Removing Pilot Line Connector

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

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

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

Information 

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

1. Read out the fault memory using PIWIS Tester II 9818  .
2. The following work must only be carried out by a person who is at least trained and qualified as a recognized high-voltage technician  .
3. Switch off the ignition (term. 15) and make sure that it cannot be switched back on again. Then remove the remote control from the ignition lock. On vehicles with "Keyless Entry and Go", release the operating lever and pull it out of the ignition lock. Store the remote control and operating lever in a safe place.
4. Remove service disconnector cover on the high-voltage battery.
   Fig 1: Removing Service Disconnector Cover

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

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6. Remove the service disconnector from the high-voltage battery.
   Fig 3: Removing Service Disconnector

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7. Release and unplug the pilot line connector.
   Fig 4: Removing Pilot Line Connector

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

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   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

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

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

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15. Release the high-voltage lines -2, 3-  at the power electronics (rapid-action coupling) and unplug them from the power electronics.
16. Plug in the high-voltage line -1-  for the air-conditioning compressor at the power electronics (rapid action coupling) until the connector engages securely.
    Fig 9: Installing High-Voltage Line

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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

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.