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Home >> Porsche >> 2016 >> Cayman GTS, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 233 (27 - Starter, Power Supply, Cruise Control -- 92A Cayenne) >> WM 279519 Removing And Installing Pilot Line Connector (Cayenne S Hybrid) >> Installing Pilot Line Connector

Installing Pilot Line Connector

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WARNING: High voltage at the high-voltage system on hybrid vehicles
  • Danger of electric shock from live parts
  • Risk of serious burns or death
  • Health risks for persons with medical devices/life-support systems.

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

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

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

  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.

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

    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.

  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
    G09934169Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  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
    G09931366Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    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 colur-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.

  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
    G09933119Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  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 Torque: 9 Nm (6.5 ft. lb.) 
    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
      G09933114Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  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.

    • If the Plug Contacts are deformed or damaged, stop working on the system and contact Technical Support  .
    • If the Plug Connections are deformed or damaged, stop working on the system and contact Technical Support  .
    • If the Lines are deformed or damaged, stop working on the system and contact Technical Support  .

    Information 

    The 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.

  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
    G09933121Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  9. Plug in the pilot line connector until it engages securely.
    Fig 6: Plugging In Pilot Line Connector
    G09933122Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  10. Insert the service disconnector in the high-voltage battery.
    Fig 7: Installing Service Disconnector
    G09933123Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  11. Lock the service disconnector -1-  and close it -2- 
    Fig 8: Locking Service Disconnector
    G09933124Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  12. Fit service disconnector cover on the high-voltage battery.
    Fig 9: Fitting Service Disconnector Cover
    G09933125Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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