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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 270819 Removing And Installing E-Box (Cayenne S E-Hybrid) >> Installing E-Box

Installing E-Box

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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

Information 

Always use insulated tools Insulated Tool Set WE 1593  when working on the high-voltage battery and 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
      G09933923Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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
      G09933924Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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
      G09933925Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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
      G09933926Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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
      G09933927Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    6. 1.6. Fasten tie-wrap -1-  on HV line.
      Fig 6: Locating HV Line
      G09933928Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    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
      G09933929Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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
      G09933930Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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
      G09933931Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  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
      G09933932Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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.) 
      Fig 11: Identifying High-Voltage Battery Control Unit
      G09933933Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 3.4. Push ground line -1-  onto the fastening bolts.
      Fig 12: Identifying Ground Line
      G09933934Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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.) 
      Fig 13: Identifying High-Voltage Battery Control Unit
      G09933935Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Remove cap -1-  .
    Fig 14: Identifying Battery Cap
    G09933936Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  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-  .
    1. 5.1. Contact point -A-  to housing.
    2. 5.2. Contact point -B-  to housing.
      Fig 15: Checking Electric Charge
      G09933937Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    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
      G09933938Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  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
    G09933939Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    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
      G09933940Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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