20/06/2022 14:55:03

HV Harness - Rear Drive Unit to HVJB - Large Rear Drive Unit (Remove and Replace)

Correction Code 44501202

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. Position the vehicle in preparation for raising it, but keep the vehicle at ground level at this time.
  2. Lower all 4 windows.
  3. Move the front seat forwards.
  4. Remove the high voltage junction box (HVJB) cover (refer to procedure).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Perform all of the voltage checks listed in the procedure. 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.
  5. Vehicles with 1st generation HVJB: Disconnect the rear drive unit to HVJB HV harness from the HVJB:
    1. Remove the bolt that secures the drive inverter and HV battery positive cables to the HV junction box (torque 9 Nm).
    2. Release the quick connectors (x2) that secure the drive inverter and HV battery positive cables to the HV junction box body, then move the cables aside.
    3. Remove the bolt that secures the drive inverter and HV battery negative cables to the HV junction box (torque 9 Nm).
    4. Release the quick connectors (x2) that secure the drive inverter and HV battery negative cables to the HV junction box body, then move the cables aside.
  6. Vehicles with 2nd generation HVJB: Disconnect the rear drive unit to HVJB HV harness from the HVJB:
    1. Remove the nuts that secure the B+ and B- battery/drive inverter HV cables to the HVJB (torque 9 Nm).
      Informational PurposesAn informational icon, calling your attention
      Note
      It is not necessary to replace the fastener(s) after it is removed. The threaded area has a reusable dry sealant, which looks similar to adhesive patch material.
    2. Move the cables aside.
  7. Release the rear drive unit to HVJB HV harness grommet from the body.
  8. Remove the rear subframe. See Large RDU.
  9. Remove the rear drive unit to HVJB HV harness from the vehicle.

Installation

Installation procedure is the reverse of removal, except for the following:
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Replace all patchbolt(s).