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Installing E-Box

WARNING: Incorrect handling of high-voltage components 
  • Electric shock 
  • Short circuit 
  • Fire 
  • 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.

    > 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE SYSTEM

Information 

Before re-installing the E-box, the radial shaft seal and sealing rings for the E-box must always be replaced.

Information 

For additional 3D information, see

> 270819 REMOVING AND INSTALLING VIDEO E-BOX 

  1. Remove old radial shaft seal on E-box.
    1. 1.1  Insert > T90024B - assembly tool  (lower part) into the radial shaft seal and spread it using the adjusting nut.
      G15551009Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Special tool for radial shaft seal

    2. 1.2  Fit > T90024B - assembly tool  (upper part) and pull off radial shaft seal.
      G15551010Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Pulling out radial shaft seal

      Information 

      When positioning the radial shaft seal, make sure that the markings on the seal (e.g. part 1 lumber, other numbers and, if present, the white marking) are facing the > T90024B - assembly tool  .

  2. Install new radial shaft seal on E-box.
    1. 2.1  Clean and oil spindle of > T90024B - assembly tool  .
      G15551011Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Spindle special tool

      1. 2.1.1  Clean spindle using a brass brush.
      2. 2.1.2  Wipe off spindle with a lint-free cloth.
      3. 2.1.3  Oil the spindle (do not grease).
      4. 2.1.4  Check that the spindle can turn very easily.
    2. 2.2  Clean the support and contact surface of the radial shaft seal with isopropanol and a lint-free cloth.
      G15551012Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Support and contact surface of radial shaft seal

    3. 2.3  Cover the inside of the E-box with a lint-free, absorbent cloth.
      G15551013Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Covering inside of E-box

    4. 2.4  Fit radial shaft seal on cup insert of > T90024B - assembly tool  .
      1. 2.4.1  Check installation direction of radial shaft seal. The markings on the radial shaft seal (e.g. part number, other numbers and, if present, the white marking) must point in the direction of the cup insert and must not be visible.
      2. 2.4.2  Make sure that the sealing lip is seated correctly.
    5. 2.5  Place radial shaft seal with cup insert of > T90024B - assembly tool  on E-box.
      G15551014Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Radial shaft seal with cup insert

      1. 2.5.1  The cut-out on the cup insert -1-  must be centered with respect to the high-voltage contacts of the E-box -2-  .
    6. 2.6  Insert feet of > T90024B - assembly tool  between E-box and radial shaft seal.
      G15551015Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Feet of assembly tool

      1. 2.6.1  The feet must be flush with the cut-out on the cup insert.
        G15551016Courtesy of PORSCHE CARS NORTH AMERICA, INC.

        Feet on cup insert cut-out

    7. 2.7  Complete > T90024B - assembly tool  .
      G15551017Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Pressing in radial shaft seal

    8. 2.8  Move > T90024B - assembly tool  into top position and check that the radial shaft seal is straight.
      G15551018Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Special tool at top position

    9. 2.9  Move > T90024B - assembly tool  into bottom position.

      The radial shaft seal mist not be touching the E-box yet.

      1. 2.9.1  Align > T90024B - assembly tool  and radial shaft seal with the E-box and make sure the gap is uniform -Arrow's-  .
        G15551019Courtesy of PORSCHE CARS NORTH AMERICA, INC.

        Radial shaft seal seating

      2. 2.9.2  There must be a small gap of 2 mm between the E-box and radial shaft seal.

        The radial shaft seal must not be touching the E-box yet.

        G15551020Courtesy of PORSCHE CARS NORTH AMERICA, INC.

        Special tool at bottom position

    10. 2.10  Coat radial shaft seal with distilled water.
      G15551021Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Coating radial shaft seal with distilled water

      1. 2.10.1  Use plenty of distilled water.

        Small water droplets can form on the outside of the E-box.

        Never let water get inside the E-box.

        Press radial shaft seal in immediately after coating it with distilled water.

        G15551022Courtesy of PORSCHE CARS NORTH AMERICA, INC.

        OK example

        G15551023Courtesy of PORSCHE CARS NORTH AMERICA, INC.

        Not OK example

    11. 2.11  Press in radial shaft seal.
      1. 2.11.1  Press in radial shaft seal by turning the spindle on the > T90024B - assembly tool  .
      2. 2.11.2  Press in radial shaft seal with 10 Nm (7.5 ftlb.)  .
        G15551024Courtesy of PORSCHE CARS NORTH AMERICA, INC.

        Pressing in radial shaft seal

      3. 2.11.3  Wait 30 seconds  .
      4. 2.11.4  Repeat steps  2 to 2.11.03 three times  .
    12. 2.12  Remove distilled water using a lint-free and absorbent cloth.
    13. 2.13  Remove > T90024B - assembly tool  .
    14. 2.14  Check that the radial shaft seal is seated correctly.
      1. 2.14.1  Dry the radial shaft seal with a lint-free and absorbent cloth.
      2. 2.14.2  Carry out a visual inspection: Ensure that the markings on the radial shaft seal (e.g. part number, other numbers and, if present, the white marking) are now visible.
      3. 2.14.3  Check press-in depth of radial shaft seal at four points using > VAS 6079 - dial gauge  and > VW382 - measuring tool  (offset by 90°).

        Select measuring points at positions on the radial shaft seal without depressions, letters/numbers or markings.

        G15551025Courtesy of PORSCHE CARS NORTH AMERICA, INC.

        Press-in depth of radial shaft seal (shown as an example)

        G15551026Courtesy of PORSCHE CARS NORTH AMERICA, INC.

        Measuring probe

      4. 2.14.4  The radial shaft seal must be at least 0.4 mm deeper than the metal collar of the E-box.
      5. 2.14.5  Press-in depth of the radial shaft seal must be uniform.

        The difference between the measuring points must not be more than 0.2 mm.

      6. 2.14.6  The radial shaft seal must not protrude beyond the edge of the E-box housing.
  3. Clean the spindle > T90024B - assembly tool  again using a lint-free cloth.
    G15551027Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Spindle special tool

  4. Fit new sealing rings on contact surfaces between the E-box and high-voltage battery.
    G15551028Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Sealing rings for E-box

    1. 4.1  Remove sealing rings.
    2. 4.2  Clean contact surface of sealing rings and remove any grease.
    3. 4.3  Stick on new sealing rings.
  5. Re-tighten spacer sleeve at screw points for the E-box to > Tightening torque 8 Nm (5.9 ftlb.)  .
    G15551029Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Spacer sleeve at screw points for E-box

  6. Fit > 9924 - centering pins  for positioning the E-box on the high-voltage battery.
    G15551030Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Centering pins on E-box

  7. Coat flange of screw points securing E-box to front of high-voltage battery with anti-corrosion grease GPL 205.
    G15551031Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Screw points for high-voltage battery

    G15551032Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Flange of screw points (shown as an example)

    1  Brush with anti-corrosion grease GPL 205
    2  Contact surface of E-box
    Arrows  Flange of screw point (side to surface to be coated)

    The contact surface of the E-box must not be coated with anti-corrosion grease GPL 205.

    Clean contact surface of E-box 2  if necessary.

  8. Coat contact surface of E-box radial shaft seal on the high-voltage battery with lubricant P80.
    1. 8.1  Shake lubricant P80 before use. Lubricant P80 must be milky white.
    2. 8.2  Apply lubricant P80 to cone of radial shaft seal contact surface on the E-box.
      G15551033Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Lubricant

    3. 8.3  Lubricant must not be applied to the laser scan surface. If necessary, clean the laser scan surface after applying the lubricant.
      G15551034Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Laser scan surface

  9. Coat sealing lip of radial shaft seal lightly with lubricant P80.

    Shake lubricant P80 before use. Lubricant P80 must be milky white.

    G15551035Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Radial shaft seal

    1. 9.1  Never apply lubricant on the flat seal.
      G15551036Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Flat seal

  10. Remove cover on electric connections for E-box at the high-voltage battery.
    G15551037Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Electric connections for E-box

  11. Carefully position the E-box on the high-voltage battery.
    1. 11.1  Position E-box over the high-voltage battery.

      Do not set the E-box down on the high-voltage battery yet.

      G15551038Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Setting up lifting equipment

    2. 11.2  Discharge capacitive voltage.
      1. 11.2.1  Screw in screw at the blind hole on the housing and connect test clamp.
        G15551039Courtesy of PORSCHE CARS NORTH AMERICA, INC.

        Test clamp on E-box

      2. 11.2.2  Connect test clamp to potential equalization line for high-voltage battery.
        G15551040Courtesy of PORSCHE CARS NORTH AMERICA, INC.

        Test clamp on potential equalization line for high-voltage battery

      3. 11.2.3  Connect both test clamps using a test cable from the > 9684 - measurement tool set  .
    3. 11.3  Carefully position the E-box on the high-voltage battery.
    4. 11.4  Remove test clamps and test cable.
  12. Remove > 9924 - centering pins  .
  13. Fit screws securing E-box to high-voltage battery and tighten in 2 steps. Level 1; > Tightening torque 8 Nm (5.9 ftlb.)  .

    Always use new screws.

    Observe specified tightening sequence.

    Screws must be tightened again after 30 minutes.

    Fit screws securing E-box to high-voltage battery and tighten to. Level 2; > Torque 9 Nm (6.6 ftlb.) 

  14. Coat screw head on fastening screws for E-box aid joint between E-box and high-voltage battery cover with anti-corrosion grease GPL 205.
    G15551041Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    E-box screws

  15. Perform potential equalization measurement.
    1. 15.1  Connect > VAS 6558A - high-voltage testing module  to > 9900 - PIWIS Tester 3  .
    2. 15.2  Start the Tester.
    3. 15.3  Select Measurement program  .
    4. 15.4  Select HV measurements  .
    5. 15.5  Select potential equalization measurement  .
    6. 15.6  Perform self-test according to menu guidance.
    7. 15.7  Attach Kelvin clamp to the positive measuring probe (red).
    8. 15.8  Set a test current of 1, 000 mA for the operating range.
    9. 15.9  Connect ground terminal to potential equalization line for battery housing -1-  .
    10. 15.10  Place measuring probe with Kelvin clamp on the E-box cover -2-  and press it on.
      G15551042Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Equipotential equalization measurement

      1. 15.10.1  Start the measurement.
      2. 15.10.2  Measured result: Resistance < 10 m Ohm.
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