2025-10-15

Pyro Disconnect (Remove and Install)

Correction code 1630010011 FRT 0.72 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional glove and safety information.

Remove

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Open the LH front door and lower the LH front window.
  3. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  4. Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
  5. Remove the pyro access cover. See Cover - Pyro Access - HV Battery (Remove and Install).
  6. Remove the bolts (x2) that attach the primary pyro fuse to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Support the pyro fuse while removing the bolts.
  7. Remove the bolts (x2) that attach the secondary pyro fuse to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Support the pyro fuse while removing the bolts.

Install

  1. Install the bolts (x2) that attach the secondary pyro fuse to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • HV Insulated 13 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque: 5 Nm + 60 Degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Support the pyro fuse while installing the bolts.
  2. Install the bolts (x2) that attach the primary pyro fuse to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • HV Insulated 13 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque: 5 Nm + 60 Degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Support the pyro fuse while installing the bolts.
  3. Perform a Hioki resistance test at each HV joint from the HV busbar lead to the pyro fuse busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    x4 HV joints
    Informational PurposesAn informational icon, calling your attention
    Note
    When using a Hioki tester, verify the meter has been properly adjusted and set prior to usage.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).
    • If the resistance is greater than 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
    • If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.
    • If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), the Hioki test passed. Proceed to next step.
  4. Install the pyro access cover. See Cover - Pyro Access - HV Battery (Remove and Install).
  5. Integrate HV power. See Vehicle HV Disablement Procedure (Test/Adjust).
  6. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  7. Raise the LH front window and close the LH front door.
  8. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.