NHTSA ID Number: 10126451
Manufacturer Communication Number: 122-W7F5R-05
TSB/Document Date: 2017-12-22
Summary
Information: This is to inform you of a voluntary Workshop Campaign on the above-mentioned vehicles. There is a possibility that parts from a certain batch that do not meet the required specifications were installed in control units for the high-voltage battery
on the affected vehicles. As a result, the high-voltage system can fail when attempting to start the vehicle. If this happens, the vehicle will not start and the warning message "Hybrid system failure" will appear in the instrument cluster.
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WF24 - Replacing High-Voltage Battery Control Unit (Workshop Campaign)
Important:
CRITICAL WARNING - This campaign includes steps where control unit(s) in the vehicle will be
programmed with the PIWIS Tester. The vehicle voltage must be maintained between 13.5 volts and 14.5
volts during this programming. Failure to maintain this voltage could result in damaged control unit(s).
Damage caused by inadequate voltage during programming is not a warrantable defect. The technician
must verify the actual vehicle voltage in the PIWIS Tester before starting the campaign and also document
the actual voltage on the repair order. Please refer to Equipment Information EQ1401 for a list of suitable
battery chargers/power supplies which should be used to maintain vehicle voltage.
Model Year:
2015
Vehicle Type:
Panamera S E-Hybrid
Concerns:
High-voltage battery control unit
Information:
This is to inform you of a voluntary Workshop Campaign on the above-mentioned vehicles. There is a
possibility that parts from a certain batch that do not meet the required specifications were
installed in control units for the high-voltage battery on the affected vehicles.
As a result, the high-voltage system can fail when attempting to start the vehicle. If this happens, the
vehicle will not start and the warning message "Hybrid system failure" will appear in the instrument
cluster.
Action
Required:
Replace and re-program high-voltage battery control unit.
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 101 vehicles in North America.
Parts Info:
NOTE: PARTS WILL NOT BE AUTOMATICALLY ALLOCATED TO YOUR DEALERSHIP. ALL PARTS
MUST BE ORDERED VIA A PTEC/PAV.
Part No.
Designation
– Use
Qty.
000.043.210.11
High-voltage battery control unit
1 ea.
970.611.901.03
1 ea.
955.606.838.00
Tie-wrap clip
5 ea.
970.555.643.01
Screw bolt for locking mechanism
2 ea.
2015© Porsche Cars North America, Inc.
AfterSales
Aug 3, 2015
Page 1 of 21
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999.507.584.02
Clamp
10 ea.
999.507.839.01
Clip
10 ea.
958.701.739.00
Warning sign for cover
1 ea.
970.611.901.17
Set of screws for control unit
1 ea.
Includes:
...
Flange nut, M5
– For securing control unit
5 ea.
...
Cheese head bolt, M6 x 25
– For securing E-box (not required during the
campaign)
5 ea.
970.611.901.14
1 ea.
Set of screws for fuse
Includes:
...
Dowel (not required during the campaign)
2 ea.
...
Oval-head screw, M6 x 12
– For securing cover to high-voltage battery
housing
3 ea.
...
Cheese head bolt, M8 x 12
– Fuse on high-voltage battery (not required
during the campaign)
2 ea.
970.611.901.05
Fuse
1 ea.
Includes:
...
Fuse cover
1 ea.
...
250 A fuse
– High-voltage battery
1 ea.
...
Cheese head bolt, M8 x 12
– Fuse on high-voltage battery
2 ea.
...
2 ea.
...
Cover
– Protective cap after removing fuse
1 ea.
Also required:
000.043.301.47
Aug 3, 2015
Page 2 of 21
Antifreeze (1-liter container)
AfterSales
approx. 1 liter
per vehicle
(As much as
required)
2015© Porsche Cars North America, Inc.
Materials:
39/15
...
1
2
Service
Technical Information
ENU
WF24
5 ea. 1
Tie-wrap, approx. 3.0 x 200 mm
e.g. 999.513.075.40
The WWS Warranty system will automatically add into the "Miscellaneous item" section (sublet) of the
claim after the claim has been submitted.
...
1 ea. 2
Tap, M6 x 1.0 with spiral grooves
Tap with spiral groove
Information
If the specified tap is not already available in the workshop or if it was not ordered for workshop
campaign WD57, it must be ordered once specifically for carrying out this work.
During this repair measure, only use taps with spiral grooves, which guide the chips out of the bore in
the opposite direction to the cutting direction.
Only one M6 x 1.0 tap may be invoiced for each affected Porsche dealer.
2
Special Tools:
The WWS Warranty system will automatically add into the "Miscellaneous item" section (sublet) of the
claim after the claim has been submitted.
Use
Designation/Comment
VAS 6558/9-6 - High-voltage test adapter HVA 280 Isolating high-voltage system from power
supply
VAS 6558/9-7 - High-voltage test adapter HVR 40
VAS 6839 - Voltage tester
T40262 - Locking cap
T40262 - Locking cap
VAS 6884 - High-voltage cordon
2015© Porsche Cars North America, Inc.
AfterSales
Setting up high-voltage work area
Aug 3, 2015
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9860 - Adapter plate
Removing and installing high-voltage battery
9874 - Assembly aid
3033 - Lifting tackle
VAS 6100 - Workshop crane
9696 - Filling device
Assembly pliers for spring band clamps, e.g. Nr.192 Hose clamping pliers
Torque wrench, e.g. 9768 - Electronic torque
wrench, 2 - 100 Nm (1.5 - 74 ftlb.) (2 – 100 Nm/1.5
– 74 ftlb.)
VAS 6883 - Insulated tool set
Torque wrench, e.g. V.A.G 1783 - Torque wrench,
2-10 Nm (1.5-7.5 ftlb.) (2 – 10 Nm/1.5 – 7.5 ftlb.)
Removing and installing high-voltage fuse and
high-voltage battery control unit
9818 - PIWIS Tester II
Installation
Position:
Installation position of high-voltage battery control unit
Aug 3, 2015
Page 4 of 21
AfterSales
2015© Porsche Cars North America, Inc.
Service
Technical Information
Claim
Submission:
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ENU
WF24
2
See Attachment “A”.
Removing high-voltage battery control unit
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'
Information
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.
Work Procedure: 1
2
Read out the values using the PIWIS Tester before
removing the old high-voltage battery control unit
Workshop Manual '279455 Replacing control unit for
HV battery'.
Observe warning notes Workshop Manual
'2X00IN General warning notes for working on the
high-voltage vehicle electrical system'.
2015© Porsche Cars North America, Inc.
AfterSales
Restricted area for HV battery
Aug 3, 2015
Page 5 of 21
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3
Isolate the high-voltage system from the power supply and complete the relevant documentation on isolating the system from the power supply.
Workshop Manual '2X00IN Isolating high-voltage electrical system from power supply/Starting
high-voltage electrical system'
4
Remove high-voltage battery Workshop Manual '270819 Removing and installing high-voltage
battery - section on "Removing"'.
5
Set up a high-voltage cordon VAS 6884 - High-voltage cordon around the high-voltage workstation.
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
•
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.
- High density negative paste, improves performance and...
- Enhanced life alloy or Silver Calcium stamped alloy...
- Calcium lead positive grid, maximizes conductivity and...
- Robust envelope separator with puncture resistant back...
- Vent cap design that resists acid leakage
- High density negative paste, improves performance and...
- Enhanced life alloy or Silver Calcium stamped alloy...
- Calcium Lead positive grid, maximizes conductivity and...
- Robust Envelope Separator with puncture-resistant back...
- Vent cap design that resists acid leakage
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TSB/Document ID: 122-W7F5R-05
Replacement Service Bulletin Number:
MFR Communication Date: 2015-04-08
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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