10/01/2023 18:35:03

Inline Fuse to Busbar - HV Harness - HVJB to Front Drive Unit - 2nd Generation (Retrofit)

Correction code 44504106

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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
This procedure may only be performed on vehicles that have a hybid pyro fuse installed on the HV battery.
  1. Perform the vehicle electrical isolation procedure and check for high voltage at the high voltage junction box (2nd generation). See Vehicle HV Disablement Procedure .
  2. Remove the bolt that attaches the ground strap to the inline fuse cover.
  3. Remove the wire from the wire guide on HVIL activation cover.
  4. Remove the bolts (x2) that attach the HVIL activation cover.
  5. Remove the bolts (x4) that attach the inline fuse cover lid to the inline fuse cover.
  6. Remove the nuts (x2) that attach the inline fuse to the front drive unit HV harness.

Installation

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Make sure that the HV battery is equipped with a hybid pyro fuse before installing the busbar.
  1. Prior to installing the busbar, wipe the leads, studs and mounting ends of the busbar with IPA wipes.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure leads, studs and busbar are clear of debris, Allow 1 minute for the IPA to dry.
  2. Install the busbar with new washers (x2) and nuts (x2) (torque 9 Nm).
  3. Put on HV insulating gloves and leather overgloves, and then use the Hioki impedance tester to measure the impedance at each busbar joint.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.150 mΩ (150 μΩ). If the resistance is not within this range, reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), the Hioki test passed, proceed with the installation procedure. For more information on Hioki resistance testing, refer to Toolbox article 218200.
  4. Install the bolts (x4) (torque 4.5 Nm) that attach the inline fuse cover lid to the inline fuse cover.
  5. Install the bolts (x2) (torque 3.5 Nm) that attach the HVIL activation cover.
  6. Install the wire into the wire guide on the HVIL activation cover.
  7. Install the bolt (torque 10 Nm) that attaches the ground strap to the inline fuse cover.
  8. After installing the 2nd row seat cushion, reconnect 12V power. See Disconnect 12V Power .