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.
Removing fuse carrier cover
7

Verify isolation from the power supply at the
high-voltage battery fuse using a voltage tester VAS
6839 - Voltage tester.
7.1

Contact point  Verifying absence of electric
charge -A- to housing.

7.2

Contact point  Verifying absence of electric
charge -B- to housing.
The measurement also prevents voltages due
to the build-up of static charge.

Verifying absence of electric 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.

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Remove high-voltage battery fuse.
8.1

Press cap  Removing cap -1- together
 Removing cap -arrows-, unscrew it 
Removing cap -A- and pull it down and out 
Removing cap -B-.

Removing cap
8.2

9874 - Assembly aid Removing fuse
-1- must now be fitted on the high-voltage
battery fuse. Then loosen fastening screws
 Removing fuse -2-.

8.3

Carefully remove assembly aid together with
fastening screws  Removing fuse -1- and
high-voltage battery fuse  Removing fuse
-2-.

Removing fuse
8.4

Re-insert cap  Installing cap -1- on the
high-voltage battery to protect exposed
high-voltage contacts.

Installing cap

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Remove high-voltage battery control unit.
9.1

9.2

Loosen fastening nuts  Removing cover
for high-voltage battery control unit -1, 2- on
the cover of the high-voltage battery control
unit and remove cover  Removing cover for
high-voltage battery control unit -3-.
Remove spacers under the fastening nuts

 Removing cover for high-voltage battery
control unit -1-.
Removing cover for high-voltage
battery control unit
9.3

Remove ground line  Removing ground line
-1- from the fastening bolt.

Removing ground line
9.4

Loosen fastening nuts  Removing
high-voltage battery control unit -1- on the
high-voltage battery control unit and pull off
high-voltage battery control unit  Removing
high-voltage battery control unit -2-.

Removing high-voltage battery control unit

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9.5

Release electric plug connection 
Releasing electric plug connections -1- at the
high-voltage battery control unit completely
 Releasing electric plug connections
-arrows a- and disconnect it  Releasing
electric plug connections -arrow A-.

9.6

Release electric plug connection  Releasing
electric plug connections -2- completely 
Releasing electric plug connections -arrow
b- and disconnect it  Releasing electric
plug connections -arrow B-.

9.7

Remove high-voltage battery control unit.

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Releasing electric plug connections

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 E-box for the high-voltage battery cannot be removed because the screw heads or rivet nuts are
damaged, for example, proceed as follows:

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•

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 3.  See Procedure: Replacing high-voltage battery - Scope 3

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10 Remove cover plates on the high-voltage battery.
10.1

Loosen fastening screws at the side 
Removing top cover plate -1- as described
above.

Removing top cover plate
10.2

Loosen fastening screws at the top 
Removing top cover plate -1, 2- as described
above.
Do not remove the top cover plate.

Removing top cover plate
10.3

Loosen fastening screws at the bottom 
Removing side cover plate -3- as described
above.

Removing side cover plate
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.

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•

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.

Comparison of taps

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When cleaning the threaded bores (M6) on
the high-voltage battery, always proceed as
follows:
1.) Insert tap  Cleaning threaded bore -1(with spiral grooves) into the threaded bore.
2.) Hold a vacuum cleaner with a plastic
nozzle  Cleaning threaded bore -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 
Cleaning threaded bore -arrow- to extract
the remaining adhesive/metal chips that are
dislodged  Cleaning threaded bore -2-.
4.) Repeat Step 3 several times until the
threaded bore is completely cleaned.
10.4

Cleaning threaded bore

Clean the threaded bores for the fastening
points for the top cover plate as described
above using an M6 x 1.0 tap with spiral
grooves.
Information
Carefully remove/fit the cover to prevent
damage to the wiring harness for the
high-voltage battery.

10.5
10.6

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

Cleaning threaded bores

Carefully remove side cover plate on the high-voltage battery by pulling it to the side.

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Clean the threaded bores for the fastening
points for the side cover plate as described
above using an M6 x 1.0 tap with spiral
grooves.

Cleaning threaded bores
11 Remove E-box.
11.1

Loosen tie-wrap  Disconnecting HV line -1on HV line.

Disconnecting HV line
11.2

Remove wiring harness  Disconnecting
wiring harness -1- by pulling it up out of
the guide  Disconnecting wiring harness
-arrows-.

Disconnecting wiring harness

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Loosen fastening screws  Loosening E-box
-1- for the E-box as described above.

Loosening E-box
11.4

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 
Removing E-box -1-.

Removing E-box
11.5

Cover exposed terminals on the high-voltage
battery  Covering battery terminals
-arrows- with adhesive tape immediately
after removing the E-box.

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.

Covering battery terminals

•

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.

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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.

Comparison of taps
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

 Cleaning threaded bore -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)  Cleaning threaded
bore -1- into the threaded bore.
3.) Hold a vacuum cleaner with a plastic nozzle 
Cleaning threaded bore -3- at the threaded bore in such a
way that the remaining pieces of adhesive/metal chips 
Cleaning threaded bore -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  Cleaning threaded bore
-arrow- to extract the remaining adhesive/metal chips
that are dislodged.

Cleaning threaded bore
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.
12 Clean the threaded bores on the upper bar of the high-voltage battery as described above.

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