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Home >> Porsche >> 2016 >> Panamera Turbo >> Repair and Diagnosis >> Electrical >> Starter >> 27 - Starter, Power Supply, Cruise Control -- PANAMERA (970) >> WM 270819 Removing And Installing E-Box (PANAMERA S E-Hybrid, PANAMERA S Hybrid) >> Removing E-Box

Removing E-Box

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 High-voltage cordon WE 1589  when working on a HV work bay.

Fig 1: Identifying Restricted Area For High-Voltage Battery
G09806204Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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 cover on fuse carrier.
    Fig 2: Identifying Fuse Carrier Cover Mounting Screws
    G09806205Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 1.1. Loosen fastening screws -1-  as described above.
    2. 1.2. Push fuse carrier cover down and remove it.

    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 a voltage tester Voltage tester WE 1380  .
    Fig 3: Checking Absence Of Electric Charge
    G09806206Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 2.1. Contact point -A-  to housing.
    2. 2.2. Contact point -B-  to housing.

      The measurement also prevents voltages due to the build-up of static charge.

    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.
    Fig 4: Removing High-Voltage Battery Fuse
    G09806207Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 3.1. Press cap -1-  together -arrows-  , unscrew it -A-  and pull it down and out -B-  .
    2. 3.2. Assembly aid 9874 -1-  must now be fitted on the high-voltage battery fuse. Then loosen fastening screws -2-  .
      Fig 5: Removing Fuse
      G09806208Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 3.3. Carefully remove assembly aid together with fastening screws -1-  and high-voltage battery fuse -2-  .
    4. 3.4. Re-insert cap -1-  on the high-voltage battery to protect exposed high-voltage contacts.
      Fig 6: Identifying Cap
      G09806209Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Remove high-voltage battery control unit.
    Fig 7: Identifying Cover For High-Voltage Battery Control Unit With Mounting Screws
    G09806210Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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-  .
    3. 4.3. Remove ground line -1-  from the fastening bolt.
      Fig 8: Removing Ground Line From Fastening Bolt
      G09806211Courtesy 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 9: Identifying High-Voltage Battery Control Unit With Mounting Nuts
      G09806212Courtesy 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-  .
      Fig 10: Removing Electric Plug Connections
      G09806213Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    6. 4.6. Release electric plug connection -2-  completely -arrow b-  and disconnect it -arrow B-  .
    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 11: Loosening Fastening Screws
      G09806214Courtesy 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
    Fig 12: Identifying Top Cover Plate On High-Voltage Battery
    G09806215Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 5.1. Loosen fastening screws -1-  as described above.
    2. 5.2. Loosen fastening screws -1, 2-  as described above.

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

    Fig 13: Identifying Top Cover Plate On High-Voltage Battery With Mounting Screws
    G09806216Courtesy 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 14: Identifying Taps
      G09806217Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

    Fig 15: Cleaning Threaded Bore
    G09806218Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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-  .
    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 microencapsulated coating/metal chips get into the battery housing. Use a vacuum cleaner to do this. 
      Fig 16: Identifying Taps
      G09806219Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

    Fig 17: Cleaning Threaded Bore
    G09806220Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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.
    6. Carefully remove fabric adhesive tape and always use a vacuum cleaner to remove any loose particles at the same time.
  6. Clean the 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 18: Cleaning Threaded Bores
    G09806221Courtesy 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.
    Fig 19: Identifying Front Cover Plate Mounting Bolts
    G09806222Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 7.1. Loosen fastening screws (M6 x 12) -1-  as described above.
    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 20: Cleaning Threaded Bores
      G09806223Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Remove E-box.
    Fig 21: Disconnecting HV Line
    G09806224Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 8.1. Loosen tie-wrap -1-  on HV line.
    2. 8.2. Remove wiring harness -1-  by pulling it up out of the guide -arrows-  .
      Fig 22: Disconnecting Wiring Harness
      G09806225Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 8.3. Loosen fastening screws -1-  for the E-box as described above.
      Fig 23: Identifying E-Box Guide Pin
      G09806226Courtesy 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 24: Removing E-box
      G09806227Courtesy 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 25: Covering Battery Terminals
      G09806228Courtesy 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 26: Identifying Taps
      G09806229Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

    Fig 27: Cleaning Threaded Bore
    G09806230Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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.
    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.
    Fig 28: Cleaning Threaded Bore
    G09806231Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. M8 through-bore
    2. M8 blind hole bore
    3. M6 through-bore
    4. Fabric adhesive tape
    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 29: Cleaning Threaded Bore
    G09806232Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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