26/06/2020 14:27:05

Forward Junction Box (Remove and Replace)

Correction Code 44200702 Correction Code 44200602 Correction Code 44201202 Correction Code 44201302

Only vehicles built after approximately January 14, 2014 are equipped with a forward junction box. For vehicles built before this date, the forward junction box is a part of the DCDC converter and is not serviceable separately.

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

1st Generation RWD

Correction Code 44200702

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 extension box from the underhood storage compartment (refer to procedure).
  3. Release the harnesses (x4) from the top of the forward junction box.
    1 HV Battery heater harness
    2 DCDC converter harness
    3 Compressor harness
    4 PTC heater harness
  4. Disconnect the 12V harness from the RH side of the forward junction box.
  5. Release the fastener that secures the ground strap to the forward junction box.
    • Ground strap secured to forward junction box cover: Torque 4.5 Nm
    • Ground strap secured to tab on RH side of forward junction box: Torque 9 Nm
    Ground strap secured to cover Ground strap secured to tab
  6. Release the bolts (x6) that secure the forward junction box cover (torque 4.2 Nm). Remove the cover.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Before continuing, put on high voltage gloves.
  7. Use a small, insulated screwdriver or similar tool to pry open the cover on the front upper left of the forward junction box.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not use a metallic tool to open the cover.
  8. Use a multimeter to check voltages between:
    • B+ to ground
    • B- to ground
    • B+ and 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.
  9. Release the bolts (x2) that secure the HV cables to the busbars inside the forward junction box (torque 4 Nm).
  10. Release the clips that secure the HV cables.
    Informational PurposesAn informational icon, calling your attention
    Note
    The O-rings on the HV cables might create suction, which makes the cables difficult to remove. It might require greater than normal force to release the cables.
  11. Release the bolts (x3) that secure the forward junction box to the body (torque 10 Nm).
  12. Carefully remove the forward junction box from the vehicle.

Installation

Installation procedure is the reverse of removal.

1st Generation Dual Motor

Correction Code 44200602

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 HV Battery (refer to procedure).
  2. Remove the fasteners (x2) that secure the mounting bracket for powertrain coolant pump 2 to the body (torque 7 Nm).
  3. Support the coolant pump and disconnect the low voltage connector.
  4. Remove and discard the bolts (x6) that secure the forward junction box cover (torque 4.2 Nm). Remove the cover.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Ensure that new bolts are installed during installation.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Before continuing, put on high voltage gloves.
  5. Use a small, insulated screwdriver or similar tool to pry open the cover on the front upper left of the forward junction box.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not use a metallic tool to open the cover.
  6. Use a multimeter to check voltages between:
    • B+ to ground
    • B- to ground
    • B+ and B-
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    If any voltage reading is more than 10V, discontinue this procedure immediately. Contact a Field Service Engineer before performing any further work.
  7. Release the harnesses (x4) from the top of the forward junction box.
    1 HV Battery heater harness
    2 DC-DC converter harness
    3 Compressor harness
    4 PTC heater harness
  8. Release the bolts (x2) that secure the HV cables to the busbars inside the forward junction box (torque 4 Nm).
  9. Release the clips (x2) that secure the HV cables.
    Informational PurposesAn informational icon, calling your attention
    Note
    The O-rings on the HV cables might create suction, which makes the cables difficult to remove. It might require greater than normal force to release the cables.
  10. Disconnect the 12V harness from the RH side of the forward junction box.
  11. Remove and discard the fastener that secures the ground strap to the forward junction box.
    • Ground strap secured to forward junction box cover: Torque 4.5 Nm
    • Ground strap secured to tab on RH side of forward junction box: Torque 9 Nm
    Ground strap secured to cover Ground strap secured to tab
  12. Release the bolts (x3) that secure the forward junction box to the body (torque 10 Nm).
  13. Carefully remove the forward junction box from the vehicle.

Installation

Installation procedure is the reverse of removal.

2nd Generation RWD

Correction Code 44201202

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. Use a hood prop to support the hood.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Ensure that the hood prop fully supports the hood before continuing.
  3. Release the RH hood strut from the hood to provide better access to the forward junction box.
  4. On the RH side of the forward junction box, disconnect the low voltage connector.
  5. Release the nut that secures the ground strap (torque 9 Nm).
  6. Release the fasteners (x2) at the base of the forward junction box (torque 7 Nm).
  7. Remove the nut on the RH side of the forward junction box (torque 7 Nm).
  8. On the RH side of the forward junction box, release the fasteners (x4) that secure the HV cables (torque 7 Nm).
  9. Disconnect the 4 harnesses on the LH side of the forward junction box.
  10. Remove the forward junction box from the vehicle.

Installation

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

If necessary, transfer the ground strap to the new forward junction box (torque 4.2 Nm).

2nd Generation Dual Motor

Correction Code 44201302

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 HV Battery (refer to procedure).
  2. For vehicles built through April 24, 2019: Release the nut that secures the ground strap (torque 9 Nm).
  3. For vehicles built after April 24, 2019, perform these steps:
    1. Release the drain tube from the body.
    2. Release the clip that attaches the HV harness at the bulkhead, allowing the HV harness to be moved out of the way for the front harness to pass behind the HV harness during removal.
  4. On the RH side of the forward junction box, release the fasteners (x4) that secure the HV cables (torque 7 Nm).
  5. On the RH side of the forward junction box, disconnect the low voltage connector.
  6. On the LH side of the forward junction box, release the fasteners (x4) that secure the HV cables (torque 7 Nm).
  7. Release the fasteners (x2) at the base of the forward junction box (torque 7 Nm).
  8. Slightly loosen the nut on the RH side of the forward junction box, but do not release it (torque 7 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    The nut secures the forward junction box to the vehicle during the next step.
  9. Disconnect the 4 harnesses on the LH side of the forward junction box.
  10. Remove the nut on the RH side of the forward junction box (torque 9 Nm).
  11. Remove the forward junction box from the vehicle.

Installation

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

If necessary, transfer the ground strap to the new forward junction box (torque 4.2 Nm).