NHTSA ID Number: 10117452
Manufacturer Communication Number: 122-W7J3A-06
TSB/Document Date: 2017-09-14
Summary
Concerns: E-box for the high-voltage system Information: This is to inform you of a voluntary Workshop Campaign on the above-mentioned vehicles. An E-box for the high-voltage system that does not comply with current standards was installed in the affected vehicles. The new E-box is considerably more robust than the existing standard version.
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WD67
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WD67 - Replacing E-box for the High-voltage System (Stop Sale Campaign/Workshop
Campaign)
Revisions:
Revision 1: April 2, 2014; This revision EXTENSIVELY amends the original WD67 in that the technical
document has gone from 6 pages to 34.
Model Year:
2014
Vehicle Type:
Panamera S E-Hybrid
Concerns:
E-box for the high-voltage system
Information:
This is to inform you of a voluntary Workshop Campaign on the above-mentioned vehicles. An E-box
for the high-voltage system that does not comply with current standards was installed in the
affected vehicles.
The new E-box is considerably more robust than the existing standard version.
Action
Required:
Replace E-box for the high-voltage system.
Affected
Vehicles:
The VIN(s) can be checked by using PIWIS Vehicle Information link to verify if the campaign affects the
vehicle. This campaign is scope specific to the VIN! Failure to verify in PIWIS may result in an improper
repair. This campaign affects 5 VINs in the United States.
Parts Info:
NOTE: Parts will not be automatically shipped to your dealership. Please submit a PTEC/PAV for parts.
7PP.915.251.A
1 ea.
970.611.901.07
Set of screws for control unit
1 ea.
7PP.915.465.A
Battery cover plate, top
1 ea.
7PP.915.151
Battery cover plate, side
1 ea.
970.611.901.02
Set of screws for cover plate
1 ea.
970.611.901.03
Battery fuse box cover
1 ea.
970.611.901.04
Set of screws for fuse
1 ea.
1
7PP.915.463
Fuse
1 ea.
N .906.661.01
5 ea.
970.555.643.01
Screw bolt for locking mechanism
2 ea.
999.507.584.02
Clamp
10 ea.
999.507.839.01
Clip
10 ea.
7PP.010.849.L
Indication sticker LI.ION HV BATTERY
1 ea.
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958.701.739.00
Warning sign for cover
2 ea.
000.043.301.47
Antifreeze, 1-liter container
approx. 1 liter per vehicle
(as much as required)
1
Part number 7PP.915.151 has been changed to 000.043.209.34. Existing stocks of part number
7PP.915.151 can be used up.
Also required:
8R0.010.539
2
Materials:
...
3
1 ea. 2
Warning sign, English
Since the cover plates for the high-voltage battery must be replaced while carrying out the work
required for replacing the E-box, new stickers must also be affixed to the new cover plates. The
required safety marking warning sign 8R0.010.539.x must be selected according to the relevant
language and country version.
5 ea. 3
Tie-wrap, approx. 3.0 x 200 mm
e.g. 999.513.075.40
WD670000001 should be entered manually as a sublet part.
...
Tap, M6 x 1.0 with spiral grooves
1 ea.
4
...
Tap, M8 x 1.25 with spiral grooves
1 ea.
4
Tap with spiral groove
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Information
If the specified taps are not already available in the workshop, they must be ordered once specifically for carrying out this task.
During this repair measure, only use taps with spiral grooves, which guide the chips out of the hole in
the opposite direction to the cutting direction.
Only one M6 x 1.0 tap and one M8 x 1.25 tap may be invoiced for each affected Porsche dealership.
4
WD670000002 should be entered manually as a sublet part.
Special Tools:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
VAS 6558/9-6 - High-voltage test adapter HVA 280
VAS 6558/9-7 - High-voltage test adapter HVR 40
VAS 6839 - Voltage tester
VAS 6884 - High-voltage cordon
VAS 6883 - Insulated tool set
9860 - Adapter plate
9874 - Assembly aid
3033 - Lifting tackle
VAS 6100 - Workshop crane
T40262 - Locking cap
9818 - PIWIS Tester II
9696 - Filling device
Nr.192 - Hose clamping pliers
Nr.90 Pos.2 - Torque wrench
Nr.90 Pos.6 - Torque wrench
Work
Procedure:
See Attachment “A”.
Claim
Submission:
See Attachment “B”.
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Installation
position:
Installation position of E-box
Attachment "A": Work Procedure
Removing E-box (high-voltage battery) - Scope 1
Procedure:
WARNING
High voltage
•
Danger of electric shock from live parts
•
Risk of serious burns or death
Work on the HV battery may only be carried out by a high-voltage technician.
Always use insulated tools VAS 6883 - Insulated tool set when working on the HV battery.
Observe general warning notes for working on the high-voltage vehicle electrical system. Workshop
Manual '2X00IN General warning notes for working on the high-voltage electrical system'
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Before starting to work on the high-voltage system, a high-voltage technician must isolate the
high-voltage system from the power supply.
The document Workshop Manual '2X00IN Isolation from supply prior to performing maintenance
tasks on hybrid vehicles' describes the various types of work for which the high-voltage system must be
isolated from the power supply.
The test log Verifying absence of electric charge and Restarting high-voltage system can be
found under Standard forms in PIWIS.
Information
Always use insulated tools VAS 6883 - Insulated tool
set when working on the high-voltage battery and a
high-voltage cordon VAS 6884 - High-voltage cordon
when working on a HV work bay.
1
Observe warning notes Workshop Manual
'2X00IN General warning notes for working on the
high-voltage electrical system'.
2
The high-voltage system must be isolated from the
power supply and the related documentation for
isolating the high-voltage system and classification of
Restricted area for HV battery
the high-voltage battery must be completed.
Workshop Manual '2X00IN Isolating high-voltage electrical system from power supply/Starting
high-voltage electrical system'
Workshop Manual '2X00IN Classification of high-voltage battery'
3
Remove high-voltage battery Workshop Manual '270819 Removing and installing high-voltage
battery - section on "Removing"'.
4
Set up a high-voltage cordon VAS 6884 - High-voltage cordon around the high-voltage workstation.
5
Remove battery cross member Workshop Manual '271119 Battery cross member - section on
"Removing"'.
NOTICE
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
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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-selflocking 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
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 Loosening
fastening screws -arrow a-.
2.) Screw the fastening screw in again by half (1/2) a turn Loosening fastening screws -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 Loosening fastening screws -arrow c-.
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Loosening fastening screws
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:
•
Stop working on the high-voltage battery immediately.
•
To find out what to do next,contact Technical Support.
•
The work carried out up to this point, including replacing the high-voltage battery, must be invoiced
under Scope 2. See Procedure: Replacing high-voltage battery - Scope 2
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Remove cover on fuse carrier.
6.1
Loosen fastening screws Removing fuse
carrier cover -1- as described above.
6.2
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TSB/Document ID: 122-W7J3A-06
Replacement Service Bulletin Number:
MFR Communication Date: 2017-04-04
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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