30/01/2023 11:53:22
HV Junction Box (Retrofit)
Correction code 44301406
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.
Note
Perform this retrofit to install a dual motor 2nd generation HV junction box into a rear
wheel drive vehicle.
- Open all four doors
- Lower all 4 windows
- Move both front seats fully forward
-
Latch all four doors
NoteDo not slam doors while latches are engaged
-
Open hood
NoteUsing MCU touchscreen > Controls > Frunk Trunk
-
Remove rear underhood apron
-
Remove LH underhood apron
-
Remove RH underhood apron
-
Remove front underhood apron
Note2x push clips, 7x trim clips, Remove push clips, then pry up evenly using trim tool
-
Remove latch cover assembly
Note2x clips, 2x connectors
-
Remove frunk carpet
Note4x anchors, 4x carpeted trim, Anchors are twisted off from studs
-
Remove frunk extension
Note4x double bolts, 10mm, 4 Nm, 5x bolts, 10mm, 4 Nm
-
Remove frunk
Note4x bolts, 13mm, 8 Nm, 2x bolts, 10mm, 6 Nm, Lift frunk slightly to remove the hood latch cable then remove frunk
-
Remove the cabin filter and cover then lift up the RH side of cowl screen panel to access cabin filter housing
Note2x push clips, Place shop rag under trim to support if needed
-
Remove bolts securing front HVAC filter housing
Note2x bolts, 10mm, 1.5 Nm
-
Remove front HVAC filter housing
Note2x tabs
-
Raise and support vehicle
NoteSet air suspension to "Jack Mode" if equipped Via Controls > ''Service''
-
Power down vehicle using MCU
NoteControls > Safety&Security > Power Off > ''POWER OFF''
-
Disconnect the 12V battery negative terminal
Note1x nut, 10mm, 5 Nm
-
Disconnect the first responder loop
NoteWait at least 2 minutes for all electrical circuits to fully discharge, Release red locking tab then disconnect.
-
Remove 2nd row seat bottom cushion
Note2x clips, 7x connectors, Number of connectors may vary based on configuration, Release the leading edge of the seat on either side
-
Remove NVH padding from underneath 2nd row seat cushion
NoteIf equipped
-
Remove bolts securing seat bottom frame
Note8x bolts, 11mm, 26 Nm
-
Lift up and support seat bottom frame
NoteRelease harness clips if necessary
- Remove all items from pockets and ensure not wearing metal items
-
Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
-
Put on HV insulating gloves and leather over gloves
-
Remove the HVIL bolt from the HV junction box
Note1x bolt, 8mm, 4 Nm (NA, JP, Discard after removal), 5 Nm (EU, APAC, fastener is reusable)
-
Remove bolts securing HVJB cover to HVJB box
Note4x nuts, 10mm, 8 Nm, 1x bolt, 10mm, 8 Nm, Fastener count may vary based on configuration
-
Verify no high voltage
NoteMake 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
-
Remove the ground nut from the ground stud located on the vehicle chassis
Note1x nut, 13mm, 8 Nm
-
Remove the charge port HV cables
Note2x nuts, 13mm, 9 Nm, Nuts are captured, Fasteners labeled 7/8
-
Remove the FJB HV cables
Note2x bolts, 8mm, 4 Nm, Bolts are captured
-
Remove the drive inverter and HV battery cables
Note2x nuts, 13mm, 9 Nm, Nuts are captured
-
Disconnect and remove all 4 HV harnesses from both chargers to HVJB
Note8x connectors
-
Release coolant hose
Note2x barrel clips, Move hose from covering HV junction box bolts
-
Remove the bolts that secure the HV junction box
Note4x bolts, 10mm, 5 Nm, Fastener count may vary based on configuration from 2,3 and 4 bolts
-
Disconnect the HVJB connector
Note1x electrical connector, Lift HV junction box assembly slightly for access
-
Remove HV junction box from vehicle
-
Inspect the HVJB to FJB HV harness
NoteIf 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.
-
Install Dual Motor HV junction box into vehicle
-
Connect HV junction box fan harness
Note1x electrical connector, Lift HV junction box assembly slightly for access
-
Install the bolts that secure the HV junction box
Note4x bolts, 10mm, 5 Nm, Fastener count may vary based on configuration from 2,3 and 4 bolts
-
Secure coolant hose
Note2x barrel clips
-
Install the HV cables from the junction box to both chargers
Note8x connectors
-
Install the charge port HV cables
Note2x bolts, 13 mm, 9 Nm, Fasteners labeled 7/8, Clean with IPA, Allow 1 min to dry
-
Install drive inverter and HV battery cables
Note2x bolts, 13mm, 9 Nm, Clean HV cables and HVJB connecting points with IPA wipes , Allow 1 min to dry
-
Install the negative FJB HV cable
Note1x bolts, 8mm, 4 Nm, Clean HV cable and HVJB connecting points with IPA wipes, Allow 1 min for IPA to dry
-
Install the positive FJB HV cable
Note1x bolts, 8mm, 4 Nm, Clean HV cable and HVJB connecting points with IPA wipes, Allow 1 min for IPA to dry
-
Install the HV junction box cover
Note4x nuts, 10mm, 8 Nm, 1x bolt, 10mm, 8 Nm, Fastener count may vary based on configuration
-
Install the HVIL bolt into the HV junction box cover
Note1x bolt, 8mm, 4 Nm (NA, JP, Install new fastener), 5 Nm (EU, APAC, fastener is reusable)
-
Cut two pieces of butyl patch
Note2x butyl patch, Cut butyl patches into 35x35mm square pieces
-
Install butyl patch squares onto openings for the front drive unit cables on the HV junction box to prevent dirt/water ingress
Note2x openings, Note always install butyl patches and install new patches if lid is removed, Butyl patches must remain installed to prevent contamination ingress
-
Install the ground nut from the ground stud located on the vehicle chassis
Note1x nut, 13mm, 8 Nm
- Remove the leather glove protectors and HV insulating gloves
-
Lower seat frame into position and secure harness clips to frame
Note8x clips
-
Install and torque bolts securing seat frame to vehicle
Note8x bolts, 11mm, 26 Nm
-
Place NVH padding onto seat frame
-
Reinstall seat bottom cushion
Note2x clips, 7x connectors if equipped, Replace clips if necessary
-
Connect first responder loop
Note1x connector, Engage red locking tab
-
Connect 12V battery negative terminal
Note1x nut, 10mm, 5 Nm
-
Install front HVAC filter housing
Note2x tabs
-
Install bolts securing front HVAC filter housing
Note2x bolts, 10mm, 1.5 Nm
-
Install cabin filter and cover then secure cowl screen panel
Note2x push clips
-
Install frunk
Note4x bolts, 13 mm, 8 Nm, 2x bolts, 10 mm, 6 Nm, before seating frunk attach hood latch cable.
-
Install frunk extension
Note4x double bolts, 10 mm, 4 Nm, 5x bolts, 10 mm, 4 Nm
-
Install frunk carpet
Note4x anchors, 4x carpeted trim, Install side covers first, Hand tighten anchors to studs, Tuck carpet under frunk seal
-
Install latch cover assembly
Note2x clips, 2x connectors
-
Install front underhood apron
Note2x push clips, 7x trim clips
-
Install RH underhood apron
-
Install LH underhood apron
-
Install rear underhood apron
Note8x clips
-
Close hood
NotePress firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
-
Remove vehicle from lift
NoteLower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode" via Controls > Service > '' JACK MODE''
-
Unlatch all doors
NoteUse a screwdriver to release latch while pulling door handle
- Move both front seats to their original positions
- Raise all 4 windows
- Close all four doors