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.
2
Cleaning threaded bore
1
2
3
4
–
–
–
–
M8 through-bore
M8 blind hole bore
M6 through-bore
Fabric adhesive tape
12.1
Clean the threaded bores for the fastening points of the top cover plate Cleaning threaded
bore -1, 2- using an M8 x 1.25 tap with spiral grooves.
12.2
Clean the threaded bore for the upper fastening points of the E-box Cleaning threaded
bore -3- using an M6 x 1.0 tap with spiral grooves.
13 Clean the threaded bores for the fastening points
Cleaning threaded bore -1- of the E-box as described
above.
Cleaning threaded bore
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Installing E-box (high-voltage battery) - Scope 1
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.
Procedure:
14 Install E-box.
14.1
Remove adhesive tape from the battery
terminals Exposing battery terminals
-arrows-.
Exposing battery terminals
14.2
Push E-box onto the guide pins Installing
E-box -1-, making sure not to tilt the E-box
and position it flat on the high-voltage battery.
Installing E-box
14.3
Screw in and tighten fastening screws
Securing E-box -1- on the E-box. Tightening
torque 10.1 Nm (7.5 ftlb.)
Securing E-box
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14.4
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Position the wiring harness Positioning
wiring harness -1- at the top of the guide
Positioning wiring harness -arrows- and
make sure that the seal Positioning wiring
harness -2- is fitted correctly.
Positioning wiring harness
14.5
Connect electric plug connection
Connecting electric plug connection -1on the E-box Connecting electric plug
connection -A- until it engages securely.
Check that the wiring harness is routed
behind the plug connection Connecting
electric plug connection -1- as shown.
Connecting electric plug connection
14.6
Fasten tie-wrap Securing HV line -1- on HV
line.
Information
When fitting the cover, check that the E-box wiring harness
is positioned correctly and is not squashed.
Securing HV line
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15 Install cover plates on the high-voltage battery.
15.1
Position side plate cover carefully on the
high-voltage battery.
15.2
Tighten fastening screws (M6 x 12)
Installing side cover plate -1-. Tightening
torque 10.1 Nm (7.5 ftlb.)
Installing side cover plate
15.3
Carefully position top cover plate on the
high-voltage battery.
15.4
Tighten fastening screws (M6 x 16)
Installing top cover plate -1-. Tightening
torque 10.1 Nm (7.5 ftlb.)
Tighten fastening screws (M6 x 12)
Installing top cover plate -2-. Tightening
torque 10.1 Nm (7.5 ftlb.)
Installing top cover plate
15.5
Tighten fastening screws (M8 x 16)
Installing top cover plate -1-. Tightening
torque 13 Nm (9.5 ftlb.)
Installing top cover plate
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16 Install high-voltage battery control unit.
16.1
Connect electric plug connection
Connecting electric plug connections -2on the high-voltage battery control unit
Connecting electric plug connections
-b- and lock it Connecting electric plug
connections -B-.
16.2
Connect electric plug connection
Connecting electric plug connections -1( Connecting electric plug connections
-a-) and lock it Connecting electric plug
connections -A-.
16.3
Connecting electric plug connections
Position control unit Installing high-voltage
battery control unit -2- on the E-box
and tighten fastening nuts Installing
high-voltage battery control unit -1-.
Tightening torque 5.9 Nm (4.5 ftlb.)
Installing high-voltage battery control unit
16.4
Push ground line Pushing on ground line
-1- onto the fastening bolts.
Pushing on ground line
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16.5
Position spacers on the bolts under fastening
nuts Installing cover for high-voltage
battery control unit -2-.
16.6
Position cover on high-voltage battery control
unit Installing cover for high-voltage
battery control unit -3- and tighten fastening
nuts Installing cover for high-voltage
battery control unit -1, 2-. Tightening
torque 5.9 Nm (4.5 ftlb.)
Installing cover for high-voltage
battery control unit
17 Remove cap Removing cap -1-.
Removing cap
18 Verify absence of electric charge at the exposed
high-voltage contacts of the high-voltage battery
using a suitable voltage tester at contact points
Verifying absence of electric charge -A, B-.
18.1
Contact point Verifying absence of electric
charge -A- to housing.
18.2
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
Insert fuse without causing any interruption to work in order to prevent an electrostatic charge.
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19 Install high-voltage battery fuse.
19.1
Fit assembly aid Installing fuse -1- on
the high-voltage battery fuse and on the
high-voltage battery using fastening screws.
19.2
Tighten fastening screws. Tightening
torque 10 Nm (7.5 ftlb.)
19.3
Pull assembly aid off the high-voltage battery
fuse.
Installing fuse
19.4
Fit cap Installing cap -1- until it engages
securely.
Installing cap
20 Position fuse carrier cover and tighten fastening
screws Installing fuse carrier cover -1-.
Tightening torque 10.1 Nm (7.5 ftlb.)
Information
Stickers (warning of dangerous electrical voltage)
The cover plates 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
plates cannot be re-used.
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Technical Information
Before re-installing the high-voltage battery, new stickers must therefore be affixed to the new cover
plates 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.
21 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
Arrangement of stickers
22 Install battery cross member Workshop Manual '271119 Battery cross member - section on
"Installing"'.
23 Install high-voltage battery Workshop Manual '270819 Removing and installing high-voltage
battery - section on "Installing"'.
24 Restart the high-voltage system and complete the relevant documentation Workshop Manual
'2X00IN Isolating high-voltage electrical system from power supply/Starting high-voltage electrical
system'.
25 Enter the campaign in the Warranty and Maintenance booklet.
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Replacing high-voltage battery - Scope 2
Information
Returning high-voltage batteries to the Porsche.
Our parts manufacturers and suppliers have informed us that in most cases where queried high-voltage
batteries were sent to Porsche, the coolant was not drained properly before packing them into the
transport box.
Given this, we must point out that a small amount of coolant can cause internal faults in the high-voltage
battery during transport and a subsequent analysis can no longer be carried out.
It is important, therefore, to point out the following:
If an analysis cannot be carried out because the high-voltage battery was not packaged correctly, we
reserve the right to reject the warranty claim in this case.
Warranty parts are not scrap or worthless material. On the one hand, the parts will be requested due to
possible recourse requirements (for the parts manufacturer or supplier), while on the other hand, the
parts are used for quality assurance and monitoring purposes. To ensure that these parts are processed
quickly, it is necessary therefore to send the high-voltage battery in accordance with the instructions in
the Workshop Manual Workshop Manual '2708IN Packaging instructions for high-voltage battery'.
1
Pack the high-voltage battery in the transport box Workshop Manual '2708IN Packaging
instructions for high-voltage battery'.
Information
Stickers (warning of dangerous electrical voltage)
As a rule, the high-voltage battery is delivered with a safety marking warning sign Safety marking
warning sign -1- in English.
If this does not correspond to the language or country version assigned to the relevant vehicle, a warning
sign in the required language or country version must be affixed over the existing warning sign before
installing the high-voltage battery.
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The required safety marking warning sign
8R0.010.539.x must be selected according to the
relevant language or country version.
When affixing the warning sign, make sure that the new
warning sign is affixed at the same position and with the
same text alignment as the previous warning sign.
2
Affix warning sign Safety marking warning sign -1to the high-voltage battery.
3
Install battery cross member Workshop Manual
'271119 Battery cross member - section on
"Installing"'.
4
Install new high-voltage battery Workshop Manual
'270819 Removing and installing high-voltage battery
- section on "Installing"'.
5
6
Safety marking warning sign
Restart the high-voltage system and complete the
relevant documentation Workshop Manual '2X00IN Isolating high-voltage electrical system from
power supply/Starting high-voltage electrical system'.
Enter the campaign in the Warranty and Maintenance booklet.
Replacing high-voltage battery - Scope 3
Information
Returning high-voltage batteries to the Porsche.
Our parts manufacturers and suppliers have informed us that in most cases where queried high-voltage
batteries were sent to Porsche, the coolant was not drained properly before packing them into the
transport box.
Given this, we must point out that a small amount of coolant can cause internal faults in the high-voltage
battery during transport and a subsequent analysis can no longer be carried out.
It is important, therefore, to point out the following:
If an analysis cannot be carried out because the high-voltage battery was not packaged correctly, we
reserve the right to reject the warranty claim in this case.
Warranty parts are not scrap or worthless material. On the one hand, the parts will be requested due to
possible recourse requirements (for the parts manufacturer or supplier), while on the other hand, the
parts are used for quality assurance and monitoring purposes. To ensure that these parts are processed
quickly, it is necessary therefore to send the high-voltage battery in accordance with the instructions in
the Workshop Manual Workshop Manual '2708IN Packaging instructions for high-voltage battery'.
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Pack the high-voltage battery in the transport box Workshop Manual '2708IN Packaging
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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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