26/07/2023 16:50:25

HV Harness - FJB to Front Drive Unit - 2nd Generation (Remove and Replace)

Correction Code 44500702

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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.

Removal

  1. Open the LH front door.
  2. Open the hood.
  3. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift .
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace) .
  5. Remove the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace) .
  6. Remove the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace) .
  7. Remove the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace) .
  8. Disconnect the 12V power. See Disconnect 12V Power .
  9. Remove the HV battery. See HV Battery (RWD/AWD) (Remove and Install) .
  10. Remove the bolt that attaches the lower i-shaft to the steering gear, and then slide the i-shaft up and away from the steering gear.
  11. Position a coolant drain container underneath the front of the vehicle to catch coolant during the next step.
  12. Disconnect the front drive unit inlet coolant hose, and then plug both ends using plugs from the coolant hose plug kit.
  13. Remove the coolant drain container from underneath the vehicle.
  14. Disconnect the front drive unit HV electrical connector by releasing the locking tab, and then rotate the release lever up to disengage the electrical connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use excessive force to move the release lever in order to prevent damage to the front drive unit HV electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the alignment tabs on the front drive unit header are not damaged.
  15. Remove and discard the bolts (x4) that attach the Front Junction Box (FJB)-to-front drive unit HV harness to the FJB.
  16. Remove the bolt that attaches the FBJ-to-front drive unit HV harness to the front drive unit.
  17. Remove the FJB to front drive unit HV harness from the vehicle.

Installation

  1. Position the FJB to front drive unit HV harness in the vehicle.
  2. Install the bolt that attaches the FBJ-to-front drive unit HV harness to the front drive unit (torque 5 Nm + 20 degrees).
  3. Install new bolts (x4) that attach the FJB-to-front drive unit HV harness to the FJB (torque 7 Nm).
  4. Connect the front drive unit HV electrical connector to the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply slight pressure to the connector as the lever is rotated into position; move the lever to the closed position slowly and make sure that the lever teeth and manifold teeth are properly engaged.
    Informational PurposesAn informational icon, calling your attention
    Note
    There should be a very small gap between the manifold and the connector when the connector is closed.
  5. Position a coolant drain container under the front of the vehicle to catch coolant during the next step.
  6. Remove the coolant plugs, and then connect the front drive unit inlet hose.
  7. Remove the coolant drain container from underneath the vehicle.
  8. Slide the lower i-shaft onto the steering gear, and then install the bolt that attaches the lower i-shaft to the steering gear (torque 30 Nm).
  9. Install the HV battery. See HV Battery (RWD/AWD) (Remove and Install) .
  10. Partially lower the vehicle.
  11. Reconnect the 12V power. See Disconnect 12V Power .
  12. Connect a laptop with Toolbox 3 to the vehicle.
  13. Unlock the gateway. See Gateway Unlock.
  14. In Toolbox 3, click the Actions tab, type "Coolant air purge" into the search field, click PROC_THC_X_COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Coolant Air Purge, click Run, and allow the routine to complete.
  15. Top off the coolant reservoir.
  16. Disconnect the Toolbox and remove the laptop from the vehicle.
  17. Install the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace) .
  18. Install the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace) .
  19. Install the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace) .
  20. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace) .
  21. Close the hood, remove the vehicle from lift, and close the LH front door.