29/11/2023 18:43:01

Seal - HV Rapid Mate (Vehicle Side) (Remove and Replace)

Correction Code 44400502

  • 2023-08-28: Updated image.
  • 2023-11-30: Added image for installation.

Removal

  1. Remove the HV Battery (refer to procedure).
  2. Release the ground strap from the HV Rapid Mate (torque 9 Nm).
  3. Remove the fasteners that secure the plastic cover to the body (torque 6 Nm).
  4. Remove and discard the ground pin from the Rapid Mate.
  5. Remove the fasteners that secure the Rapid Mate bracket to the body.
  6. Use a slotted screwdriver or similar tool to release the tab on the RH side of the Rapid Mate bracket; gently lift up the RH side of the bracket, then release the tab on the LH side of the bracket.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The Rapid Mate bracket houses spring-loaded clips. When releasing the bracket in the next steps, take care that the clips do not suddenly release and fly away from the vehicle.
  7. Gently lift up the Rapid Mate bracket to remove it.
  8. Remove the side clips from the sides of the Rapid Mate housing.
  9. Remove the cable ties that secure the HV cable covers.
  10. Use a pick or similar tool to release the tabs that secure the HV cable covers.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The Rapid Mate housing encloses the ground pin washer inside the blade retainer. When separating the housing and blade retainer in the next step, do not allow the washer to fall out of the blade retainer.
  11. While gently pulling down on the HV blades, pull up on the housing to separate the housing from the blade retainer.
    1 Housing
    2 Blade retainer
  12. Remove the ground pin washer from the blade retainer. Retain the washer.
  13. Release the clips that secure the blade retainer to the HV cables. Remove the blade retainer from the vehicle and discard it.
  14. Remove and discard the seal.

Installation

  1. Use alcohol wipes to clean the insdie of the housing. Allow the alcohol to fully dry before continuing.
  2. Loosely install the new seal onto the housing.
  3. Secure the new blade retainer to the HV cables.
  4. Gently pull down on the housing to cover most of the blade retainer, but do not fully secure it at this time.
  5. Install the grounding washer into the blade retainer. Insert the new ground pin into the Rapid Mate to secure the washer in place, but do not fully tighten the ground pin at this time.
  6. Pull the seal off of the housing and allow it to sit on the blade retainer.
  7. Push the seal and blade retainer up and pull the housing down to secure them together.
  8. Ensure that the seal is fully seated.
  9. Fully tighten the new ground pin (torque 3 Nm).
  10. Reinstall the side clips onto the housing.
  11. Reinstall the HV cable covers and install new cable ties.
  12. Reinstall the bolts that secure the Rapid Mate to the vehicle (torque 9 Nm).
  13. Reinstall the ground strap (torque 9 Nm).
  14. Reinstall the HV Battery.