31/05/2024 10:43:39

DCDC Converter (Remove and Replace)

Correction Code 44200102 Correction Code 44200302 Correction Code 44200402 Correction Code 44202002 Correction Code 44202202

Choose the appropriate procedure based on the vehicle's configuration and date of manufacture:

1st Generation

Correction Code 44200102

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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
To avoid personal injury or equipment damage from electrostatic discharge, an ESD wrist strap must be worn while carrying out this procedure.

Removal

  1. Perform the vehicle HV disablement procedure (refer to procedure).
  2. Remove the front RH upper wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace).
  3. Clamp the DCDC converter feed and return coolant hoses.
  4. Position a container to collect the coolant.
  5. Release the clips (x2) that attach the feed and return coolant hoses to the DCDC converter. Release the hoses from the converter.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Plug pipe connections to prevent ingress of moisture or dirt.
    Informational PurposesAn informational icon, calling your attention
    Note
    Note installed position of components before removal.
  6. Remove the nut and washers that attach the 12V ground terminal to the DCDC converter (torque 16 Nm). Release the harness and move it aside.
  7. Release the DCDC converter 12V positive terminal insulation cover.
  8. Remove the nut and washers securing the 12V positive terminal to the DCDC converter (torque 9 Nm). Release the harness and move it aside.
  9. Release the clip that attaches the harness to the DCDC converter.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 00 (500V) must be worn while performing the remainder of this procedure.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure that the multimeter and leads are capable of handling at least 500V.
  10. Remove the bolt that attaches the HV connector cover (torque 18 Nm).
  11. Use a multimeter to check voltages across the HV cables and to ground:
    • B+ to ground
    • B- to ground
    • B+ to B-
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      If any voltage reading is more than 10V, the high voltage contactors are not fully opened. Due to the risk of electrocution, contact Service Engineering before performing any further work.
  12. Disconnect the HV harness from the DCDC converter (torque 5 Nm).
  13. Disconnect the HV harness connectors (x3) that attach the battery coolant, electric heater, cabin heater and compressor to the DCDC converter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Note installed position of components before removal.
  14. Disconnect the signal harness connector from the DCDC converter.
  15. Release the clips (x3) that attach the harness to the DCDC converter.
  16. Remove the bolt and nuts (x2) that attach the DCDC converter to the body (torque 9 Nm).
  17. Remove the DCDC converter from the vehicle.

Installation

Installation procedure is the reverse of removal, except for the following:
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Warning
Only use cleaning agents and solvents in a well-ventilated area.
Informational PurposesAn informational icon, calling your attention
Note
Clean the affected areas before installation.

2nd Generation RWD

Correction Code 44200302

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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

This procedure only applies to vehicles with the 2nd generation High Voltage configuration. For vehicles with the 1st generation High Voltage configuration, refer to DCDC Converter (Remove and Replace).

Removal

  1. Perform the vehicle HV disablement procedure (refer to procedure).
  2. Remove the battery coolant heater. See Coolant Heater - Electric - Battery - 2nd Generation (Remove and Replace).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not allow coolant to spill onto the High Voltage Battery, forward junction Box, DCDC Converter, battery coolant heater, or any harnesses.
    Informational PurposesAn informational icon, calling your attention
    Note
    After removing the heater, it might be helpful to plug the upper coolant hose on the DCDC converter and remove the clamp. This provides additional clearance in the working area to remove the DCDC converter.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not allow coolant to spill onto the High Voltage Battery, forward junction Box, DCDC Converter, battery coolant heater, or any harnesses.
    1 Plugged coolant hose
  3. Cut the zip tie that holds the top coolant hose to the bulkhead. Move the coolant hose out of the way.
  4. Release the 2 bolts that attach the bracket on the top of the DCDC converter to the bulkhead (torque 22 Nm).
  5. Release the nut that attaches the bracket on the lower LH side of the DCDC converter (torque 22 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    This nut is very difficult to retrieve if dropped. It might be helpful to use a magnet to hold the nut while it is being removed.
  6. Release the 2 harnesses on the RH side of the DCDC converter.
  7. Release the ground bolt (torque 25 Nm).
  8. Release the 12V positive bolt (torque 13 Nm).
  9. Release the fastener that attaches the ground strap to the body (torque 9 Nm).
  10. Remove the cable tie that attaches the coolant hose to the lower crossmember.
  11. Place absorbent material in the base of the front trunk to catch any coolant that is spilled in the next steps.
  12. Place a container in the front trunk to catch coolant.
  13. Gently pull the DCDC into the front trunk area, but do not fully remove it.
  14. Clamp the coolant hose close to the DCDC converter.
  15. Release the locking clamp that attaches the coolant hose to the DCDC converter. Drain the coolant from the DCDC converter and from the hose into the container.

2nd Generation Dual Motor

Correction Code 44200402

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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Removal

  1. Disconnect 12V power. See Disconnect 12V Power.
  2. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure
  3. Remove the fuse box. See Fusebox - Underhood - 2nd Generation (Remove and Replace).
  4. Remove the wiper motor. See Wiper Module (Remove and Replace).
  5. Remove the LH and RH shock tower braces. See Wiper Module (Remove and Replace).
  6. Release the bolts (x2) that attach each fuse box to the front crossmember (torque 5 Nm).
  7. If the vehicle is equipped with air suspension, release the bolts (x2) that attach the air reservoir (torque 2.5 Nm). Carefully set the reservoir in the RH side of the underhood area.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is not necessary to disconnect the air lines.
  8. Remove the electric battery coolant heater. See Coolant Heater - Electric - Battery (Dual Motor) (Remove and Replace).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not allow coolant to spill onto the High Voltage Battery, forward junction box, DCDC converter, battery coolant heater, or any other harnesses.
  9. Remove the top bolts (x2) that attach the DCDC brackets to the body (torque 22 Nm).
  10. Remove the HV battery. See HV Battery (RWD/AWD) (Remove and Install).
  11. Remove the bolts (x4) that attach the FJB to FDU HV harness to the FJB (torque 7 Nm).
  12. Remove the bolt (torque 12 Nm) that attaches the 12V cable to the DCDC converter.
  13. Remove the bolt (torque 25 Nm) that attaches the ground cable to the DCDC converter.
  14. Disconnect the 12V logic connector from the DCDC converter.
  15. Disconnect the black HV connector from the DCDC converter.
  16. Release the battery coolant heater 12V harness clip from the DCDC converter bracket.
  17. Position a coolant drain container under the front of the vehicle.
  18. Clamp the lower coolant hose, and then release the lower coolant hose from the DCDC converter.
  19. Clamp the upper coolant hose, and then release the upper coolant hose from the DCDC converter.
  20. Remove the nut (torque 22 Nm) that attaches the bottom DCDC converter bracket to the body.
  21. Remove the DCDC converter from the vehicle

3rd Generation RWD

Correction Code 44202002

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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Removal

  1. Perform the vehicle HV disablement procedure (refer to procedure).
  2. Remove the underhood fuse box. See Fusebox - Underhood - 2nd Generation (Remove and Replace).
  3. Remove the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
  4. Release the fastener that attaches the wiper motor to the LH shock tower brace (torque 9 Nm).
  5. Release the clip that attaches the harness to the LH shock tower brace.
  6. Release the fastener that attaches the LH side of the air suspension reservoir to the bracket (torque 2.5 Nm).
  7. Release the fasteners that attach the LH air suspension reservoir bracket to the LH shock tower brace (torque 6 Nm).
  8. Release the fastener that attaches the LH shock tower brace to the bulkhead (torque 20 Nm).
  9. Release the fasteners that attach the LH shock tower brace to the shock tower (torque 20 Nm).
  10. Remove the LH shock tower brace from the vehicle.
  11. Slide the LH air suspension reservoir bracket outboard to remove it from the reservoir.
  12. Release the fastener that attaches the RH side of the air suspension reservoir to the bracket (torque 2.5 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not disconnect the air line from the air suspension reservoir.
  13. Remove the air suspension reservoir from the RH bracket and set it aside.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the reservoir is attached out of the working area so that it does not fall and damage the air suspension line.
  14. Release the clip that attaches the fuse box cable to the battery coolant heater.
  15. Release the fastener that attaches the fuse box cable to the DCDC converter (torque 12 Nm). Remove the fuse box cable from the vehicle.
  16. Release the fastener that attaches the DCDC converter large ground strap to the body (torque 9 Nm).
  17. Disconnect the harnesses from the DCDC converter.
  18. Clamp the DCDC converter coolant hoses.
  19. Place absorbent material beneath the DCDC converter.
  20. Release both coolant hoses from the DCDC converter. Plug the hole as each hose is removed.
  21. Remove the nut that secures the lower DCDC converter bracket to the bulkhead (torque 22 Nm).
  22. Release the 12V harness clip from the battery coolant heater.
  23. Release the fasteners that attach the DCDC converter to the battery coolant heater (torque 7.7 Nm).
  24. Release the fasteners that attach the upper DCDC converter bracket to the body (torque 22 Nm).
  25. Pull the DCDC converter away from the bulkhead and release the nut that attaches the small ground strap to the body (torque 9 Nm).
  26. Remove the DCDC converter from the vehicle.
  27. Remove the fasteners that attach the upper DCDC converter bracket (torque 3 Nm).
  28. Remove the fasteners that attach the lower DCDC converter bracket (torque 3 Nm).
  29. Remove the nut that attaches the large ground strap to the DCDC converter (torque 24.5 Nm).
  30. Remove the nut that attaches small ground strap to the DCDC converter (torque 5.2 Nm).

3rd Generation Dual Motor

Correction Code 44202202

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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Removal

  1. Remove the forward junction box. See Forward Junction Box (Remove and Replace).
  2. Release the fastener that attaches the DCDC converter small ground strap to the body (torque 9 Nm).
  3. Release the fastener that attaches the DCDC converter large ground strap to the body (torque 9 Nm).
  4. Release the fastener that attaches the HV cable bracket to the front drive unit (torque 15 Nm).
  5. Release the fastener that attaches the fuse box cable to the DCDC converter (torque 12 Nm).
  6. Disconnect the harnesses from the DCDC converter.
  7. Clamp the DCDC converter coolant hoses.
  8. Place absorbent material beneath the DCDC converter.
  9. Release both coolant hoses from the DCDC converter. Plug the hole as each hose is removed.
  10. Release the 12V harness clip from the battery coolant heater.
  11. Remove the nut that secures the lower DCDC bracket to the bulkhead (torque 22 Nm).
  12. Release the fasteners that attach the DCDC converter to the battery coolant heater (torque 7.7 Nm).
  13. Release the fasteners that attach the upper DCDC converter bracket to the body (torque 22 Nm).
  14. Pull the DCDC converter away from the bulkhead and release the nut that attaches the small ground strap to the body (torque 9 Nm).
  15. Remove the DCDC converter from the vehicle.
  16. Remove the fasteners that attach the upper DCDC converter bracket (torque 3 Nm).
  17. Remove the fasteners that attach the lower DCDC converter bracket (torque 3 Nm).
  18. Remove the nut that attaches the large ground strap to the DCDC converter (torque 24.5 Nm).
  19. Remove the nut that attaches small ground strap to the DCDC converter (torque 5.2 Nm).

Installation

Installation procedure is the reverse of removal, except for the following: