Installing E-Box

→ 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.
   Fig 2: Exposing Battery Terminals

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   1. 1.1. Remove adhesive tape from the battery terminals -arrows-  .
   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 3: Identifying E-Box Guide Pins

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   3. 1.3. Screw in and tighten fastening screws -1-  on the E-box. → Tightening torque: 10.1 Nm (7.5 ftlb.) 
      Fig 4: Identifying E-box Fastening Screws

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   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 5: Positioning Wiring Harness

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   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 6: Connecting Electric Plug Connection

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   6. 1.6. Fasten tie-wrap -1-  on HV line.
      Fig 7: Securing HV Line

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   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.
   Fig 8: Identifying Side Cover Plate Mounting Bolts

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   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 ftlb.) 
   3. 2.3. Carefully position top cover plate on the high-voltage battery.
      Fig 9: Installing Top Cover Plate

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   4. 2.4. Tighten fastening screws (M6 x 16) -1-  . → Tightening torque: 10.1 Nm (7.5 ftlb.) 

      Tighten fastening screws (M6 x 12) -2-  . → Tightening torque: 10.1 Nm (7.5 ftlb.) 

   5. 2.5. Tighten fastening screws (M8 x 16) -1-  . → Tightening torque: 13 Nm (9.5 ftlb.) 
      Fig 10: Identifying Top Cover Plate Fastening Screws

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3. Install high-voltage battery control unit.
   Fig 11: Connecting Electric Plug Connections

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   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-  .
   3. 3.3. Position control unit -2-  on the E-box and tighten fastening nuts -1-  . → Tightening torque: 5.9 Nm (4.5 ftlb.) 
      Fig 12: Installing High-Voltage Battery Control Unit

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   4. 3.4. Push ground line -1-  onto the fastening bolts.
      Fig 13: Identifying Ground Line Fastening Bolts

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   5. 3.5. Position spacers on the bolts under fastening nuts -2-  .
      Fig 14: Identifying Cover For High-Voltage Battery Control Unit Fastening Nuts

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   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 ftlb.) 
4. Remove cap -1-  .
   Fig 15: Identifying Cap

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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-  .
   Fig 16: Checking Electric Charge Absence

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   1. 5.1. Contact point -A-  to housing.
   2. 5.2. Contact point -B-  to housing.

      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.
   Fig 17: Installing High-Voltage Battery Fuse

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   1. 6.1. Fit assembly aid -1-  on the high-voltage battery fuse and on the high-voltage battery using fastening screws.
   2. 6.2. Tighten fastening screws. → Tightening torque: 10 Nm (7.5 ftlb.) 
   3. 6.3. Pull assembly aid off the high-voltage battery fuse.
   4. 6.4. Fit cap -1-  until it engages securely.
      Fig 18: Identifying Cap

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7. Position fuse carrier cover and tighten fastening screws -1-  . → Tightening torque: 10.1 Nm (7.5 ftlb.) 
   Fig 19: Identifying Fuse Carrier Cover Fastening Screws

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   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 20: Arrangement Of Stickers

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