Code de correction 44000134 REMARQUE : À moins d’indications explicites contraires dans la procédure, le code de correction et le temps forfaitaire indiqués ci-dessus représentent tout le travail à être fait pour cette procédure, notamment les procédures connexes. N’appliquez pas plusieurs codes de correction à la fois, à moins qu’il vous soit explicitement indiqué de le faire. REMARQUE : Consultez Temps forfaitaires pour en apprendre plus à propos des temps forfaitaires et de leur création. NOTE : Consultez Protection individuelle pour vous assurer de porter l’équipement de protection individuelle adéquat lorsque vous effectuez la procédure ci-dessous. REMARQUE : Voir Précautions ergonomiques pour consulter les pratiques de travail sécuritaires et saines.

1. Ouvrez la porte avant gauche et abaissez la glace avant gauche.
2. Soulevez et soutenez le véhicule. Voir Soulever le véhicule - pont élévateur à 2 poteaux,
3. Connect a laptop with Toolbox to the vehicle. See Toolbox 3.0 (connecter et déconnecter).
4. Navigate to interactive HV isolation issues diagnosis
   Remarque

   Vehicle hub>High voltage>Diagnose HV isolation issues

   

5. Select "Start interactive procedure"

   

6. Read "HV System Global Check Autodiag" question and select "Yes" to continue

   

7. Read "HV Awareness" warning and select "Yes" to continue

   

8. Select the appropriate vehicle platform type and then select "Start interactive procedure"

   

9. Ouvrez le coffre avant électrique.
10. Ouvrez le hayon.
11. Power down vehicle via UI
    Remarque

    Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off

    

12. Retirez le tablier arrière situé sous le capot. Voir Underhood Apron - Rear (Remove and Install),
13. Secure MV battery maintainer and support vehicle
    Remarque

    1x cover, Secure MV maintainer but leave the Li-ion battery connected, Secure positive terminal to jump post, Secure negative terminal to bolt located between brake fluid reservoir and front trunk, Connect maintainer to power supply, DO NOT allow positive cable to make contact with other metal components, Prevent shorting the cables,Do not have a MV maintainer and the Li-ion battery simultaneously connected for any extended period of time

    

    

    

    

14. Verify operation of multimeter
    Remarque

    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals

    

    

15. Once the vehicle is in service mode plus and a MV battery maintainer is connected click next

    

16. Run the DCA and DI backup routines via Service mode plus UI then select next
    Remarque

    Service mode Plus > High voltage > Procedures

    

    

    

17. Confirm vehicle is actively faulting
    Remarque

    Service mode plus > High voltage > Hv battery > Clear blocked contactors

    

18. Observe UI for active HV battery low isolation alerts
    Remarque

    Wait up to 5 minutes while observing for active HV battery low isolation alerts then select "Low isolation alert present" if low isolation alerts are present

    

19. Disconnect Toolbox and remove the laptop from the vehicle. See Toolbox 3.0 (connecter et déconnecter).
20. Débranchez l’alimentation MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
21. Remove MV battery maintainer
    Remarque

    1x cover, Unplug the maintainer first, then remove positive and negative leads from jump posts, Re-secure any jump post covers

    

    

    

22. Raise vehicle fully
    Remarque

    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
23. Remove Mid-aero shield
    Remarque

    Rotate down as far as the battery armor will allow to clear the rear lower control arms, Pull Mid-aero shield out from between battery armor and rear venting bracket, Be careful not to engage any of the breathers during removal

    

24. Remove all items from pockets and ensure not wearing metal items
    Remarque

    This includes phones, badges, metal belt buckles airpods and headphones
25. Inspect HV insulating gloves
    Remarque

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

    

26. Put on HV insulating gloves and leather over gloves
    Remarque

    Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 R5 for PPE requirements depending on vehicle configuration

    

27. Remove clips securing AC compressor HV harness
    Remarque

    3x clips

    

28. Verify no HV - Install amp clamp to RDU HV harness
    Remarque

    Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.Release locking tab and rotate the release lever up to disengage the connector, Release harness clip, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damagedMake sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering

    

    

    

    

    

    

29. Select next once vehicle HV disablement procedure is completed

    

30. Select rear drive unit configuration
    Remarque

    Select "single rear drive unit"

    

31. Disconnect RDU HV harness
    Remarque

    1x connector, Release locking tab and rotate release lever up, Do not force release lever up, Ensure alignment tabs on header are not damaged

    

32. Perform isolation test on LH RDU HV cable at HV battery
    Remarque

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to subframe bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

33. Enter the lowest stable isolation resistance value recorded in MOhm and then click "next"

    

34. Read "Heat Pump A/C Compressor + HV Harness' Isolation Tests" panel and select "Finish Later" to prevent timeout error

    

35. Release A/C compressor HV harness from HV battery
    Remarque

    1x locking connector, 4x clips, Pull down red locking tab and disengage the release lever, Do not force the release lever up, Number of connections may vary by vehicle configuration

    

    

    

36. Perform isolation test on ancillary HV harness at rear of HV battery
    Remarque

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to subframe bolt, Position leads then press test button, Amber light will turn on, Test all four terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

37. Enter the lowest stable isolation resistance value recorded in MOhm
    Remarque

    Select "next" to continue

    

38. Read CP HV Harness FC contactor question and select "Yes" to continue

    

39. Read "CP HV Harness Isolation Test" panel and select "Finish Later" to prevent timeout error

    

    

40. Lower vehicle until tires are touching the ground
    Remarque

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
41. Remove the bed floor. See Bed Floor Assembly (Remove and Install).
42. Remove bolt securing busbar HV connector lid
    Remarque

    1x bolt, EP10, 9 Nm

    

43. Remove bolts securing HV connector to DC FC header
    Remarque

    2x bolts, 10mm, 9 Nm

    

44. Release HV connector from DC FC header
    Remarque

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

    

45. Secure CP busbar connector aside
    Remarque

    Move connector away from header, Install bags or bungees as needed, Do not open tonneau to prevent damage

    

46. Perform isolation test on CP HV busbar connector
    Remarque

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to door striker, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

47. Select "Resume" to continue to "CP HV Harness Isolation Test" panel
    Remarque

    Read panel and submit resistance to continue

    

    

48. Read Ancillary certification question and select "Yes" to continue

    

49. Read "PCS2 DC Isolation Test" panel and select "Finish Later" to prevent timeout error

    

    

50. Connect HV harness connector to AC compressor

    

51. Install the frunk assembly. See Frunk Assembly (Remove and Install).
52. Branchez l'alimentation électrique MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
53. Débranchez l’alimentation MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
54. Raise vehicle fully
    Remarque

    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
55. Verify no HV - Install amp clamp to RDU HV harness
    Remarque

    Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.Release locking tab and rotate the release lever up to disengage the connector, Release harness clip, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damagedMake sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering

    

    

    

    

    

    

56. Remove pyro fuse access cover
    Remarque

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

    

57. Remove primary pyro fuse
    Remarque

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

    

    

58. Remove secondary pyro fuse
    Remarque

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

    

    

59. Lower vehicle until tires are touching the ground
    Remarque

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
60. Clean all debris from ancillary cover
    Remarque

    During removal of ancillary cover any debris on top of the cover may be deposited into the ancillary bay

    

61. Disconnect ancillary bay MV connector
    Remarque

    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

    

    

    

    

    

62. Support HV Busbar assembly
    Remarque

    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

    

    

63. Remove fast charger header doubler
    Remarque

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

64. Remove mid voltage header bolts
    Remarque

    2x bolts, EP10, 6 Nm

    

65. Release fasteners securing ancillary cover to HV battery
    Remarque

    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

    

    

    

66. Remove ancillary cover
    Remarque

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

    

    

    

67. Disconnect device cluster HV DC harness from PCS
    Remarque

    1x connector, Release locking tab, Gently pull up

    

68. Perform isolation test on PCS2 DC connector at ancillary
    Remarque

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to HV battery chassis bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

69. Enter the lowest stable isolation resistance value recorded in MOhm
    Remarque

    Select "next " to continue

    

70. Read "ACJB Isolation Test" panel and select "Finish Later" to prevent timeout error

    

    

71. Release ancillary bay MV connector header
    Remarque

    4x tabs, Move aside as needed

    

    

72. Disconnect HVC logic connector
    Remarque

    1x connector

    

73. Disconnect negative pack contactor sense connectors
    Remarque

    2x connectors

    

74. Disconnect positive pack contactor sense connectors
    Remarque

    2x connectors

    

    

75. Disconnect ACJB HV connector
    Remarque

    1x connector, Release locking tab, Gently pull up

    

76. Perform isolation test on ACJB HV connector
    Remarque

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to HV battery chassis bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

77. Select "Resume" to continue to "ACJB Isolation Test" panel
    Remarque

    Read panel and submit resistance to continue

    

    

78. Read "External Side DC Link Isolation Test" panel and select "Finish Later" to prevent timeout error

    

79. Perform isolation test on external side of negative and positive pack contactors
    Remarque

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to HV battery chassis bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

    

80. Select "Resume" to continue to "External Side DC Link Isolation Test" panel
    Remarque

    Read panel and submit resistance to continue

    

    

81. Read "Internal Side DC Link Isolation Test" panel and select "Finish Later" to prevent timeout error

    

    

82. Perform isolation test on internal side of negative and positive pack contactors and pyro disconnect
    Remarque

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to HV battery chassis bolt, Position leads then press test button, Amber light will turn on, Test all four terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

    

    

83. Select "Resume" to continue to "Internal Side DC Link Isolation Test" panel
    Remarque

    Read panel and submit resistance to continue

    

    

84. Read "Warm Heat Pump A/C Compressor Isolation Test" panel and select "Finish Later" to prevent timeout error

    

85. Connect ACJB HV connector
    Remarque

    1x connector, Secure locking tab

    

86. Connect positive pack contactor sense connectors
    Remarque

    2x connectors

    

    

87. Connect negative pack contactor sense connectors
    Remarque

    2x connectors

    

88. Connect HVC logic connector
    Remarque

    1x connector

    

89. Secure ancillary bay MV connector header
    Remarque

    4x tabs

    

90. Connect device cluster HV DC harness to PCS
    Remarque

    1x connector, Secure locking tab

    

91. Install ancillary cover
    Remarque

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

92. Secure ancillary cover fasteners to HV battery
    Remarque

    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

    

    

    

93. Install mid voltage header bolts
    Remarque

    2x bolts, EP10, 6 Nm

    

94. Install fast charger header doubler
    Remarque

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

95. Clean HV connector contact surface of residual Penetrox
    Remarque

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

    

96. Clean busbar HV connector contact surface of residual Penetrox
    Remarque

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

    

97. Apply Penetrox onto HV connector joints
    Remarque

    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

    

98. Position busbar connector and lower onto HV header
    Remarque

    Release bungee cord

    

99. Install bolts securing charge port busbar kit to HV Header
    Remarque

    2x bolts, 10mm, 9 Nm

    

100. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
     Remarque

     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

     

     

101. Install bolt securing busbar HV connector lid
     Remarque

     1x bolt, EP10, 9 Nm

     

102. Connect ancillary bay MV connector
     Remarque

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

     

     

     

     

     

103. Raise vehicle fully
     Remarque

     Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
104. Clean pyro fuse mating surfaces
     Remarque

     Using an insulated tool wipe all four busbar mating surfaces within pyro fuse bay, Wipe top and bottom mating surfaces of each pyro fuse, Ensure no debris is present on any mating surface, Process shown with device cluster removed for clarity and safety, HV gloves and associated PPE must be worn at all times when cleaning mating surfaces, Allow 1 minute for IPA to dry

     

     

     

105. Install secondary pyro fuse
     Remarque

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

     

     

106. Install primary pyro fuse
     Remarque

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

     

     

107. Perform Hioki resistance test at each HV joint from HV busbar lead to pyro fuse busbar
     Remarque

     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

     

     

108. Remove HV insulating gloves
109. Install pyro fuse access cover with airlines attached
     Remarque

     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

     

     

     

110. Secure A/C compressor HV harness onto battery
     Remarque

     1x locking connector, 4x clips, Engage locking tab, Do not force lever up, Number of connections may vary by vehicle configuration

     

     

     

111. Connect RDU HV harness
     Remarque

     1x connector, Verify lever is upright and in open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins

     

112. Connect LHS RDU HV harness
     Remarque

     1x connector, Verify lever is upright and in open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins

     

113. Install clips securing AC compressor HV harness
     Remarque

     3x clips

     

114. Install rear skid plate. See Skid Plate - Rear (Remove and Install).
115. Lower vehicle until tires are touching the ground
     Remarque

     Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
116. Branchez l'alimentation électrique MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
117. Remove the frunk assembly. See Frunk Assembly (Remove and Install)
118. Warm up AC compressor via UI
     Remarque

     Via Climate Control > ON, Set fan speed to 10, Set temperature to HI or LO, Allow 20 minute run time

     

119. Turn off the AC and blower motor

     

120. Débranchez l’alimentation MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
121. Disconnect HV harness connector from AC compressor
     Remarque

     1x locking electrical connector, Pull red locking tab away from compressor then slide black lock upwards to release

     

     

122. Perform isolation test on AC compressor
     Remarque

     Move HV harness aside as needed, Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to shock tower brace, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

     

     

     

     

     

123. Select "Resume" to continue to "Warm Heat Pump A/C Compressor Isolation Test" panel
     Remarque

     Read panel and submit resistance to continue

     

124. Read "HV Isolation Diagnostic Debug" results
     Remarque

     If this panel is reached then screenshot and escalate a Toolbox session, Select "X" at top right of window to close once complete

     

125. Branchez l'alimentation électrique MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
126. Installez le tablier sous le capot. Voir Underhood Apron - Rear (Remove and Install),
127. Install the bed floor assembly. See Bed Floor Assembly (Remove and Install).
128. Quitter mode Entretien. Voir Mode Entretien,
129. Retirez le véhicule du pont élévateur. Voir Soulever le véhicule - pont élévateur à 2 poteaux,
130. Remontez la glace avant gauche et fermez la porte avant gauche.