30/01/2023 11:53:22

HV Junction Box (Retrofit)

Correction code 44301406

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Warning
Only technicians who have been trained in High Voltage (HV) 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
Perform this retrofit to install a dual motor 2nd generation HV junction box into a rear wheel drive vehicle.
  1. Open all four doors
  2. Lower all 4 windows
  3. Move both front seats fully forward
  4. Latch all four doors
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    Note
    Do not slam doors while latches are engaged
  5. Open hood
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    Note
    Using MCU touchscreen > Controls > Frunk Trunk
  6. Remove rear underhood apron
  7. Remove LH underhood apron
  8. Remove RH underhood apron
  9. Remove front underhood apron
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    Note
    2x push clips, 7x trim clips, Remove push clips, then pry up evenly using trim tool
  10. Remove latch cover assembly
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    Note
    2x clips, 2x connectors
  11. Remove frunk carpet
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    Note
    4x anchors, 4x carpeted trim, Anchors are twisted off from studs
  12. Remove frunk extension
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    Note
    4x double bolts, 10mm, 4 Nm, 5x bolts, 10mm, 4 Nm
  13. Remove frunk
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    Note
    4x bolts, 13mm, 8 Nm, 2x bolts, 10mm, 6 Nm, Lift frunk slightly to remove the hood latch cable then remove frunk
  14. Remove the cabin filter and cover then lift up the RH side of cowl screen panel to access cabin filter housing
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    Note
    2x push clips, Place shop rag under trim to support if needed
  15. Remove bolts securing front HVAC filter housing
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    Note
    2x bolts, 10mm, 1.5 Nm
  16. Remove front HVAC filter housing
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    Note
    2x tabs
  17. Raise and support vehicle
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    Note
    Set air suspension to "Jack Mode" if equipped Via Controls > ''Service''
  18. Power down vehicle using MCU
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    Note
    Controls > Safety&Security > Power Off > ''POWER OFF''
  19. Disconnect the 12V battery negative terminal
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    Note
    1x nut, 10mm, 5 Nm
  20. Disconnect the first responder loop
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    Note
    Wait at least 2 minutes for all electrical circuits to fully discharge, Release red locking tab then disconnect.
  21. Remove 2nd row seat bottom cushion
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    Note
    2x clips, 7x connectors, Number of connectors may vary based on configuration, Release the leading edge of the seat on either side
  22. Remove NVH padding from underneath 2nd row seat cushion
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    Note
    If equipped
  23. Remove bolts securing seat bottom frame
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    Note
    8x bolts, 11mm, 26 Nm
  24. Lift up and support seat bottom frame
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    Note
    Release harness clips if necessary
  25. Remove all items from pockets and ensure not wearing metal items
  26. Inspect HV insulating gloves
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    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
  27. Put on HV insulating gloves and leather over gloves
  28. Remove the HVIL bolt from the HV junction box
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    Note
    1x bolt, 8mm, 4 Nm (NA, JP, Discard after removal), 5 Nm (EU, APAC, fastener is reusable)
  29. Remove bolts securing HVJB cover to HVJB box
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    Note
    4x nuts, 10mm, 8 Nm, 1x bolt, 10mm, 8 Nm, Fastener count may vary based on configuration
  30. Verify no high voltage
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    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
  31. Remove the ground nut from the ground stud located on the vehicle chassis
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    Note
    1x nut, 13mm, 8 Nm
  32. Remove the charge port HV cables
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    Note
    2x nuts, 13mm, 9 Nm, Nuts are captured, Fasteners labeled 7/8
  33. Remove the FJB HV cables
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    Note
    2x bolts, 8mm, 4 Nm, Bolts are captured
  34. Remove the drive inverter and HV battery cables
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    Note
    2x nuts, 13mm, 9 Nm, Nuts are captured
  35. Disconnect and remove all 4 HV harnesses from both chargers to HVJB
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    Note
    8x connectors
  36. Release coolant hose
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    Note
    2x barrel clips, Move hose from covering HV junction box bolts
  37. Remove the bolts that secure the HV junction box
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    Note
    4x bolts, 10mm, 5 Nm, Fastener count may vary based on configuration from 2,3 and 4 bolts
  38. Disconnect the HVJB connector
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    Note
    1x electrical connector, Lift HV junction box assembly slightly for access
  39. Remove HV junction box from vehicle
  40. Inspect the HVJB to FJB HV harness
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    Note
    If the positive and negative cables of the HVJB to FJB HV harness are of the same length, then replacement of the HVJB to FJB HV Harness will also be required. Discontinue this procedure and go to the identical step in HV Junction Box and HV Harness (Retrofit). If the positive and negative cables are of different lengths, then continue to the next step.
  41. Install Dual Motor HV junction box into vehicle
  42. Connect HV junction box fan harness
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    Note
    1x electrical connector, Lift HV junction box assembly slightly for access
  43. Install the bolts that secure the HV junction box
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    Note
    4x bolts, 10mm, 5 Nm, Fastener count may vary based on configuration from 2,3 and 4 bolts
  44. Secure coolant hose
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    Note
    2x barrel clips
  45. Install the HV cables from the junction box to both chargers
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    Note
    8x connectors
  46. Install the charge port HV cables
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    Note
    2x bolts, 13 mm, 9 Nm, Fasteners labeled 7/8, Clean with IPA, Allow 1 min to dry
  47. Install drive inverter and HV battery cables
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    Note
    2x bolts, 13mm, 9 Nm, Clean HV cables and HVJB connecting points with IPA wipes , Allow 1 min to dry
  48. Install the negative FJB HV cable
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    Note
    1x bolts, 8mm, 4 Nm, Clean HV cable and HVJB connecting points with IPA wipes, Allow 1 min for IPA to dry
  49. Install the positive FJB HV cable
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    Note
    1x bolts, 8mm, 4 Nm, Clean HV cable and HVJB connecting points with IPA wipes, Allow 1 min for IPA to dry
  50. Install the HV junction box cover
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    Note
    4x nuts, 10mm, 8 Nm, 1x bolt, 10mm, 8 Nm, Fastener count may vary based on configuration
  51. Install the HVIL bolt into the HV junction box cover
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    Note
    1x bolt, 8mm, 4 Nm (NA, JP, Install new fastener), 5 Nm (EU, APAC, fastener is reusable)
  52. Cut two pieces of butyl patch
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    Note
    2x butyl patch, Cut butyl patches into 35x35mm square pieces
  53. Install butyl patch squares onto openings for the front drive unit cables on the HV junction box to prevent dirt/water ingress
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    Note
    2x openings, Note always install butyl patches and install new patches if lid is removed, Butyl patches must remain installed to prevent contamination ingress
  54. Install the ground nut from the ground stud located on the vehicle chassis
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    Note
    1x nut, 13mm, 8 Nm
  55. Remove the leather glove protectors and HV insulating gloves
  56. Lower seat frame into position and secure harness clips to frame
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    Note
    8x clips
  57. Install and torque bolts securing seat frame to vehicle
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    Note
    8x bolts, 11mm, 26 Nm
  58. Place NVH padding onto seat frame
  59. Reinstall seat bottom cushion
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    Note
    2x clips, 7x connectors if equipped, Replace clips if necessary
  60. Connect first responder loop
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    Note
    1x connector, Engage red locking tab
  61. Connect 12V battery negative terminal
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    Note
    1x nut, 10mm, 5 Nm
  62. Install front HVAC filter housing
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    Note
    2x tabs
  63. Install bolts securing front HVAC filter housing
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    Note
    2x bolts, 10mm, 1.5 Nm
  64. Install cabin filter and cover then secure cowl screen panel
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    Note
    2x push clips
  65. Install frunk
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    Note
    4x bolts, 13 mm, 8 Nm, 2x bolts, 10 mm, 6 Nm, before seating frunk attach hood latch cable.
  66. Install frunk extension
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    Note
    4x double bolts, 10 mm, 4 Nm, 5x bolts, 10 mm, 4 Nm
  67. Install frunk carpet
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    Note
    4x anchors, 4x carpeted trim, Install side covers first, Hand tighten anchors to studs, Tuck carpet under frunk seal
  68. Install latch cover assembly
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    Note
    2x clips, 2x connectors
  69. Install front underhood apron
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    Note
    2x push clips, 7x trim clips
  70. Install RH underhood apron
  71. Install LH underhood apron
  72. Install rear underhood apron
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    Note
    8x clips
  73. Close hood
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    Note
    Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
  74. Remove vehicle from lift
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    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode" via Controls > Service > '' JACK MODE''
  75. Unlatch all doors
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    Note
    Use a screwdriver to release latch while pulling door handle
  76. Move both front seats to their original positions
  77. Raise all 4 windows
  78. Close all four doors