Roewe Plug-in Hybrid Low-Voltage Battery and High-Voltage Wiring Harness Repair Guide

Fault Background

The low-voltage battery and its management system of the Roewe plug-in hybrid (1012 manual) revolve around the EBS (battery sensor): any operation involving the negative terminal post must use a holding tool to secure the post to prevent EBS damage; after battery replacement, a "battery ID write" must be performed on the battery sensor. The high-voltage wiring harness section follows the manual's high-voltage discipline (training threshold / disconnect 12V+MSD / glove leak check / prevent liquids / wait 5 minutes for capacitor discharge), and provides lock operation details for three types of high-voltage connectors: compressor connector "press locks simultaneously, locks open, pull outward"; battery pack to PEB connector "pull out the safety lock, press the black sheath lock, pull the sheath inward to the bottom, pull outward"; battery pack to electric A/C compressor connector "press lock 1 to pull out partially, press lock 2 then pull out". This article is compiled as a repair guide.

Low-Voltage Battery Family

Battery positive cable: Remove right side trim of luggage compartment → disconnect negative terminal → loosen positive terminal post nut (1) and move cable away → remove nut (2) securing body harness to positive cable → remove D-pillar lower trim → right sill trim → A-pillar lower trim → A/C box assembly → PEB tray → engine compartment fuse box cover → remove nut securing positive cable to fuse box → release harness clips and remove. Installation in reverse: tighten positive terminal post nut to specified torque (approx. 4~6N·m range) and check torque.

Battery negative cable (Note: use holding tool to prevent damage to battery sensor): Remove right side trim of luggage compartment → use open-end wrench to hold the battery negative terminal post to secure EBS → remove nut securing negative cable to battery sensor (18~22N·m range) → remove nut securing to body (8~10N·m range) → remove. Installation in reverse: body nut 8~10N·m, sensor nut 18~22N·m, hold post with holding tool throughout.

Battery replacement: Remove right side trim → loosen EBS negative terminal post nut → loosen positive terminal clamp nut → disconnect exhaust pipe → loosen clamp nut and move clamp away → remove battery assembly. Installation: secure to tray → clamp nut 3~5N·m → connect exhaust pipe → positive cable 4~N·m → negative cable 5~N·m → perform "battery ID write" on battery sensor (refer to "Module Self-Learning and Programming Manual" EBS replacement section).

Battery tray: After battery removal, remove 4 bolts securing to body; installation 19~25N·m.

Battery sensor (EBS): Use holding tool + open-end wrench to secure post → remove negative cable nut → disconnect harness connector → loosen negative terminal post nut → remove sensor. Installation: EBS negative terminal clamp grips post, fits over battery negative post, screw to bottom and align → tighten post nut → connector → fit negative cable over EBS connection terminal 18~22N·m.

Main High-Voltage Harness (19 Steps)

Removal: ①High-voltage discipline three warnings (persons not trained in this vehicle's high-voltage system knowledge are prohibited from disassembling high-voltage system; when removing/installing high-voltage components, must disconnect 12V power and high-voltage battery pack manual service disconnect; check insulated gloves for leaks before wearing, wear high-voltage insulated shoes) → ②Wait 5 minutes → ③Disconnect negative terminal → ④Remove MSD → ⑤Remove PEB → ⑥Disconnect clips securing main high-voltage harness to PEB tray → ⑦Disconnect compressor high-voltage harness connector from compressor (press locks simultaneously, locks open, pull outward) → ⑧Lift vehicle (do not work under a vehicle supported only by jacks) → ⑨Disconnect high-voltage battery pack to PEB main high-voltage harness connector (pull out connector safety lock, press lock on black sheath, pull sheath inward to bottom, pull outward) → ⑩Disconnect battery pack to electric A/C compressor connector (press lock 1 to pull out partially, press lock 2 then pull out) → ⑪Remove center exhaust pipe heat shield → ⑫Remove battery cooler to water pump lines → ⑬Remove body underfloor fasteners: 8 nuts + 2 bolts → ⑭Remove front exhaust pipe bracket 2 bolts → ⑮Use tool to support subframe, loosen 4 bolts → ⑯Remove front 1 bolt → ⑰Remove front 4 studs → ⑱Remove rear 2 nuts → ⑲Release body clips and pull main high-voltage harness out from front.

Installation (Before all high-voltage system installation is complete, keep negative cable and manual service disconnect disconnected): With assistance, route harness to body underfloor and front bulkhead → rear 2 nuts → front 4 bolts → body underfloor and front bulkhead 9 nuts + 2 bolts 5~7N·m → battery pack to PEB connector: align black sheath with port and pull outward until two "clicks" are heard to confirm seating, then press lock to secure → battery pack to compressor connector align and push in until "click" confirms fully seated → clips → heat shield → install PEB → compressor connector → install MSD → connect negative terminal.

Charger High-Voltage Harness

Removal: High-voltage discipline + wait 5 minutes → disconnect negative terminal → remove luggage compartment storage box → remove MSD → disconnect charging high-voltage harness connector from on-board charger → disconnect charging high-voltage harness connector from high-voltage battery pack → release harness clips and remove.

Installation: Route harness to tray and secure with clips → connect battery pack end → connect OBC end → install MSD → install storage box → connect negative terminal.

Safety Warnings

• This article is for technical reference. High-voltage harness repair must be performed by personnel trained in this vehicle's high-voltage system knowledge; low-voltage battery repair by professional technicians per OEM specifications.
• EBS discipline: Any negative terminal post operation must use a holding tool to prevent battery sensor damage; after battery replacement, always perform "battery ID write".
• High-voltage four steps: Wait 5 minutes (capacitor discharge) → disconnect 12V → remove MSD → glove leak check; keep negative terminal and MSD disconnected until installation is complete.
• High-voltage connectors operate per their respective lock structures (compressor "press locks simultaneously", PEB "pull sheath to bottom", two-step lock), never pull harness by force.

Repair Insights

This manual clearly explains two "small parts, big pitfalls": EBS battery sensor and high-voltage connector locks. The EBS pitfall is "damage from improper force"—when removing the negative cable, if you don't use an open-end wrench to hold the post, torque transfers directly to the sensor. EBS is the core component for monitoring SOC/battery status; if damaged, the entire charging strategy becomes chaotic; after battery replacement, "battery ID write" is the same discipline as EDU initial angle and VCM EOL configuration—replace part without writing ID, system calculates with old battery parameters, new battery quickly misjudged as aged. High-voltage connector lock structures differ: compressor "press locks simultaneously", PEB "pull black sheath to bottom then pull", battery pack to compressor "two-step lock"—each must be unlocked properly before applying force; forced pulling will damage terminals; during installation, confirm seating by "click" sound (PEB needs two clicks), which is more reliable than visual inspection. Finally, torque range memory: EBS nut 18~22, body ground 8~10, clamp 3~5, tray 19~25—negative side always more critical than positive side because negative connects to sensor.

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【This article is for reference only】