Aug 3, 2015
Page 6 of 21

AfterSales

2015© Porsche Cars North America, Inc.

Service

Technical Information

39/15

ENU

WF24

2

4.) After Step 3, the torque should be much lower so that the fastening screw can be loosened
completely  Loosening fastening screws -arrow c-.

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.

2015© Porsche Cars North America, Inc.

AfterSales

Aug 3, 2015
Page 7 of 21

2

Service
WF24

ENU

6

Technical Information

39/15

Remove fuse carrier cover.
6.1

Loosen fastening screws  Removing fuse
carrier cover -1- as described above.

6.2

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 contact point  Verifying
absence of electric charge -B-.

7.2

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

7.3

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

7.4

Verifying absence of electric charge
Check contact point  Verifying absence
of electric charge -A- to contact point  Verifying absence of electric charge -B- again to
prevent static 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.

Aug 3, 2015
Page 8 of 21

AfterSales

2015© Porsche Cars North America, Inc.

Service

Technical Information
8

9

39/15

ENU

WF24

2

Remove high-voltage battery fuse.
8.1

Unscrew and remove fastening screws 
Removing fuse -3- for cap  Removing fuse
-1- and fuse  Removing fuse -2-.

8.2

Carefully remove cap  Removing fuse -1together with fuse  Removing fuse -2-.

Unclip cap  Installing cap -1- from fuse and insert it
on the high-voltage battery again.
Removing fuse

Installing cap
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.
•

All tasks required for cleaning the thread must be done manually. Wear the prescribed personal
protective equipment.

•

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 or metal chips get into the battery housing. Use a vacuum cleaner to do this.

2015© Porsche Cars North America, Inc.

AfterSales

Aug 3, 2015
Page 9 of 21

2

Service
WF24

ENU

Technical Information

39/15

Comparison of taps
When cleaning the threaded bores (M6) 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 and 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 and 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 pull off fabric adhesive tape and always use a vacuum cleaner to remove any loose particles
at the same time.
10 Clean the screw threads of the fastening points as described above using an M6 x 1.0 tap with
spiral grooves.

Aug 3, 2015
Page 10 of 21

AfterSales

2015© Porsche Cars North America, Inc.

Service

Technical Information

39/15

ENU

WF24

2

11 Remove high-voltage battery control unit.
11.1

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-.

11.2

Remove spacers under the fastening nuts
 Removing cover for high-voltage battery
control unit -1-.
Removing cover for high-voltage
battery control unit

11.3

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

Removing ground line
11.4

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

Removing high-voltage battery control unit

2015© Porsche Cars North America, Inc.

AfterSales

Aug 3, 2015
Page 11 of 21

2

Service
WF24

ENU

Technical Information

39/15

11.5

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-.

11.6

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-.

11.7

Remove high-voltage battery control unit.

Releasing electric plug connections

Installing high-voltage battery control unit
Work Procedure: 1

Install high-voltage battery control unit.
1.1

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-.

1.2

Connect electric plug connection 
Connecting electric plug connections -1( Connecting electric plug connections
-a-) and lock it  Connecting electric plug
connections -A-.

1.3

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

Aug 3, 2015
Page 12 of 21

AfterSales

2015© Porsche Cars North America, Inc.

Service

Technical Information
1.4

39/15

ENU

WF24

2

Push ground line  Pushing on ground line
-1- onto the fastening bolts.

Pushing on ground line
1.5

Position spacers on the bolts under the
fastening nuts  Installing cover for
high-voltage battery control unit -2-.

1.6

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
2

Remove cap  Removing cap -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.

Removing cap

2015© Porsche Cars North America, Inc.

AfterSales

Aug 3, 2015
Page 13 of 21

2

Service
WF24

ENU

3

Technical Information

39/15

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-.
3.1

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

3.2

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.
4

Install high-voltage battery fuse.
4.1

Clip fuse into cap.

4.2

Position cap  Installing fuse -1- together
with fuse  Installing fuse -2-.

4.3

Screw on fastening screws  Installing fuse
-3- for cap  Installing fuse -1- and fuse
 Installing fuse -2-. Tightening torque
10 Nm (7.5 ftlb.)

Installing fuse
5

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)
In the course of the work required for replacing the control
unit, the fuse carrier cover must be replaced.
The warning sticker affixed to the cover cannot be
re-used.

Installing fuse carrier cover
Before re-installing the high-voltage battery, a sticker must
therefore be affixed to the new cover at the same position and with the same text alignment as on the
removed cover.

Aug 3, 2015
Page 14 of 21

AfterSales

2015© Porsche Cars North America, Inc.

Service

Technical Information
6

39/15

ENU

WF24

2

Affix warning signs  Warning sign pictograms -1- to the high-voltage battery.

Warning sign pictograms
7

Install high-voltage battery  Workshop Manual '270819 Removing and installing high-voltage
battery - section on "Installing"'.

8

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'.

Re-programming and coding high-voltage battery control unit
NOTICE
Fault entry in the fault memory and control unit programming aborted due to low-voltage.