Roewe Plug-in Hybrid High-Voltage Battery and Charging System Removal and Installation Guide

Fault Background

For the Roewe plug-in hybrid (847 manual), the removal and installation of the high-voltage battery and its charging system revolves around two special tools: TEL00022 (manual service disconnect replacement protection tool) and TEL00023 (high-voltage battery pack cradle tool). The fixed action throughout the entire process is "wait 5 minutes" — after the ignition key is turned off, the high-voltage system still retains high voltage (energy stored in the capacitors of the power electronics box/motor controller), and you must wait for the capacitors to fully discharge. The manual service disconnect has a two-stage unlocking structure: press the locking tab → release the detent lever (first stage) → rotate to approximately 45° (second-stage lock), press the locking tab again for second-stage unlock → rotate to 90° upright → pull upward to remove. Torque specifications: battery pack mounting 9 bolts at 64–72 N·m, ground wire 9–11 N·m, shield cover 8–10 N·m, heat shield clips 1.5–2 N·m / bolts 7–10 N·m. This article is organized as a removal and installation guide.

Manual Service Disconnect (MSD)

Removal: ① Turn off the ignition key and wait at least 5 minutes; ② Disconnect the negative battery terminal; ③ Remove the manual service disconnect protective cover under the trunk carpet (located in the center of the trunk); ④ Press the locking tab, rotate the detent lever upward for first-stage unlock → when the detent lever reaches the second-stage lock (approx. 45°), press the locking tab again for second-stage unlock → continue rotating the detent lever to upright (approx. 90°) → pull the manual service disconnect upward to remove; ⑤ Install TEL00022 onto the MSD base (replacement protection), and store the MSD in a safe location.

Installation: Remove TEL00022 → install MSD → install protective cover → reconnect negative terminal.

High-Voltage Battery Pack Removal and Installation (16 Steps)

Removal: ① Wait 5 minutes; ② Disconnect negative terminal; ③ Remove MSD; ④ Raise vehicle on lift; ⑤ Drain high-voltage battery pack coolant; ⑥ Disconnect coolant hoses; ⑦ Remove 2 bolts securing shield cover to battery pack tray + 1 bolt securing to upper cover; ⑧ Remove 1 bolt securing shield cover to body floor; ⑨ Remove 2 bolts + 2 clips securing rear exhaust heat shield to battery pack and body, then remove heat shield; ⑩ Disconnect 5 connectors on high-voltage battery pack; ⑪ Remove 1 bolt securing ground wire to body; ⑫ Slowly raise the support platform of TEL00023 cradle tool and position it under the battery pack at the lift station; ⑬ Continue raising until it contacts the bottom of the battery pack; ⑭ Remove 9 bolts securing to body and mounting brackets; ⑮ Lower and move away from lift station — Warning: Do not drag the high-voltage battery pack cradle tool after lifting.

Installation: ① Slowly raise TEL00023 support platform to suitable installation position (do not drag after lifting); ② Install 9 bolts, tighten to 64–72 N·m; ③ Lower cradle platform and remove tool; ④ Ground wire 1 bolt 9–11 N·m; ⑤ Connect 5 connectors; ⑥ Secure coolant hose clamps; ⑦ Shield cover: tray 2 bolts 8–10 N·m + upper cover 1 bolt 8–10 N·m + body floor 1 bolt 8–10 N·m; ⑧ Heat shield: body 2 clips 1.5–2 N·m + battery pack 2 bolts 7–10 N·m; ⑨ Fill high-voltage battery pack coolant; ⑩ Install MSD; ⑪ Connect negative terminal; ⑫ Program and code the BMS (refer to BMS self-learning chapter in the Module Self-Learning and Programming Manual).

On-Board Charger (OBC)

Removal: Wait 5 minutes → disconnect negative terminal → remove MSD → remove trunk storage box → disconnect connectors on OBC → remove 2 bolts + 2 nuts securing to body floor → remove 2 bolts securing ventilation duct to charger and move aside → remove OBC.

Installation: ① Align outlet with ventilation duct and insert, install ventilation duct 2 bolts 3–5 N·m; ② Secure to body floor 2 bolts + 2 nuts 7–10 N·m; ③ Connect connectors; ④ Install storage box; ⑤ Install MSD; ⑥ Connect negative terminal; ⑦ Program and code the OBC (OBC self-learning chapter).

Slow Charging Port and Hybrid Control Unit

Slow Charging Port: Wait 5 minutes → open slow charging port flap → disconnect negative terminal → remove MSD → remove trunk storage box → remove right side trim panel in trunk → disconnect low-voltage harness connector → release harness clips and disconnect high-voltage connector → remove 4 bolts securing to body → remove. Installation: bracket 4 bolts 4–6 N·m → harness clips + high-voltage connector → low-voltage connector → right side trim panel → MSD → negative terminal → close flap.

Hybrid Control Unit (HCU): Disconnect negative terminal → remove left front wheel arch liner → disconnect harness connector → remove 2 bolts securing bracket assembly to body → remove 4 screws securing to bracket → remove HCU. Installation: connect harness connector → connect negative terminal → program and code the HCU (HCU self-learning chapter) → 4 screws 7–10 N·m → bracket 2 bolts 19–25 N·m → install liner.

Safety Warnings

• This article is for technical reference only. High-voltage battery and charging system service must be performed by qualified technicians (with electrician certification + company training authorization) in accordance with OEM specifications.
• Four-step fixed procedure: Wait 5 minutes (high-voltage capacitor discharge) → disconnect negative terminal → remove MSD (two-stage unlock 45°/90°) → install TEL00022 over base.
• Do not drag TEL00023 cradle after lifting; battery pack 9 bolts at 64–72 N·m must be achieved.
• After replacing battery pack/OBC/HCU, programming and coding must be completed (BMS/OBC/HCU self-learning), otherwise malfunctions will occur.

Repair Insights

The most noteworthy point in this removal and installation manual is the "two-stage unlock" feel of the MSD: pressing the locking tab once only releases the first stage; rotate the detent lever to 45° and press again for second-stage unlock, then 90° upright before pulling out — skipping steps and pulling hard will damage the locking mechanism, which is the direct cause of many technicians getting stuck on the first MSD removal. TEL00022 serves as "replacement protection": after the MSD is pulled out, the base is exposed; installing it prevents metal debris from entering the socket (similar to the K-ZE E700101 concept). High-voltage battery pack removal and installation is a "cradle relay": the 9 bolts at 64–72 N·m are just the final step; the real safety point is do not drag the cradle after lifting — dragging a fully loaded battery pack cradle is the number one cause of tip-over accidents. Don't skip the three "programming and coding" steps after part replacement: battery pack replacement → BMS self-learning; OBC replacement → OBC self-learning; HCU replacement → HCU self-learning — missing one will result in new DTCs. Finally, a memory aid for torque layering: load-bearing parts 64–72 (battery pack), medium parts 7–10/8–10 (shield cover/heat shield/HCU screws), small parts 1.5–6 (clips/vent duct/slow charge port) — just distinguish the three levels.

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【This article is for reference only】