Cayenne Electrical System 01

Service Manual: 27 - STARTER, POWER SUPPLY, CRUISE CONTROL -- 92A CAYENNE
WM 270419 REMOVING AND INSTALLING VOLTAGE CONVERTER FOR START/STOP

(ALL MODELS) > TOOLS
Designation Type Number Description
PIWIS Tester II Special Tool 9818

(ALL MODELS) > PRELIMINARY WORK
1. If a new control unit has to be installed, the values/coding must be read out using PIWIS
Tester II 9818 prior to removing the "old" control unit. → 270455 REPLACING VOLTAGE
CONVERTER FOR START/STOP .
2. Remove glove compartment. → 681519 REMOVING AND INSTALLING GLOVE

COMPARTMENT

(ALL MODELS) > REMOVING VOLTAGE CONVERTER FOR START/STOP
Information
Always comply with the regulations for handling ESD-sensitive components!
Assembly work may only be carried out if the mechanic is wearing the working clothes and shoes
approved by Porsche .
The new part must only be removed from the ESD (electrostatic discharge) protective packaging
just before installation and at the position at which the part is to be installed .
Never touch the electric pins and plug contacts .

Fig 1: Identifying Voltage Converter For Start/Stop Installation Position
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
NOTE: Voltage peaks
Risk of damage to electrical load or to the control unit
1. Unscrew and remove fastening screw -1- and fastening nut -2- from the bracket for the
voltage converter.
Fig 2: Removing Voltage Converter From Bracket
2. Remove bracket with voltage converter from the dashboard bracket.
3. Release electric plug connection -3- (-a- ) and unplug it from the voltage converter.
Fig 3: Identifying Start/Stop Voltage Converter Connector

(ALL MODELS) > INSTALLING VOLTAGE CONVERTER FOR START/STOP
Information
Always comply with the regulations for handling ESD-sensitive components!
Assembly work may only be carried out if the mechanic is wearing the working clothes and shoes
approved by Porsche .
The new part must only be removed from the ESD (electrostatic discharge) protective packaging
just before installation and at the position at which the part is to be installed .
Never touch the electric pins and plug contacts .
1. Plug electric plug connection -3- into the voltage converter and lock it -a- .
Fig 1: Identifying Start/Stop Voltage Converter Connector
2. Position bracket with voltage converter on the dashboard bracket.
3. Secure voltage converter for Start/Stop to the dashboard bracket using the fastening screw -1-
and fastening nut -2- .
Fig 2: Installing Bracket Fasteners

(ALL MODELS) > SUBSEQUENT WORK
1. Install glove compartment. → 681519 REMOVING AND INSTALLING GLOVE

COMPARTMENT
2. If the control unit was replaced, the "new" control unit must be taught to suit the vehicle using
PIWIS Tester II 9818 . → 270455 REPLACING VOLTAGE CONVERTER FOR START/STOP .
WM 270455 REPLACING VOLTAGE TRANSFORMER FOR START/STOP (ALL

MODELS) > TOOLS

PIWIS Tester II Special tool 9818

MODELS) > TECHNICAL VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
Current rating Nominal value 40 A

MODELS) > READING AND WRITING VALUES
NOTE: Voltage drop
Risk of irreparable damage to control unit
Risk of damage to control unit
Fault entries in the control unit
Coding in the control unit is aborted
Malfunctions in control unit, even during programming
→ Prior to disconnecting the control unit, switch off ignition and remove ignition key.
→ Ensure that the power supply is not interrupted during programming.
→ Connect a battery charger with a current rating of at least → Nominal value: 40 A to the vehicle
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 additional
information may appear in PIWIS Tester II 9818 .
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on
ignition and press [F12] to continue.
2. Select the vehicle type and start the PIDT.
3. Select the Gateway control unit in the overview and press [F12] to continue.
4. Select the DC/DC converter control unit.
5. Maintenance/repairs must then be selected.
6. Control unit replacement must now be selected. Then press [F12] to continue.
7. Read data must be selected. Then press [F12] to continue.
8. Press [F8] to start reading out data.
9. Check the chassis number.
10. Switch off ignition and replace control unit. → 270419 REMOVING AND INSTALLING
VOLTAGE CONVERTER FOR START/STOP .
11. Switch on ignition, select Maintenance/repairs , Control unit replacement , Write data and
press [F12] to continue. Then press [F8] to start.
The data that was read out is loaded.
12. The System Tester displays the message: Data has been written , press [F12] to continue.
13. Read out the fault memory and erase it if necessary.
WM 270519 REMOVING AND INSTALLING BATTERY SENSOR (ALL MODELS) >

TECHNICAL VALUES
Tolerance Tolerance
Location Description Type Basic value
1 2
Terminal clamp to battery Tightening 6 Nm (4.5 ft.

terminal Torque lb.)
Ground line for battery to Tightening 20 Nm (15 ft.

body Torque lb.)

PRELIMINARY WORK
1. Remove battery cover. → ________271219 Removing and installing battery cover

REMOVING BATTERY SENSOR
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.
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 sensor and battery ground strap form one unit and can only be replaced together.
1. Switch off ignition and pull remote control out of ignition lock.
2. Release electric plug connection on the battery sensor and disconnect it -arrow- .
Fig 1: Disconnecting Battery Sensor Connector
3. Disconnect ground line for battery. → 270619 REMOVING AND INSTALLING BATTERY
4. Open the service flap in the driver's footwell.
5. Unscrew fastening nut -1- and guide battery sensor with ground line -2- through the opening
-arrow- in the battery box.
6. Remove battery sensor with ground line -2- .
Fig 2: Locating Battery Sensor With Ground Line

INSTALLING BATTERY SENSOR
Information
After replacing the battery sensor, the battery sensor will be detected automatically by the gateway
control unit.
1. Installation is performed in reverse order to removal.
2. Tighten fastening nut securing ground line to the body. Tightening Torque 20 Nm (15 ft. lb.)
3. Tighten terminal clamp on ground line. Tightening Torque 6 Nm (4.5 ft. lb.)
4. Check that the rubber sleeve is seated correctly in the opening of the battery box.

SUBSEQUENT WORK
1. Install battery cover. → 271219 REMOVING AND INSTALLING BATTERY COVER
2. Follow work instructions after disconnecting the battery. → 2X00IN WORK INSTRUCTIONS
AFTER DISCONNECTING THE BATTERY
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > TECHNICAL

VALUES
Basic Tolerance Tolerance

Location Description Type
value 1 2
Tightening 6 Nm (4.5
Terminal clamp to battery terminal
Torque ft. lb.)
Fastening screw securing battery in Tightening 23 Nm (17

battery housing Torque ft. lb.)
Fastening screw securing retaining Tightening 8 Nm (6 ft.

bracket to battery housing Torque lb.)
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > PRELIMINARY

WORK
1. Remove battery cover. → 271219 REMOVING AND INSTALLING BATTERY COVER
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > REMOVING

BATTERY
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: Static battery charge
Battery can explode
Electrical discharges
→ Do not rub the battery with a dry cloth.
Information
The battery is located in the battery box under the left front seat .
The vehicle must be supplied with external power at the jump-lead starting points so that the seat
can be moved even when the battery is fully discharged . → WM 2706IN EXTERNAL POWER
CONNECTION, JUMP-LEAD STARTING (ALL MODELS)
Fig 1: Identifying Battery Installation Position
Information
1. Release and disconnect electric plug connection at the battery sensor.

Fig 2: Disconnecting Battery Sensor Connector
2. Risk of short circuit! First disconnect the negative cable, then the positive cable.
Fig 3: Disconnecting Cables
3. Unscrew the fastening screw -1- on the sheetmetal bracket and remove the battery mount.
4. Unscrew the screw for the battery mount -2- and remove the battery mount.
5. Pull the vent hose -3- off the battery.

Fig 4: Removing Battery Mount
6. Lift the battery up and out.
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > INSTALLING

BATTERY
WARNING: Incorrect handling of safety bolts
Danger of injury
Loss of torque
→ Always use new fastening screws and nuts following removal.
→ Observe specified Tightening Torques.
→ Carry out a visual inspection of all re-used parts.
Information
Make sure that the two ends of the vent hose are routed and inserted correctly .
1. The battery is installed in reverse order to removal.
2. Fit battery mount and secure with the fastening screw. Tightening Torque 23 Nm (17 ft. lb.)
3. Fit sheetmetal bracket and secure with the fastening screw. Tightening Torque 8 Nm (6 ft.
lb.)
4. Risk of short circuit! First connect the positive cable, then the negative cable. Tighten fastening
nuts. Tightening Torque 6 Nm (4.5 ft. lb.)
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > SUBSEQUENT

WORK
1. Install battery cover. → 271219 REMOVING AND INSTALLING BATTERY COVER
WM 270655 REPLACING BATTERY (ALL MODELS) > PRELIMINARY WORK
1. Remove and install battery. → 270619 REMOVING AND INSTALLING BATTERY
WM 270655 REPLACING BATTERY (ALL MODELS) > REPLACING AGM BATTERY
Information
The AGM (A bsorbent G lass M at) battery is a Maintenance-Free , Sealed battery.
This battery must not be opened. If the battery is opened, it must be replaced .
There is a Serial Number -A- and a Part Number -B- on the top right-hand side of the battery .
Fig 1: Identifying Serial Number And Part Number On Battery
ignition and press [F12] to continue.
3. Select the Gateway control unit in the Overview and press [F12] to continue.
4. Maintenance/Repairs must then be selected.
5. Change Battery must now be selected. Then press [F12] to continue.
6. Enter The Serial Number And Part Number and press [F12] to continue.
7. Enter the battery size and manufacturer and press [F12] to continue.
WM 270655 REPLACING BATTERY (ALL MODELS) > SUBSEQUENT WORK
WM 2706IN EXTERNAL POWER CONNECTION, JUMP-LEAD STARTING (ALL
MODELS) > INFORMATION
Information
If the battery is flat, jump leads can be used together with the battery of another vehicle to start the
car or to supply external power to the vehicle .
Both batteries must be 12 V batteries.
The capacity (Ah) of the battery supplying the power must not be significantly lower than that of the flat
battery.
WARNING: Live jump leads
Risk of electric shock
Risk of short circuit
→ Route the jump leads so that they do not become entangled in moving parts in the engine
compartment.
→ There must be no contact between the vehicles.
The flat battery must be properly connected to the vehicle electrical system.
1. Remove cover for jump-lead starting terminal.
2. Open protective cover on the positive terminal for jump-lead starting -+- .
Fig 1: Identifying Jump-Lead Starting Terminals
3. Connect the positive cable to the positive terminal for jump-lead starting -+- , then to the
positive terminal of the donor battery.
4. Connect the negative cable to the negative terminal of the donor battery first, then to the
ground point for jump-lead starting - .
5. Have the engine of the vehicle supplying the power run at a higher speed.
6. Start engine. Do not spend longer than 15 seconds trying to start the vehicle with the jump
leads - after 15 seconds have elapsed, wait for at least one minute.
7. Disconnect the two jump leads in reverse sequence when the engine is running.
8. Close protective cover.
9. Position the cover.
WM 270819 REMOVING AND INSTALLING E-BOX (CAYENNE S E-HYBRID) > TOOLS

Voltage Tester Workshop Equipment WE 1380
High-Voltage Cordon Workshop Equipment WE 1589
Insulated Tool Set Workshop Equipment WE 1593
WM 270819 REMOVING AND INSTALLING E-BOX (CAYENNE S E-HYBRID) >

TECHNICAL VALUES

value 1 2
Tightening 10.1 Nm
E-Box To High-Voltage Battery
Torque (7.5 ft. lb.)
Fastening Screws (M6 X 12) Securing

Tightening 10.1 Nm
Side Cover Plate To High-Voltage
Battery

Tightening 10.1 Nm
Top Cover Plate To High-Voltage
Battery
Fastening screws (M6 x 12) securing Tightening 10.1 Nm

top cover plate to high-voltage battery Torque (7.5 ft. lb.)

Top Cover Plate To High-Voltage
Torque ft. lb.)
Battery
Fastening Nuts Securing High-Voltage Tightening 5.9 Nm

Battery Control Unit To E-Box Torque (4.5 ft. lb.)
Fastening nuts securing cover for

Tightening 5.9 Nm
high-voltage battery control unit to
E-box
Fuse
Torque ft. lb.)
Fastening screws securing fuse carrier Tightening 10.1 Nm

cover to high-voltage battery Torque (7.5 ft. lb.)

PRELIMINARY WORK
1. Observe warning notes. → 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE
HIGH-VOLTAGE VEHICLE ELECTRICAL SYSTEM
2. Remove high-voltage battery. → REMOVING HIGH-VOLTAGE BATTERY - section on

"Removing"
3. Set up a High-Voltage Cordon High-Voltage Cordon WE 1589 around the high-voltage

workstation.
Fig 1: Caution For Battery Restricted Area

REMOVING E-BOX
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
NOTE: Incorrect removal or fitting of safety-related screws for the high-voltage battery.
Risk of damage to rivet nuts
Risk of damage to screw heads
Risk of damage to high-voltage battery
→ Loosen and tighten fastening screws without using electric tools.
→ Only loosen and tighten fastening screws using special tool VAS 6883 Insulated Tool Set.
→ Be extremely careful when loosening fastening screws. See Note: → "Procedure For Loosening
Micro-Self-Locking Screws" .
→ Clean the threaded bores before fitting the fastening screws. See Note: → "Procedure For Cleaning
Threaded Bores On The High-Voltage Battery" .
→ Always use new fastening screws.
Information
Always use insulated tools Insulated Tool Set WE 1593 when working on the high-voltage battery and
a High-Voltage Cordon WE 1589 when working on a HV work bay.
Information
If the E-box for the high-voltage system Cannot Be Removed because the screw heads or rivet nuts
are damaged, for example, proceed as follows:
Stop working on the high-voltage battery immediately .
To find out what to do next, get in touch with your contact person at your importer's Technical
Competence Centre (TCC) .
Information
If the Cover On The Fuse Carrier for the high-voltage battery Cannot Be Removed because the
screw heads or rivet nuts are damaged, for example, proceed as follows:
Stop working on the high-voltage battery Immediately .
To find out what to do next, get in touch with your contact person at your importer's Technical
Competence Centre (TCC) .
1. Remove fuse carrier cover.
1. 1.1. Loosen fastening screws -1- as described above.
2. 1.2. Push fuse carrier cover down and remove it.

Fig 1: Identifying Fuse Carrier Cover Screws
Information
Perform function test on voltage tester at the vehicle jump-start terminals using a reference
voltage.
2. Verify isolation from the power supply at the high-voltage battery fuse using voltage tester
Voltage Tester WE 1380 .
1. 2.1. Contact point -A- to contact point -B- .
2. 2.2. Contact point -A- to housing.
3. 2.3. Contact point -B- to housing.
4. 2.4. Check contact point -A- to contact point -B- again to prevent static charge.
Fig 2: Checking Absence Of Electric Charge
Information
Further steps may only be carried out if the measured voltage is less than 1 V. If this is not the
case, stop working on the system and contact Technical Support.
Information
Once absence of electric charge has been verified using the voltage tester, the fuse must be
replaced without any interruption to work.
3. Remove high-voltage battery fuse.
1. 3.1. Unscrew and remove fastening screws -3- for cap -1- and fuse -2- .
2. 3.2. Remove cap -1- together with fuse -2- .

Fig 3: Removing Fuse
3. 3.3. Unclip cap -1- from the fuse and re-insert it on the high-voltage battery to
protect exposed high-voltage contacts.
Fig 4: Installing Battery Cap
4. Remove high-voltage battery control unit.
1. 4.1. Loosen fastening nuts -1, 2- on the cover of the high-voltage battery control unit
and remove cover -3- .
2. 4.2. Remove spacers under the fastening nuts -1- .

Fig 5: Identifying Cover For High-Voltage Battery Control Unit
3. 4.3. Remove ground line -1- from the fastening bolt.

Fig 6: Identifying Ground Line
4. 4.4. Loosen fastening nuts -1- on the high-voltage battery control unit and pull off
high-voltage battery control unit -2- .
Fig 7: Identifying High-Voltage Battery Control Unit
5. 4.5. Release electric plug connection -1- at the high-voltage battery control unit
completely -arrows a- and disconnect it -arrow A- .
6. 4.6. Release electric plug connection -2- completely -arrow b- and disconnect it
-arrow B- .
Fig 8: Releasing Electric Plug Connections
7. 4.7. Remove high-voltage battery control unit.
Information
Procedure For Loosening Micro-Self-Locking Screws .
The covers on the high-voltage batteries are secured using fastening screws with high-strength
screw locking agent. However, these can be difficult to loosen as a result of certain
environmental conditions and depending on the service life of the vehicle.
To avoid breaking off or damaging fastening screws, always loosen the fastening screws as
follows:
1. Mark the fastening screw using a felt-tip pen and carefully loosen it by half (1/2) a
turn -arrow a- .
2. Screw the fastening screw in again by half (1/2) a turn -arrow b- .
3. Repeat Steps 1 and 2 at least five times (5x) until the loosening torque of the
fastening screw is reduced significantly. The fastening screw can then be turned
easily.
4. After Step 3, the torque should be much lower so that the fastening screw can be
loosened completely -arrow c- .
Fig 9: Loosening Fastening Screws
Information
If the Cover Plate for the high-voltage battery Cannot Be Removed because the screw
heads or rivet nuts are damaged, for example, proceed as follows:
1. Stop Working on the high-voltage battery Immediately .
2. To find out what to do next, get in touch with your contact person at your
importer's Technical Competence Centre (TCC) .
5. Remove top cover plate on the high-voltage battery
2. 5.2. Loosen fastening screws -1, 2- as described above.

Fig 10: Identifying Top Cover Plate On High-Voltage Battery
Do not remove top cover plate on the high-voltage battery.

Fig 11: Identifying Top Cover Plate On High-Voltage Battery
Information
Procedure For Cleaning Threaded Bores (Blind Hole Bore) On The High-Voltage Battery
.
After loosening micro-self-locking fastening screws, it is important to remove the particles of

screw locking agent from the threaded bores.
1. All tasks that are necessary for cleaning the threaded bores must be carried out by hand
and the required personal protective gear must always be used .
2. Never use lubricant for cleaning the threaded bores .
3. When cleaning the threaded bores, always make sure that no remaining pieces of the
micro-encapsulated coating/metal chips get into the battery housing. Use a vacuum
cleaner to do this .
Fig 12: Identifying Tap Comparison
When cleaning the threaded bores (M6 and M8) on the high-voltage battery, always proceed
as follows:
1. Insert tap -1- (with spiral grooves) into the threaded bore.
2. Hold a vacuum cleaner with a plastic nozzle -3- at the threaded bore in such a way
that the remaining pieces of adhesive/metal chips will be removed.
3. Turn the tap back and forth by a quarter (1/4) to a half (1/2) a turn several times
-arrow- to extract the remaining adhesive/metal chips that are dislodged -2- .
Fig 13: Cleaning Threaded Bore
4. Repeat Step 3 several times until the threaded bore is completely cleaned.
Information
Procedure For Cleaning Threaded Bores (Through-Bore) On The Side Bar Of The
High-Voltage Battery .

as follows:
1. Stick two strips (50 x 80 mm) of fabric adhesive tape -4- on the inside of the bar on
the high-voltage battery using a plastic wedge. The bores must be completely
sealed.
2. Insert tap (with spiral grooves) -1- into the threaded bore.
that the remaining pieces of adhesive/metal chips -2- will be removed.
-arrow- to extract the remaining adhesive/metal chips that are dislodged.
5. Repeat Step 3 several times until the threaded bore is completely cleaned. Make
sure not to puncture the fabric adhesive tape.
6. Carefully remove fabric adhesive tape and always use a vacuum cleaner to remove
any loose particles at the same time.
6. Clean threaded bores -1- for the fastening points for the top cover plate as described above
Using An M6 X 1.0 Tap With Spiral Grooves .
Fig 16: Identifying Threaded Bores
Information
Carefully remove the top cover plate to prevent damage to the E-box wiring harness.
1. 6.1. Carefully lift up the top cover plate on the high-voltage battery and remove it.
Information
If the Cover Plate for the high-voltage battery Cannot Be Removed because the screw
heads or rivet nuts are damaged, for example, proceed as follows:
1. Stop Working On the high-voltage battery Immediately .
2. To find out what to do next, get in touch with your contact person at your importer's
Technical Competence Centre (TCC) .
7. Check seal on front cover plate and if it is damaged, replace the front cover plate.
1. 7.1. Loosen fastening screws (M6 x 12) -1- as described above.

Fig 17: Removing Front Cover Plate
2. 7.2. Carefully remove front cover plate on the high-voltage battery by pulling it to the
side.
3. 7.3. Clean the threaded bores -1- for the fastening points for the side cover plate as
described above Using An M6 X 1.0 Tap With Spiral Grooves .
8. Remove E-box.
1. 8.1. Loosen tie-wrap -1- on HV line.

Fig 19: Disconnecting HV Line
2. 8.2. Remove wiring harness -1- by pulling it up out of the guide -arrows- .
Fig 20: Disconnecting Wiring Harness
3. 8.3. Loosen fastening screws -1- for the E-box as described above.
Fig 21: Identifying E-Box Screws
4. 8.4. Carefully pull the E-box straight off the high-voltage battery and make sure not to
tilt the E-box when pulling it off the guide pins -1- .
Fig 22: Identifying E-Box Guide Pins
5. 8.5. Cover exposed terminals on the high-voltage battery -arrows- with adhesive
tape immediately after removing the E-box.
Fig 23: Identifying Battery Terminals
Information

as follows:
sealed.
9. Clean the threaded bores on the upper bar of the high-voltage battery as described above.
1. M8 Through-Bore
2. M8 Blind Hole Bore
3. M6 Through-Bore
4. Fabric Adhesive Tape
1. 9.1. Clean the threaded bores for the fastening points of the top cover plate -1, 2-
using An M8 X 1.25 Tap With Spiral Grooves .
2. 9.2. Clean the threaded bore for the upper fastening points of the E-box -3- using an
M6 X 1.0 Tap With Spiral Grooves .
10. Clean the threaded bores for the fastening points -1- of the E-box as described above.
Fig 27: Cleaning Threaded Bores

INSTALLING E-BOX
Information
a High-Voltage Cordon High-Voltage Cordon WE 1589 when working on a HV work bay.
Information
When fitting the cover, check that the E-box wiring harness is positioned correctly and is not squashed.
Information
Fastening screws and fastening nuts must not be re-used and must be replaced with new ones.
1. Install E-box.
1. 1.1. Remove adhesive tape from the battery terminals -arrows- .

Fig 1: Locating Battery Terminals
2. 1.2. Push E-box onto the guide pins -1- , making sure not to tilt the E-box and
position it flat on the high-voltage battery.
Fig 2: Identifying E-Box Guide Pins
3. 1.3. Screw in and tighten fastening screws -1- on the E-box. → Tightening Torque:
10.1 Nm (7.5 ft. lb.)
Fig 3: Identifying E-Box Screws
4. 1.4. Position the wiring harness -1- at the top of the guide -arrows- and make sure
that the seal -2- is fitted correctly.
Fig 4: Positioning Wiring Harness
5. 1.5. Connect electric plug connection -1- on the E-box -A- until it engages securely.
Check that the wiring harness is routed behind the plug connection -1- as shown.
Fig 5: Connecting Electric Plug Connection
6. 1.6. Fasten tie-wrap -1- on HV line.

Fig 6: Locating HV Line
Information
When fitting the cover, check that the E-box wiring harness is positioned correctly and is not
squashed.
Information
The high-voltage battery cover must not be re-used and must be replaced by a new cover. The
new cover is supplied without warning signs. These must be ordered separately and affixed on
the cover.
2. Install cover plates on the high-voltage battery.
1. 2.1. Position side cover plate carefully on the high-voltage battery.
2. 2.2. Tighten fastening screws (M6 x 12) -1- . → Tightening Torque: 10.1 Nm (7.5 ft.
lb.)
Fig 7: Identifying Side Cover Plate Screws
3. 2.3. Carefully position top cover plate on the high-voltage battery.
4. 2.4. Tighten fastening screws (M6 x 16) -1- . → Tightening Torque: 10.1 Nm (7.5 ft.
lb.)
Tighten fastening screws (M6 x 12) -2- . → Tightening Torque: 10.1 Nm (7.5 ft.
lb.)
Fig 8: Identifying Top Cover Plate Screws
5. 2.5. Tighten fastening screws (M8 x 16) -1- . → Tightening Torque: 13 Nm (9.5 ft.
lb.)
Fig 9: Identifying Top Cover Plate Screws
3. Install high-voltage battery control unit.
1. 3.1. Connect electric plug connection -2- on the high-voltage battery control unit -b-
and lock it -B- .
2. 3.2. Connect electric plug connection -1- (-a- ) and lock it -A- .
Fig 10: Connecting Electric Plug Connections
3. 3.3. Position control unit -2- on the E-box and tighten fastening nuts -1- . →
Tightening Torque: 5.9 Nm (4.5 ft. lb.)
4. 3.4. Push ground line -1- onto the fastening bolts.

Fig 12: Identifying Ground Line
5. 3.5. Position spacers on the bolts under fastening nuts -2- .
6. 3.6. Position cover on high-voltage battery control unit -3- and tighten fastening nuts
-1, 2- . → Tightening Torque: 5.9 Nm (4.5 ft. lb.)
4. Remove cap -1- .

Fig 14: Identifying Battery Cap
5. Verify absence of electric charge at the exposed high-voltage contacts of the high-voltage
battery using a suitable voltage tester at contact points -A, B- .

Fig 15: Checking Electric Charge
The measurement also prevents voltages due to the build-up of static charge.
Information
Insert fuse without causing any interruption to work in order to prevent an electrostatic charge.
6. Install high-voltage battery fuse.
1. 6.1. Clip fuse into cap
2. 6.2. Position cap -1- together with fuse -2-
3. 6.3. Screw on fastening screws -3- for cap -1- and fuse -2- . → Tightening
Torque: 10 Nm (7.5 ft. lb.)
Fig 16: Identifying Fuse
7. Position fuse carrier cover and tighten fastening screws -1- . → Tightening Torque: 10.1 Nm
(7.5 ft. lb.)
Fig 17: Identifying Fuse Carrier Cover
Information
Stickers (Warning Of Dangerous Electrical Voltage)
The cover and possibly the front cover plate for the high-voltage battery must be replaced
while carrying out the work required for replacing the E-box.
The identification and warning stickers affixed to the cover and cover plate cannot be re-used.
Before re-installing the high-voltage battery, new stickers must be affixed to the new cover and
possibly to the new front cover plate at the same position and with the same text alignment as
on the removed cover plates.
The required safety marking warning sign 8R0.010.539.x must be selected according to the
relevant language and country version.
8. Affix warning signs to the high-voltage battery.
1. Warning Sign Pictograms
2. Indication Sticker For Lithium-Ion High-Voltage Battery
3. Safety Marking Warning Sign

Fig 18: Identifying Warning Sign Stickers

SUBSEQUENT WORK
1. Install high-voltage battery. → INSTALLING HIGH-VOLTAGE BATTERY - section on

"Installing"
WM 270819 REMOVING AND INSTALLING FUSE AT E-BOX (CAYENNE S E-HYBRID) >

TOOLS


PRELIMINARY WORK
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 (AFES)
3. Remove high-voltage battery. → INSTALLING HIGH-VOLTAGE BATTERY - section on

"Removing"
4. Set up a High-Voltage Cordon WE 1589 around the high-voltage workstation.


REMOVING FUSE AT E-BOX
Information
a High-Voltage Cordon WE 1589 when working on a HV work bay.
1. Open retaining clip -A- and carefully pull the fuse up and out -B- .

INSTALLING FUSE AT E-BOX

Information
Before installing the fuse, the seal must be checked for damage. If the seal is damaged, the fuse must
be replaced.
1. Carefully insert fuse -A- and lock it with the retaining clip -B- . Check that the retaining clip
locks correctly.
2. Check that the fuse is positioned correctly and fitted securely.

Fig 1: Installing Fuse

SUBSEQUENT WORK

"Installing"
2. Start the high-voltage system and complete the relevant documentation. → 2X00IN
ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER SUPPLY/STARTING
HIGH-VOLTAGE ELECTRICAL SYSTEM (AFES)
WM 270819 REMOVING AND INSTALLING HIGH-VOLTAGE BATTERY (CAYENNE S

E-HYBRID) > TOOLS
Workshop Crane Workshop

WE 1188
VAS 6100 Equipment
Workshop
Insulated Tool Set WE 1593
Equipment
Lifting tackle VW tool 3033

Adapter plate Special tool 9860
guide rod Special tool 9860/2

E-HYBRID) > TECHNICAL VALUES

value 1 2
Fastening bracket securing Tightening 23 Nm (17

high-voltage battery to body Torque ft. lb.)
Electric potential line to Tightening 17 Nm (13

high-voltage battery Torque ft. lb.)
Electric potential to body
Torque ft. lb.)
HV line from power Tightening 7 Nm (5 ft.

electronics to battery Torque lb.)
Mounting for cover for HV Lens-head screw Tightening 23 Nm (17

battery (micro-self-locking) Torque ft. lb.)

E-HYBRID) > PRELIMINARY WORK

HIGH-VOLTAGE ELECTRICAL SYSTEM
2. Carry out classification of high-voltage battery. → 2X00IN CLASSIFICATION OF

HIGH-VOLTAGE BATTERY
4. Drain low-temperature cooling system → 193817 DRAINING AND FILLING COOLANT

(INCLUDES BLEEDING) .
5. Remove luggage compartment cover. → 700619 REMOVING AND INSTALLING TRIM PANEL
FOR LUGGAGE COMPARTMENT (LUGGAGE COMPARTMENT COVER)
6. Remove side trim panel for rear luggage compartment. → REMOVING SIDE TRIM PANEL
FOR REAR LUGGAGE COMPARTMENT - section on "Removing"
7. Remove cover for rear lock support. → REMOVING COVER FOR REAR LOCK SUPPORT -
section on "Removing"

E-HYBRID) > REMOVING HIGH-VOLTAGE BATTERY
Fig 1: Identifying High-Voltage Battery Installation Position
Information
To prevent coolant from getting into the high-voltage battery and damaging the high-voltage battery, the
cooling system must only be disconnected at the specified position.
1. Release and pull off breather hoses for the cooling system -6- .
Fig 2: Disconnecting Breather Hoses
2. Release and disconnect high-voltage line for on-board charger -1- from the high-voltage
battery -3- .
3. Unscrew and disconnect high-voltage lines for the power electronics unit -2- from the
high-voltage battery -3- .
Fig 3: Disconnecting High-Voltage Lines
4. Electric plug connections for the hybrid or drive CAN -4- must be removed -a - from the
bracket and then released -b - and disconnected -c- .
Fig 4: Disconnecting Electric Plug Connections
5. Open cable duct -5- and remove high-voltage lines.
6. Unclip and remove cable duct -5- .

Fig 5: Removing Cable Duct
7. Remove equipotential bonding line -7- .
1. 7.1. Loosen fastening screw for equipotential bonding line at the body -9- .
2. 7.2. Loosen fastening screw for equipotential bonding line at the high-voltage battery
-8- .
3. 7.3. Remove equipotential bonding line.

Fig 6: Removing Equipotential Bonding Line
Information
The fastening screws for the cover on the high-voltage battery are micro-self-locking and must
not be re-used.
8. Unscrew fastening bracket for high-voltage battery -12- and screw in Guide Rod 9860/2 -10-
.
1. 8.1. First loosen the outer fastening screws.
2. 8.2. Guide Rod 9860/2 must then be screwed into the outer thread.
3. 8.3. Loosen inner fastening screws -11- .

Fig 7: Identifying Fastening Bracket
Information
Procedure for loosening micro-self-locking screws .
The covers on the high-voltage batteries are secured using fastening screws with high-strength
screw locking agent. However, these can be difficult to loosen as a result of certain
environmental influences and depending on the service life of the vehicle.
To avoid breaking off or damaging fastening screws, always loosen the fastening screws as
follows:
1. Mark the fastening screw using a felt-tip pen and carefully loosen it by half (1/2) a
turn -arrow a- .
3. Repeat Steps 1 and 2 at least five times (5x) until the loosening torque of the
fastening screw is reduced significantly. The fastening screw can then be turned
easily.
4. After Step 3, the torque should be much lower so that the fastening screw can be
loosened completely -arrow c- .
9. Unscrew and remove center fastening screws -13- from the high-voltage battery in order to fit
the adapter plates.
Fig 9: Identifying Fastening Screws
10. Position adapter plates -15- Adapter Plate 9860 and use fastening screws -14- to fit them on
the high-voltage battery.
Fig 10: Identifying Adapter Plates
11. Fit lifting tackle -16- Lifting Tackle 3033 on the adapter plates.
Information
Depending on the workshop crane used, lifting tackle may have to be attached first and then
secured to the adapter plates.
Fig 11: Identifying Lifting Tackle Tool (3033)
Information
Before removing the high-voltage battery, have a table or trolley and two plastic or rubber
blocks ready for lowering the high-voltage battery. The high-voltage battery must not be
lowered onto the floor to prevent damage to the water drains on the underside of the
high-voltage battery.
Information
When lifting out the battery, it is a good idea to get another person to guide the battery on the
crane.
12. Workshop Crane VAS 6100 WE 1188 must be engaged in the lifting tackle Lifting Tackle
3033 . Then lift it carefully at the center.
Fig 12: Lifting Vehicle Battery
13. Lift up the high-voltage battery and get another person to pull it towards the rear and lift it
carefully out of the luggage compartment pan.
Information
The battery must not be left hanging on the crane for a long time.
14. Lift the high-voltage battery up further, push the workshop crane forward slightly and turn it 90
degrees as soon as possible and guide the high-voltage battery out of the vehicle.
Fig 13: Lifting Out High-Voltage Battery
15. Lower the high-voltage battery onto the blocks on the prepared table or trolley.
WARNING: Danger of fire, explosion
1. Insulation fault as a result of coolant leaking into high-voltage battery
→ Always drain the high-voltage battery cooling lines completely before transporting/handling
16. Drain the cooling system completely using compressed air set to max. 2.5 bar .
Fig 14: Draining Cooling System
1. 16.1. Hold the coolant hose -18- in a suitable container -3- .
2. 16.2. Flush the coolant hose -17- using compressed air set to max. 2.5 bar until no
more coolant emerges at the coolant hose -18- .
Information
Close off/mask high-voltage connections on the high-voltage battery using suitable stoppers or
adhesive tape to prevent dirt and fluids from getting in.
17. Disconnect cooling lines -19- for the high-voltage battery -3- at the bayonet lock.
Fig 15: Disconnecting Cooling Line From Battery
18. Fit cooling system stoppers on cooling system connections on the old high-voltage battery and
secure with adhesive tape.

E-HYBRID) > INSTALLING HIGH-VOLTAGE BATTERY
Information
The contact surfaces of the equipotential bonding line 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.
Information
When connecting or screwing the high-voltage lines to the high-voltage battery connections, carefully
check the plug contacts and make sure that they are connected properly.
The connector pins on conventional plug connections must be checked before connecting them and the
plug connections must be inserted carefully.
Information
Check seal on connector for high-voltage lines for the power electronics unit before installation and
replace it if necessary
Information
Remove stoppers or adhesive tape from the high-voltage connection for the high-voltage battery and
check for dirt and fluid leaking in.
Information
Only a high-voltage battery designed specifically for the Cayenne S E-Hybrid may be used. High-voltage
batteries from other model lines (e.g. Panamera S E-Hybrid) must not be installed.
Information
When inserting the high-voltage battery into the vehicle, make sure that no lines or connectors are
trapped by the battery.
1. Guide Rods 9860/2 -1- must then be screwed into the outer thread.
Fig 1: Identifying Guide Rods
2. Clean the thread if you have not already done so.
Information
Procedure For Cleaning Threaded Bores (Blind Hole Bore) On The High-Voltage Battery
.

When cleaning the threaded bores (M6) on the high-voltage battery, always proceed as
follows:
1. Insert tap -1- (with spiral grooves) into the threaded bore.
that the remaining pieces of adhesive/metal chips will be removed.
-arrow- to extract the remaining adhesive/metal chips that are dislodged -2- .
4. Repeat Step 3 several times until the threaded bore is completely cleaned.
3. Position adapter plates -2- Adapter Plate 9860 and use fastening screws -3- to fit them on
Fig 4: Identifying Adapter Plate
4. Fit lifting tackle -5- Lifting Tackle 3033 on the adapter plates.
Fig 5: Identifying Lifting Tackle Tool (3033)
5. Workshop Crane VAS 6100 WE 1188 must be engaged in the lifting tackle Lifting Tackle
3033 . Then lift it carefully at the center.
6. Carefully lift the high-voltage battery into the vehicle with the help of another person.
Fig 6: Positioning High-Voltage Battery
7. Guide high-voltage battery -6- fully into the luggage compartment, turn it 90 degrees as soon
as possible and position outer thread of the fastening brackets for the high-voltage battery over
the luggage compartment pan onto the Guide Rods 9860/2 .
8. Get another person to guide the outer thread of the fastening brackets for the high-voltage
battery -7- into all the Guide Rods 9860/2 -1- . Carefully lower the high-voltage battery into
the luggage compartment pan.
Fig 7: Lowering High-Voltage Battery Into Vehicle
Information
The fastening screws for the fastening brackets are micro-self-locking and must not be
re-used.
9. Tighten fastening brackets for high-voltage battery. Tightening Torque 23 Nm (17 ft. lb.)
1. 9.1. Always screw in the inner fastening screws first.
2. 9.2. Guide Rod 9860/2 must be loosened from the outer threads.
3. 9.3. Tighten outer fastening screws.
Information
not be re-used.
10. Loosen fastening screws for the high-voltage battery and remove adapter plate together with
the lifting tackle. Screw fastening screws into the open threaded bores. Tightening Torque 23
Nm (17 ft. lb.)
11. Connect cooling system hoses and secure with hose clamps.
12. Install equipotential bonding line -8- .
1. 12.1. Secure equipotential bonding line -8- to the high-voltage battery -6- .
Tightening Torque 17 Nm (13 ft. lb.)
2. 12.2. Secure equipotential bonding line -8- to the body -9- . Tightening Torque 9
Nm (6.5 ft. lb.)
Fig 8: Securing Equipotential Bonding Line
13. Connect breather hoses for the cooling system and secure with hose clamps.
14. Fit cable duct, insert high-voltage lines and close the cable duct.
15. Plug in electric plug connections for the hybrid or drive CAN until they engage securely.
16. Insert electric plug connections into the bracket.
17. Plug in high-voltage lines for the power electronics unit -10- and secure with fastening screws.
18. Plug in high-voltage line for the on-board charger until it engages securely.
Fig 9: Fitting High-Voltage Lines

E-HYBRID) > SUBSEQUENT WORK
1. Install cover for rear lock support. → REMOVING COVER FOR REAR LOCK SUPPORT -
2. Install side trim panel for rear luggage compartment. → REMOVING SIDE TRIM PANEL FOR
REAR LUGGAGE COMPARTMENT - section on "Removing"
3. Install luggage compartment cover. → 700619 REMOVING AND INSTALLING TRIM PANEL
4. Fill low-temperature cooling system. → 193817 DRAINING AND FILLING COOLANT

(INCLUDES BLEEDING)
WM 270819 REMOVING AND INSTALLING HIGH-VOLTAGE BATTERY FUSE

(CAYENNE S E-HYBRID) > TOOLS
Voltage Tester Workshop Equipment WE 1380

(CAYENNE S E-HYBRID) > TECHNICAL VALUES
Fuse Tightening Torque 10 Nm (7.5 ft. lb.)
Fuse carrier cover Tightening Torque 10.1 Nm (7.5 ft. lb.)

(CAYENNE S E-HYBRID) > PRELIMINARY WORK

"Removing"
3. Set up a High-Voltage Cordon High-Voltage Cordon WE 1589 around the high-voltage

workstation.

(CAYENNE S E-HYBRID) > REMOVING HIGH-VOLTAGE BATTERY FUSE
NOTE: Incorrect removal or fitting of safety-related screws for the high-voltage battery.
Risk of damage to rivet nuts
Risk of damage to screw heads
Risk of damage to high-voltage battery
→ Loosen and tighten fastening screws without using electric tools.
→ Only loosen and tighten fastening screws using special tool VAS 6883 Insulated Tool Set.
→ Be extremely careful when loosening fastening screws. See Note: → "Procedure For Loosening
Micro-Self-Locking Screws" .
→ Clean the threaded bores before fitting the fastening screws. See Note: → "Procedure For Cleaning
Threaded Bores On The High-Voltage Battery" .
→ Always use new fastening screws.
Information
Information
Procedure For Loosening Micro-Self-Locking Screws .
The covers on the high-voltage batteries are secured using fastening screws with high-strength screw
locking agent. However, these can be difficult to loosen as a result of certain environmental conditions
and depending on the service life of the vehicle.
To avoid breaking off or damaging fastening screws, always loosen the fastening screws as follows:
1. Mark the fastening screw using a felt-tip pen and carefully loosen it by half (1/2) a turn -arrow
a- .
3. Repeat Steps 1 and 2 at least five times (5x) until the loosening torque of the fastening screw
is reduced significantly. The fastening screw can then be turned easily.
4. After Step 3, the torque should be much lower so that the fastening screw can be loosened
completely -arrow c- .
1. Remove fuse carrier cover.
2. 1.2. Push fuse carrier cover down and remove it.

Information
If the Cover On The Fuse Carrier for the high-voltage system Cannot Be Removed
because the screw heads or rivet nuts are damaged, for example, proceed as follows:
1. Stop Working on the high-voltage battery Immediately .
2. To find out what to do next, get in touch with your contact person at your
importer's Technical Competence Centre (TCC) .
Information
Perform function test on voltage tester at the vehicle jump-start terminals using a reference
voltage.
2. Verify isolation from the power supply at the high-voltage battery fuse using voltage tester
Voltage Tester WE 1380 .
1. 2.1. Contact point -A- to contact point -B- .
4. 2.4. Check contact point -A- to contact point -B- again to prevent static charge.
Information
Further steps may only be carried out if the measured voltage is less than 1 V. If this is not the
case, stop working on the system and contact Technical Support.
Information
Once absence of electric charge has been verified using the voltage tester, the fuse must be
replaced without any interruption to work.
3. Remove high-voltage battery fuse.
1. 3.1. Unscrew and remove fastening screws -3- for cap -1- and fuse -2- .
2. 3.2. Carefully remove cap -1- together with fuse -2- .

Information

as follows:
sealed.
4. Clean the screw threads of the fastening points as described above Using An M6 X 1.0 Tap
With Spiral Grooves .
5. Unclip cap -1- from fuse and insert it on the high-voltage battery again.
Fig 7: Identifying Battery Cap

(CAYENNE S E-HYBRID) > INSTALLING HIGH-VOLTAGE BATTERY FUSE
Information
Fastening screws for the fuse and fuse carrier cover must not be re-used and must be replaced with new
fastening screws.
1. Remove cap.
2. Verify absence of electric charge at the open terminals of the high-voltage battery fuse using a
suitable voltage tester at contact points -A, B- .

Information
Insert fuse without causing any interruption to work in order to prevent an electrostatic charge.
3. Install high-voltage battery fuse.
1. 3.1. Clip fuse into cap
2. 3.2. Position cap -1- together with fuse -2-
3. 3.3. Screw on fastening screws -3- for cap -1- and fuse -2- . → Tightening
Fig 2: Identifying Fuse
Information
Check seal on fuse carrier cover for damage. The cover must not be re-used if damaged and
must be replaced.
4. Position fuse carrier cover and tighten fastening screws -1- . → Tightening Torque: 10.1 Nm
(7.5 ft. lb.) .

(CAYENNE S E-HYBRID) > SUBSEQUENT WORK

"Installing"
WM 270855 REPLACING HIGH-VOLTAGE BATTERY (CAYENNE S E-HYBRID) >

TOOLS
Insulated Tool Workshop

WE 1593
Set Equipment
Lifting Tackle VW Tool 3033

TECHNICAL VALUES

value 1 2
Fastening bracket to Lens-head screw (micro- 23 Nm (17

Contact force
high-voltage battery self-locking) ft. lb.)
Mounting For Cover For Lens-Head Screw Tightening 23 Nm (17

HV Battery (Micro-Self-Locking) Torque ft. lb.)
Mounting For Hollow Tightening 10 Nm (7.5

M6 x 14
Section To Battery Torque ft. lb.)

REPLACING HIGH-VOLTAGE BATTERY

"Removing"
2. Remove lifting tackle Lifting tackle 3033 and adapter plates Adapter Plate 9860 from the
→ Always drain the high-voltage battery cooling lines completely before transporting/handling
3. Drain the cooling system completely using compressed air set to max. 2.5 Bar .

4. Remove the two coolant lines for the high-voltage battery and fit them on the new high-voltage
battery. Check that the lines are fitted and sealed correctly.
5. Fit suitable cooling system caps (from the new high-voltage battery) on the cooling system
connections -1- and high-voltage connections of the old high-voltage battery and secure with
adhesive tape.
Fig 2: Identifying Cooling System Connections
Information
The fastening screws for the fastening brackets are micro-self-locking and must not be
re-used.
6. Unscrew fastening brackets -1- from the removed high-voltage battery and fit them on the new
high-voltage battery -2- . Contact Force 23 Nm (17 ft. lb.)
Fig 3: Identifying Fastening Brackets
7. Unscrew hollow section -1- from the removed high-voltage battery and fit it on the new
high-voltage battery -2- . Tightening Torque 10 Nm (7.5 ft. lb.)
Fig 4: Identifying Hollow Section
Information
Stickers (Warning Of Dangerous Electrical Voltage)
The cover and possibly the front cover plate for the high-voltage battery must be replaced
while carrying out the work required for replacing the E-box.
The identification and warning stickers affixed to the cover and cover plate cannot be re-used.
Before re-installing the high-voltage battery, new stickers must be affixed to the new cover and
possibly to the new front cover plate at the same position and with the same text alignment as
on the removed cover plates.
The required safety marking warning sign 8R0.010.539.x must be selected according to the
relevant language and country version.
8. Affix warning signs to the new high-voltage battery.
1. Warning Sign Pictograms
2. Indication Sticker For Lithium-Ion High-Voltage Battery
3. Safety Marking Warning Sign

Fig 5: Warning Sign Stickers
9. Fit lifting tackle Lifting Tackle 3033 and adapter plates Adapter Plate 9860 on the

"Installing"
Information
not be re-used.
11. Screw fastening screws -1- into the high-voltage battery. Tightening Torque 23 Nm (17 ft.
lb.)
Fig 6: Identifying Screw Fastening Screws
12. Screw grub screws -1- into the center bores.

Fig 7: Identifying Grub Screws
WM 2708IN PACKAGING INSTRUCTIONS FOR HIGH-VOLTAGE BATTERY (CAYENNE

S E-HYBRID) > TOOLS
Workshop Workshop
WE 1188
Crane Equipment
Lifting Tackle VW tool 3033

S E-HYBRID) > PRELIMINARY WORK

"Removing"

S E-HYBRID) > PACKING HIGH-VOLTAGE BATTERY IN TRANSPORT BOX
WARNING: Danger of objects or loads falling down
Risk of squashing or crushing
→ Secure components to prevent them from falling down.
Information
Always wear safety gloves when packing the high-voltage battery.
1. Prepare the transport box -1- .
1. 1.1. Prepare cut pieces from honeycomb board. Set consists of two cover and floor
elements and six side elements
1. 1.1.1. Remove cover element -2- .
2. 1.1.2. Remove side elements -3- .
3. 1.1.3. Leave floor element -4- fitted.

Fig 1: Identifying Transport Box, Cover Element And Side Elements
2. 1.2. Remove large plastic bag from the upright box.
3. 1.3. Remove desiccant -2- from the upright box.
4. 1.4. Remove Vermiculite bag -1- from the upright box.

Fig 2: Identifying Vermiculite And Desiccant
→ Always drain the high-voltage battery cooling lines completely before

transporting/handling the high-voltage battery.
2. Drain the cooling system completely when it is outside of the vehicle using compressed air set
to max. 2.5 bar .
Information
Cooling line connections must be closed off to prevent fluid from leaking out during transport.
Coolant leaks and the resulting damage to the high-voltage battery can mean that repairs to
the high-voltage battery can no longer be carried out in certain cases.
3. Fit supplied cooling system caps on cooling system connections -1- and secure with adhesive
tape.
Fig 4: Identifying Cooling System Caps
4. Position adapter plates -1- Adapter Plate 9860 on the high-voltage battery and use fastening
screws -2- to fit them on the high-voltage battery.
Fig 5: Identifying Adapter Plates Screws
5. Fit lifting tackle -1- Lifting Tackle 3033 on the adapter plates -2- .
Fig 6: Identifying Lifting Tackle (3033)
Information
Set the workshop crane Workshop Crane WE 1188 to the fourth detent (500 kg).
6. Workshop Crane WE 1188 must be engaged in the lifting tackle Lifting Tackle 3033 . Then
lift it carefully at the center.
7. Centre transport box lengthways with respect to the workshop crane.
8. Place two honeycomb boards -1- at the short side of the box -x1- .
Information
Make sure not to damage the honeycomb boards when positioning the high-voltage battery.
9. Wrap a large plastic bag around the high-voltage battery and lower it until it is flush with the
two positioned honeycomb boards so that four honeycomb boards -x2- can be positioned at
the opposite side of the box.
Fig 7: Wrapping High-Voltage Battery
10. Remove workshop crane Workshop Crane WE 1188 with lifting tackle Lifting Tackle 3033
from the high-voltage battery.
11. Loosen and remove adapter plates Adapter Plate 9860 from the high-voltage battery.
Information
The threads in the high-voltage battery without fastening screws can remain open.
12. Insert the remaining four honeycomb boards -2- at the opposite side of the box for the
high-voltage battery E-box.
Information
If the remaining honeycomb boards cannot be inserted without damaging them, the
high-voltage battery must be lifted up again and re-aligned.
Fig 8: Identifying Honeycomb Boards
13. Centre the desiccant In the large plastic bag on the long sides of the box.
14. Fold over the large plastic bag and seal with commercially available adhesive tape.
Information
A large plastic bag must be wrapped around the sides. The fold of the bag must be centered
on the long side of the box.
15. Place Vermiculite bag diagonally in the corners of the box.
16. Fit honeycomb board cover element -1- on the high-voltage battery.
Fig 9: Identifying Honeycomb Board Cover Element
17. Place a copy of the test log -1- for classification of lithium-ion high-voltage batteries in the box.
Fig 10: Identifying Test Log
18. Fit cover on the box and seal with the supplied clips.
1. 18.1. Push in clips -A- and check that they engage correctly -B- .
Fig 11: Pushing Clips On Box
19. Affix labels -1, 2, 3, 4- to the transport box.
1. 19.1. Affix "Hazardous goods class 9" label -1- to one long side of the box.
2. 19.2. Affix "UN 3480, lithium-ion batteries" label -2- to one long side of the box to the
right of label -1- .
3. 19.3. Affix document bag -3- to one long side of the box to the right of label -2- .
4. 19.4. Affix "Item number" label -4- to one long side of the box to the right of label -3-
.
Fig 12: Identifying Transport Box Labels
20. Complete accompanying documentation and place it in the document bag together with
another copy of the test log for classification of lithium-ion high-voltage batteries.
Information
The original test log for classification of lithium-ion high-voltage batteries must be kept in the
Porsche Centre.
21. Affix "Item number" label -2- to one short side of the box.
Fig 13: Identifying Transport Box Item Number Label
WM 271219 REMOVING AND INSTALLING BATTERY COVER (ALL MODELS) >

TECHNICAL VALUES
Air vent to battery cover Tightening Torque 2 Nm (1.5 ft. lb.)

PRELIMINARY WORK
1. Loosen the left front seat and tilt it to the rear with lines connected. → 720119 REMOVING
AND INSTALLING FRONT SEAT

REMOVING AND INSTALLING BATTERY COVER
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: Static battery charge
Battery can explode
Electrical discharges
→ Do not rub the battery with a dry cloth.
Information
The battery is located in the battery box under the left front seat .
The vehicle must be supplied with external power at the jump-lead starting points so that the seat
can be moved even when the battery is fully discharged . → WM 2706IN EXTERNAL POWER
CONNECTION, JUMP-LEAD STARTING (ALL MODELS)
Fig 1: Identifying Battery Position
Information
1. When removing the carpeted floor for the first time, cut along the perforation using a carpet
knife.
2. Unscrew screw -1- and remove air guide -2- .
3. Open the tension hooks -arrows- on the battery cover -3- using a suitable tool.
4. Remove battery cover -3- .

Fig 2: Removing Battery Cover
5. The battery cover -3- is installed in reverse order to removal.
6. Tighten screw -1- . Tightening Torque 2 Nm (1.5 ft. lb.)

SUBSEQUENT WORK
1. Install left front seat. → 720119 REMOVING AND INSTALLING FRONT SEAT
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > TECHNICAL

VALUES
Tolerance Tolerance
1 2
Fastening screw securing Tightening 20 Nm (15

generator to engine, M8 Torque ft. lb.)
Tightening 15 Nm (11 ft.

B+ line to generator, M8
Torque lb.)
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > PRELIMINARY
WORK
1. Before the generator can be removed, the battery must be disconnected and the terminal
covered. → DISCONNECTING THE BATTERY
2. Remove air box for throttle housing (intake manifold). → REMOVING AIR BOX FOR
THROTTLE HOUSING - section on "Removing"
3. Remove air cleaner housing lid. → 242455 REPLACING AIR-CLEANER ELEMENT
4. Remove belt tensioner. → REMOVING BELT TENSIONER - section on "Removing"
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > REMOVING

GENERATOR
Fig 1: Overview Of Generator
1. Release the connector -1- and unplug it -arrow A- (-arrow B- ).
2. Screw off fastening nut -2- and pull off the B+ line -3- (-arrow C- ).
Fig 2: Disconnecting Electric Connections On Generator
3. Unscrew fastening screws -3- and remove the generator to the side -arrow- . Press the
generator out of the bracket using a lever if necessary.
Fig 3: Removing Generator
4. Lift generator up and out. Press the upper cooling water hose aside if necessary.
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > INSTALLING

GENERATOR
Information
Before installing the new generator, tap the threaded bushes -1- out by approx. 4 mm .
Fig 1: Identifying Generator Bushes
1. Insert the generator -3- from above.
2. Place the generator in installation position -arrow- and secure with the fastening screws
-arrows 3- .. → Tightening Torque: 20 Nm (15 ft. lb.)
Fig 2: Securing Generator
3. Connect the B+ line -3- to the generator -arrow A- and secure with the fastening nut -2- . →
Tightening Torque: 15 Nm (11 ft. lb.)
4. Plug in connector -1- (-arrow B- ) until it engages securely.

Fig 3: Securing Electric Connections On Generator
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > SUBSEQUENT

WORK
1. Install the belt tensioner. → INSTALLING BELT TENSIONER - section on "Installing"
2. Install air cleaner housing lid. → 242455 REPLACING AIR-CLEANER ELEMENT
3. Install air box for throttle housing (intake manifold). → INSTALLING AIR BOX FOR THROTTLE
HOUSING - section on "Installing"
4. Connect the battery and carry out the work instructions. → CONNECTING THE BATTERY
WM 276019 REMOVING AND INSTALLING STARTER (V6) (CAYENNE GTS &

CAYENNE S) > TECHNICAL VALUES
Tolerance
Location Description Type Basic value Tolerance 1
2
Tightening 45 Nm (33 ft. +8 Nm (+6 ft.

Fastening screw for starter
Torque lb.) lb.)
Fastening nut securing B+ line Tightening 18 Nm (13 ft.
to starter Torque lb.)
Fastening nut securing terminal Tightening 10 Nm (7.5

50 line to starter Torque ft. lb.)

CAYENNE S) > PRELIMINARY WORK
1. Disconnect the battery → DISCONNECTING THE BATTERY .
2. Remove intake-air distributor. → REMOVING INTAKE-AIR DISTRIBUTOR
3. Remove vacuum reservoir. → REMOVING VACUUM RESERVOIR

CAYENNE S) > REMOVING STARTER
Fig 1: Identifying Installation Position Of Starter
1. Loosen screws on the rear cable guide. → Rear cable guide

Fig 2: Locating Rear Cable Guide
2. Screw off fastening nuts -1 and 2- on the electric connections at the starter.
3. Remove electric connections -3 and 4- (-arrow- ).

Fig 3: Fastening Nuts On Electric Connections At Starter
4. Unscrew and remove fastening screws -2- on the cable duct.
5. Disconnect connectors for injectors -1- on cylinder bank 1.

Fig 4: Identifying Cable Duct And Connectors For Injectors
6. Release connector on the rear knock sensor for cylinder bank 1 -1- and disconnect it.
Fig 5: Identifying Cable Plug For Knock Sensor
7. Carefully hold the cable duct to one side.
8. Unscrew and remove fastening screws -1- on the starter.

Fig 6: Identifying Starter Screws
9. Remove starter.
Fig 7: Removing Starter

CAYENNE S) > INSTALLING STARTER
Information
Tightening Torques, tightening sequence and assembly overviews for the engine and transmission:
Group 1: → 1X00IN TECHNICAL VALUES

Fig 1: Identifying Starter Installation Position
1. The starter is installed in reverse order to removal.
1. 1.1. Fastening nut securing terminal 50 to starter Tightening Torque 10 Nm (7.5 ft.
lb.)
2. 1.2. Fastening screws for starter Tightening Torque 45 Nm (33 ft. lb.) +8 Nm (+6 ft.
lb.)
3. 1.3. Fastening nut securing B+ line to starter Tightening Torque 18 Nm (13 ft. lb.)

CAYENNE S) > SUBSEQUENT WORK
1. Install vacuum reservoir. → 245419 REMOVING AND INSTALLING VACUUM RESERVOIR
2. Install intake-air distributor. → 244619 REMOVING AND INSTALLING INTAKE-AIR

DISTRIBUTOR
3. Connect the battery.
WM 276019 REMOVING AND INSTALLING STARTER (V8) (CAYENNE GTS, CAYENNE

S, CAYENNE TURBO & CAYENNE TURBO S) > TECHNICAL VALUES
Basic Tolerance
Location Description Type Tolerance 1
value 2
Fastening screw securing starter Tightening 45 Nm (33 +8 Nm (+6 ft.

to engine housing Torque ft. lb.) lb.)
Tightening 18 Nm (13
Fastening nut for B+ line
Torque ft. lb.)
Tightening 6.5 Nm (5 ft.

Fastening nut for electric line
Torque lb.)

S, CAYENNE TURBO & CAYENNE TURBO S) > PRELIMINARY WORK
1. Disconnect the battery. → 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE

BATTERY .
2. Remove fuel distributor pipe. → REMOVING FUEL DISTRIBUTOR PIPE (FUEL RAIL) -

S, CAYENNE TURBO & CAYENNE TURBO S) > REMOVING STARTER
Fig 1: Installation Position Of Starter
NOTE: Voltage peaks
Risk of damage to electrical load or to the control unit
1. Undo electric change-over valve.
1. 1.1. Pull electric change-over valve -1- off the holder -arrow- and set it aside with
the lines connected.
Fig 2: Removing Electric Change-Over Valve
2. Unscrew fastening nuts -2 and 3- on the starter and remove lines -4 and 5- (-arrow- ).
Fig 3: Removing Fastening Nuts On Starter
3. Unscrew the two fastening screws -6- .

Fig 4: Identifying Fastening Screws
4. Remove the starter.
1. 4.1. Pull starter -7- towards the front in direction of travel -arrow A- and lift it up
-arrow B- .
2. 4.2. Remove line -8- (-arrow C- ).
3. 4.3. Lift the starter -7- up and remove it -arrow D- .


S, CAYENNE TURBO & CAYENNE TURBO S) > INSTALLING STARTER
1. Install the starter.
1. 1.1. Insert the starter -7- from above -arrow A- .
2. 1.2. Fit line -8- (-arrow B- ).
3. 1.3. Lower the starter -7- (-arrow C- ) and slide it into the engine housing -arrow
D- .
Fig 1: Installing Starter
2. Secure the starter with the fastening screws -6- and tighten to → Tightening Torque: 45 Nm
(33 ft. lb.) +8 Nm (+6 ft. lb.) .
Fig 2: Identifying Starter Fastening Screws
3. Position lines -4 and 5- on the starter -arrow- and secure with the fastening nuts -2 and 3- .
→ Tightening Torque: 18 Nm (13 ft. lb.) , → Tightening Torque: 6.5 Nm (5 ft. lb.)
Fig 3: Securing Electric Lines To Starter
4. Push electric change-over valve -1- onto the holder -arrow- .

Fig 4: Securing Electric Change-Over Valve

S, CAYENNE TURBO & CAYENNE TURBO S) > SUBSEQUENT WORK
1. Install fuel distributor pipe. → INSTALLING FUEL DISTRIBUTOR PIPE (FUEL RAIL) - section
on "Installing".
2. Connect the battery. → CONNECTING THE BATTERY
WM 276019 REMOVING AND INSTALLING STARTER (VR6) (CAYENNE) > TECHNICAL

VALUES

value 1 2
Fastening screw securing starter on Tightening 75 Nm (56

-6-
the transmission side, M12 Torque ft. lb.)
Fastening screw securing starter to Tightening 75 Nm (56

-8-
engine block, M12 Torque ft. lb.)
Fastening nut on solenoid switch, M6
Torque lb.)
Tightening 15 Nm (11
Fastening nut for B+ line, M8 -1-
Torque ft. lb.)
WM 276019 REMOVING AND INSTALLING STARTER (VR6) (CAYENNE) >

PRELIMINARY WORK
1. Disconnect battery. → REMOVING BATTERY - section on "Removing"; → DISCONNECTING

THE BATTERY
2. Remove engine guard. → REMOVING ENGINE GUARD - section on "Removing"
WM 276019 REMOVING AND INSTALLING STARTER (VR6) (CAYENNE) > REMOVING

STARTER
WARNING: Working on the vehicle electrical system
Risk of burns
Risk of short circuit or fire.
→ Disconnect the battery.
→ Prevent battery from reconnecting.
→ Cover the battery.
→ Remove ground terminal and cover the terminals.
→ Route electric lines without tensile strength.
→ Secure electric lines to existing lines/components.

Fig 1: Overview Of Starter
1. Open the press-studs -arrow- and remove the heat protection cover on the solenoid switch.
Fig 2: Identifying Press Studs For Heat Insulation Cover
2. Pull off protection cap -A- .
3. Screw off the fastening nut -1- and remove the line from the threaded bolt -B- .
4. Pull off protection cap -3- (-C- ).
5. Screw off the fastening nut -2- and remove the line from the threaded bolt -C- .
Fig 3: Disconnecting Lines On Starter
6. Unscrew the fastening screw -3- and pull line bracket away in a downward direction -A- .
7. Unscrew the fastening screw -4- .
8. Screw off the fastening nuts -5- and remove the holder -B- . To do this, turn the holder slightly
if necessary.
Fig 4: Identifying Starter Fasteners
9. Unscrew the fastening screw -6- on the transmission side of the starter.
Fig 5: Fastening Screw For Starter
10. Unscrew the fastening screw -7- .
11. Unscrew the lower fastening screw -8- on the starter.
12. Pull the line carefully downwards -A- and remove the starter -B- . Turn the starter if
necessary.
WM 276019 REMOVING AND INSTALLING STARTER (VR6) (CAYENNE) > INSTALLING

STARTER
Information
Before installing the starter, check the smooth operation of the thread for securing the starter.
Threads that do not open/close smoothly must be repaired before installing the starter .
1. Pull the line carefully downwards -A- and insert the starter -B- . Turn the starter if necessary
-C- .
Fig 1: Inserting Starter
2. Lift the starter forwards and screw in fastening screw -8- but do not tighten it.
3. Screw in the fastening screw -6- on the transmission side and tighten the two fastening
screws on the starter. → Tightening Torque: 75 Nm (56 ft. lb.) , → Tightening Torque: 75
Nm (56 ft. lb.)
Fig 2: Identifying Fastening Screw For Starter
4. Insert the holder -A- and screw on the fastening nuts -5- , but do not tighten them.
5. Screw in and tighten the fastening screw -4- , then tighten the fastening nuts -5- .
6. Place the protective tube in installation position -B- and secure with the fastening screw -3- .
Fig 3: Identifying Starter Fasteners
7. Connect the line to the threaded bolt -A- and secure with the fastening nut -2- . → Tightening
Torque: 8 Nm (6 ft. lb.)
8. Fit protection cap -3- (-A- ).
9. Connect the line to the B+ connection -B- and secure with the fastening nut -1- . →
10. Fit protection cap on the B+ connection -C- .
Fig 4: Securing Lines On Starter
11. Place heat protection cover around solenoid switch -A- and secure with the press-studs -B- .
Fig 5: Pressing Studs For Heat Insulation Cover
12. Secure the line with the fastening screw -7- .

Fig 6: Screwing Down Line
WM 276019 REMOVING AND INSTALLING STARTER (VR6) (CAYENNE) >

SUBSEQUENT WORK
1. Install engine guard. → INSTALLING ENGINE GUARD - section on "Installing"
2. Connect the battery. → INSTALLING BATTERY - section on "Installing"; → CONNECTING

THE BATTERY
WM 278515 ADJUSTING CONTROL UNIT FOR DISTANCE MEASURING SENSOR (ALL

MODELS) > TOOLS

Wheel Alignment
Workshop
System ML 5000 WE 1272
Equipment
Porsche
Axle Alignment System

Workshop
With DSP508XF WE 1328
Equipment
Sensors
Adjustment Device
Workshop
With Reflector VAS WE 1362
Equipment
6430/1
Mirror For Adjustment Workshop
WE 1363
Device VAS 6430/3 Equipment
T-socket wrench for

Workshop
ACC sensor VAS WE 1364
Equipment
6190/2

MODELS) > PRELIMINARY WORK
The distance measuring sensor must be re-adjusted as part of the following tasks
1. Suspension was aligned and adjusted.
2. The distance measuring sensor (ACC sensor) control unit and/or the control unit holder was
removed, replaced and re-installed.
3. The lock carrier was loosened.
4. The front end is damaged.
5. Fault memory entry: ACC sensor incorrectly adjusted (D00004).
1. 5.1. The misalignment angle is outside of the range -1.5° to +1.5°.

MODELS) > PRELIMINARY WORK > TEST PREREQUISITES
1. The tread depth on one axle must not differ by more than 2 mm.
2. Air pressure of tires in accordance with regulations (regardless of "Comfort" or "Normal" air
pressure).
3. As with complete suspension alignment, make sure that there is no sliding base or turnplate at
the end stop during alignment.
1. 3.1. Take the track width and wheel base into consideration.
4. Check that vehicle weight corresponds to empty weight. Weight of the vehicle ready for driving
(completely full fuel tank and water tank for the windscreen washer/headlight cleaning system,
spare wheel, tool kit, jack) without driver.
5. Spare wheel, tool kit, jack must be located at the positions specified by the vehicle
manufacturer.
6. Vehicle aligned correctly, having been bounced and allowed to settle multiple times.
7. Check wheel suspension, steering and steering linkage for play and damage.
1. 7.1. Carry out repairs if necessary.
8. Adjust vehicles with levelling system (air spring) to normal level*.
1. 8.1. *Information: Engine/ignition off, doors closed, lock the vehicle.
2. 8.2. Wait for 15 seconds (air spring corrects vehicle).
3. 8.3. Unlock vehicle, open door and leave open during measurement, switch on
ignition.

MODELS) > PRELIMINARY WORK > DESIGN OF MEASURING SYSTEM
Information
Check that there is sufficient floor space between the vehicle and the adjustment device - the gap
between the adjustment device and vehicle must be approx. 120 cm.
The vehicle can be reversed onto the axle alignment platform if there is not enough floor space in front
of the measuring platform.
The vehicle must be positioned so that the front and rear axles are centered on turnplates/sliding plates.
Information
The procedure described here is for the wheel alignment system ML 5000 Porsche WE 1272 and the
axle alignment system with DSP508XF sensors WE 1328 .
Deviations can occur with other alignment systems.
1. Fit instrument holders onto the wheels on the rear axle.
2. Fit the rear sensors on the rear axle using the spoiler adapter (Beissbarth only, this sets the
sensors to a lower position).
3. Align the rear sensors on the rear axle using the spirit level and clamp the instrument holders
using the wing screws.
Information
Once the vehicle and adjustment tool are aligned, the vehicle and adjustment tool must no
longer be moved.
1. The vehicle is standing on turnplates/sliding plates that are released on one side ,
allowing the vehicle to be moved slightly .
2. If the vehicle is moved while taking measurements on the turnplates, the measurement
process must be repeated .
3. If the adjustment tool is moved following alignment, the measurement process must be
repeated .
4. Attach front sensors to the measuring mirror, align using the spirit level and clamp.
1. 4.1. Centre the adjustment tool.
2. 4.2. Set distance of adjustment tool and vehicle in accordance with the specifications
provided by the measuring equipment manufacturer.
3. 4.3. The distance between the left sensor and the vehicle -Bl- should be identical to
the distance between the right sensor and the vehicle -Br- .
Fig 1: Adjusting Device Setup
5. Switch on (initialize) the sensors.

MODELS) > PRELIMINARY WORK > PREPARATION FOR ADJUSTING DISTANCE
MEASURING SENSOR
1. Connect a battery charger with a current rating of at least 40 A to the external power feed
points.
2. Read out the fault memory using PIWIS Tester II 9818 , create a VAL if necessary → 0X03IN
CREATING VEHICLE ANALYSIS LOG (VAL) and correct any faults.
Fig 1: Identifying Diagnostic Socket
3. Adjust vehicles with levelling system (air spring) to normal level*.
1. 3.1. *Information: Engine/ignition off, doors closed, lock the vehicle.

2. 3.2. Wait for 15 seconds (air spring corrects vehicle).
3. 3.3. Unlock vehicle, open door and leave open during the measurement, switch on
ignition.
4. Remove cover on sensor. → Removing cover

Fig 2: Removing Cover
1. 4.1. Release cover at the top -arrows- .
2. 4.2. Fold cover forward and remove it.
5. Clean sensor and cover using a commercially available cleaning agent.
6. Fit the front sensors onto the adjustment device, align using spirit levels and clamp using the
wing screws, and switch them on (initialize).
7. The gap between the ACC adjustment device adjustment device with reflector VAS 6430/1
WE 1362 and the vehicle must be approx. 120 cm.
1. 7.1. Position the ACC adjustment device adjustment device with reflector VAS
6430/1 WE 1362 at a distance of 130 +/- 10 cm between the sensor lens and
mirror face mirror for adjustment device VAS 6430/3 WE 1363 .
2. 7.2. The distance between the left sensor and the vehicle -Bl- should be identical to
the distance between the right spirit level and the vehicle -Br- .
Fig 3: Adjusting Device Setup
8. On the adjustment device, move the mirror into position -2- so that it is aligned with the
marking (-A- number 2 on the rotary knob must point towards the vehicle).
Fig 4: Positioning Adjustment Device
Information
Once the vehicle and adjustment tool are aligned, the vehicle and adjustment tool must no
longer be moved.
1. The vehicle is standing on turnplates/sliding plates that are released on one side ,
allowing the vehicle to be moved .
2. If the vehicle is moved while taking measurements on the turnplates, the measurement
process must be repeated .
3. If the adjustment tool is moved following alignment, the measurement process must be
repeated .
9. Release turnplates/sliding plates on One Side Of The Vehicle .
10. Open the corresponding menu (Use Operating Instructions For Measuring Platform) in
order to adjust the distance measuring sensor.
11. Before starting the adjustment process, use the laser beam -3- at the mirror on the adjustment
device (for switching on the laser beam >> see operating instructions for adjustment device) to
check that the laser beam strikes the sensor lens. Info:
1. 11.1. The adjustment device is aligned (positioned) correctly if the laser beam still
strikes the sensor lens even after the identical individual toe values have been set.
2. 11.2. If the laser beam does not strike the sensor lens, alignment of the adjustment
device must be repeated.
Fig 5: Identifying Laser Beam At Mirror
12. Align adjustment device at the side:
1. 12.1. The laser beam of the adjustment device must strike the center of the sensor
lens.
Fig 6: Aligning Adjustment Device
13. Use the adjusting screws -1, 2, 3, 4, 5- on the adjustment device to level the mirror's spirit
levels -A, B- .
Fig 7: Aligning Mirror's Spirit Levels
14. Use the crank -arrow- on the adjustment device to adjust the mirror so that the laser beam
(for switching on the laser beam >> see operating instructions for adjustment device) strikes
the center of the sensor lens on the vertical line.
Fig 8: Example Of Adjustment Bar Display
15. Turn the adjustment bar on the adjustment device to the side using the adjusting screw -5-
until the green indicator on the adjustment bar is displayed on the measuring platform screen.
Fig 9: Example Of Hunter Display

MODELS) > ADJUSTING CONTROL UNIT FOR DISTANCE MEASURING SENSOR
1. A battery charger with a current rating of at least 40 A must be connected to the external
power feed points.
2. Connect PIWIS Tester II 9818 to the vehicle and start it.
3. Switch on ignition.
4. Select the required vehicle and select Adaptive Cruise Control control unit, then press [F12]
to continue.
5. In the Adaptive Cruise Control menu, select the Maintenance/Repairs submenu and press
[F12] to continue.
6. Follow the instructions on the Tester and, if necessary, adjust the sensor -1- using the
adjusting tool T-Socket Wrench For ACC Sensor VAS 6190/2 WE 1364 in line with the
Tester specifications.
Fig 1: Adjusting Screws For Distance Measuring Sensor
7. The process must be repeated until the message Adjustment Successful is displayed on the
Tester.

MODELS) > SUBSEQUENT WORK
1. Switch off ignition and remove remote control (hand-held transmitter).

2. PIWIS Tester II 9818 can now be disconnected from the vehicle.
3. Disconnect the battery charger.
4. Remove sensors and instrument holders.
Information
Before and after fitting the trim cover for the distance measuring sensor control unit, check the
following points:
1. The holder for the distance measuring sensor control unit must not show any signs of
deformation, which may have been caused, for example, by removing or installing the
trim cover for the distance measuring sensor control unit. If the holder for the distance
measuring sensor control unit is deformed, carefully push it back into shape .
2. If the trim cover is damaged or cracked, replace the trim cover .
3. After fitting the trim cover, check that it is seated correctly and securely .
5. Install cover on sensor and clip it in at the top -arrows- .

Fig 1: Installing Cover
6. Perform a test drive and check operation of distance measuring sensor control unit.
7. Read out the fault memory of the distance measuring sensor (ACC) control unit and erase it if
necessary.
WM 278519 REMOVING AND INSTALLING CONTROL UNIT FOR DISTANCE

MEASURING SENSOR (ALL MODELS) > TECHNICAL VALUES

value 1 2
Holder for distance measuring

Internal Torx Tightening 8 Nm (6
sensor control unit to closing
screw, M6 x 12 Torque ft. lb.)
panel

MEASURING SENSOR (ALL MODELS) > REMOVING CONTROL UNIT FOR DISTANCE
MEASURING SENSOR
1. Switch off ignition and pull remote control out of ignition lock.
2. Remove cover on sensor. → Removing cover


1. 2.1. Release cover at the top -arrows- .
2. 2.2. Fold cover forward and remove it.
3. Release electric plug connection -arrow a- and disconnect it -arrow b- .

Fig 2: Disconnecting Electric Plug Connection
4. Unclip electric wire harness from holder for distance measuring sensor control unit.
5. Unscrew fastening screws -1- .

Fig 3: Identifying Sensor Control Unit Screws
6. Remove holder together with control unit for distance measuring sensor.

MEASURING SENSOR (ALL MODELS) > INSTALLING CONTROL UNIT FOR
DISTANCE MEASURING SENSOR
Information
Before and after fitting the trim cover for the distance measuring sensor control unit, check the
following points:
1. The holder for the distance measuring sensor control unit must not show any signs of
deformation, which may have been caused, for example, by removing or installing the
trim cover for the distance measuring sensor control unit. If the holder for the distance
measuring sensor control unit is deformed, carefully push it back into shape .
2. If the trim cover is damaged or cracked, replace the trim cover .
3. After fitting the trim cover, check that it is seated correctly and securely .
Tighten fastening screws. Tightening Torque 8 Nm (6 ft. lb.)

MEASURING SENSOR (ALL MODELS) > SUBSEQUENT WORK > SUBSEQUENT
WORK AFTER REMOVING AND INSTALLING CONTROL UNIT FOR DISTANCE
MEASURING SENSOR
If the distance measuring sensor control unit was removed and installed or replaced, the distance
measuring sensor control unit will need to be re-adjusted on a measuring platform using adjustment tool
VAS 6430 . → 278515 ADJUSTING CONTROL UNIT FOR DISTANCE MEASURING SENSOR .
WM 278555 REPLACING CONTROL UNIT FOR DISTANCE MEASURING SENSOR

(ALL MODELS) > TOOLS

(ALL MODELS) > TECHNICAL VALUES

(ALL MODELS) > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
1. Connect the Porsche System Tester to the vehicle and start the System Tester.
2. Switch on ignition and press [F12] to continue.
4. Select Adaptive cruise control control unit in the overview .
6. Control unit replacement must now be selected. Then press [F12] to continue.
7. Read data must be selected. Then press [F12] to continue.
9. Check the chassis number and press [F12] to continue.
CONTROL UNIT FOR DISTANCE MEASURING SENSOR
11. Switch on ignition. Select the Write data menu (procedure described above), press [F12] to
continue and then press [F8] to start installing the data that was read out.
12. The System Tester displays the message Data has been written . Press [F12] to continue.

WM 279019 REMOVING AND INSTALLING ELECTRIC MOTOR WITH DECOUPLER
(HYBRID MODULE) (CAYENNE S HYBRID) > PRELIMINARY WORK
1. Observe warning notes. → WM 2X00IN GENERAL WARNING NOTES FOR WORKING ON

THE HIGH-VOLTAGE VEHICLE ELECTRICAL SYSTEM (CAYENNE S E-HYBRID)
2. Isolate the high-voltage electrical system from the power supply and complete the relevant
POWER SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM .
3. Remove the engine. → REMOVING V6 HYBRID ENGINE - section on "Removing".
4. Unscrew the transmission from the engine. → REMOVING TRANSMISSION - section on

"Removing".

(HYBRID MODULE) (CAYENNE S HYBRID) > REMOVING ELECTRIC MOTOR WITH
DECOUPLER (HYBRID MODULE)
The procedure is described in the document → 100127 REMOVING ENGINE FROM TRANSMISSION
AND MOUNTING ENGINE ON TRANSMISSION .

(HYBRID MODULE) (CAYENNE S HYBRID) > INSTALLING ELECTRIC MOTOR WITH

(HYBRID MODULE) (CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Install transmission on engine. → INSTALLING TRANSMISSION - section on "Installing".
2. Start the high-voltage electrical system and complete the relevant documentation. → 2X00IN
HIGH-VOLTAGE ELECTRICAL SYSTEM .
3. Read about how to calibrate the electric motor in "Guided Fault Finding and the latest
Technical Information releases for special tasks to be performed after servicing and repairing
the Cayenne Hybrid".
WM 279119 REMOVING AND INSTALLING FUSE FOR POWER ELECTRONICS FOR

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > TOOLS

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > TECHNICAL VALUES
value 1 2
Cover on power electronics unit
Torque lb.)
Media shield to power electronics Tightening 7 Nm (5 ft.

unit Torque lb.)
Fuse for power electronics unit to Tightening 2 Nm (1.5

power electronics unit Torque ft. lb.)

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > INFORMATION
Information
Further steps may only be carried out if the voltage measured at the power electronics is < 5 V. If this is
not the case, stop working on the system and contact Technical Support.
Fig 1: Identifying Power Electronics Unit Installation Position

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > PRELIMINARY WORK
3. Disconnect the battery. → 978509 LOOSENING AND SECURING GROUND STRAP FOR
BATTERY
4. Remove engine compartment cover at the left. → 700219 REMOVING AND INSTALLING
FRONT TRIM PANEL (ENGINE COMPARTMENT)
5. If fitted: Remove acoustic simulator.

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > REMOVING FUSE FOR POWER
ELECTRONICS UNIT
1. Unclip clips for high-voltage line at the media shield.
2. Unscrew media shield -1- .

Fig 1: Identifying Media Shield Screws
3. Release and disconnect high-voltage connector for air-conditioning compressor
1. 3.1. Release 1: Press red tab -a- and pull it -A-
2. 3.2. Release 2: Press black knob -b- and pull it off -B-
Fig 2: Disconnecting High-Voltage Connector
4. Check that power electronics unit for high-voltage system -1- is de-energized.
Information
Further steps may only be carried out if the voltage measured at the power electronics is < 5 V.
If this is not the case, stop working on the system and contact Technical Support.
Fig 3: Identifying High-Voltage System
5. Unscrew cover on power electronics unit -1- .

Fig 4: Identifying Power Electronics Unit Cover
6. Loosen fastening screws -1- on fuse for power electronics for the high-voltage system -2- and
remove fuse.
Fig 5: Identifying Power Electronics Unit Fuse

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > INSTALLING FUSE FOR POWER
ELECTRONICS UNIT
1. Position fuse for power electronics unit for high-voltage system -2- and tighten fastening
screws -1- . Tightening Torque 2 Nm (1.5 ft. lb.)
Fig 1: Identifying Power Electronics Unit Fuse
Information
As soon as the cover on the power electronics unit is removed, it must be replaced by a new
cover for safety reasons.
2. Fit and secure cover on power electronics unit -1- . Tightening Torque 7 Nm (5 ft. lb.)
Fig 2: Installing Power Electronics Unit Cover
3. Plug in high-voltage connector for air-conditioning compressor at the power electronics unit
until it engages securely.
Information
Check that the HV connector is locked correctly. The hook (red) must be locked after
connecting the HV connector.
4. Fit and secure media protective plate. Tightening Torque 7 Nm (5 ft. lb.)
5. Clip high-voltage lines onto media protective plate.

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > SUBSEQUENT WORK
1. If fitted: Install acoustic simulator.
2. Install engine compartment cover at the left. → INSTALLING FRONT TRIM PANEL (ENGINE
COMPARTMENT)
3. Connect the battery. → 978509 LOOSENING AND SECURING GROUND STRAP FOR
BATTERY
4. Start the vehicle again and complete the relevant documentation. → 2X00IN ISOLATING
HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER SUPPLY/STARTING
WM 279155 REPLACING POWER ELECTRONICS FOR HIGH-VOLTAGE SYSTEM

Insulated Tool Workshop

WE 1593
Set Equipment


(CAYENNE S E-HYBRID) > TEACHING POWER ELECTRONICS
NOTE: Voltage drop
battery.
Information
Tester releases.
Information
All remote controls (keys) are required for teaching a DME, front-end electronics (front BCM), rear-end
electronics (rear BCM), electronic steering lock (ELV) control unit or remote controls (keys) for example.
Remote controls (keys) that are not taught during this teaching procedure will no longer be recognized
by the vehicle.
1. Switch off ignition and replace power electronics unit. → 279119 REMOVING AND
INSTALLING POWER ELECTRONICS FOR HIGH-VOLTAGE SYSTEM
2. Connect the PIWIS Tester to the vehicle and start the diagnostic application. Switch on ignition.
3. To activate the control units, switch on the hazard warning lights.
4. Select the On-Line Teaching Function menu on the Start page.
5. Vehicle must now be selected. Then press [F12] to continue. Vehicle data will be read out.
6. The vehicle identification number (VIN) is displayed. Change the vehicle identification number
if necessary.
7. Enter the repair order number and press [F12] to continue.
8. Enter the PPN user name and password and press [F12] to continue.
9. Login is performed.
10. The Tester displays the message Login Successful . Press [F12] to continue.
11. Follow the instructions on the Tester and perform the teaching process.
12. Once the teaching process is completed successfully, the Tester shows the components that
were taught and the overall status of the vehicle, for example: Taught . Press [F12] to
continue.
13. Press [EXIT] To End The On-Line Teaching Function and select the Vehicle Type on the
Start page.
14. Select the High-Voltage Power Electronics control unit in the Overview .
15. Select the Codings/Adaptations menu and carry out the Automatic Coding function in
accordance with the instructions on the Tester.
16. Press [F7] Read All Fault Memories And Erase If Required and delete all faults.
17. Function test: Lock, open and start the vehicle using all remote controls (hand-held
transmitters).
WM 279219 REMOVING AND INSTALLING ELECTRIC MOTOR (CAYENNE S HYBRID)

> PRELIMINARY WORK
4. Unscrew the transmission from the engine. → REMOVING TRANSMISSION - section on

"Removing".

> REMOVING ELECTRIC MOTOR

> INSTALLING ELECTRIC MOTOR

> SUBSEQUENT WORK
1. Install transmission on engine. → INSTALLING TRANSMISSION - section on "Installing".
3. Read about how to calibrate the electric motor in "Guided Fault Finding and the latest
the Cayenne Hybrid".

(HYBRID MODULE) (CAYENNE S E-HYBRID) > TOOLS
Insulated Tool Set Workshop equipment WE 1593

(HYBRID MODULE) (CAYENNE S E-HYBRID) > PRELIMINARY WORK
3. Remove engine. → REMOVING V6 HYBRID ENGINE - section on "Removing".
4. Unscrew transmission from the engine. → REMOVING AUTOMATIC TRANSMISSION

(HYBRID MODULE) (CAYENNE S E-HYBRID) > REMOVING ELECTRIC MOTOR WITH

(HYBRID MODULE) (CAYENNE S E-HYBRID) > INSTALLING ELECTRIC MOTOR WITH

(HYBRID MODULE) (CAYENNE S E-HYBRID) > SUBSEQUENT WORK
1. Install transmission on engine. → 373519 REMOVING AND INSTALLING AUTOMATIC

TRANSMISSION .
3. Read about how to calibrate the electric motor in "Guided Fault Finding" and the latest
Technical Information releases for special tasks to be performed after servicing and repair
work.
WM 279319 REMOVING AND INSTALLING HIGH-VOLTAGE LINE BETWEEN

HIGH-VOLTAGE CHARGER AND HIGH-VOLTAGE BATTERY (CAYENNE S E-HYBRID)
> TOOLS

> PRELIMINARY WORK
4. Remove side trim panel for rear luggage compartment at the left. → REMOVING SIDE TRIM
PANEL FOR REAR LUGGAGE COMPARTMENT - section on "Removing"
5. Remove cover for rear lock support. → REMOVING COVER FOR REAR LOCK SUPPORT -

> REMOVING HIGH-VOLTAGE LINE BETWEEN HIGH-VOLTAGE CHARGER AND
HIGH-VOLTAGE BATTERY > REMOVING HIGH-VOLTAGE LINE
Fig 1: Identifying High-Voltage Line Installation Position
1. Release high-voltage connector -1- from the high-voltage battery -2- and disconnect it.
2. Open cable duct -3- and remove right high-voltage line -4- .
Fig 2: Disconnecting High-Voltage Line
3. Unclipping high-voltage line
4. Release high-voltage connector -1- from the high-voltage charger -2- and disconnect it.
Fig 3: Disconnecting High-Voltage Connector From High-Voltage Charger

> INSTALLING HIGH-VOLTAGE LINE BETWEEN HIGH-VOLTAGE CHARGER AND
HIGH-VOLTAGE BATTERY

> SUBSEQUENT WORK
1. Install cover for rear lock support. → INSTALLING COVER FOR REAR LOCK SUPPORT -
section on "Installing"
2. Install side trim panel for rear luggage compartment at the left. → INSTALLING SIDE TRIM
PANEL FOR REAR LUGGAGE COMPARTMENT - section on "Installing"
WM 279319 REMOVING AND INSTALLING HIGH-VOLTAGE LINE FROM

BATTERY/HIGH-VOLTAGE CHARGER TO POWER ELECTRONICS/PTC AT THE
FRONT (CAYENNE S E-HYBRID) > TOOLS

FRONT (CAYENNE S E-HYBRID) > TECHNICAL VALUES
Tolerance Tolerance
1 2
High-voltage line cover to Fastening nut Tightening 9 Nm (6.5 ft.

body -4- Torque lb.)


FRONT (CAYENNE S E-HYBRID) > PRELIMINARY WORK
1. Read and comply with warning notes. → 2X00IN GENERAL WARNING NOTES FOR
WORKING ON THE HIGH-VOLTAGE ELECTRICAL SYSTEM .
3. Remove rear side trim panel at the left. → REMOVING SIDE TRIM PANEL FOR REAR
LUGGAGE COMPARTMENT - section on "Removing".
4. Remove cover for left underbody. → 519319 REMOVING AND INSTALLING COVER FOR
CENTER UNDERBODY .
5. Remove the lower fastening clamp from the heat shield next to the left front silencer.
6. Remove left front wheel.
7. Remove front wheel housing liner at the left. → 505619 REMOVING AND INSTALLING
FRONT WHEEL HOUSING LINER
8. Remove power electronics for high-voltage system. → 279119 REMOVING AND INSTALLING
POWER ELECTRONICS FOR HIGH-VOLTAGE SYSTEM

FRONT (CAYENNE S E-HYBRID) > REMOVING HIGH-VOLTAGE LINE FROM BATTERY
TO POWER ELECTRONICS
Fig 1: High-Voltage Line Routing Diagram
1. Release and disconnect high-voltage connector from auxiliary heater (front PTC) -1- .
2. Release and disconnect electric plug connection -2- .
3. Unscrew coolant line -3- .
4. Cut tie-wraps -4- and unscrew fastening screw for cable guides -5- .
5. Guide high-voltage line down through the gap opening on the heat shield -6- .
Fig 2: Disconnecting High-Voltage Line From Front PTC
6. Unscrew the three fastening nuts -1- for the high-voltage line (engine area).
1. 6.1. Cut the tie-wraps for the high-voltage line cover -arrow- and remove cover in a
downward direction.
Fig 3: Removing High-Voltage Line Cover
7. Unscrew universal joint at the steering column and set it aside. → 481519 REMOVING AND
INSTALLING STEERING COLUMN
8. Open the two corrugated tube clips and unclip the high-voltage lines from the two corrugated
tube holders -1- (left door sill area, center).
1. 8.1. Cut tie-wraps -arrow- .

Fig 4: Removing High-Voltage Line
9. Remove the two fixing clips -1- (left door sill area, rear).
10. Unclip the cable guides on the body (expanding anchor) three times -arrow- .
11. Unclip the high-voltage lines from the corrugated tube holder -1- (left door sill area, rear).
12. Remove high-voltage line in luggage compartment area.
1. 12.1. Unscrew coolant lines -1- and set them aside.

Fig 7: Removing Coolant Lines
2. 12.2. Unclip high-voltage line from battery to high-voltage charger -1 - .
3. 12.3. Unclip high-voltage line from power electronics to high-voltage charger -6- .
4. 12.4. Unscrew the three fastening nuts -2- for the high-voltage line cover -3- and
remove it.
5. 12.5. Open the cable duct -4- .
6. 12.6. Release and disconnect high-voltage connector for high-voltage line for
on-board charger -7- .
7. 12.7. Unscrew high-voltage lines from the battery -5- .
8. 12.8. Guide the rubber sleeve for the cable bushing for the high-voltage lines on the
body floor (luggage compartment area) down through the body floor -A- .
9. 12.9. Pull out the high-voltage lines in a downward direction -B- .


FRONT (CAYENNE S E-HYBRID) > INSTALLING HIGH-VOLTAGE LINE FROM
BATTERY TO POWER ELECTRONICS
Information
For correct longitudinal positioning in the vehicle, a plastic eyelet is fitted on the high-voltage wire
harness for the hybrid battery close to the line shielding in the luggage compartment. During installation,
this plastic eyelet must be attached to the center threaded bolt on the line shielding in the luggage
compartment.
1. Install high-voltage line in luggage compartment area.
1. 1.1. Push the high-voltage lines down through the opening in the luggage
compartment floor -A- .
2. 1.2. Coat the rubber sleeve with sliding compound and press it onto the body until
the rubber sleeve is positioned correctly.
3. 1.3. Push the plastic eyelet of the high-voltage line onto the fastening bolt. Fit the
cover -3- and secure with the three fastening nuts -2- . → Tightening Torque: 9
Nm (6.5 ft. lb.) .
4. 1.4. Plug high-voltage lines into the high-voltage battery -5- and secure them. →
270819 REMOVING AND INSTALLING HIGH-VOLTAGE BATTERY
5. 1.5. Plug in high-voltage line for the high-voltage charger -7- until it engages
securely.
6. 1.6. Place high-voltage lines in the cable duct -4- and fit cable duct.
7. 1.7. Clip in high-voltage line from battery to high-voltage charger -1- .
8. 1.8. Clip in high-voltage line from power electronics to high-voltage charger -6- .
Fig 1: Installing High-Voltage Line
9. 1.9. Screw on coolant line -1- .

Fig 2: Identifying Coolant Line Screws
2. Clip the two high-voltage lines into the corrugated tube holders -1- (left door sill area, rear).
1. 2.1. Close corrugated tube holders.

Fig 3: Installing High-Voltage Lines
3. Clip in the cable guides on the body (expanding anchor) three times -arrow- .
4. Install the high-voltage lines using the two fixing clips -1- (left door sill area, rear).
5. Clip the high-voltage lines into the two corrugated tube holders -1- (left door sill area, center).
1. 5.1. Close corrugated tube holders.
2. 5.2. Secure the high-voltage line with a tie-wrap -arrow- .

6. Secure universal joint to the steering column. → 481519 REMOVING AND INSTALLING
STEERING COLUMN
7. Install high-voltage line in engine area.
1. 7.1. Fit high-voltage line cover and screw on the three fastening nuts -1- . →
Tightening Torque: 9 Nm (6.5 ft. lb.) .
2. 7.2. Secure the high-voltage line and cover using three tie-wraps -arrow- .
Fig 6: Installing High-Voltage Line Cover
8. Fit high-voltage line through the gap opening on the heat shield -6- into the wheel housing.
9. Secure cable guides using tie-wraps -4- and tighten fastening screw on the cable guides -5- .
10. Plug in electric plug connection -2- until it engages securely.
11. Plug in high-voltage connector for auxiliary heater (front PTC) -1- until it engages securely.
12. Screw on coolant line -3- .

Fig 7: Securing High-Voltage Line For Front PTC
Information
The plug connection and connector holder must be checked for wear and damage before
connecting the high-voltage lines.
The high-voltage lines are color-coded and must only be connected to the color-coded
connector holder.
The high-voltage lines can only be connected at one position. Check the connection position
before connecting the lines.

FRONT (CAYENNE S E-HYBRID) > SUBSEQUENT WORK
1. Install fuel tank. Install the left running board on the fuel tank and fit the two restraining straps
at the front left. → INSTALLING FUEL TANK - section on "Installing".
2. Fill the fuel tank. → 200317 DRAINING AND FILLING FUEL .
3. Install the lower fastening clamp on the heat shield next to the left front silencer.
4. Install cover for left underbody. → 519319 REMOVING AND INSTALLING COVER FOR
CENTRE UNDERBODY .
5. Install side trim panel at the rear right. → INSTALLING SIDE TRIM PANEL FOR REAR
LUGGAGE COMPARTMENT - section on "Installing".
7. Install front wheel housing liner at the left. → 505619 REMOVING AND INSTALLING FRONT
WHEEL HOUSING LINER
8. Install left front wheel.
WM 279319 REMOVING AND INSTALLING HIGH-VOLTAGE LINE FROM POWER

ELECTRONICS TO AIR-CONDITIONING COMPRESSOR (CAYENNE S E-HYBRID) >
TOOLS

PRELIMINARY WORK
3. Remove engine compartment cover at the left. → 700219 REMOVING AND INSTALLING
4. If fitted: Remove acoustic simulator.

REMOVING HIGH-VOLTAGE LINE FROM POWER ELECTRONICS TO
AIR-CONDITIONING COMPRESSOR
Fig 1: Identifying High-Voltage Line Installation Position
1. Unclip high-voltage line.
2. Unscrew media shield -1- .

Fig 2: Identifying Media Shield
3. Release high-voltage connector at the power electronics unit and disconnect it.
1. 3.1. Release 1: Press red tab -a- and pull it -A-
2. 3.2. Release 2: Press black knob -b- and pull it off -B Removing
4. Release high-voltage line at the air-conditioning compressor and disconnect it.
5. Carefully remove high-voltage line.

INSTALLING HIGH-VOLTAGE LINE FROM POWER ELECTRONICS TO

SUBSEQUENT WORK
1. If fitted: Install acoustic simulator.
2. Install engine compartment cover at the left. → 700219 REMOVING AND INSTALLING
3. Start the vehicle again and complete the relevant documentation. → 2X00IN ISOLATING
HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER SUPPLY/STARTING

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > TOOLS

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > TECHNICAL
VALUES

value 1 2
Line bracket for high-voltage Fastening Tightening 8 Nm (6 ft.

line to electric motor screws - 3- Torque lb.)
High-voltage line to electric Tightening 20 Nm (15

Fastening nut -2-
motor Torque ft. lb.)
Connection box cover on Fastening Tightening 7 Nm (5 ft.

electric motor screws - 1- Torque lb.)

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > PRELIMINARY
WORK
3. Remove engine. → REMOVING V6 HYBRID ENGINE - section on "Removing".

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > REMOVING
HIGH-VOLTAGE LINE FROM POWER ELECTRONICS TO ELECTRIC MOTOR >
REMOVING HIGH-VOLTAGE LINE
Information
Always replace all three high-voltage lines if necessary.
Use new seals.
Use new screws.
Check contacts on the line connections for corrosion and clean them if necessary.
Fig 1: High-Voltage Line Routing Diagram
1. Unscrew and remove the four fastening screws -1- for the cover. Then lift up the cover and
swivel it to one side.
2. Unscrew and remove the three fastening nuts -2- for the high-voltage line contacts.
3. Unscrew and remove the fastening screws -3- for the high-voltage lines on the electric motor.
Fig 3: Identifying High-Voltage Contacts Nuts And Screws
4. Lift up high-voltage line -4- , turn it approx. 75 ° to the left and carefully pull it out of the electric
motor.
1. 4.1. Lift up high-voltage line -5- , turn it approx. 75 ° to the right and carefully pull it
out of the electric motor.
Fig 4: Removing High-Voltage Lines

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > INSTALLING
INSTALLING HIGH-VOLTAGE LINE
Information
Use new seals.
Use new screws.
Information
The three high-voltage lines are coded differently.

Fig 1: Identifying High-Voltage Line And Electric Motor Coding
Make sure that the coding for the electric motor matches the coding for the line.
Information
Always replace the connection box cover seal for the electric motor after opening it.
1. Push the three high-voltage lines -6, 5, 4- one after the other into the electric motor, attach
them to the contacts and secure with the fastening screws -3- . → Tightening Torque: 8 Nm
(6 ft. lb.) .
2. Secure the contacts of the three high-voltage lines with the fastening nuts -2- . → Tightening
Fig 3: Identifying High-Voltage Line Contacts
3. Fit the cover for the electric motor and secure with the four fastening screws -1- . →
Fig 4: Fitting Electric Motor Cover

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > SUBSEQUENT
WORK
1. Install engine. → INSTALLING V6 HYBRID ENGINE - section on "Installing".
WM 279319 REMOVING AND INSTALLING HIGH-VOLTAGE LINE FROM BATTERY TO

POWER ELECTRONICS (CAYENNE S HYBRID) > TECHNICAL VALUES
Tolerance Tolerance
1 2


POWER ELECTRONICS (CAYENNE S HYBRID) > PRELIMINARY WORK
3. Remove rear side trim panel at the left. → REMOVING SIDE TRIM PANEL FOR REAR
LUGGAGE COMPARTMENT - section on "Removing".
4. Remove cover for left underbody. → 519319 REMOVING AND INSTALLING COVER FOR
CENTRE UNDERBODY .
5. Remove the lower fastening clamp from the heat shield next to the left front silencer.
6. Empty the fuel tank. → 200317 DRAINING AND FILLING FUEL .
7. Remove fuel tank. → REMOVING FUEL TANK - section on "Removing".
8. Remove left front wheel.
9. Remove left wheel housing liner.

POWER ELECTRONICS (CAYENNE S HYBRID) > REMOVING HIGH-VOLTAGE LINE
FROM BATTERY TO POWER ELECTRONICS
Fig 1: Overview Of High-Voltage Line
1. Disengage the holder -arrow- for the two high-voltage lines at the power electronics.
Fig 2: Disengaging High-Voltage Lines From Power Electronics
2. Unscrew the three fastening nuts -1- for the high-voltage line (engine area).
1. 2.1. Cut the tie-wraps for the high-voltage line cover -arrow- and remove cover in a
downward direction.
Fig 3: Removing High-Voltage Line In Engine Area
3. Open the two corrugated tube clips and unclip the high-voltage lines from the two corrugated
tube holders -2- (left door sill area, center).
1. 3.1. Cut tie-wraps -arrow- .

Fig 4: Removing High-Voltage Line In Centre Area
4. Remove the two fixing clips -3- (left door sill area, rear).
Fig 5: Removing High-Voltage Line In Rear Area
5. Unclip the cable guides on the body (expanding anchor) three times -arrow- .
6. Unclip the two high-voltage lines from the corrugated tube holder -2- (left door sill area, rear).
Fig 6: Removing High-Voltage Line In Rear Area
7. Remove high-voltage line in luggage compartment area.
1. 7.1. Unscrew the three fastening nuts -4- for the high-voltage line cover -1- and
remove it.
2. 7.2. Guide the rubber sleeve for the cable bushing for the high-voltage lines on the
body floor (luggage compartment area) down through the body floor -2- .
3. 7.3. Pull out the high-voltage lines in a downward direction -3- .

Fig 7: Removing High-Voltage Line In Luggage Compartment Area

POWER ELECTRONICS (CAYENNE S HYBRID) > INSTALLING HIGH-VOLTAGE LINE
FROM BATTERY TO POWER ELECTRONICS
Information
For correct longitudinal positioning in the vehicle, a plastic eyelet is fitted on the high-voltage wire
harness for the hybrid battery close to the line shielding in the luggage compartment. During installation,
this plastic eyelet must be attached to the center threaded bolt on the line shielding in the luggage
compartment.
1. Install high-voltage line in luggage compartment area.
1. 1.1. Slide the high-voltage lines down through the opening on the luggage
compartment floor -2- .
2. 1.2. Coat the rubber sleeve with sliding compound and press it onto the body -1-
until the rubber sleeve is positioned correctly.
3. 1.3. Push the plastic eyelet of the high-voltage line onto the fastening bolt. Fit the
cover -3- and secure it with the three fastening nuts -4- . → Tightening Torque: 9
Nm (6.5 ft. lb.) .
Fig 1: Installing High-Voltage Line In Luggage Compartment Area
2. Clip the two high-voltage lines into the corrugated tube holders -2- (left door sill area, rear).
1. 2.1. Close the corrugated tube holder.

Fig 2: Installing High-Voltage Lines Into Corrugated Tubes
3. Clip in the cable guides on the body (expanding anchor) three times -arrow- .
4. Install the two high-voltage lines with the two fixing clips -3- (left door sill area, rear).
Fig 3: Installing High-Voltage Line In Rear Area
5. Clip the two high-voltage lines into the two corrugated tube holders -2- (left door sill area,
center).
1. 5.1. Close the corrugated tube holders.
2. 5.2. Secure the high-voltage line with a tie-wrap -arrow- .

Fig 4: Installing High-Voltage Line In Centre Area
6. Install high-voltage line in engine area.
1. 6.1. Fit high-voltage line cover and screw on the three fastening nuts -1- . →
Tightening Torque: 9 Nm (6.5 ft. lb.) .
2. 6.2. Secure the high-voltage line and cover with three tie-wraps -arrow- .
Fig 5: Installing High-Voltage Line In Engine Area
7. Secure high-voltage lines to the power electronics with the holding claw.
Fig 6: Locating High-Voltage Lines To Power Electronics
Information
connector holder.

POWER ELECTRONICS (CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Install the fuel tank. Install the left running board on the fuel tank and fit the two restraining
straps at the front left. → INSTALLING FUEL TANK - section on "Installing".
2. Fill the fuel tank. → 200317 DRAINING AND FILLING FUEL .
3. Install the lower fastening clamp on the heat shield next to the left front silencer.
4. Install cover for left underbody. → 519319 REMOVING AND INSTALLING COVER FOR
CENTRE UNDERBODY .
5. Install side trim panel at the rear right. → INSTALLING SIDE TRIM PANEL FOR REAR
LUGGAGE COMPARTMENT - section on "Installing".

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > TECHNICAL VALUES

value 1 2
Line bracket for high-voltage Fastening Tightening 8 Nm (6 ft.

line to electric motor screws - 3- Torque lb.)
High-voltage line to electric Tightening 20 Nm (15

Fastening nut -2-
motor Torque ft. lb.)
Connection box cover on Fastening Tightening 7 Nm (5 ft.

electric motor screws - 1- Torque lb.)

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > PRELIMINARY WORK

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > REMOVING
HIGH-VOLTAGE LINE FROM POWER ELECTRONICS TO ELECTRIC MOTOR
Information
Use new seals.
Use new screws.
1. Unscrew the four fastening screws -1- for the cover. Then lift up the cover and swivel it to one
side.
Fig 1: Removing Electric Motor Cover
2. Unscrew the three fastening nuts -2- for the high-voltage line contacts.
3. Unscrew the fastening screws -3- for the high-voltage lines on the electric motor
Fig 2: Identifying High-Voltage Contacts Nuts And Screws
4. Lift up high-voltage line -4- , turn it approx. 75 ° to the left and carefully pull it out of the electric
motor.
Fig 3: Removing High-Voltage Lines

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > INSTALLING
INSTALLING HIGH-VOLTAGE LINE ON POWER ELECTRONICS FOR ELECTRIC
MOTOR
Information
Use new seals.
Use new screws.
Information
The three high-voltage lines are coded differently.

Fig 1: Identifying High-Voltage Line And Electric Motor Coding
Make sure that the coding for the electric motor matches the coding for the line.
Information
Always replace the connection box cover seal for the electric motor after opening it.
1. Push the three high-voltage lines -6, 5, 4- one after the other into the electric motor, attach
them to the contacts and secure with the fastening screws -3- . → Tightening Torque: 8 Nm
(6 ft. lb.) .
2. Secure the contacts of the three high-voltage lines with the fastening nuts -2- . → Tightening
Fig 3: Identifying High-Voltage Line Contacts
3. Fit the cover for the electric motor and secure with the four fastening screws -1- . →
Fig 4: Installing Motor Cover

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Install the engine. → INSTALLING V6 HYBRID ENGINE - section on "Installing".

ELECTRONICS TO AIR-CONDITIONING COMPRESSOR (CAYENNE S HYBRID) >
PRELIMINARY WORK
2. The high-voltage system must be isolated from the power supply. Isolate the high-voltage
system from the power supply and complete the relevant documentation. → 2X00IN
REMOVING HIGH-VOLTAGE LINE FROM POWER ELECTRONICS TO
Information
The high-voltage lines and connector holder at the power electronics are color-coded
1. Release the high-voltage line -1- at the power electronics (rapid-action coupling) and unplug it.
Fig 1: Removing High-Voltage Lines From Power Electronics
2. Release the high-voltage line from the power electronics to the air-conditioning compressor
(rapid-action coupling) and unplug it.
Fig 2: Removing High-Voltage Line From Air-Conditioning Compressor
3. Take the high-voltage line from the power electronics to the air-conditioning compressor out of
the engine compartment.

INSTALLING HIGH-VOLTAGE LINE FROM POWER ELECTRONICS TO
Information
The plug connection and connector holder must be checked for wear and damage before connecting the
high-voltage lines.
The high-voltage lines are color-coded and must only be connected to the color-coded connector holder.
The high-voltage lines can only be connected at one position. Check the connection position before
connecting the lines.
1. Plug in the high-voltage line from the power electronics to the air-conditioning compressor
(rapid-action coupling) until the connector engages securely.
Fig 1: Connecting High-Voltage Line To Air-Conditioning Compressor
2. Plug the high-voltage line -1- into the power electronics until the connector engages securely.
Fig 2: Connecting High-Voltage Lines To Power Electronics
Replacing high-voltage line
Information
When replacing the high-voltage line, the cable must be routed differently because it now has a
different length and an additional tie-wrap holder must be fitted.
3. Plug in the high-voltage line from the power electronics to the air-conditioning compressor at
the air-conditioning compressor -2- (quick connector) until the connector engages securely.
4. Secure the high-voltage line to the line from the air-conditioning compressor with a tie-wrap
-3- .
5. Plug the high-voltage line -1- into the power electronics until the connector engages securely.
Fig 3: Replacing High-Voltage Line

SUBSEQUENT WORK
WM 279419 REMOVING AND INSTALLING HIGH-VOLTAGE BATTERY CONTROL UNIT

High-Voltage Workshop
WE 1589
Cordon Equipment
Workshop
Insulated Tool Set WE 1593
Equipment

Tolerance Tolerance
1 2
Tightening 5.9 Nm (4.5 ft.

HV battery control unit
Torque lb.)
Cover for HV battery control Tightening 5.9 Nm (4.5 ft.

unit Torque lb.)

(CAYENNE S E-HYBRID) > PRELIMINARY WORK
1. If a new control unit has to be installed, the values must be read out using PIWIS Tester II
9818 before removing the "old" control unit. → 279455 REPLACING CONTROL UNIT FOR
HV BATTERY

"Removing"
5. Remove high-voltage battery fuse. → REMOVING HIGH-VOLTAGE BATTERY FUSE - section

on "Removing"

(CAYENNE S E-HYBRID) > REMOVING HIGH-VOLTAGE BATTERY CONTROL UNIT

Information
Fig 1: Caution For Restricted Area For Battery
1. Loosen fastening nuts -1, 2- on the cover of the HV battery control unit and remove cover -3-
.
Fig 2: Identifying HV Battery Control Unit Cover
2. Remove spacers under the fastening nuts -1- .
3. Remove ground line.

Fig 3: Removing Ground Line
4. Loosen fastening nuts -1- on the HV battery control unit and pull off HV battery control unit -2-
.
Fig 4: Removing Control Unit For HV Battery
5. Release electric plug connection -1- at the HV battery control unit completely -a- and
disconnect it -A- .
6. Release electric plug connection -2- completely -b- and disconnect it -B- .
Fig 5: Disconnecting Electric Plug Connections
7. Remove control unit for HV battery.
8. Clean screw thread at the fastening points carefully with a vacuum cleaner. Make sure that no
dirt gets into the battery housing. Only use a vacuum cleaner with a plastic nozzle.

(CAYENNE S E-HYBRID) > INSTALLING HIGH-VOLTAGE BATTERY CONTROL UNIT
Information
Information
Fastening screws and fastening nuts must not be re-used and must be replaced with new ones.
1. Connect electric plug connection -2- on the HV battery control unit -b- and lock it -B- .
2. Connect electric plug connection -2- (-a- ) and lock it -A- .

Fig 1: Connecting Electric Plug Connections
3. Push control unit -2- onto the E-box and tighten fastening nuts -1- to → Tightening Torque:
5.9 Nm (4.5 ft. lb.) .
Fig 2: Identifying Control Unit For HV Battery
4. Position spacers on the bolts under fastening nuts -2- .
5. Position cover for HV battery control unit -3- and tighten fastening nuts -1, 2- to →
Tightening Torque: 5.9 Nm (4.5 ft. lb.) .
Fig 3: Identifying Cover For HV Battery Control Unit

(CAYENNE S E-HYBRID) > SUBSEQUENT WORK
1. Install high-voltage battery fuse. → INSTALLING HIGH-VOLTAGE BATTERY FUSE - section

on "Installing"

"Installing"
4. If the control unit was replaced, the "new" control unit must be adapted to suit the vehicle using
PIWIS Tester II 9818 . → 279455 REPLACING CONTROL UNIT FOR HV BATTERY
WM 279419 REMOVING AND INSTALLING CONTROL UNIT FOR HV BATTERY

(CAYENNE S HYBRID) > TOOLS

TORX Screwdriver Workshop
WE 1382
Set VAS 6633 Equipment

(CAYENNE S HYBRID) > PRELIMINARY WORK
1. If a new control unit has to be installed, the values/coding must be read out using PIWIS
Tester II 9818 prior to removing the "old" control unit. → 279455 REPLACING BATTERY
MANAGEMENT SYSTEM CONTROL UNIT .
4. Remove the high-voltage battery. → REMOVING HIGH-VOLTAGE BATTERY - section on

"Removing"

(CAYENNE S HYBRID) > REMOVING CONTROL UNIT FOR HV BATTERY
Fig 1: Identifying Control Unit For HV Battery Installation Position
WARNING: High voltage at the E-box
→ Work on the HV battery control unit may only be carried out by a high-voltage technician.
→ Always use insulated tools when working on the HV battery control unit.
→ Observe general warning notes for working on the high-voltage vehicle electrical system.
1. Unscrew the eight fastening screws -1- on the E-box cover and remove it.
Fig 2: Identifying E-Box Cover Screws
2. Loosen the two fastening screws -2- on the service disconnector mounting.
Fig 3: Identifying Service Mounting Screws
3. Cut tie-wrap -arrow- for the electric line.
4. Release and unplug the three electric connectors -1, 2, 3- on the HV battery control unit.
Fig 4: Removing Electric Connectors
5. Unscrew the two fastening screws -3- from the HV battery control unit using the TORX
Screwdriver Set VAS 6633 WE 1382 .
Fig 5: Identifying HV Battery Control Unit Screws
6. Lift up the HV battery control unit and release and unplug the electric connectors -4- and -5- .
Fig 6: Removing Connectors
7. Lift the HV battery control unit out of the E-box.

Fig 7: Removing Control Unit
8. To replace the control unit, release and unplug the electric connector -6- on the HV battery
control unit and remove it together with the HV battery wire harness.

(CAYENNE S HYBRID) > INSTALLING CONTROL UNIT FOR HV BATTERY
WARNING: High voltage at the E-box
→ Work on the HV battery control unit may only be carried out by a high-voltage technician.
→ Always use insulated tools when working on the HV battery control unit.
→ Observe general warning notes for working on the high-voltage vehicle electrical system.
1. Plug in electric connector -6- with the HV battery wire harness at the control unit until the
connector engages securely.
Fig 1: Installing HV Battery Control Unit And Electric Connectors
2. Insert the HV battery control unit into the E-box and plug in both connectors -4- and -5- until
they engage securely.
Fig 2: Installing HV Battery Control Unit
3. Position HV battery control unit in the E-box.
4. Secure the ground strap (cable shoe) to the HV battery control unit in the E-box.
1. 4.1. Secure the HV battery control unit and ground strap using the two fastening
screws -3- and the TORX Screwdriver Set VAS 6633 WE 1382 .
Fig 3: Securing HV Battery Control Unit
5. Secure the service disconnector mounting with the two fastening screws -2- .
Fig 4: Identifying Service Screws
6. Plug electric connectors -1, 2, 3- into the HV battery control unit until the connectors engage
securely.
Fig 5: Installing Electric Connectors
7. Fit tie-wrap for the electric line -arrow- .
8. Before positioning the E-box cover, check the line routing of the HV battery wire harness from
the E-box.
1. 8.1. The rubber sleeve -arrow- on the wire harness must be engaged properly in the
E-box housing.
Fig 6: Locating E-Box Wire Harness Sleeve
9. Fit E-box cover and secure with the eight fastening screws -1- .
Fig 7: Installing E-Box Cover

(CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Install the high-voltage battery. → INSTALLING HIGH-VOLTAGE BATTERY - section on

"Installing".
3. If the control unit was replaced, the control unit must be adapted to the vehicle using PIWIS
Tester II 9818 . → 279455 REPLACING BATTERY MANAGEMENT SYSTEM CONTROL
UNIT .
4. If the fault memory was erased, the electric motor must be calibrated fully.
WM 279455 REPLACING HIGH-VOLTAGE BATTERY CONTROL UNIT (CAYENNE S

E-HYBRID) > TOOLS



E-HYBRID) > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
ignition.
3. Select the High-voltage battery control unit in the overview .
5. Control unit replacement must now be selected. Then press [F12].
6. Read data must now be selected. Then press [F12].
8. Check the chassis number and press [F12].
HIGH-VOLTAGE BATTERY CONTROL UNIT .
10. Switch on ignition. Select the Write data menu (procedure described above), press [F12] and
then press [F8] to start installing the data that was read out.
13. Select the Calibrate phase angle function and follow the instructions on the Tester.
14. Function test: Perform a test drive.
15. Read out the fault memory.
WM 279455 REPLACING CONTROL UNIT FOR HV BATTERY (CAYENNE S HYBRID) >

TOOLS

TECHNICAL VALUES

READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
ignition.
3. Select the High-voltage battery control unit in the overview .
4. Select Maintenance/repairs .
5. Select Control unit replacement and press [F12].
6. Select Read data and press [F12].
8. Check the chassis number and press [F12].
BATTERY MANAGEMENT SYSTEM CONTROL UNIT .
10. Switch on ignition. Select the Write data menu (procedure described above), press [F12] and
then press [F8] to start installing the data that was read out.
13. Select the Calibrate phase angle function and follow the instructions on the Tester.
14. Function test: Perform a test drive.
15. Read out fault memory.
WM 279519 REMOVING AND INSTALLING PILOT LINE CONNECTOR (CAYENNE S

HYBRID) > TOOLS
Hybrid Test Adapter Workshop

WE 1378
VAS 6558/1 Equipment
Workshop
Voltage Tester WE 1380
Equipment

HYBRID) > TECHNICAL VALUES
Tolerance Tolerance
1 2
Crash panel to power Fastening screw Tightening 9 Nm (6.5 ft.

electronics -4- Torque lb.)
Crash panel to power Fastening screw Tightening 9 Nm (6.5 ft.

electronics -5- Torque lb.)

HYBRID) > PRELIMINARY WORK
1. Open the rear lid.
2. Open the front lid.
3. Open the loadspace floor.

HYBRID) > REMOVING PILOT LINE CONNECTOR
WARNING: High voltage at the high-voltage system on hybrid vehicles
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
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
5. Release the service disconnector by moving it to the right -1- and lift up the securing clip -2- .
Fig 2: Releasing Service Disconnector
6. Remove the service disconnector from the high-voltage battery.

Fig 3: Removing Service Disconnector
7. Release and unplug the pilot line connector.

Fig 4: Removing Pilot Line Connector
8. The lock -1- for the two high-voltage lines -2- opens.
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. → REMOVING FRONT TRIM PANEL (ENGINE
COMPARTMENT) - section on "Removing".
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 Power Electronics Crash Panel
13. Release the high-voltage line -1- at the power electronics (rapid-action coupling) and unplug it
from the power electronics.
14. Open the securing clip for the high-voltage line -2- .
Fig 8: Opening High-Voltage Line Clip
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.
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.
19. Remove engine compartment cover at the left. → REMOVING FRONT TRIM PANEL (ENGINE
COMPARTMENT) - section on "Removing".
20. Release the pilot line connector -1- at the power electronics (rapid-action coupling) and unplug
it.
Fig 10: Removing Pilot Line Connector And High-Voltage Lines For Electric Motor

HYBRID) > INSTALLING PILOT LINE CONNECTOR
WARNING: High voltage at the high-voltage system on hybrid vehicles
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
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.
Information
connector holder.
3. Close the lock for the high-voltage line and connect and lock the pilot line connector -1- (rapid-
action coupling).
Fig 1: Connecting High-Voltage Lines And Pilot Line Connector
4. Release the high-voltage line -1- for the air-conditioning compressor at the power electronics
(rapid-action coupling) and unplug it.
Fig 2: Removing High-Voltage Line For Air-Conditioning Compressor
Information
The high-voltage lines are colur-coded and must only be connected to the color-coded
connector holder.
5. Plug the high-voltage lines -3, 2, 1- into the power electronics one after the other until the
connectors engage securely.
Fig 3: Connecting High-Voltage Lines To Power Electronics
6. Install crash panel on the power electronics.
1. 6.1. Fit the crash panel.
2. 6.2. Secure the crash panel with the three fastening screws -4- . → Tightening
3. 6.3. Secure the crash panel with the fastening nut -5- . → Tightening Torque: 9 Nm
(6.5 ft. lb.)
Fig 4: Identifying Power Electronics Crash Panel
7. Install engine compartment cover at the left. → INSTALLING FRONT TRIM PANEL (ENGINE
COMPARTMENT) - section on "Installing"
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 .
Information
connector holder.
8. Fit the lock for the two high-voltage lines -2- and secure them to the pilot line connector.
Fig 5: Installing High-Voltage Lines On Power Electronics
9. Plug in the pilot line connector until it engages securely.

Fig 6: Plugging In Pilot Line Connector
10. Insert the service disconnector in the high-voltage battery.

Fig 7: Installing Service Disconnector
11. Lock the service disconnector -1- and close it -2-

Fig 8: Locking Service Disconnector
12. Fit service disconnector cover on the high-voltage battery.

Fig 9: Fitting Service Disconnector Cover

HYBRID) > SUBSEQUENT WORK
1. 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.
2. Create the test log under Standard forms in the PPN "Restarting high-voltage system" and
place it in the vehicle documents folder.
3. Close front and rear lid.
4. Proceed according to the current specifications in "Guided Fault Finding" and in the latest
the Cayenne Hybrid.
WM 279555 REPLACING PILOT LINES FOR CONNECTOR (SERVICE

DISCONNECTOR) (CAYENNE S E-HYBRID) > REMOVING SERVICE DISCONNECTOR
1. Unclip service disconnector.
2. Detach cover -1- using a small screwdriver -2- and remove it from the green housing -3- .
Fig 1: Detaching Service Disconnector Cover
3. Loosen fabric adhesive tape on the cable at the end of the connector and cut it off.
4. Release secondary lock using a small screwdriver.

Fig 2: Releasing Secondary Lock
Information
CAUTION: Risk of damage to locking lugs
5. Release pins -1- using press-out tool VAS 1978/35-2 -2- and pull them out carefully at the
cable -3- .
Fig 3: Pressing Pilot Lines Connector Pins
6. Release and pull off clips -1- on the old connector -2- using a thin screwdriver -3- .
Fig 4: Removing Pilot Lines Connector Clips
WM 279555 REPLACING PILOT LINES FOR CONNECTOR (SERVICE

DISCONNECTOR) (CAYENNE S E-HYBRID) > INSTALLING SERVICE DISCONNECTOR
1. Prepare new service disconnector for installation.
1. 1.1. Release and pull off cover -1- on the new service disconnector -3- using a small
screwdriver -2- .
Fig 1: Installing Service Disconnector Cover
2. 1.2. Secure clips -1- on the new service disconnector -2- .

Fig 2: Securing Service Disconnector Clips
3. 1.3. Release secondary lock on the new service disconnector using a small
screwdriver.
Fig 3: Releasing Secondary Lock
Information
Check that the pins (upper locking lugs) are aligned correctly
If the locking lugs do not lock with an audible click, bend up the locking lugs at the pin first
using press-out tool
2. Press in pins in the following sequence until they engage securely.
1. 2.1. Red/lilac cable in pin 1
2. 2.2. Red/yellow cable in pin 2
3. 2.3. Green/black cable in pin 3
4. 2.4. Yellow/black cable in pin 4
3. Close secondary lock.
4. Fit black cap on the green connector until it engages securely on both sides.
5. Wrap new fabric tape around the cable.
6. Clip in service disconnector at the same position as before.
WM 279619 REMOVING AND INSTALLING CHARGING SOCKET (CAYENNE S

E-HYBRID) > TOOLS

Charging socket to body Tightening Torque 9.7 Nm (7.5 ft. lb.)

5. Release and disconnect high-voltage connector for PTC at the front, high-voltage battery and
charging socket at the high-voltage charger. → 279719 REMOVING AND INSTALLING
ON-BOARD CHARGER
6. Release and disconnect electric plug connection at the high-voltage charger. → 279719
REMOVING AND INSTALLING ON-BOARD CHARGER

E-HYBRID) > REMOVING CHARGING SOCKET
Fig 1: Identifying Charging Socket Installation Position
1. Release and disconnect electric plug connection -1- and unclip it from the body.
2. Unscrew fastening nuts -1- on charging socket -2- .

Fig 3: Loosening Charging Socket Nuts
3. Remove charging socket -1- by carefully turning it anti-clockwise -a- .

Fig 4: Removing Charging Socket
4. Cut tie-wrap -2- and pull water drain -1- off the charging socket.
Fig 5: Pulling Water Drain

E-HYBRID) > INSTALLING CHARGING SOCKET
Information
The high-voltage line for the charging socket must be routed behind the 12 V line.
Information
Make sure not to kink the water drain during installation.
1. Installation is performed in reverse order to removal. Tightening Torque 9.7 Nm (7.5 ft. lb.)

1. Plug in electric plug connection at the high-voltage charger until it engages securely. →
279719 REMOVING AND INSTALLING ON-BOARD CHARGER
2. Plug in high-voltage connectors for PTC at the front, high-voltage battery and high-voltage
charger until they engage securely. → 279719 REMOVING AND INSTALLING ON-BOARD
CHARGER
3. Install side trim panel for rear luggage compartment at the left. → REMOVING SIDE TRIM
WM 279719 REMOVING AND INSTALLING HIGH-VOLTAGE CHARGER (CAYENNE S

E-HYBRID) > TOOLS

Tolerance Tolerance
1 2
High-voltage charger to body
Torque ft. lb.)
Equipotential bonding line to Tightening 7 Nm (5 ft.

high-voltage charger Torque lb.)

3. Drain low-temperature cooling system → 193817 DRAINING AND FILLING COOLANT
6. Remove subwoofer. → REMOVING SUBWOOFER - section on "Removing"

E-HYBRID) > REMOVING HIGH-VOLTAGE CHARGER
Fig 1: Identifying High-Voltage Charger Installation Position
1. Disconnect low-temperature lines -1- and seal them on both sides.

Fig 2: Disconnecting Low-Temperature Lines
Information
Collect emerging coolant in a suitable container.
Information
High-voltage connectors are released using the red tab in 2 steps:
1. 1) Release 1: Press red tab -a- and pull it -A-
2. 2) Release 2: Press black knob -b- and pull it off -B-

2. Release and disconnect high-voltage line to PTC at the rear -2- using the red tab.
3. Release and disconnect high-voltage line to PTC at the front -1- using the red tab.
4. Release and disconnect high-voltage line to high-voltage battery -3- .

Fig 4: Disconnecting High-Voltage Lines
5. Release and disconnect electric plug connection -1- .

6. Release and disconnect high-voltage line to charging socket -1- .

Fig 6: Releasing High-Voltage Line
7. Screw off equipotential bonding line -1- at the high-voltage charger.

Fig 7: Removing Equipotential Bonding Line
8. Loosen fastening screws for high-voltage charger and carefully remove high-voltage charger.
Fig 8: Removing High-Voltage Charger

E-HYBRID) > INSTALLING HIGH-VOLTAGE CHARGER
1. Installation is performed in reverse order to removal. Tightening Torque 10 Nm (7.5 ft. lb.)

1. Install subwoofer. → INSTALLING SUBWOOFER - section on "Installing"
2. Install side trim panel for rear luggage compartment at the left. → INSTALLING SIDE TRIM
PANEL FOR REAR LUGGAGE COMPARTMENT - section on "Installing"
4. Fill low-temperature cooling system. → 193817 DRAINING AND FILLING COOLANT


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Service Manual: 27 - STARTER, POWER SUPPLY, CRUISE CONTROL -- 92A CAYENNE

WM 270419 REMOVING AND INSTALLING VOLTAGE CONVERTER FOR START/STOP

Designation Type Number Description

PIWIS Tester II Special Tool 9818

WM 270419 REMOVING AND INSTALLING VOLTAGE CONVERTER FOR START/STOP

2. Remove glove compartment. → 681519 REMOVING AND INSTALLING GLOVE

WM 270419 REMOVING AND INSTALLING VOLTAGE CONVERTER FOR START/STOP

Always comply with the regulations for handling ESD-sensitive components!

Never touch the electric pins and plug contacts .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

NOTE: Voltage peaks

Risk of damage to electrical load or to the control unit

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Remove bracket with voltage converter from the dashboard bracket.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

WM 270419 REMOVING AND INSTALLING VOLTAGE CONVERTER FOR START/STOP

Always comply with the regulations for handling ESD-sensitive components!

Never touch the electric pins and plug contacts .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Position bracket with voltage converter on the dashboard bracket.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

WM 270419 REMOVING AND INSTALLING VOLTAGE CONVERTER FOR START/STOP

1. Install glove compartment. → 681519 REMOVING AND INSTALLING GLOVE

WM 270455 REPLACING VOLTAGE TRANSFORMER FOR START/STOP (ALL

Designation Type Number Description

WM 270455 REPLACING VOLTAGE TRANSFORMER FOR START/STOP (ALL

Location Description Type Basic value Tolerance 1 Tolerance 2

Current rating Nominal value 40 A

WM 270455 REPLACING VOLTAGE TRANSFORMER FOR START/STOP (ALL

NOTE: Voltage drop

Risk of irreparable damage to control unit

Risk of damage to control unit

Fault entries in the control unit

Coding in the control unit is aborted

Malfunctions in control unit, even during programming

→ Ensure that the power supply is not interrupted during programming.

4. Select the DC/DC converter control unit.

5. Maintenance/repairs must then be selected.

7. Read data must be selected. Then press [F12] to continue.

8. Press [F8] to start reading out data.

9. Check the chassis number.

The data that was read out is loaded.

13. Read out the fault memory and erase it if necessary.

WM 270519 REMOVING AND INSTALLING BATTERY SENSOR (ALL MODELS) >

Terminal clamp to battery Tightening 6 Nm (4.5 ft.

Ground line for battery to Tightening 20 Nm (15 ft.

WM 270519 REMOVING AND INSTALLING BATTERY SENSOR (ALL MODELS) >

1. Remove battery cover. → ________271219 Removing and installing battery cover

WM 270519 REMOVING AND INSTALLING BATTERY SENSOR (ALL MODELS) >

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

Risk of damage to battery sensors.

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 .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Open the service flap in the driver's footwell.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

WM 270519 REMOVING AND INSTALLING BATTERY SENSOR (ALL MODELS) >