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Home >> Porsche >> 2021 >> Taycan Base >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Converters and Controllers >> 27 Starter, Power Supply, Cruise Control 2.0L (1 Of 2) -- Y1A - TAYCAN (Y1A) >> WM, 270855 Replacing Cell Block Module >> Subsequent Work

Subsequent Work

WARNING: Incorrect handling of high-voltage components
  • Electric shock
  • Risk of short circuit
  • Risk of fire
  • Risk of explosion

    → Only appropriately trained and authorized persons are permitted to work on high-voltage vehicles and components.

    → Required qualification: High voltage expert.

    → Observe national requirements and legislation for this work.

    → Always use insulated tools, e.g. > VAS 6883 - Insulated tool set  , when working on these components.

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

    > 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE VEHICLE ELECTRICAL SYSTEM

Information 

  1. Always use personal protective equipment.

    > 2X00IN SPECIFICATIONS FOR PREPARING A HIGH-VOLTAGE WORKPLACE

    Only on high-voltage battery module exchange with 28 modules: 

  2. Reinstall module connector -1-  , which was removed to reduce overall voltage.

    Module connectors must be replaced following removal.

    G15551502Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Reduction of total voltage

  3. Remove protection caps on module terminals > T40421 - Shock-proof protection cap  .
    G15551503Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Protection cap on module terminals (shown as an example)

  4. Fitting and assembling module connector.

    Module connectors must be replaced following removal.

    G15551504Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Module connectors (shown as an example)

    1. 4.1  Before fitting the module connector, press screws to the rear (inner) -Arrow-  until they engage.
      G15551505Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Screws for module connector

    2. 4.2  Tighten module connector to > Tightening torque 6 Nm 
  5. Discharge capacitive voltage.
    1. 5.1  Connect > VAS 6558A - high-voltage testing module  to > 9900 - PIWIS Tester 3  .
    2. 5.2  Start the Tester.
    3. 5.3  Select Measurement program  .
    4. 5.4  Select HV measurements  .
    5. 5.5  Select DC voltage measurement  .
    6. 5.6  Perform self-test according to menu guidance.
    7. 5.7  Connect test clamp to potential equalization line.
    8. 5.8  Place measuring probe on the module's positive terminal.
      G15551506Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Capacitive voltage (shown as an example)

      1. 5.8.1  Start the measurement.
      2. 5.8.2  Repeat the measurement until the voltage is < 10 volts.
      3. 5.8.3 Only for replacing modules on lower layer: 
  6. Check high-voltage battery communication wire harness on lower layer.
    IMPORTANT: The connection sequence for the diagnostic lines must be observed.
    1. 6.1  Connect battery communication wire harness upper layer and communication wire harness lower layer with > VAS 6558A/39-1 - diagnostic line  .
      G15551507Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Communication wire harness upper layer and lower layer

    2. 6.2  Connect communication wire harness lower layer and E-box with > VAS 6558A/39-2 - diagnostic cable  .
      G15551508Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Communication wire harness lower layer and E-box

    3. 6.3  Connect E-box with > VAS 5581 - diagnostic box  and > 9900 - PIWIS Tester 3  to > VAS 5581 A/12-the diagnostic line  with the diagnostic cable.
      G15551509Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Setup for communication wire harness test

      1  E-box
      2  > VAS 5581 - Diagnostic Box 
      3  > 9900 - PIWIS Tester 3 
    4. 6.4  Start the Tester. Select the vehicle type if necessary.
    5. 6.5  In the overview  , select the high-voltage battery  control unit (BMS). Press to continue. Should a "Vehicle Analysis Log (VAL)" be created? Press to continue.
    6. 6.6  Select the Actual values/input signals  tab.
    7. 6.7  Check whether the actual values of all modules are displayed.

      Only for replacing modules on upper layer: 

  7. Check high-voltage battery communication wire harness on upper layer.
    1. 7.1  Connect E-box with > VAS5581 - diagnostic box  and > 9900 - PIWIS Tester 3  with > VAS5581A/12 - diagnostic line  .
      G15551510Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Setup for communication wire harness test

      1  E-box
      2  > VAS5581 - Diagnostic Box 
      3  > 9900 - PIWIS Tester 3 
    2. 7.2  Start the Tester. Select the vehicle type if necessary.
    3. 7.3  In the overview  , select the high-voltage battery  control unit (BMS). Press to continue. Should a "Vehicle Analysis Log (VAL)" be created? Press to continue.
    4. 7.4  Select the Actual values/input signals  tab.
    5. 7.5  Check whether the actual values of all modules are displayed.

      All: 

      If a module has been replaced and a workshop mobile phone is available, continue with Step 8.

      If a module has been replaced and no workshop mobile phone is available, continue with Step  9.

      If no module was replaced, continue with Step  10.

  8. Store new module serial numbers in PCSS.
    1. 8.1  Select Porsche service.
    2. 8.2  Select Job management.
    3. 8.3  Select Job documentation.
      G15551511Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Job documentation (shown as an example)

    4. 8.4  Enter data in the PCSS using the workshop mobile phone.
      1. 8.4.1  Select "Photo" icon.
        G15551512Courtesy of PORSCHE CARS NORTH AMERICA, INC.

        "Photo" icon (shown as an example)

    5. 8.5  Read in the QR code using the workshop mobile phone.
      G15551513Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      QR code (shown as an example)

    6. 8.6  Read and follow the instructions and information on the workshop mobile phone.
    7. 8.7  Enter the new serial number of the cell module in the PCSS according to menu guidance.
    8. 8.8  Enter the old serial number of the cell module in the PCSS.

      If there is no workshop mobile phone, the serial number can also be entered in the PCSS without a workshop mobile phone.

  9. Store new serial number for the cell module in the PCSS.
    1. 9.1  Select Porsche service.
    2. 9.2  Select Job management.
    3. 9.3  Select the required workshop process.
    4. 9.4  Enter old serial number of the cell module.
    5. 9.5  Enter new serial number of the cell module.
  10. Safety test after assembly work on the high-voltage battery

    > 270803 PERFORMING MEASUREMENTS ON THE HIGH-VOLTAGE BATTERY 

  11. Fit cover on high-voltage battery.

    > 270819 REMOVING AND INSTALLING COVER ON HIGH-VOLTAGE BATTERY  - on "Removing"

  12. Verify absence of electric charge on the high-voltage battery.

    > 270803 PERFORMING MEASUREMENTS ON THE HIGH-VOLTAGE BATTERY 

  13. After the specified hardening time has elapsed, perform leak test on battery housing of the high-voltage battery and record the results.

    > 270803 PERFORMING MEASUREMENTS ON THE HIGH-VOLTAGE BATTERY 

  14. Installing high-voltage battery

    > 270819 REMOVING AND INSTALLING HIGH-VOLTAGE BATTERY  - on "renewing"

    If a module was replaced, continue with Step 15.

    If no module was replaced, continue with Step  21.

  15. Teach component protection.
    1. 15.1  Connect the Tester to the vehicle and start it.
    2. 15.2  In the Overview  press to switch to the Additional menu  .
    3. 15.3  Select Commission component protection  .
      1. 15.3.1  Select High-voltage battery  .
      2. 15.3.2  Read and follow the instructions and information on the Tester.
      3. 15.3.3  Teach component protection according to menu guidance.
      4. 15.3.4  The tester displays the message: Component protection taught.
  16. Go back to the Overview  .
  17. In the overview  , select the High-voltage battery  control unit.
  18. Select Drive links checks  .
  19. Select Reset cell module switch-off  .
    1. 19.1  Read and follow the instructions and information on the Tester.
    2. 19.2  Perform reset according to menu support.
  20. Set high-voltage control units to sleep and wake up again.
    1. 20.1  End operational readiness.
    2. 20.2  Disconnect the VCI module and PIWIS tester from the vehicle.
    3. 20.3  Switch off and disconnect the charger.
    4. 20.4  Close all doors and covers.
    5. 20.5  Lock the vehicle.
    6. 20.6  Wait 15 minutes.
    7. 20.7  Unlock the vehicle and connect VCI module and PIWIS tester.
    8. 20.8  Connect and start the charger.
    9. 20.9  Establish operational readiness.
  21. Start the high-voltage system and complete the log.

    > Refer to 2X00IN Isolating high-voltage system from power supply/Starting high-voltage system in the appropriate service information.

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