10/01/2023 18:49:52

Inline Fuse - HV Harness - HVJB to Front Drive Unit - 2nd Generation (Remove and Replace)

Correction code 44504102

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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.
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Note
If the vehicle has a hybrid pyro fuse installed in the HV battery, preferably a busbar is installed instead of the inline fuse. See Inline Fuse to Busbar - HV Harness - HVJB to Front Drive Unit - 2nd Generation (Retrofit).
  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 (torque 10 Nm) 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) (torque 3.5 Nm) that attach the HVIL activation cover.
  5. Remove the bolts (x4) (torque 4.5 Nm) that attach the inline fuse cover lid to the inline fuse cover.
  6. Remove the nuts (x2) (torque 9 Nm) that attach the inline fuse to the front drive unit HV harness.

Installation

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

  1. Prior to installing the new inline fuse, wipe the mountingstuds of the inline fuse and the busbar leads with IPA wipes.
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    Note
    Ensure leads and studs are clear of debris, Allow 1 minute for the IPA to dry.
  2. Install the new inline fuse with new washers (x2) and nuts (x2) (torque 9 Nm).
  3. After installing the new inline fuse, put on HV insulating gloves and leather overgloves, and then use the Hioki impedance tester to measure the impedance at each busbar joint.
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    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. After installing the 2nd row seat cushion, reconnect 12V power. See See Disconnect 12V Power .