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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) >> Removing E-Box

Removing 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

NOTE: Incorrect removal or fitting of safety-related screws for the high-voltage battery.
  • Risk of damage to rivet nuts
  • Risk of damage to screw heads
  • Risk of damage to high-voltage battery

→ Loosen and tighten fastening screws without using electric tools.

→ Only loosen and tighten fastening screws using special tool VAS 6883 Insulated Tool Set.

→ Be extremely careful when loosening fastening screws. See Note: → "Procedure For Loosening Micro-Self-Locking Screws"  .

→ Clean the threaded bores before fitting the fastening screws. See Note: → "Procedure For Cleaning Threaded Bores On The High-Voltage Battery"  .

→ Always use new fastening screws.

→ Observe specified Tightening Torques.

Information 

Always use insulated tools Insulated Tool Set WE 1593  when working on the high-voltage battery and a High-Voltage Cordon WE 1589  when working on a HV work bay.

Information 

If the E-box  for the high-voltage system Cannot Be Removed  because the screw heads or rivet nuts are damaged, for example, proceed as follows:

Information 

If the Cover On The Fuse Carrier  for the high-voltage battery Cannot Be Removed  because the screw heads or rivet nuts are damaged, for example, proceed as follows:

  1. Remove fuse carrier cover.
    1. 1.1. Loosen fastening screws -1-  as described above.
    2. 1.2. Push fuse carrier cover down and remove it.
      Fig 1: Identifying Fuse Carrier Cover Screws
      G09933896Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    Perform function test on voltage tester at the vehicle jump-start terminals using a reference voltage.

  2. Verify isolation from the power supply at the high-voltage battery fuse using voltage tester Voltage Tester WE 1380  .
    1. 2.1. Contact point -A-  to contact point -B-  .
    2. 2.2. Contact point -A-  to housing.
    3. 2.3. Contact point -B-  to housing.
    4. 2.4. Check contact point -A-  to contact point -B-  again to prevent static charge.
      Fig 2: Checking Absence Of Electric Charge
      G09933897Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    Further steps may only be carried out if the measured voltage is less than 1 V. If this is not the case, stop working on the system and contact Technical Support.

    Information 

    Once absence of electric charge has been verified using the voltage tester, the fuse must be replaced without any interruption to work.

  3. Remove high-voltage battery fuse.
    1. 3.1. Unscrew and remove fastening screws -3-  for cap -1-  and fuse -2-  .
    2. 3.2. Remove cap -1-  together with fuse -2-  .
      Fig 3: Removing Fuse
      G09933898Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 3.3. Unclip cap -1-  from the fuse and re-insert it on the high-voltage battery to protect exposed high-voltage contacts.
      Fig 4: Installing Battery Cap
      G09933899Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Remove high-voltage battery control unit.
    1. 4.1. Loosen fastening nuts -1, 2-  on the cover of the high-voltage battery control unit and remove cover -3-  .
    2. 4.2. Remove spacers under the fastening nuts -1-  .
      Fig 5: Identifying Cover For High-Voltage Battery Control Unit
      G09933900Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 4.3. Remove ground line -1-  from the fastening bolt.
      Fig 6: Identifying Ground Line
      G09933901Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 4.4. Loosen fastening nuts -1-  on the high-voltage battery control unit and pull off high-voltage battery control unit -2-  .
      Fig 7: Identifying High-Voltage Battery Control Unit
      G09933902Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    5. 4.5. Release electric plug connection -1-  at the high-voltage battery control unit completely -arrows a-  and disconnect it -arrow A-  .
    6. 4.6. Release electric plug connection -2-  completely -arrow b-  and disconnect it -arrow B-  .
      Fig 8: Releasing Electric Plug Connections
      G09933903Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    7. 4.7. Remove high-voltage battery control unit.

    Information 

    Procedure For Loosening Micro-Self-Locking Screws  .

    The covers on the high-voltage batteries are secured using fastening screws with high-strength screw locking agent. However, these can be difficult to loosen as a result of certain environmental conditions and depending on the service life of the vehicle.

    To avoid breaking off or damaging fastening screws, always loosen the fastening screws as follows:

    1. Mark the fastening screw using a felt-tip pen and carefully loosen it by half (1/2) a turn -arrow a-  .
    2. Screw the fastening screw in again by half (1/2) a turn -arrow b-  .
    3. Repeat Steps  1 and  2 at least five times (5x) until the loosening torque of the fastening screw is reduced significantly. The fastening screw can then be turned easily.
    4. After Step  3, the torque should be much lower so that the fastening screw can be loosened completely -arrow c-  .
      Fig 9: Loosening Fastening Screws
      G09933904Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    If the Cover Plate  for the high-voltage battery Cannot Be Removed  because the screw heads or rivet nuts are damaged, for example, proceed as follows:

    • Stop Working on the high-voltage battery Immediately  .
    • To find out what to do next, get in touch with your contact person at your importer's Technical Competence Centre (TCC)  .
  5. Remove top cover plate on the high-voltage battery
    1. 5.1. Loosen fastening screws -1-  as described above.
    2. 5.2. Loosen fastening screws -1, 2-  as described above.
      Fig 10: Identifying Top Cover Plate On High-Voltage Battery
      G09933905Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Do not remove top cover plate on the high-voltage battery.

    Fig 11: Identifying Top Cover Plate On High-Voltage Battery
    G09933906Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    Procedure For Cleaning Threaded Bores (Blind Hole Bore) On The High-Voltage Battery  .

    After loosening micro-self-locking fastening screws, it is important to remove the particles of screw locking agent from the threaded bores.

    • All tasks that are necessary for cleaning the threaded bores must be carried out by hand and the required personal protective gear must always be used  .
    • Never use lubricant for cleaning the threaded bores  .
    • When cleaning the threaded bores, always make sure that no remaining pieces of the micro-encapsulated coating/metal chips get into the battery housing. Use a vacuum cleaner to do this  .
      Fig 12: Identifying Tap Comparison
      G09933907Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    When cleaning the threaded bores (M6 and M8) on the high-voltage battery, always proceed as follows:

    1. Insert tap -1-  (with spiral grooves) into the threaded bore.
    2. Hold a vacuum cleaner with a plastic nozzle -3-  at the threaded bore in such a way that the remaining pieces of adhesive/metal chips will be removed.
    3. Turn the tap back and forth by a quarter (1/4) to a half (1/2) a turn several times -arrow-  to extract the remaining adhesive/metal chips that are dislodged -2-  .
      Fig 13: Cleaning Threaded Bore
      G09933908Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. Repeat Step  3 several times until the threaded bore is completely cleaned.

    Information 

    Procedure For Cleaning Threaded Bores (Through-Bore) On The Side Bar Of The High-Voltage Battery  .

    After loosening micro-self-locking fastening screws, it is important to remove the particles of screw locking agent from the threaded bores.

    • All tasks that are necessary for cleaning the threaded bores must be carried out by hand and the required personal protective gear must always be used  .
    • Never use lubricant for cleaning the threaded bores  .
    • When cleaning the threaded bores, always make sure that no remaining pieces of the micro-encapsulated coating/metal chips get into the battery housing. Use a vacuum cleaner to do this  .
      Fig 14: Identifying Tap Comparison
      G09933909Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    When cleaning the threaded bores (M6 and M8) on the high-voltage battery, always proceed as follows:

    1. Stick two strips (50 x 80 mm) of fabric adhesive tape -4-  on the inside of the bar on the high-voltage battery using a plastic wedge. The bores must be completely sealed.
    2. Insert tap (with spiral grooves) -1-  into the threaded bore.
    3. Hold a vacuum cleaner with a plastic nozzle -3-  at the threaded bore in such a way that the remaining pieces of adhesive/metal chips -2-  will be removed.
    4. Turn the tap back and forth by a quarter (1/4) to a half (1/2) a turn several times -arrow-  to extract the remaining adhesive/metal chips that are dislodged.
    5. Repeat Step  3 several times until the threaded bore is completely cleaned. Make sure not to puncture the fabric adhesive tape.
      Fig 15: Cleaning Threaded Bore
      G09933910Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    6. Carefully remove fabric adhesive tape and always use a vacuum cleaner to remove any loose particles at the same time.
  6. Clean threaded bores -1-  for the fastening points for the top cover plate as described above Using An M6 X 1.0 Tap With Spiral Grooves  .
    Fig 16: Identifying Threaded Bores
    G09933911Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    Carefully remove the top cover plate to prevent damage to the E-box wiring harness.

    1. 6.1. Carefully lift up the top cover plate on the high-voltage battery and remove it.

    Information 

    If the Cover Plate  for the high-voltage battery Cannot Be Removed  because the screw heads or rivet nuts are damaged, for example, proceed as follows:

    • Stop Working On the high-voltage battery Immediately  .
    • To find out what to do next, get in touch with your contact person at your importer's  Technical Competence Centre (TCC)  .
  7. Check seal on front cover plate and if it is damaged, replace the front cover plate.
    1. 7.1. Loosen fastening screws (M6 x 12) -1-  as described above.
      Fig 17: Removing Front Cover Plate
      G09933912Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 7.2. Carefully remove front cover plate on the high-voltage battery by pulling it to the side.
    3. 7.3. Clean the threaded bores -1-  for the fastening points for the side cover plate as described above Using An M6 X 1.0 Tap With Spiral Grooves  .
      Fig 18: Identifying Threaded Bores
      G09933913Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Remove E-box.
    1. 8.1. Loosen tie-wrap -1-  on HV line.
      Fig 19: Disconnecting HV Line
      G09933914Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 8.2. Remove wiring harness -1-  by pulling it up out of the guide -arrows-  .
      Fig 20: Disconnecting Wiring Harness
      G09933915Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 8.3. Loosen fastening screws -1-  for the E-box as described above.
      Fig 21: Identifying E-Box Screws
      G09933916Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 8.4. Carefully pull the E-box straight off the high-voltage battery and make sure not to tilt the E-box when pulling it off the guide pins -1-  .
      Fig 22: Identifying E-Box Guide Pins
      G09933917Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    5. 8.5. Cover exposed terminals on the high-voltage battery -arrows-  with adhesive tape immediately after removing the E-box.
      Fig 23: Identifying Battery Terminals
      G09933918Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    Procedure For Cleaning Threaded Bores (Through-Bore) On The Side Bar Of The High-Voltage Battery  .

    After loosening micro-self-locking fastening screws, it is important to remove the particles of screw locking agent from the threaded bores.

    • All tasks that are necessary for cleaning the threaded bores must be carried out by hand and the required personal protective gear must always be used  .
    • Never use lubricant for cleaning the threaded bores  .
    • When cleaning the threaded bores, always make sure that no remaining pieces of the micro-encapsulated coating/metal chips get into the battery housing. Use a vacuum cleaner to do this  .
      Fig 24: Identifying Tap Comparison
      G09933919Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    When cleaning the threaded bores (M6 and M8) on the high-voltage battery, always proceed as follows:

    1. Stick two strips (50 x 80 mm) of fabric adhesive tape -4-  on the inside of the bar on the high-voltage battery using a plastic wedge. The bores must be completely sealed.
    2. Insert tap (with spiral grooves) -1-  into the threaded bore.
    3. Hold a vacuum cleaner with a plastic nozzle -3-  at the threaded bore in such a way that the remaining pieces of adhesive/metal chips -2-  will be removed.
    4. Turn the tap back and forth by a quarter (1/4) to a half (1/2) a turn several times -arrow-  to extract the remaining adhesive/metal chips that are dislodged.
      Fig 25: Cleaning Threaded Bore
      G09933920Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    5. Repeat Step  3 several times until the threaded bore is completely cleaned. Make sure not to puncture the fabric adhesive tape.
    6. Carefully remove fabric adhesive tape and always use a vacuum cleaner to remove any loose particles at the same time.
  9. Clean the threaded bores on the upper bar of the high-voltage battery as described above.
    1. M8 Through-Bore
    2. M8 Blind Hole Bore
    3. M6 Through-Bore
    4. Fabric Adhesive Tape
      Fig 26: Identifying Threaded Bores
      G09933921Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 9.1. Clean the threaded bores for the fastening points of the top cover plate -1, 2-  using An M8 X 1.25 Tap With Spiral Grooves  .
    2. 9.2. Clean the threaded bore for the upper fastening points of the E-box -3-  using an M6 X 1.0 Tap With Spiral Grooves  .
  10. Clean the threaded bores for the fastening points -1-  of the E-box as described above.
    Fig 27: Cleaning Threaded Bores
    G09933922Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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