10/01/2023 18:35:03
Inline Fuse to Busbar - HV Harness - HVJB to Front Drive Unit - 2nd Generation (Retrofit)
Correction code 44504106
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
This procedure may
only be performed on vehicles that have a hybid pyro fuse installed on the HV
battery.
- Perform the vehicle electrical isolation procedure and check for high voltage at the high voltage junction box (2nd generation). See Vehicle HV Disablement Procedure .
-
Remove the bolt that attaches
the ground strap to the inline fuse cover.
-
Remove the wire from the wire
guide on HVIL activation cover.
-
Remove the bolts (x2) that
attach the HVIL activation cover.
-
Remove the bolts (x4) that
attach the inline fuse cover lid to the inline fuse cover.
-
Remove the nuts (x2) that attach
the inline fuse to the front drive unit HV harness.
Installation
Warning
Make sure that the HV battery is equipped with a hybid pyro
fuse before installing the busbar.
-
Prior to installing the
busbar, wipe the leads, studs and mounting ends of the busbar with IPA
wipes.
NoteEnsure leads, studs and busbar are clear of debris, Allow 1 minute for the IPA to dry.
- Install the busbar with new washers (x2) and nuts (x2) (torque 9 Nm).
-
Put on HV insulating gloves
and leather overgloves, and then use the Hioki impedance tester to measure
the impedance at each busbar joint.
NoteThe 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.
-
Install the bolts (x4) (torque 4.5 Nm) that attach the inline fuse cover
lid to the inline fuse cover.
-
Install the bolts (x2) (torque 3.5 Nm) that attach the HVIL activation
cover.
-
Install the wire into the
wire guide on the HVIL activation cover.
-
Install the bolt (torque 10 Nm) that attaches the ground strap to the
inline fuse cover.
- After installing the 2nd row seat cushion, reconnect 12V power. See Disconnect 12V Power .