Korrekturcode 16014567 FRT 1.02 HINWEIS: Sofern im Verfahren nicht ausdrücklich anders angegeben, spiegeln der obige Korrekturcode und die FRT den gesamten für die Durchführung dieses Verfahrens erforderlichen Aufwand wider, einschließlich der damit verbundenen Verfahren. Schichten Sie keine Korrekturcodes, wenn Sie nicht ausdrücklich dazu aufgefordert werden. HINWEIS: Weitere Informationen über FRTs und darüber, wie sie erstellt werden, finden Sie unter Richtzeiten. HINWEIS: Siehe Persönlicher Schutz, um sicherzustellen, dass Sie die richtige persönliche Schutzausrüstung tragen, wenn Sie das folgende Verfahren durchführen. HINWEIS: Siehe Maßnahmen zur Ergonomie für sichere und gesunde Arbeitsmethoden.

1. Remove the pyrotechnic disconnect and install the dummy disconnect. See Pyrotechnische Batteriesicherung (Ausbauen und Ersetzen)
2. Lift HV Controller up to access fuse insulator
   Anmerkung

   Setup seatbelt to hold HVC assembly and tray in upward position

   

3. Install HVC logic cap
   Anmerkung

   1x cap

   

4. Install insulator for DC input assembly to both fastcharge busbars inlet side
   Anmerkung

   1x insulator

   

5. Install negative AC inlet terminal cover
   Anmerkung

   1x cover, 3x clips, Use caution as the clips are very easy to damage

   

6. Install positive AC inlet terminal cover
   Anmerkung

   1x cover, 3x clips, Use caution as the clips are very easy to damage

   

7. Use bungee to secure HVC in an upwards position
   Anmerkung

   Wrap bungee around RH headrest

   

8. Remove the nuts securing the 700VDC 63A compressor fuse
   Anmerkung

   2x patch nuts, 8mm, 2.5 Nm, Discard after removal

   

9. Remove the 700VDC 63A PCS output fuse from AWD bus and dist assembly
   Anmerkung

   1x fuse

   

10. Remove the nuts securing the 700VDC 63A PCS output fuse
    Anmerkung

    2x patch nuts, 8mm, 2.5 Nm, Discard after removal

    

11. Remove the 700VDC 63A compressor fuse from AWD bus and dist assembly
    Anmerkung

    1x fuse

    

12. Remove the nut that secures the HV battery ancillary positive busbar
    Anmerkung

    1x nut, 10mm, 4.5 Nm

    

13. Remove the HV battery ancillary positive busbar from AWD bus and dist assembly

    

14. Remove nut securing negative AC harness to negative HV battery DC link busbar
    Anmerkung

    1x nut, 8mm, 4.5 Nm

    

15. Remove nuts securing PTC negative harness
    Anmerkung

    2x nut, 8mm, 4.5 Nm

    

16. Disconnect HV carrier connector
    Anmerkung

    1x connector

    

17. Remove screw securing HV carrier assembly
    Anmerkung

    1x screw, T20, 3 Nm

    

18. Remove HV carrier assembly

    

    

19. Position the heat shrink sleeve on the new HV carrier wire as illustrated (green rectangle).
    
20. Attach the 2 HV carrier terminals together using an M4 nut and bolt.
    TIp

    Use of the following tool(s) is recommended:

    • Torx T20 bit
    

    2.5 Nm (1.8 lbs-ft)
    
21. Slide the heat shrink sleeve over the fastened terminals, and then install the sleeve with a heat gun.
    Warnung

    Use caution and if necessary, PPE such as protective gloves when handling the heat gun.
    
22. Remove the bolt that secures the HV carrier assembly.
    TIp

    Use of the following tool(s) is recommended:

    • Torx T20 bit

    

23. Route the harness through the HV carrier assembly

    

    

    

    

24. Install screw securing HV carrier assembly
    Anmerkung

    1x screw, T20, 3 Nm

    

25. Connect HV carrier connector
    Anmerkung

    1x connector

    

26. Install nut securing negative AC harness to negative HV battery DC link busbar
    Anmerkung

    1x nut, 8mm, 4.5 Nm

    

28. Install two upside-down M5 nuts on the ancillary tray.
    
29. Install the HV battery ancillary positive busbar to AWD bus and dist assembly

    

30. Install the nut securing the HV battery ancillary positive busbar
    Anmerkung

    1x nut, 10mm, 4.5 Nm

    

31. Perform Hioki resistance test at 63A fuse input joint
    Anmerkung

    55 μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

32. Install 700VDC 63A PCS output fuse to AWD bus and dist assembly
    Anmerkung

    1x fuse

    

33. Install nuts securing the 700VDC 63A PCS output fuse
    Anmerkung

    2x patch nuts, 8mm, 4.5 Nm, Install new patch nuts, Mark after torque

    

34. Perform Hioki resistance test at 63A fuse input joint
    Anmerkung

    1x HV joint, 145μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

35. Install the 700VDC 63A compressor fuse to AWD bus and dist assembly
    Anmerkung

    1x fuse

    

36. Install the nuts securing the 700VDC 63A compressor fuse
    Anmerkung

    2x patch nuts, 8mm, 4.5 Nm, Install new patch nuts

    

37. Perform Hioki resistance test at 63A fuse out joint
    Anmerkung

    1x HV joint, 145 μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

38. Perform Hioki resistance test at 63A fuse in joint
    Anmerkung

    1x HV joint, 105μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

39. Install fuses access insulator
    Anmerkung

    3x clips

    

40. Remove pyro disconnect dummy

    

41. Clean mating surface of pyro
    Anmerkung

    Use 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

    

    

    

42. Set multimeter to "LoZ" (low impedance) mode

    

43. Position pyro disconnect to ancillary bay for installation
    Anmerkung

    1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way

    

    

44. Install bolts securing pyro disconnect to ancillary bay
    Anmerkung

    2x patch bolts, 13mm, 9 Nm, Install new patch bolts

    

45. Measure resistance from module 2 busbar to pyro disconnect
    Anmerkung

    1x HV joint, 60μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

46. Measure resistance from pyro disconnect to shunt
    Anmerkung

    1x HV joint, 45μΩ or less

    

    

47. Install battery pyro and shunt insulators
    Anmerkung

    2x insulators

    

48. Clean HVC studs and ancillary bay cover underside with isopropyl alcohol
    Anmerkung

    Ensure no plastisol residue on ancillary bay or HVC, Remove plastisol residue if necessary, Fastener count may vary on new vehicles, Allow 1 minute for IPA to dry

    

    

49. Wipe penthouse with IPA to clean surface
    Anmerkung

    Allow to 1 minute dry time

    

50. Inspect penthouse walls for damage
    Anmerkung

    Any dent or depression in the seal that causes it to not be flat will result in a leak, and cannot be reused, Any paint that comes off the penthouse wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled, It can still be reused

    

51. Inspect penthouse cover seal to confirm it has no visual damage
    Anmerkung

    Image up close for clarity, Delaminated and torn seals cannot be reused

    

    

    

    

52. Remove HVC logic cap
    Anmerkung

    1x cap

    

53. Remove ancillary Service Insulator Kit

    

    

    

    

    

    

    

    

54. Remove the ancillary cover. See Abdeckung – HV-Gehäuse (Ausbauen und Ersetzen)