Código de corrección NEW NOTA: Salvo que se indique lo contrario explícitamente en el procedimiento, el código de corrección y el FRT mencionados anteriormente reflejan todo el trabajo necesario para realizar este procedimiento, incluidos los procedimientos vinculados. No acumule códigos de corrección a menos que se le indique explícitamente que lo haga. NOTA: Consulte Tiempos de tarifa plana para obtener más información sobre los FRT y cómo se crean. NOTA: Consulte Protección personal para asegurarse de llevar el EPI adecuado al realizar el siguiente procedimiento. NOTA: Consulte Precauciones ergonómicas para ver información sobre prácticas de trabajo seguras.

1. Eleve y apoye el vehículo. Consulte Elevación del vehículo - Elevador de 2 columnas.
2. Abra la puerta delantera izquierda y baje la ventanilla.
3. Connect a laptop with toolbox 3 to the vehicle. See Toolbox 3 (Conexión y desconexión).
4. Coloque el vehículo en el Modo de servicio. Consulte Modo de servicio.
5. Desbloquee la puerta de enlace del vehículo. Consulte Puerta de enlace (Desbloquear).
6. Ejecutar la rutina ODIN PROC_HVBATT_X_DEVICE-CLUSTER-REPLACEMENT-BACKUPvia Service Mode Plus:High Voltage Battery ➜ Device Cluster Assembly (DCA) Replacement ➜ Backup Old DCAvia Toolbox:(link)
7. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
8. Desconecte la alimentación de media tensión. Consulte Mid-Voltage Power (Disconnect and Connect) (Modify).
9. Perform vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
10. Remove pyro fuse access cover
    Nota

    4x bolts, E-Torx 5 lobe, 10 Nm

    

11. Remove primary pyro fuse
    Nota

    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts

    

    

12. Remove secondary pyro fuse
    Nota

    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts

    

    

13. Release connectors at 2x4 header (AC compressor and Inductive Charger headers)
    Nota

    2x connectors, Fully release red lock tab, Pull black latch down to release connector

    

    

14. Release 2x4 header assembly
    Nota

    4x bolts, 5-lobe 10mm, 6 Nm

    

    

15. Release drive unit connectors from ancillary headers
    Nota

    3x connectors, Release blue lock tab, Rotate black latch

    

    

    

16. Remove bolts securing HC-Stak HV Headers for LHRDU, FDU, RHRDU from ancillary flange
    Nota

    6x bolts, 5-lobe 10mm, 10 Nm

    

    

17. Remove LHRDU, FDU, RHRDU headers from ancillary flange
    Nota

    3x headers, No tools required, inspect header seals, Replace header if damaged

    

    

18. Lower vehicle until tires are touching the ground
    Nota

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
19. Remove the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
20. Remove the NVH barrier. See Tonneau NVH Barrier Assembly (Remove and Install).
21. Disconnect ancillary bay MV connector
    Nota

    1x connector, Double locking, Release tab then pivot lever, Release second tab to disengage connector, Wait 1 second between locking tab release to discharge and prevent arcing

    

    

    

    

    

22. Remove bolt securing busbar HV connector lid
    Nota

    1x bolt, EP10, 9 Nm

    

23. Remove bolts securing HV connector to DC FC header
    Nota

    2x bolts, 10mm, 9 Nm

    

24. Release HV connector from DC FC header
    Nota

    1x connector, Use inflatable airbag if needed to suspend busbar assembly above ancillary assembly

    

25. Support HV Busbar assembly
    Nota

    1X Bungee, Suspend assembly to maintain clearance, wrap bungee around busbar assembly to achieve required cord length, Connect bungee to tie down hook on bed side

    

    

26. Remove fast charger header doubler
    Nota

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

27. Remove mid voltage header bolts
    Nota

    2x bolts, EP10, 6 Nm

    

28. Release fasteners securing ancillary bay cover to HV battery
    Nota

    22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order

    

    

    

29. Remove ancillary bay cover
    Nota

    Install vacuum cup to ancillary bay cover surface, Lift and maneuver cover around busbar and tonneau cage to remove

    

    

    

30. Inspect ACJB to PCS Harness
    Nota

    Inspect harness part number, If REV is earlier than J then replace with REV J or later, If REV is J or later then proceed with current procedure

    

31. Remove ACJB to PCS HV jumper harness
    Nota

    2x connectors, Release locking tab and pull connector out of respective header, Do not pull on harness

    

    

    

    

32. Release ACJB LV connector & ACJB to device cluster HV connector
    Nota

    2x connectors, Release connector locks, Depress levers and pull at connectors, Do not pull at harness, inspect ACJB to DC HV harness part number, if not rev J or newer, replace harness

    

    

    

33. Release ancillary bed outlet and dummy plug connectors
    Nota

    1x connector,1x dummy plug Release locking tabs, Slide locks to release

    

    

34. Release ACJB fasteners
    Nota

    6x bolts, E10 5 Lobe Torx, 6Nm

    

    

35. Release ACJB from ancillary tray
    Nota

    2x clips, 2x datums, Release clips at headers, Slide ACJB inboard on datums

    

    

36. Remove ACJB from ancillary tray
    Nota

    Lift over and out of PCS once headers clear outboard side of ancillary tray

    

    

37. Install ACJB onto ancillary tray
    Nota

    Align headers and slide openings to datums in ancillary tray

    

    

    

38. Slide ACJB into ancillary tray until header clips are fully engaged
    Nota

    Ensure all fastener holes are aligned

    

    

    

39. Secure ACJB fasteners
    Nota

    6x bolts, E10 5 Lobe Torx, 6Nm

    

    

40. Secure ancillary bed outlet connector and dummy plug to ancillary
    Nota

    1x connector,1x dummy plug, Slide locks to fully engage, Secure locking tabs

    

    

41. Install ACJB to PCS HV jumper harness
    Nota

    2x connectors, Secure at ACJB first then fold harness over to PCS, Secure locking tab on both connectors

    

    

    

    

    

42. Secure ACJB LV harness connector & ACJB HV harness to device cluster connector
    Nota

    2x connectors, Secure connector locks

    

    

43. Install ancillary cover
    Nota

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

44. Secure ancillary cover fasteners to HV battery
    Nota

    22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order

    

    

    

45. Install mid voltage header bolts
    Nota

    2x bolts, EP10, 6 Nm

    

46. Install fast charger header doubler
    Nota

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

47. Clean HV connector contact surface of residual Penetrox
    Nota

    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector

    

48. Clean busbar HV connector contact surface of residual Penetrox
    Nota

    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar

    

49. Apply Penetrox onto HV connector joints
    Nota

    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered

    

50. Position busbar connector and lower onto HV header
    Nota

    Release bungee cord

    

51. Install bolts securing charge port busbar kit to HV Header
    Nota

    2x bolts, 10mm, 9 Nm

    

52. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Nota

    2x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe 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), stop work and escalate the Toolbox session.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), hioki test passed, proceed to next step

    

    

53. Install bolt securing busbar HV connector lid
    Nota

    1x bolt, EP10, 9 Nm

    

54. Remove leather over gloves and HV insulating gloves
55. Connect ancillary bay MV connector
    Nota

    1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly

    

    

    

    

    

56. Raise vehicle fully and lower lift onto locks
    Nota

    Set vehicle to comfortable working height, Ensure an audible click of locks on both sides is heard before lowering, Vehicle may tilt to the side if both locks are not engaged
57. Inspect HV insulating gloves
    Nota

    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.

    

58. Put on HV insulating gloves and leather over gloves

    

59. Install LHRDU, FDU, RHRDU headers to ancillary flange
    Nota

    3x headers, No tools required, inspect header seals, Replace header if damaged

    

    

60. Secure bolts to HC-Stak HV Headers for LHRDU, FDU, RHRDU to ancillary flange
    Nota

    6x bolts, 5-lobe 10mm, 10 Nm

    

    

61. Secure 2x4 header assembly
    Nota

    4x bolts, 5-lobe 10mm, 6 Nm, Confirm alignment of assembly with fastener openings

    

    

    

62. Secure connectors at 2x4 header (AC compressor and Inductive Charger headers)
    Nota

    2x connectors, Fully engage red lock tab

    

    

63. Secure drive unit connectors to ancillary headers
    Nota

    3x connectors, Rotate black latch, Ensure blue locking tab is fully engaged

    

    

    

64. Install secondary pyro fuse
    Nota

    2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts, Bolts may be reused

    

    

65. Install primary pyro fuse
    Nota

    2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts, Bolts may be reused

    

    

66. Perform Hioki resistance test at each HV joint from HV busbar lead to pyro fuse busbar
    Nota

    4x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe 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), stop work and escalate the Toolbox session.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), hioki test passed, proceed to next step

    

    

67. Install pyro fuse access cover with airlines attached
    Nota

    4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged, Secure 2 airline mounting clips to HV Battery, If HV pack is being shipped then pyro fuses must be removed

    

    

    

68. Remove leather over gloves and HV insulating gloves
69. Install the rear skid plate. See Skid Plate - Rear (Remove and Install).
70. Lower vehicle until tires are touching the ground
    Nota

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
71. Vuelva a conectar la alimentación de media tensión. Consulte Mid-Voltage Power (Disconnect and Connect) (Modify).
72. Coloque el faldón trasero del vano del motor. Consulte Underhood Apron - Rear (Remove and Install).
73. Install the NVH barrier. See Tonneau NVH Barrier Assembly (Remove and Install).
74. Install the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
75. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
76. Salga del Modo de servicio. Consulte Modo de servicio.
77. Suba la ventanilla delantera izquierda y cierre la puerta delantera izquierda.
78. Retire el vehículo del elevador. Consulte Elevación del vehículo - Elevador de 2 columnas.