08/10/2024 17:34:06

HV/LV Ancillary Unit (HV Battery 2.0) (Remove and Replace)

Correction Code 16011052

  • 2024-08-12: Added Pack Contactor Replacement routine for vehicles with Tegra MCU.
  • 2024-07-29: Swapped illustrations in steps for Hioki measurement on positive and negative terminals.
  • 2024-06-25: Added alternative sealants to replace ThreeBond 1216E due to non-availability of ThreeBond in certain markets.
  • 2024-05-29: Added parts lists.
  • 2024-03-29: Made procedure Model X applicable.
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 at all times a high voltage cable, busbar, or fitting 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
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
Required Parts
  • 1032635-00-I – COVER,ANCILLARY,REAR,HVBAT,STAMPED – 1 pcs
  • 1014830-00-A – SCR,M5x10,TRX FLNGE,THRD FRMNG,STL,ZN-NI – 28 pcs
  • 1042040-00-A – SCR,M4-0.7x12,PH,TRX,SST,PATCH – 12 pcs
  • 1006381-00-A – BLT HEX FL M6-1.25x16 8.8 -M-ZnAl – 4 pcs
  • 1004405-00-A – SCR,M8-1.25X18,HEX,STL,ZN,PTCH,W/WSHRS – 2 pcs
  • 1036815-00-B – SEAL,HDR,HV RAPID,MDLS – 1 pcs
  • 1036893-00-B – SEAL,HDR,LV RPDMTE,MDLS – 1 pcs
  • 1004409-00-A – SCR,M5-0.8X12,H,BRSS,PTCH,W/WSHRS,STL,ZN – 1 pcs
Vehicle Production Date Before April 25, 2019:
  • 1099841-90-A – ASY,HV/LV ANCILLARY UNIT,HVBAT – 1 pcs
Vehicle Production Date Between April 25, 2019 and January 2021:
  • 1099841-00-C – ASY,HV/LV ANCILLARY UNIT,HVBAT RAVEN CONTACTOR – 1 pcs
If Necessary
  • If cfg_energy is ENERGY100: 1111445-00-F – DISCONNECT,PYROTECHNIC,CUR POWERED,2366A – 1 pcs
  • If cfg_energy is NOT ENERGY100:1111313-00-F – DISCONNECT,PYROTECHNIC,CUR POWERED,2000A – 1 pcs
  • 1009210-00-A – SCR,M6-1x16,HEX,w/WSHR,SEM,ST,BK,ZNC,PAT – As required
  • 1005146-00-A – SCR,M5-0.8x12,PH,TRX,STL 8.8,ZNC,W/PATCH – As required
  • 1064644-00-A – SCREW,PN,M6x10,TAPTITE,SS – As required
Sealant required for this procedure:
  • Threebond 1216E (1089956-00-A), Permatex Right Stuff (1031099-00-A), or Dowsil 7091 (1962594-00-A)

Remove

  1. Remove the HV battery. See HV Battery (RWD/AWD) (Remove and Install).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Inspect the HV battery for damage. If any dents, fluid leaks, or other signs of instability present, escalate a Toolbox session.
  2. Ensure the entire work area is clear and then place an HV Danger placard on the top of the battery.
  3. Place barricades around the work area.
  4. Remove the pyrotechnic fuse. See Fuse - Pyrotechnic - HV Battery 2.0 (Remove and Install).
  5. Use an electrostatic discharge-safe (ESD-safe) vacuum to clean the area around the ancillary tray, the LV Rapid Mate, and the HV Rapid Mate to make sure that there is no dust or debris that can enter the battery.
  6. Clean the area around the ancillary tray with alcohol wipes, and allow 1 minute to dry.
  7. Put a piece of tape along the rear of the HV battery to prevent accidental removal of any fasteners that attach the pack cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not place tape on the ancillary cover.
  8. Remove and discard the M4 screws (x6) that attach the top ring to the HV Rapid Mate connector. Put these screws into the designated container so that they can be accounted for before reinstalling components.
    Tip: Use of the following tool(s) is recommended:
    • Insulated Torx T25 socket
  9. Lift the top ring with the screws still attached to remove it from the HV Rapid Mate.
  10. Remove and discard the M4 screws (x6) that attach the ancillary cover to the LV Rapid Mate connector. Put these screws into the designated container so that they can be accounted for before reinstalling components.
    Tip: Use of the following tool(s) is recommended:
    • Insulated Torx T25 socket
  11. Remove and discard the M5 screws (x28) that attach the ancillary cover to the HV battery. Put these screws into the designated container so that they can be accounted for before reinstalling components.
    Informational PurposesAn informational icon, calling your attention
    Note
    Some fasteners might be M6 screws instead of M5. Note the locations of any M6 fasteners and make sure that new M6 fasteners are used when reinstalling the cover.
    Tip: Use of the following tool(s) is recommended:
    • Insulated External Torx Plus EP7
  12. Install the HV chisel stop onto the non-marring scraper approximately 20 mm from the end of the scraper.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    To avoid damaging internal components, do not insert the scraper unless the HV chisel stop is installed in the proper location.
  13. Use the non-marring scraper with a dead blow hammer to separate the sealant in the areas and order shown.
    Informational PurposesAn informational icon, calling your attention
    Note
    Work around the ancillary cover in a counter-clockwise manner.
  14. Lift the ancillary cover straight up off of the LH and RH pins, and then discard the ancillary cover.
  15. Put on the HV-safe static control wrist strap, and then clip the strap’s ground connection to the ground busbar.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Put the static control wrist strap on as soon as the cover is opened. Otherwise, damage to sensitive electrical components might result.
  16. Disconnect HV sense harness, shunt harness, and pack contactor harness from the ancillary tray circuit board.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the harnesses to the LH side of the ancillary tray, away from the circuit board.
  17. Pull straight up on the orange insulating cap to remove it. Put the cap into the designated container so that it can be accounted for before reinstalling components.
  18. Use the insulation multimeter to measure the voltage between the fasteners that attach the spine to the ancillary unit:
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do NOT skip this step. Failure to perform this step may cause severe arcing, which may lead to injury and/or damage to components.
    • If the voltage is 50V or greater, make sure that the HV battery fuse has been removed. If the fuse has been removed, escalate the Toolbox session.
    • If the voltage is less than 50V, continue to the next step.
  19. Remove the M8 bolt that attaches the ancillary unit positive terminal to the positive spine terminal. Put this bolt into the designated container so that it can be accounted for before reinstalling components.
    Tip: Use of the following tool(s) is recommended:
    • Insulated 13 mm socket
    • Insulated 6 in extension
  20. Remove the M8 bolt that attaches the ring terminal and ancillary unit negative terminal to the negative spine terminal. Put this bolt into the designated container so that it can be accounted for before reinstalling components.
    Tip: Use of the following tool(s) is recommended:
    • Insulated 13 mm socket
    • Insulated 6 in extension
  21. Remove the bolt that attaches the busbar to the mounting boss. Put this bolt into the designated container so that it can be accounted for before reinstalling components.
    Informational PurposesAn informational icon, calling your attention
    Note
    This bolt might be an 8 mm M5 or 10 mm M6.
    Tip: Use of the following tool(s) is recommended:
    • Insulated 8 mm socket
    • Insulated 6 in extension
  22. Unclip the HV-safe static control wrist strap ground connection from the busbar. Move the busbar out of the way and clip the ground connection to the bolt hole in the mounting boss.
  23. Disconnect the LV Rapid Mate harness from the ancillary tray circuit board RH side connector.
  24. Remove the M6 bolts (x4) that attach the HV ancillary unit to the ancillary tray. Put these bolts into the designated container so that they can be accounted for before reinstalling components.
    Tip: Use of the following tool(s) is recommended:
    • Insulated 10 mm 12-point socket
    • Insulated 6 in extension
  25. Release the retaining clips (x2) that attach the LV Rapid Mate connector to the HV battery, and then slide the LV Rapid Mate connector up and off of the dowel pin.
  26. Put the LV Rapid Mate connector on top of the ancillary unit.
  27. Place one hand in the cutout at the bottom of the HV ancillary unit and the other hand on top of the HV Rapid Mate connector. Lift the HV ancillary unit straight up to remove it from the ancillary tray.
  28. Inspect the container that was designated to hold the removed fasteners. Make sure that all of the fasteners listed below are present.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Check the fasteners that were removed from the HV battery and compare to any remaining new fasteners. Make sure that all fasteners have been accounted for. If any of the removed fasteners are missing, they might have dropped inside the ancillary tray area. If they cannot be located, escalate the Toolbox session.
  29. Retain the orange insulating cap.

Install

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Make sure that the green fuse flag has been installed and both HV insulating gloves and leather glove protectors are on before performing this procedure.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Install only the ancillary unit that is correct for the vehicle. The vehicle production date must match for the proper ancillary unit.
  • A vehicle production date before April 25, 2019 requires ancillary unit part number 1099841-00-A.
  • A vehicle production date between April 25, 2019 and January 2021 requires ancillary unit part number 1099841-00-B or 1099841-00-C.

The different ancillary units are visually identified by the mounting and design of the contactors as seen on the underside of the ancillary unit.

Figure 1. 1099841-00-A; recessed, waffle surface
Figure 2. 1099841-00-B, -C; flush, smooth surface
  1. Record the part number and serial number of the new ancillary unit in the correction part record of the Repair Order.
  2. Make sure that the HV-safe static control wrist strap ground connection is attached to the mounting boss.
  3. Use the non-marring scraper to clean off any large chunks or beads of old sealant from the sealing surface of the ancillary tray, and use a small pick to remove any old sealant from the ancillary tray screw holes, if necessary.
    Informational PurposesAn informational icon, calling your attention
    Note
    The sealing surface should be smooth and consistent, however the sealant does not need to be completely removed.
  4. Use the ESD-safe vacuum to clean the areas that were covered by sealant, and inside the ancillary tray.
  5. Use an alcohol wipe to clean the positive spine terminal, then clean the negative spine terminal.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not attempt to clean both spine terminals at the same time.
  6. Use an alcohol wipe to clean the bottom of the HV terminals and the ground busbar on the new ancillary unit.
  7. Align the dowel pins with the guide holes in the ancillary unit, then install the ancillary unit into the ancillary tray. Do not install new bolts at this time.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not unclip the ground connection. If necessary, gently bend the busbar to allow installation of the ancillary unit.
  8. Install the LV Rapid Mate connector onto the dowel pin in the ancillary tray, and then press down to fasten the retaining clips (x2).
  9. Route the large LV Rapid Mate harness along the rear RH side of the ancillary tray, and then connect the harness to the ancillary tray circuit board RH side connector. Perform a “push-pull-push” check at the connector to make sure that it is properly secured.
  10. Route the small LV Rapid Mate harness in the groove in the ancillary tray and the groove in the Rapid Mate bracket.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the all slack in the harness is on the LH side of the tray. Use a trim tool to tuck the wire into the grooves.
  11. Install new M6 bolts (x4) to attach the HV ancillary unit to the ancillary tray. Use an orange paint pen to mark the surface of the ancillary unit near each bolt after it is torqued.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Insulated 10 mm 12-point socket
    • Insulated 6 in extension
    • Insulated Ratchet/torque wrench
  12. Disconnect the HV-safe static control wrist strap ground connection from the mounting boss, and then connect it to the busbar.
  13. Apply a small drop of Penetrox A-13 electrical joint compound to either side of the hole in the mounting boss.
  14. Install a new bolt to attach the busbar to the mounting boss. Use a pink paint pen to mark the head of the bolt after it is torqued.
    • M6 bolt (HV batteries with serial numbers T15G0096937 and earlier): Torque 4.5 Nm
    • M5 bolt (HV batteries with serial numbers after T15G0096937): Torque 2.8 Nm
    Tip: Use of the following tool(s) is recommended:
    • Insulated 8 mm socket
    • Insulated 6 in extension
    • Insulated Ratchet/torque wrench
  15. Install a new M8 bolt to attach the ring terminal and ancillary unit positive terminal to the positive spine terminal. Use a pink paint pen to mark the head of the bolt after it is torqued.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Insulated 13 mm socket
    • Insulated 6 in extension
    • Insulated Ratchet/torque wrench
  16. Install a new M8 bolt to attach the ancillary unit negative terminal to the negative spine terminal. Use a pink paint pen to mark the head of the bolt after it is torqued.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Insulated 13 mm socket
    • Insulated 6 in extension
    • Insulated Ratchet/torque wrench
  17. Use the Hioki resistance meter to measure the resistance between the ancillary unit positive terminal and the positive spine terminal at the points shown.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The acceptable resistance is between 0.080 mΩ (80 μΩ) and 0.150 mΩ (150 μΩ). If the resistance is lower than 0.080 mΩ (80 μΩ), reposition the probes and measure again. If the resistance is greater than 0.150 mΩ (150 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
  18. Use the Hioki resistance meter to measure the resistance between the ancillary unit negative terminal and the negative spine terminal at the points shown.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The acceptable resistance is between 0.080 mΩ (80 μΩ) and 0.150 mΩ (150 μΩ). If the resistance is lower than 0.080 mΩ (80 μΩ), reposition the probes and measure again. If the resistance is greater than 0.150 mΩ (150 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
  19. Use the Hioki resistance meter to measure the resistance between the busbar and the mounting boss.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The acceptable resistance is between 0.080 mΩ (80 μΩ) and 0.150 mΩ (150 μΩ). If the resistance is lower than 0.080 mΩ (80 μΩ), reposition the probes and measure again. If the resistance is greater than 0.150 mΩ (150 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
  20. Install the orange insulating cap over the spine terminal busbars. Use a pink paint pen to mark the top of each cap after it is installed.
  21. Route the pack contactor harness through the inboard groove of the LV Rapid Mate bracket, and then connect the pack contactor harness to the ancillary tray circuit board connector. Perform a “push-pull-push” check at the connector to make sure that it is properly secured.
  22. Connect the shunt and HV sense harnesses to the ancillary tray circuit board connectors. Perform a “push-pull-push” check at the connectors to make sure that they are properly secured.
  23. Use IPA wipes to clean all sealing surfaces on the ancillary tray and the new ancillary cover, and allow 1 minute to dry.
  24. Load the sealant in the caulking gun, and then cut the nozzle approximately 15 mm from the tip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check the expiration date on the tube of the sealant. Do not use expired sealant.
  25. Apply a bead of sealant to the ancillary tray sealing surface on the HV battery.
  26. Position the LH hole of the new ancillary cover over the LH pin on the HV battery, then position the RH hole over the RH pin. Press down firmly on the cover.
  27. Install new M5 screws (x28) to attach the ancillary cover to the ancillary tray. Use an orange pen to mark the head of each screw after it is torqued.
    4.5 Nm (3.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    If any of the threads are stripped, use an M6 bottoming tap to expand the hole. Install a stainless M6 screw and make sure that it is fully seated. Torque the screw to 6 Nm and mark the head of the screw with an orange paint pen.
    Tip: Use of the following tool(s) is recommended:
    • Insulated External Torx Plus EP7
    • Insulated Ratchet/torque wrench
  28. Install new M4 screws (x6) to attach the LV Rapid Mate connector to the ancillary cover. Torque the screws in the order shown. Use an orange paint pen to mark the head of each screw after it is torqued.
    2.8 Nm (2.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Insulated Torx T25 socket
    • Insulated Ratchet/torque wrench
  29. Install the top ring around the HV Rapid Mate connector, and then install new M4 screws (x6) to attach the HV Rapid Mate connector to the ancillary cover. Use an orange paint pen to mark the head of each screw after it is torqued.
    2.8 Nm (2.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Insulated Torx T25 socket
    • Insulated Ratchet/torque wrench
  30. Install a new HV warning label to the ancillary cover.
  31. Remove the tape from the rear fasteners that attach the pack cover.
  32. Record part and serial number of HV battery pyro fuse.
  33. Connect the ESD ground strap to the HV battery fuse case.
  34. Install the pyrotechnic fuse. See Fuse - Pyrotechnic - HV Battery 2.0 (Remove and Install).
    Informational PurposesAn informational icon, calling your attention
    Note
    Terminate the pyro fuse installation procedure and back to this one after removing the leather glove protectors and the HV insulating gloves.
  35. Remove the HV Danger placard from top of the battery.
  36. Remove the barriers from around the battery.
  37. Install the HV battery. See HV Battery (RWD/AWD) (Remove and Install).
    Informational PurposesAn informational icon, calling your attention
    Note
    Pause before connecting the LV power.
  38. Connect the First Responder Loop, and then connect 12V negative terminal only.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • Ratchet/torque wrench
  39. Connect a 12V charger while the vehicle 12V system remain supported.
  40. Locally connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  41. Unlock the vehicle gateway. See Gateway Unlock.
  42. Perform Pack Contactor Replacement routine.
    • For vehicles with Tegra MCU only: On the laptop, select Actions tab and search for PROC_BMS_X_CONTACTOR-REPLACEMENT, click on PROC_BMS_X_CONTACTOR-REPLACEMENTvia Toolbox: (link)via Service Mode Plus: High Voltage Battery ➜ Pack Contactor Replacement ➜ Pack Contactor Replacement Routine, click Run, and allow the routine to complete.
    • For the other vehicles: On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap High Voltage > Procedures > Pack Contactor Replacement > Pack Contactor Replacement Routine, select Run, and allow the routine to complete.
  43. If the pyro fuse was replaced, write the pyro fuse data into the BMS through Toolbox 3. Select Actions tab and search for Write or Read BMS Pyro Fuse Type, click on PROC_BMS_X_PYROFUSE-READWRITE-TYPE-YEAR-MONTHvia Toolbox: (link)via Service Mode: High Voltage ➜ HV Battery ➜ Read/Write Fuse Type, select the correct Pyro Fuse Type based on what was determined earlier, select Write from the Write or Read Pyro Fuse Data section, then click Run, and allow the routine to complete.
  44. Search for Coolant Air Purge in the Actions tab, click on PROC_THC_X_COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Coolant Air Purge, click Run, and allow the routine to complete.
  45. Remove the coolant bottle cap, inspect the coolant level and top off to the Max line, and then install the coolant bottle cap.
  46. Disconnect the laptop.
  47. Disconnect the 12V charger from vehicle.
  48. Finish the remaining steps of installing the HV battery. See HV Battery (RWD/AWD) (Remove and Install).
  49. Charge the vehicle for at least 10 minutes.
  50. Perform vehicle test drive to verify no BMS alerts are present.