HV Isolation Diagnostics (Tri Motor) (Test)
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.
- 2025-08-28: Released new procedure.
- Ouvrez la porte avant gauche et abaissez la glace avant gauche.
- Soulevez et soutenez le véhicule. Voir Soulever le véhicule - pont élévateur à 2 poteaux,
- Connect a laptop with Toolbox to the vehicle. See Toolbox 3.0 (connecter et déconnecter).
- Select "Actions" and search for "diagnostic_path_network.HV_isolationCheck"
- Select "HV Isolation Diagnostic Debug", enter VIN, and click run
- Read "HV System Global Check Autodiag" question and select "Yes" to continue
- Read "HV Awareness" warning and select "Yes" to continue
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Read interactive procedure instructions and select "Next" to continue
RemarqueSelect "Finish Later" every time you need to perform a task to prevent timeout error, Select "Resume" after task has been performed and you are ready to submit input
- Read "Vehicle Electrical Isolation Procedure" panel and select "Finish Later" to prevent timeout error
- Ouvrez le coffre avant électrique.
- Ouvrez le hayon.
- Débranchez l’alimentation MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
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Verify operation of multimeter
RemarqueSet multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
- Disconnect Toolbox and remove the laptop from the vehicle. See Toolbox 3.0 (connecter et déconnecter).
- Remove rear skid plate. See Skid Plate - Rear (Remove and Install).
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Remove all items from pockets and ensure not wearing metal items
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Inspect HV insulating gloves
RemarqueCheck gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
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Put on HV insulating gloves and leather over gloves
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Remove clips securing AC compressor HV harness
Remarque3x clips
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Verify no HV - Install amp clamp to RDU HV harness
RemarqueVerify 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
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Select "Resume" to continue to "Vehicle Electrical Isolation Procedure" panel
RemarqueRead panel and select "Yes" to continue
- Read "Rear Left DU + HV Harness Isolation Test" panel and select "Finish Later" to prevent timeout error
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Perform isolation test on LH RDU HV cable at HV battery
RemarqueSet 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
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Select "Resume" to continue to "Rear Left DU + HV Harness Isolation Test" panel
RemarqueRead panel and submit resistance to continue
- Read "Rear Left DU + HV Harness Voltage Check" panel and select "Continue"
- Read "Rear Right DU + HV Harness Isolation Test" panel and select "Finish Later" to prevent timeout error
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Disconnect RDU HV harness
Remarque1x connector, Release locking tab and rotate release lever up, Do not force release lever up, Ensure alignment tabs on header are not damaged
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Perform isolation test on RH RDU HV cable at HV battery
RemarqueSet 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
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Select "Resume" to continue to "Rear Right DU + HV Harness Isolation Test" panel
RemarqueRead panel and submit resistance to continue
- Read "Rear Right DU + HV Harness Voltage Check" panel and select "Continue"
- Read "FDU + HV Harness Isolation Test" panel and select "Finish Later" to prevent timeout error
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Disconnect FDU HV harness from HV battery
Remarque1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
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Perform isolation test on FDU HV cable at rear of HV battery
RemarqueSet 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
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Select "Resume" to continue to "FDU + HV Harness Isolation Test" panel
RemarqueRead panel and submit resistance to continue
- Read "FDU + HV Harness Voltage Check" panel and select "Continue"
- Read "Heat Pump A/C Compressor + HV Harness' Isolation Tests" panel and select "Finish Later" to prevent timeout error
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Release A/C compressor HV harness from HV battery
Remarque1x 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
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Perform isolation test on ancillary HV harness at rear of HV battery
RemarqueSet 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
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Select "Resume" to continue to "Heat Pump A/C Compressor + HV Harness' Isolation Tests" panel
RemarqueRead panel and submit resistance to continue
- Read CP HV Harness FC contactor question and select "Yes" to continue
- Read "CP HV Harness Isolation Test" panel and select "Finish Later" to prevent timeout error
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Lower vehicle until tires are touching the ground
RemarqueRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Remove bed floor assembly
Remarque10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance
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Remove bolt securing busbar HV connector lid
Remarque1x bolt, EP10, 9 Nm
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Remove bolts securing HV connector to DC FC header
Remarque2x bolts, 10mm, 9 Nm
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Release HV connector from DC FC header
Remarque1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly
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Secure CP busbar connector aside
RemarqueMove connector away from header, Install bags or bungees as needed, Do not open tonneau to prevent damage
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Perform isolation test on CP HV busbar connector
RemarqueSet insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to door stricker, 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
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Select "Resume" to continue to "CP HV Harness Isolation Test" panel
RemarqueRead panel and submit resistance to continue
- Read Ancillary certification question and select "Yes" to continue
- Read "PCS2 DC Isolation Test" panel and select "Finish Later" to prevent timeout error
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Connect HV harness connector to AC compressor
Remarque1x locking electrical connector, Slide down black lock then push in red locking tab, Perform a push-pull-push test, Ensure red locking tab is fully engaged, Black tab will protrude from red locking tab when engaged correctly, Refer to images and video for clarity
- Remove the frunk assembly. See Frunk Assembly (Remove and Install).
- Branchez l'alimentation électrique MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
- Ouvrez le couvre-caisse.
- Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
- Remove the tonneau NVH barrier. See Tonneau NVH Barrier Assembly (Remove and Install).
- Débranchez l’alimentation MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
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Raise vehicle fully
RemarqueSet to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
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Verify no HV - Install amp clamp to RDU HV harness
RemarqueVerify 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
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Disconnect pressurized pack lines
Remarque2x VOSS fittings, 12mm, 8Nm
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Remove VOSS fitting from pressurized pack air lines
Remarque2x VOSS fitting, Slide threaded section back, Remove the collet, Then slide threaded section off of air line
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Remove pyro fuse access cover
Remarque4x bolts, E-Torx 5 lobe, 10 Nm
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Remove primary pyro fuse
Remarque2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts
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Remove secondary pyro fuse
Remarque2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts
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Lower vehicle until tires are touching the ground
RemarqueRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Remove rear tonneau cover box cross supports
Remarque8x screws, T25, 5 Nm
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Clean all debris from ancillary cover
RemarqueDuring removal of ancillary cover any debris on top of the cover may be deposited into the ancillary bay
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Release ANC air line from pressurized pack valve block
Remarque1x VOSS fitting, 12mm, 8 Nm, Do not release air line to reservoir, Rapid loss of pressure will result if wrong air line is released
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Remove VOSS air fitting from ANC air line
Remarque1x VOSS fitting, Slide threaded section back, Remove collet, Then slide threaded section off of air line, Discard after removal
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Release pressurized pack valve block from air suspension reservoir
Remarque1x bolt, 10mm, 5 Nm, 1x connector, 1x clip, 1x zip tie, Release lock before connector disengagement, Cut zip tie at reservoir and ancillary air line bundle
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Release air suspension valve block
Remarque3x rubber grommets, Rotate clockwise until top 2 rubber feet have released from bracket, Pull upwards at 45 degree angle to release bottom rubber foot from bracket, Leave all air lines and connections secured and set assembly aside
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Release air suspension reservoir
Remarque2x nuts, 13mm, 33 Nm, 2x fir tree clips
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Place air suspension reservoir in service position then install Ancillary Access Bench
RemarqueRaise and swing air suspension reservoir to the side of the bed, Place Ancillary Access Bench onto rear casting ensuring no air lines or harnesses are being pinched
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Disconnect ancillary bay MV connector
Remarque1x 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
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Support HV Busbar assembly
RemarqueSuspend assembly to maintain clearance
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Remove fast charger header doubler
Remarque2x bolts, E10 5 Lobe Torx, 10 Nm
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Release low voltage header
Remarque2x bolts, EP10, 6 Nm
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Release fasteners securing ancillary cover to HV battery
Remarque22x 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
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Remove ancillary cover
RemarqueUse suction cup and maneuver around busbar and tonneau cage
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Disconnect PCS2 DC HV connector
Remarque1x connector, Release locking tab, Gently pull up
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Perform isolation test on PCS2 DC connector at ancillary
RemarqueSet 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
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Select "Resume" to continue to "PCS2 DC Isolation Test" panel
RemarqueRead panel and submit resistance to continue
- Read "ACJB Isolation Test" panel and select "Finish Later" to prevent timeout error
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Release ancillary bay MV connector header
Remarque4x tabs, Move aside as needed
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Disconnect HVC logic connector
Remarque1x connector
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Disconnect negative pack contactor sense connectors
Remarque2x connectors
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Disconnect positive pack contactor sense connectors
Remarque2x connectors
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Disconnect ACJB HV connector
Remarque1x connector, Release locking tab, Gently pull up
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Perform isolation test on ACJB HV connector
RemarqueSet 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
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Select "Resume" to continue to "ACJB Isolation Test" panel
RemarqueRead panel and submit resistance to continue
- Read "External Side DC Link Isolation Test" panel and select "Finish Later" to prevent timeout error
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Perform isolation test on external side of negative and positive pack contactors
RemarqueSet 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
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Select "Resume" to continue to "External Side DC Link Isolation Test" panel
RemarqueRead panel and submit resistance to continue
- Read "Internal Side DC Link Isolation Test" panel and select "Finish Later" to prevent timeout error
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Perform isolation test on internal side of negative and positive pack contactors and pyro disconnect
RemarqueSet 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
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Select "Resume" to continue to "Internal Side DC Link Isolation Test" panel
RemarqueRead panel and submit resistance to continue
- Read "Warm Heat Pump A/C Compressor Isolation Test" panel and select "Finish Later" to prevent timeout error
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Connect ACJB HV connector
Remarque1x connector, Secure locking tab
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Connect positive pack contactor sense connectors
Remarque2x connectors
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Connect negative pack contactor sense connectors
Remarque2x connectors
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Connect HVC logic connector
Remarque1x connector
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Secure ancillary bay MV connector header
Remarque4x tabs
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Connect PCS2 DC HV connector
Remarque1x connector, Secure locking tab
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Install ancillary cover
RemarqueUse suction cup and maneuver around busbar and tonneau cage
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Secure fasteners of cover to HV battery
Remarque22x 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
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Secure low voltage header
Remarque2x bolts, EP10, 6 Nm
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Secure fast charger header doubler
Remarque2x bolts, E10 5 Lobe Torx, 10Nm
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Clean HV connector contact surface of residual Penetrox
RemarqueAllow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
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Clean busbar HV connector contact surface of residual Penetrox
RemarqueAllow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
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Apply Penetrox onto HV connector joints
RemarqueApply 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
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Position busbar connector and lower onto HV header
RemarqueRelease bungee cord
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Install bolts securing charge port busbar kit to HV Header
Remarque2x bolts, 10mm, 9 Nm
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Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
Remarque2x 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
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Install bolt securing busbar HV connector lid
Remarque1x bolt, EP10, 9 Nm
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Connect Ancillary bay MV connector
Remarque1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly
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Secure rear tonneau cover box cross supports
Remarque8x screws, T25, 5 Nm, Supports install in the same direction of the fasteners
- Install the tonneau NVH barrier. See Tonneau NVH Barrier Assembly (Remove and Install).
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Remove Ancillary Access Bench then place air suspension reservoir into position for installation
RemarqueEnsure air lines are not twisted, Ensure no harnesses are caught
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Secure air suspension reservoir
Remarque2x nuts, 13mm, 33 Nm, 2x fir tree clips
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Secure air suspension valve block
Remarque3x rubber grommets, Rotate counter-clockwise until top 2 rubber feet are secured onto bracket, Push downwards at 45 degree angle to secure bottom rubber foot into bracket, Position air lines and connections into place for installation
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Install new VOSS air fitting onto ANC air line
Remarque1x VOSS fitting, 12mm, 8 Nm, Do not remove VOSS plastic plug until pressurized pack line is installed
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Secure ANC air line onto pressurized pack valve block
Remarque1x line, Remove plastic cap from VOSS fittings, Press air lines onto fitting until mark aligns with top of fitting, Verify line is properly secured by performing push and pull test
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Secure pressurized pack valve block onto air suspension reservoir
Remarque1x bolt, 10mm, 5 Nm, 1x connector, 1x clip, 1x zip tie, Secure reservoir and ancillary air lines at white marked sections
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Raise vehicle fully
RemarqueSet to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
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Clean mating surface of the pyro
RemarqueUse a non-conductive plastic tool to clean the busbar side, Allow 1 minute for IPA to fully dry, Do not use any other types of cleaner
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Install secondary pyro fuse
Remarque2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts
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Install primary pyro fuse
Remarque2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts
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Perform Hioki resistance test at each HV joint from HV busbar lead to pyro fuse busbar
Remarque4x 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
- Remove HV insulating gloves
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Install new Voss fittings and nut onto pyro cover
Remarque2x VOSS fittings, 12mm, 8 Nm, Do not remove VOSS plastic plug until pressurized pack air line install
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Install pyro fuse access cover
Remarque4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged, If HV pack is being shipped then pyro fuses must be removed
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Install pressurized pack lines
Remarque2x VOSS fittings, 12mm, 8 Nm, Remove plastic caps from VOSS fittings if installing new fuse cover, Press air lines into fitting until mark aligns with top of fitting, Verify line is properly secured by performing push and pull test
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Secure A/C compressor HV harness onto battery
Remarque1x locking connector, 4x clips, Engage locking tab, Do not force lever up, Number of connections may vary by vehicle configuration
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Connect FDU HV harness to HV battery
Remarque1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
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Connect RDU HV harness
Remarque1x 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
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Connect LHS RDU HV harness
Remarque1x 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
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Install clips securing AC compressor HV harness
Remarque3x clips
- Install the rear skid plate. See Skid Plate - Rear (Remove and Install).
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Lower vehicle until tires are touching the ground
RemarqueRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
- Branchez l'alimentation électrique MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
- Remove the frunk assembly. See Frunk Assembly (Remove and Install).
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Warm up AC compressor via UI
RemarqueVia Climate Control > ON, Set fan speed to 10, Set temperature to HI or LO, Allow 20 minute run time
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Turn off the AC and blower motor
- Débranchez l’alimentation MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
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Disconnect HV harness connector from AC compressor
Remarque1x locking electrical connector, Pull red locking tab away from compressor then slide black lock upwards to release
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Perform isolation test on AC compressor
RemarqueMove 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
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Select "Resume" to continue to "Warm Heat Pump A/C Compressor Isolation Test" panel
RemarqueRead panel and submit resistance to continue
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Read "HV Isolation Diagnostic Debug" results
RemarqueIf this panel is reached then screenshot and escalate a Toolbox session, Select "X" at top right of window to close once complete
- Branchez l'alimentation électrique MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
- Branchez l'alimentation électrique MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
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Install bed floor assembly
Remarque10x bolts, 15mm, 56 Nm, 4x anchors, Open and close anchors as needed, Recommend assistance
- Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
- Quitter mode Entretien. Voir Mode Entretien,
- Retirez le véhicule du pont élévateur. Voir Soulever le véhicule - pont élévateur à 2 poteaux,
- Remontez la glace avant gauche et fermez la porte avant gauche.