OF HIGH-VOLTAGE COMPONENTS

Is the high-voltage system

isolated from the power supply
by the HVT before starting Minimum
When working on the following components
work? qualification

Yes No

Removing and installing design cover X Eip

Spark plugs X Eip

(1)
Left catalytic converter Eip

Right catalytic converter X Eip

Exhaust system X Eip

Cardan shaft X Eip

 (2)
Removing and installing engine with transmission Eip

Removing and installing engine (2) Eip

(2)
Removing and installing transmission Eip

Auxiliary hydraulic pump for transmission oil (12 V) X Eip

Transfer gear X Eip

Fuel tank X Eip

Front unit carrier X Eip

Rear axle housing X Eip

Underbody panelling X Eip

Welding work (covering high-voltage components and

X Eip
then carrying out visual inspection)
(2)
Body repair work (using straightening bench) Eip

Body repair work (assembly work and dent removal) X Eip

Working close to high-voltage components and

high-voltage lines using cutting, deforming and (1) Eip
sharp-edged tools or heat sources, such as welding,
soldering, hot air and thermal bonding

Removing and installing left and right headlights X Eip

Removing and installing headlight bulbs X Eip

(1)
X1 Use measuring box Hybrid test adapter VAS 6558/1 WE 1378 to take measurements at the
high-voltage battery and measuring box Hybrid test adapter VAS 6558/8 WE 1446 to take
measurements on the high-voltage lines with power electronics.
(2)
X2 Use measuring box Hybrid test adapter VAS 6558/1 WE 1378 to take measurements at the
high-voltage battery and then at the front at the power electronics.

WM 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON HYBRID VEHICLES (CAYENNE S HYBRID) > ISOLATION FROM SUPPLY
PRIOR TO PERFORMING MAINTENANCE TASKS ON HYBRID VEHICLES > GENERAL
WORK

Is the high-voltage system

isolated from the power
supply by the HVT before Minimum
When working on the following components:
starting work? qualification:

Yes No

Removing and installing 12 volt battery X Eip

Removing and installing general control units and

X Eip
electric battery (12 V)
Draining and filling fluids (coolant and oils) X Eip

Removing refrigerant by suction, evacuating and filling (1) Eip

(2)
Refrigerant line directly on air-conditioning compressor Eip

Air conditioning performance test (for checking the

pressure transmitter, using air conditioning service X Eip
unit)

Refrigerant line in peripheral vehicle equipment (work

that is not directly on the air-conditioning compressor,
X Eip
without opening the refrigerant circuit, e.g. loosening
and securing refrigerant lines).

Work in the engine/chassis area for which the cover

X Eip
plate on the power electronics must be removed.

Work in the engine area for which the cover plate must
(2)
be removed and lines must be disconnected at the HVT
power electronics.

Work for which the engine is raised by up to approx. (1)

Eip
20 cm (e.g. engine mountings).

Hydraulic pump for steering (12 V) X Eip

Electric vacuum pump (12 V) X Eip

Emissions inspection X Eip

(1)
X1 Use measuring box Hybrid test adapter VAS 6558/1 WE 1378 to take measurements at the
high-voltage battery and measuring box Hybrid test adapter VAS 6558/8 WE 1446 to take
measurements on the high-voltage lines with power electronics.
(2)
X2 Use measuring box Hybrid test adapter VAS 6558/1 WE 1378 to take measurements at the
high-voltage battery and then at the front at the power electronics.

WM 2X00IN BATTERY TRICKLE CHARGING (EXCEPT CAYENNE, CAYENNE GTS,

CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO,
CAYENNE (3.0), CAYENNE TIP (3.0)) > INFORMATION > BATTERY TRICKLE
CHARGING

Information

When working or carrying out tests on the vehicle or when the vehicle is in the workshop, a battery
charger with a rated current of at least 40 A must be connected .

As soon as the vehicle is unlocked, e.g. the vehicle is in the workshop or salesroom, it must be
trickle charged with a battery charging device .

NOTE: Using charging cables/jump leads directly on the vehicle battery.

Risk of damage to battery sensors.

→ Always connect charging cables/jump leads to the external power supply for jump-lead starting.

1. Open protective cover on the positive terminal for jump-lead starting -+- (-arrow- ).
Fig 1: Opening Protective Cover On Positive Terminal For Jump-Lead Starting

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. First, connect the positive cable from the charger to the positive terminal -+- .

3. Then connect the negative cable from the charger to the ground point for jump-lead starting - .

4. Read operating instructions for the charger.

 5. Switch off all loads.

6. Switch on the charger.

WM 2X00IN BATTERY TRICKLE CHARGING (EXCEPT CAYENNE, CAYENNE GTS,

CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO,
CAYENNE (3.0), CAYENNE TIP (3.0)) > INFORMATION > CONNECTING THE BATTERY
FOR TRICKLE CHARGING

A suitable battery charger must be connected to the vehicle electrical system when performing
the following tasks. All unnecessary electrical loads must be switched off .

When working on the vehicle for more than 15 minutes

When running a diagnosis using the Porsche System Tester

When adjusting the headlights

When working on or with the Infotainment system

If the doors, bonnet and rear lid are open for a long period of time or if these components are actuated
frequently

WM 2X00IN RULES RELATING TO CLEANLINESS AND INSTRUCTIONS FOR

WORKING ON THE FUEL SYSTEM (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE
TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) >
INFORMATION > RULES RELATING TO CLEANLINESS AND INSTRUCTIONS FOR
WORKING ON THE FUEL SYSTEM

WARNING: Highly inflammable or explosive materials

Danger of fire or explosion

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapors.

→ Attach warning sign in a clearly visible position.

WARNING: Caustic fluids

Danger of chemical burns

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if
necessary.

WARNING: Hot fuel and hot fuel lines.

Danger of scalding

→ Allow the fuel to cool down before opening line connections.

→ Wear protective gloves.

→ Wear protective goggles.

The work area and tools must be cleaned before working on the injection system.

Thoroughly clean connection points and adjacent areas before loosening them using engine or
brake cleaner and dry the cleaned area thoroughly.

During disassembly work, close off all open connections immediately using suitable clean
protection caps.

Do not remove the protection caps from any components until immediately before installation.
Pack components to be used again in new, sealable plastic bags.

Check the injection units and installation positions before installation by performing a visual
inspection for damage and soiling. Check that the injection unit stem is clean. If necessary, clean
the stem using a clean cloth, making sure not to damage it (no sharp tools!).

If the high-pressure lines will not be replaced, always mark the high-pressure lines during removal.
The high-pressure lines must only be re-fitted on the same cylinder.

Make sure not to damage the injection unit when removing the old sealing ring.

Check all new O-rings for signs of damage before fitting them. Coat O-rings with assembly oil or
engine oil before fitting them.

Align high-pressure lines without tension. Tighten all connections hand-tight at first and then
tighten to the specified torque.

High-pressure lines must never be re-bent.

A tool can only be used to loosen and tighten lines on the entire high-pressure system. All other
assembly and disassembly processes must be carried out by hand and without tools.

Press fuel return hoses onto the injection units from above using your hand until they lock on each
injection unit with an audible click (do not press in the release pin while doing this). Then press the
release pin down. Check that the fuel return hoses are seated securely by pulling them upwards
with your hand and check for leaks.

Individual common rail components cannot be disassembled. All the components must be replaced
in the event of a fault.

No assembly work must be carried out on the common rail system when the engine is running.

The common rail system must not be bled by loosening high-pressure components after starting
 the engine.

Fit all tie-wraps, which you removed or cut during removal, back at the same position during
installation.

When the fuel system is open: Never use compressed air if at all possible. Do not move the vehicle
if possible.

Also make sure that no diesel gets onto the coolant hoses. The hoses must be cleaned
immediately if necessary. Always replace worn hoses.

To avoid letting the high-pressure pump run dry and to start the engine quickly after replacing
parts, the following points must always be observed:

CAUTION: Danger of irreparable damage to the high-pressure pump if it runs dry

To avoid letting the fuel high-pressure pump run dry and to start the engine quickly after replacing
parts, the following points must always be observed:

If parts/components of the fuel system between the fuel tank and fuel high-pressure pump are
removed or replaced, the basic setting must be performed in order to bleed the fuel system.

Perform initial fuel fill procedure after installing the high-pressure pump.

WM 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > DISCONNECTING THE BATTERY

WARNING: Static battery charge

Battery can explode

Electrical discharges

→ Do not rub the battery with a dry cloth.

Information

Switch off all loads and remove the ignition key.

Do not disconnect the battery while the engine is running .

Disconnect and reconnect battery with extreme caution .

Do not rub the battery with a dry cloth .

Information

The battery is located under the driver's seat.

1. Detach and fold over carpet in front of the driver's seat. → 704119 REMOVING AND
INSTALLING CARPET
 2. Screw off ground strap at the ground point in front of the driver's seat:

3. Risk of short circuit! Screw off the ground strap -2- at the ground point -1- under the driver's
seat in front of the battery box.
Fig 1: Identifying Ground Point

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Route or isolate the ground strap -2- so that all contact with a ground carrier (e.g. body,
battery terminal) is avoided.

WM 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > DISCONNECTING THE BATTERY >
CONNECTING THE BATTERY

1. Connect the battery

1. 1.1. Connect the ground strap -2- to the ground point -1- on the body in front of the
driver's seat and secure with the fastening nut.
 Fig 1: Identifying Ground Point

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Re-lay the carpet.

Effect of disconnection or total discharge of battery on electrical systems in the vehicle and the
precautions to be taken

Information

Control unit memories

Values and faults stored in the control units can be deleted if the battery is disconnected or completely
discharged.

If possible, all fault memories should be checked and, if necessary, printed out before the battery is
disconnected .

Information

Supply voltage fault entry

The entry "supply voltage" may be stored in various control units if the battery has been completely
discharged.

Delete the "supply voltage" entry from the control units in question .

Information
Ready status

In some countries (presently the U.S.A. and Canada), after disconnecting the battery, it is necessary to
reach the Ready status by a test drive and/or by using the Porsche System Tester DME control module
menu). If in doubt about this, contact the relevant importer.

Information

2470 DME control module

With all DME systems, the engine must run for several minutes before the engine control module can
relearn the idle speed and mixture adaptation values!

After disconnection of the power supply, the idle speed might change or fluctuate briefly until the throttle
valve adjusting unit has been readapted.

The mixture adaptation is also lost.

After the battery is connected:

With the DME, it is necessary to carry out a learning and adaptation routine as described below:

Switch ignition on for 30 seconds without starting the engine .

Do not actuate accelerator pedal .

This completes the adaptation of the throttle valve adjusting unit.

Information

Tyre pressure monitoring system

When the battery is disconnected and connected, the tire pressure is first displayed as "- - - ".

Once the battery has been disconnected and work is complete, the vehicle must be driven for a
short distance .

The actual pressures will then be displayed again.

Information

4560 Steering angle sensor

The steering angle sensor must be re-initialised when the battery is disconnected and connected.

Turn wheels to straight-ahead position .

Switch ignition off and then on again twice .

Start engine .

From the straight-ahead position, turn steering wheel approx. 20° to the right, past the
straight-ahead position .

Drive the vehicle straight ahead for at least one second at a speed above 4 km/h (2.5 mph) .

The steering angle sensor segment is recognized again in this process.

Once the sensor has been successfully initialized, the fault code that is stored in the fault memory is
documented using the fault deletion counter.

The fault memory erases itself automatically.

The PSM indicator light in the instrument cluster goes out.

Information

6014 Motor for sunroof

The limit positions of the sunroof are deleted from the control unit when the battery is disconnected and
connected.

Switch on ignition .

Press the sunroof button for several seconds in direction of travel .

After approx. 10 seconds, the sunroof performs an automatic standardization process and resets
all positions .

Keep the button pressed during the standardization process .

Afterwards, the sunroof is standardized correctly.

Information

6452 Power windows

The limit positions of the power windows are deleted from the control unit when the battery is
disconnected and connected.

Perform the following procedure for all power windows:

Pull rocker switch and fully close window once .

Pull rocker switch once more .

The upper end position of the window is stored.

Press rocker switch and fully open window once .

Press rocker switch once more .

The lower end position of the window is stored.

Information

4815 Electrical steering column adjustment (ELVS)

The electrical steering column adjustment end positions (ELVS) are deleted when the battery is
disconnected and connected.

The following buttons must be pressed in sequence in order to reinitializes electrical steering column
adjustment.

Press the extend button three times (extend towards the driver) .

Press the retract button once .

 Press the extend button once (towards the driver) .

Press the up button once .

Press the down button once .

Once the buttons have been pressed correctly, the steering column automatically moves all axles and
stops at the center position (only works when the vehicle is stationary).

1. Carry out a test drive after connecting the battery.

WM 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > DISCONNECTING THE BATTERY >
TEST DRIVE AFTER CONNECTING BATTERY

Information

Depending on the vehicle equipment fitted, all these work steps are carried out during the test drive.

Read out the fault memories of all control units after the test drive.

If there is a fault present, check to see if the fault was caused by an undervoltage .

If faults were caused by an undervoltage (or CAN timeout error), erase the fault memory, perform
another test drive and read out the fault memory .

If faults were not caused by an undervoltage, correct the faults in accordance with GFF (Guided
Fault Finding) .

1. Check function of electric components.

WM 2X00IN IMPORTANT INFORMATION ON ADAPTING THE DME CONTROL UNIT

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) >
INFORMATION

Information

1. Adaptation values are deleted or stored in EEPROM when ignition is switched off after control
unit run-on has ended.

(Run-on period: 1 minute when engine is cold; up to 45 minutes when engine is hot)

Information

2. The following adaptations will be deleted automatically when you erase the fault memory (see
information under 1)):

1. Mixture adaptation

2. Lambda adaptation

3. Camshaft adaptation
 4. Knock adaptation

5. Map-controlled thermostat adaptation

WM 2X00IN IMPORTANT INFORMATION ON ADAPTING THE DME CONTROL UNIT

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) > DELETING
ADAPTATION VALUES > ALL ADAPTATIONS

Necessary after:

Replacing engine.

How?

1. PIWIS Tester:

1. 1.1. Meet preconditions:

1. 1.1.1. Engine off

2. 1.1.2. Ignition on

3. 1.1.3. Engine cold

2. 1.2. Select menu:

1. 1.2.1. DME

2. 1.2.2. Programming

3. 1.2.3. Automatic programming

3. 1.3. Start function by pressing [F8].

Information

The RBM data is also deleted here.

WM 2X00IN IMPORTANT INFORMATION ON ADAPTING THE DME CONTROL UNIT

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) > DELETING
ADAPTATION VALUES > FUEL HIGH-PRESSURE ADAPTATION

Necessary after:

Replacing high-pressure pump

All work that must be carried out as a result of high-pressure faults, e.g. electric fuel pump, control
unit for electric fuel pump, etc.

WM 2X00IN IMPORTANT INFORMATION ON ADAPTING THE DME CONTROL UNIT

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) > DELETING
ADAPTATION VALUES > OIL PUMP ADAPTATION

Necessary after:

Replacing oil pump

Replacing oil pressure control valve

WM 2X00IN IMPORTANT INFORMATION ON ADAPTING THE DME CONTROL UNIT

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) > DELETING
ADAPTATION VALUES > MIXTURE ADAPTATION AND LAMBDA ADAPTATION

Necessary after:

Replacing high-pressure injectors

Correcting faults during load detection, mixture control, emissions measurement

WM 2X00IN IMPORTANT INFORMATION ON ADAPTING THE DME CONTROL UNIT

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) > DELETING
ADAPTATION VALUES > INTAKE MANIFOLD PRESSURE SENSOR ADAPTATION

Necessary after:

Replacing intake manifold pressure sensor

Replacing boost pressure sensor (Turbo only)

WM 2X00IN IMPORTANT INFORMATION ON ADAPTING THE DME CONTROL UNIT

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) > DELETING
ADAPTATION VALUES > BOOST PRESSURE CONTROL ADAPTATION (TURBO
ONLY)

Necessary after:

Replacing turbocharger

Correcting faults in boost pressure control system

How?

1. PIWIS Tester:

1. 1.1. Meet preconditions:

1. 1.1.1. Engine off

2. 1.1.2. Ignition on

3. 1.1.3. Engine cold

 2. 1.2. Select menu:

1. 1.2.1. DME

2. 1.2.2. Maintenance/repairs

3. 1.2.3. Delete adaptation values

3. 1.3. Press [F12] to continue.

1. 1.3.1. Information on deleting adaptation values.

4. 1.4. Press [F8] to confirm.

1. 1.4.1. Submenu of adaptation ranges.

5. 1.5. Select adaptation range and press [F12] to continue.

Information

1. Adaptation values are deleted or stored in EEPROM when ignition is

switched off after control unit run-on has ended.

(Run-on period: 1 minute when engine is cold; up to 45 minutes when engine is hot)

6. 1.6. Switch off ignition.

7. 1.7. Adapt throttle valve (see below).

WM 2X00IN IMPORTANT INFORMATION ON ADAPTING THE DME CONTROL UNIT

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) > WRITING
ADAPTATION VALUES (FOLLOWING DELETION) > SENSOR WHEEL ADAPTATION

Necessary after:

Re-programming DME control unit

Replacing DME control unit

Necessary before:

Misfire diagnostics

How?

1. Drive with engine overrun:

1. 1.1. Meet preconditions:

1. 1.1.1. Engine at operating temperature.

2. 1.2. Accelerate to 3, 000 rpm (U /Min ) three times in quick succession in 2nd gear and
allow vehicle to roll with gear engaged (engine overrun).

Information
 1. Adaptation values are deleted or stored in EEPROM when ignition is
switched off after control unit run-on has ended.

(Run-on period: 1 minute when engine is cold; up to 45 minutes when engine is hot)

3. 1.3. Switch off ignition.

WM 2X00IN IMPORTANT INFORMATION ON ADAPTING THE DME CONTROL UNIT

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) >
OVERWRITING ADAPTATION VALUES (WITHOUT DELETION) > THROTTLE VALVE

Necessary after:

Re-programming DME control unit

Replacing DME control unit

Replacing throttle valve

Information

Consequences of Tester adaptation if conditions for automatic adaptation are not met (violated boundary
conditions):

For a fault entry in the load detection range (P0068 + P1069... P1077), the limits are extended in
order to prevent incorrect detections .

This extension is cancelled if an adaptation is performed when the conditions for automatic
adaptation are met, or after 15 warm-up cycles at the latest .

(Warm-up cycle = coolant temperature increases by more than 23 °C after start-up and reaches at
least 73 °C)

Following manual throttle valve adaptation when ambient conditions are not met, throttle valve
adaptation is carried out again automatically as soon as the ambient conditions are met .

There is NO 30-second waiting time here, but a slightly delayed engine start is possible once .

The ambient conditions for automatic adaptation are as follows:

Engine off and ignition on for > 30 seconds

Accelerator pedal not pressed

Vehicle is stationary

Power supply for throttle valve adjusting unit is OK

Coolant temperature 5 °C... 100 °C

Intake air temperature 5 °C... 40 °C

How?

1. Ignition on > 30 seconds if preconditions are met.

 or

PIWIS Tester:

1. 1.1. Meet preconditions:

1. 1.1.1. Engine off.

2. 1.1.2. Ignition on.

2. 1.2. Select menu:

1. 1.2.1. DME

2. 1.2.2. Maintenance/repairs

3. 1.2.3. Adaptations

4. 1.2.4. Throttle valve adaptation

3. 1.3. Start function by pressing [F12].

1. 1.3.1. Information.

4. 1.4. Press [F12] for detail view.

Information

1. Adaptation values are deleted or stored in EEPROM when ignition is

switched off after control unit run-on has ended.

(Run-on period: 1 minute when engine is cold; up to 45 minutes when engine is hot)

5. 1.5. Switch off ignition.

WM 2X00IN IMPORTANT INFORMATION ON ADAPTING THE DME CONTROL UNIT

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) >
OVERWRITING ADAPTATION VALUES (WITHOUT DELETION) > KICKDOWN
ACCELERATOR PEDAL MODULE (CAYENNE TIPTRONIC ONLY)

Necessary after:

Re-programming DME control unit

Replacing DME control unit

Replacing accelerator pedal module

How?

1. PIWIS Tester:

1. 1.1. Meet preconditions:

1. 1.1.1. Engine off.

 2. 1.1.2. Ignition on.

2. 1.2. Select menu:

1. 1.2.1. DME

2. 1.2.2. Maintenance/repairs

3. 1.2.3. Adaptations

4. 1.2.4. Kickdown adaptation

3. 1.3. Start function by pressing [F12].

4. 1.4. Press accelerator pedal fully and release it again after 30 seconds.

Information

1. Adaptation values are deleted or stored in EEPROM when ignition is

switched off after control unit run-on has ended.

(Run-on period: 1 minute when engine is cold; up to 45 minutes when engine is hot)

5. 1.5. Switch off ignition.

WM 2X00IN IMPORTANT INFORMATION ON ADAPTING THE DME CONTROL UNIT

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) > TORQUE
LOSS > ONLY NECESSARY FOR VEHICLES WITH PDK

Necessary after:

Re-programming DME control unit

Replacing DME control unit

Re-programming PDK control unit

Necessary before:

Re-calibrating PDK

Information

The accelerator pedal must always be pressed after approx. 1.5 minutes since each adaptation step is
limited to 5 Nm.

How?

1. Engine idling:

1. 1.1. Meet preconditions:

1. 1.1.1. Engine at operating temperature.

2. 1.2. Engine idling for 3 minutes without activating loads, press accelerator pedal
once after approx. 1.5 minutes during this time.
3. 1.3. Engine idling for 3 minutes with air conditioning switched on, press accelerator
pedal once after approx. 1.5 minutes during this time.

4. 1.4. Engine idling for 3 minutes with air conditioning switched on and transmission
range engaged, press accelerator pedal once after approx. 1.5 minutes during this
time.

Information

1. Adaptation values are deleted or stored in EEPROM when ignition is

switched off after control unit run-on has ended.

(Run-on period: 1 minute when engine is cold; up to 45 minutes when engine is hot)

5. 1.5. Switch off ignition.