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5

WLK2 Workshop Campaign - Replacing Wire Harnesses for Electric Charge Port Doors

Important:

CRITICAL WARNING - This campaign includes steps where control unit(s) in the vehicle will be
programmed with the PIWIS Tester. The vehicle voltage must be maintained between 13.5 volts and 14.5
volts during this programming. Failure to maintain this voltage could result in damaged control unit(s).
Damage caused by inadequate voltage during programming is not a warrantable defect. The technician
must verify the actual vehicle voltage in the PIWIS Tester before starting the campaign and also document
the actual voltage on the repair order.

Model Year:

2020

Model Line:

Taycan (Y1A)

Equipment:

Electric charge port door (I-no. 2W9)

Concerns:

Electric charge port door

Information:

There is a possibility that the end position of the charge port door is not determined correctly
on the affected vehicles due to an incorrect sensor signal.
The charge port door on the opposite side of the vehicle is then locked automatically and can no longer
be operated. The defective charge port door can still be actuated without restriction from the center
console or by hand at the charge port door.

Action required: Replace wire harnesses for electric charge port doors on driver and passenger side.
Affected
Vehicles:

Only vehicles assigned to the campaign (see also PCSS Vehicle Information).

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Installation
Position:

1

Installation position of wire harness for charge port doors
– Wire harness for charge port door on driver and passenger side (replace)

Parts required
Parts Info:
Part No.

Designation
– Use

Qty.

9J1898352Q

 Wire harness for charge port door
– Charge port door A (driver side, LHD vehicle)

1 ea.

9J1898352R

 Wire harness for charge port door
– Charge port door B (passenger side, LHD vehicle)

1 ea.

PAF008485

 Hexagon flange bolt M6 x 12
– Door hinge

4 ea.

PAF912032

 Countersunk screw with internal serration, M8 x 22
– Door arrester

2 ea.

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Technical Information

166/20 ENU

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Required tools
Tools:

•
•
•
•
•

9900 - PIWIS Tester 3
Battery charger with a current rating of at least 90 A and a current and voltage-controlled
charge map for lithium starter batteries, e.g. VAS 5908 Battery charger 90A
Torque wrench, 6–50 Nm (4.5–37 ftlb.), e.g. VAG 1331A Torque wrench, 6-50 Nm (4.5-37
ftlb.)
Torque wrench, 20–100 Nm (15–74 ftlb.), e.g. VAS 5820 - Torque wrench, 20-100 Nm (15-74
ftlb.)
Plastic assembly wedge (commercially available)

Preparatory work
WARNING
Incorrect handling of high-voltage components
•

Electric shock

•

Risk of short circuit

•

Fire

•

Risk of explosion



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



Required qualification: High voltage technician or 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 system.  Workshop Manual '2X00IN
General warning notes for working on the high-voltage system'

Information
Handling high-voltage lines:
•

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

•

Work involving metal-removing, deforming and sharp-edged tools close to high-voltage components
and lines is prohibited.

•

Work involving heat sources such as welding, soldering, hot air and thermal bonding close to
high-voltage components and lines is prohibited.

•

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

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•

A visual inspection of the high-voltage connectors must be performed before installing the
high-voltage lines. If there are signs of damage to the connectors, contacts and seals, the
high-voltage line must be replaced.

•

If you have questions or if you are unclear about anything, consult the relevant high voltage technician.

Work Procedure: 1

Raise the vehicle on the lifting platform  Workshop Manual '4X00IN Lifting the vehicle'.

2

See General warning notes  Workshop Manual '2X00IN General warning notes for working on the
high-voltage system'.

3

Isolate the high-voltage system from the power supply  Workshop Manual '2X00IN Isolating
high-voltage system from power supply/Starting high-voltage system'.
Information
The procedure described here shows the work required for replacing the wire harness on charge
port door A on the driver's side. Depending on the result of the check, the work listed here must be
carried out either on the driver side or passenger side.

4

Remove wheel on driver side on the front axle  Workshop Manual '440519 Removing and installing
wheel'.

5

Remove wheel housing liner on driver side  Workshop Manual '505619 Removing and installing
front wheel housing liner'.

6

Remove door on driver side  Workshop Manual '575119 Removing and installing door'.

7

Unclip the cover  Electric power supply flap (lid)
-1- of the electric charge port door (charging socket
A) on the driver side using a suitable tool  Electric
power supply flap (lid) -Arrow-.

Electric power supply flap (lid)

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Replacing wire harness for electric charge port door
Information
Handling high-voltage lines:
•

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

•

Work involving metal-removing, deforming and sharp-edged tools close to high-voltage components
and lines is prohibited.

•

Work involving heat sources such as welding, soldering, hot air and thermal bonding close to
high-voltage components and lines is prohibited.

•

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

•

A visual inspection of the high-voltage connectors must be performed before installing the
high-voltage lines. If there are signs of damage to the connectors, contacts and seals, the
high-voltage line must be replaced.

•

If you have questions or if you are unclear about anything, consult the relevant high voltage technician.

Work Procedure: 1

Remove wing on the driver's side.
To do this, unclip pull knob  Wing trim panel -1- and remove all fastening screws  Wing trim panel
-3-.
Remove cover  Wing trim panel -2- and feed out
pull knob  Wing trim panel -1-.

2

Loosen charge port door module.

Wing trim panel

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2.1

Unscrew side fastening screw  Unscrewing
fastening screw securing charging socket to
the wing -1-.

Unscrewing fastening screw securing
charging socket to the wing
2.2

Release and disconnect electric plug
connection  Loosening charge port
doorFastening charge port door module -3-.

2.3

Unscrewing fastening nuts  Loosening
charge port doorFastening charge port door
module -2-

Loosening charge port door
2.4

3

Swivel charge port door module  Swivelling
out charge port door module -1- out towards
the wheel housing.  Swivelling out charge
port door module -Arrow-

Replace wire harness for electric charge port door.

Swivelling out charge port door module

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Technical Information
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On the front of the energy supply module,
remove the lock ring and  Removing reed
sensor for charge port door -1- remove the
charge port door reed sensor Removing
reed sensor for charge port door -2-.

Removing reed sensor for charge port door
3.2