2024-06-03

DCDC Converter (Remove and Replace)

Code de correction 44200102 Code de correction 44200302 Code de correction 44200402 Code de correction 44202002 Code de correction 44202202

Choose the appropriate procedure based on the vehicle's configuration and date of manufacture:

1st Generation

Code de correction 44200102

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Seuls les techniciens qui ont été sensibilisés aux dangers de la haute tension et qui ont complété toutes les formations de certification requises (le cas échéant) sont autorisés à effectuer cette procédure. Portez toujours un équipement de protection personnelle et des gants isolants haute tension ayant un classement minimal de 0 (1000 volts) avant de manipuler un câble à haute tension. Se référer à la note technique TN-15-92-003, « Mises en garde relatives à la haute tension » pour obtenir des renseignements supplémentaires sur la sécurité.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
To avoid personal injury or equipment damage from electrostatic discharge, an ESD wrist strap must be worn while carrying out this procedure.

Dépose

  1. Effectuez la procédure de désactivation HT du véhicule (voir la procédure).
  2. Remove the front RH upper wheel arch liner. See Doublure d’aile - avant - gauche (retirez et remplacez).
  3. Clamp the DCDC converter feed and return coolant hoses.
  4. Position a container to collect the coolant.
  5. Release the clips (x2) that attach the feed and return coolant hoses to the DCDC converter. Release the hoses from the converter.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Bouchez les raccords de tuyaux pour éviter que l’humidité ou la saleté y pénètre.
    Informational PurposesAn informational icon, calling your attention
    Note
    Notez la position des composants avant de les enlever.
  6. Remove the nut and washers that attach the 12V ground terminal to the DCDC converter (torque 16 Nm). Release the harness and move it aside.
  7. Release the DCDC converter 12V positive terminal insulation cover.
  8. Remove the nut and washers securing the 12V positive terminal to the DCDC converter (torque 9 Nm). Release the harness and move it aside.
  9. Release the clip that attaches the harness to the DCDC converter.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 00 (500V) must be worn while performing the remainder of this procedure.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure that the multimeter and leads are capable of handling at least 500V.
  10. Remove the bolt that attaches the HV connector cover (torque 18 Nm).
  11. Use a multimeter to check voltages across the HV cables and to ground:
    • B+ to ground
    • B- to ground
    • B+ to B-
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      Si une lecture de tension affiche plus de 10 volts, c’est que les contacteurs haute tension ne sont pas complètement ouverts. En raison du risque d’électrocution, communiquez avec le service d’ingénierie avant de procéder avec les travaux.
  12. Disconnect the HV harness from the DCDC converter (torque 5 Nm).
  13. Disconnect the HV harness connectors (x3) that attach the battery coolant, electric heater, cabin heater and compressor to the DCDC converter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Notez la position des composants avant de les enlever.
  14. Disconnect the signal harness connector from the DCDC converter.
  15. Release the clips (x3) that attach the harness to the DCDC converter.
  16. Remove the bolt and nuts (x2) that attach the DCDC converter to the body (torque 9 Nm).
  17. Remove the DCDC converter from the vehicle.

Installation

La procédure d’installation est l’inverse de la procédure de retrait, à l’exception de ce qui suit :
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Utilisez les produits de nettoyage et les solvants dans un endroit bien aéré.
Informational PurposesAn informational icon, calling your attention
Note
Nettoyez les zones touchées avant l'installation.

2nd Generation RWD

Code de correction 44200302

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Seuls les techniciens qui ont été sensibilisés aux dangers de la haute tension et qui ont complété toutes les formations de certification requises (le cas échéant) sont autorisés à effectuer cette procédure. Portez toujours un équipement de protection personnelle et des gants isolants haute tension ayant un classement minimal de 0 (1000 volts) avant de manipuler un câble à haute tension. Se référer à la note technique TN-15-92-003, « Mises en garde relatives à la haute tension » pour obtenir des renseignements supplémentaires sur la sécurité.

This procedure only applies to vehicles with the 2nd generation High Voltage configuration. For vehicles with the 1st generation High Voltage configuration, refer to DCDC Converter (Remove and Replace).

Dépose

  1. Effectuez la procédure de désactivation HT du véhicule (voir la procédure).
  2. Remove the battery coolant heater. See Coolant Heater - Electric - Battery - 2nd Generation (Remove and Replace).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not allow coolant to spill onto the High Voltage Battery, forward junction Box, DCDC Converter, battery coolant heater, or any harnesses.
    Informational PurposesAn informational icon, calling your attention
    Note
    After removing the heater, it might be helpful to plug the upper coolant hose on the DCDC converter and remove the clamp. This provides additional clearance in the working area to remove the DCDC converter.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not allow coolant to spill onto the High Voltage Battery, forward junction Box, DCDC Converter, battery coolant heater, or any harnesses.
    1 Plugged coolant hose
  3. Cut the zip tie that holds the top coolant hose to the bulkhead. Move the coolant hose out of the way.
  4. Release the 2 bolts that attach the bracket on the top of the DCDC converter to the bulkhead (torque 22 Nm).
  5. Release the nut that attaches the bracket on the lower LH side of the DCDC converter (torque 22 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    This nut is very difficult to retrieve if dropped. It might be helpful to use a magnet to hold the nut while it is being removed.
  6. Release the 2 harnesses on the RH side of the DCDC converter.
  7. Release the ground bolt (torque 25 Nm).
  8. Release the 12V positive bolt (torque 13 Nm).
  9. Release the fastener that attaches the ground strap to the body (torque 9 Nm).
  10. Remove the cable tie that attaches the coolant hose to the lower crossmember.
  11. Place absorbent material in the base of the front trunk to catch any coolant that is spilled in the next steps.
  12. Place a container in the front trunk to catch coolant.
  13. Gently pull the DCDC into the front trunk area, but do not fully remove it.
  14. Clamp the coolant hose close to the DCDC converter.
  15. Release the locking clamp that attaches the coolant hose to the DCDC converter. Drain the coolant from the DCDC converter and from the hose into the container.

2nd Generation Dual Motor

Code de correction 44200402

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Seuls les techniciens qui ont été sensibilisés aux dangers de la haute tension et qui ont complété toutes les formations de certification requises (le cas échéant) sont autorisés à effectuer cette procédure. Portez toujours un équipement de protection personnelle et des gants isolants haute tension ayant un classement minimal de 0 (1000 volts) avant de manipuler un câble à haute tension. Se référer à la note technique TN-15-92-003, « Mises en garde relatives à la haute tension » pour obtenir des renseignements supplémentaires sur la sécurité.

Dépose

  1. Disconnect 12V power. See Disconnect 12V Power.
  2. Perform Vehicle HV Disablement Procedure. See Procédure de désactivation HT du véhicule
  3. Remove the fuse box. See Fusebox - Underhood - 2nd Generation (Remove and Replace).
  4. Remove the wiper motor. See Module d’essuie-glace (retirez et remplacez).
  5. Remove the LH and RH shock tower braces. See Module d’essuie-glace (retirez et remplacez).
  6. Release the bolts (x2) that attach each fuse box to the front crossmember (torque 5 Nm).
  7. If the vehicle is equipped with air suspension, release the bolts (x2) that attach the air reservoir (torque 2.5 Nm). Carefully set the reservoir in the RH side of the underhood area.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is not necessary to disconnect the air lines.
  8. Remove the electric battery coolant heater. See Réchauffeur de fluide frigorigène - Électrique - Batterie (moteur double) (retrait et remplacement).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not allow coolant to spill onto the High Voltage Battery, forward junction box, DCDC converter, battery coolant heater, or any other harnesses.
  9. Remove the top bolts (x2) that attach the DCDC brackets to the body (torque 22 Nm).
  10. Remove the HV battery. See Batterie HT (à propulsion/transmission intégrale) (retrait et installation).
  11. Remove the bolts (x4) that attach the FJB to FDU HV harness to the FJB (torque 7 Nm).
  12. Remove the bolt (torque 12 Nm) that attaches the 12V cable to the DCDC converter.
  13. Remove the bolt (torque 25 Nm) that attaches the ground cable to the DCDC converter.
  14. Disconnect the 12V logic connector from the DCDC converter.
  15. Disconnect the black HV connector from the DCDC converter.
  16. Release the battery coolant heater 12V harness clip from the DCDC converter bracket.
  17. Position a coolant drain container under the front of the vehicle.
  18. Clamp the lower coolant hose, and then release the lower coolant hose from the DCDC converter.
  19. Clamp the upper coolant hose, and then release the upper coolant hose from the DCDC converter.
  20. Remove the nut (torque 22 Nm) that attaches the bottom DCDC converter bracket to the body.
  21. Remove the DCDC converter from the vehicle

3rd Generation RWD

Code de correction 44202002

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Seuls les techniciens qui ont été sensibilisés aux dangers de la haute tension et qui ont complété toutes les formations de certification requises (le cas échéant) sont autorisés à effectuer cette procédure. Portez toujours un équipement de protection personnelle et des gants isolants haute tension ayant un classement minimal de 0 (1000 volts) avant de manipuler un câble à haute tension. Se référer à la note technique TN-15-92-003, « Mises en garde relatives à la haute tension » pour obtenir des renseignements supplémentaires sur la sécurité.

Dépose

  1. Effectuez la procédure de désactivation HT du véhicule (voir la procédure).
  2. Remove the underhood fuse box. See Fusebox - Underhood - 2nd Generation (Remove and Replace).
  3. Remove the cowl screen panel. See Panneau - Écran d’auvent (retrait et remplacement).
  4. Release the fastener that attaches the wiper motor to the LH shock tower brace (torque 9 Nm).
  5. Release the clip that attaches the harness to the LH shock tower brace.
  6. Release the fastener that attaches the LH side of the air suspension reservoir to the bracket (torque 2.5 Nm).
  7. Release the fasteners that attach the LH air suspension reservoir bracket to the LH shock tower brace (torque 6 Nm).
  8. Release the fastener that attaches the LH shock tower brace to the bulkhead (torque 20 Nm).
  9. Release the fasteners that attach the LH shock tower brace to the shock tower (torque 20 Nm).
  10. Remove the LH shock tower brace from the vehicle.
  11. Slide the LH air suspension reservoir bracket outboard to remove it from the reservoir.
  12. Release the fastener that attaches the RH side of the air suspension reservoir to the bracket (torque 2.5 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not disconnect the air line from the air suspension reservoir.
  13. Remove the air suspension reservoir from the RH bracket and set it aside.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the reservoir is attached out of the working area so that it does not fall and damage the air suspension line.
  14. Release the clip that attaches the fuse box cable to the battery coolant heater.
  15. Release the fastener that attaches the fuse box cable to the DCDC converter (torque 12 Nm). Remove the fuse box cable from the vehicle.
  16. Release the fastener that attaches the DCDC converter large ground strap to the body (torque 9 Nm).
  17. Disconnect the harnesses from the DCDC converter.
  18. Clamp the DCDC converter coolant hoses.
  19. Place absorbent material beneath the DCDC converter.
  20. Release both coolant hoses from the DCDC converter. Plug the hole as each hose is removed.
  21. Remove the nut that secures the lower DCDC converter bracket to the bulkhead (torque 22 Nm).
  22. Release the 12V harness clip from the battery coolant heater.
  23. Release the fasteners that attach the DCDC converter to the battery coolant heater (torque 7.7 Nm).
  24. Release the fasteners that attach the upper DCDC converter bracket to the body (torque 22 Nm).
  25. Pull the DCDC converter away from the bulkhead and release the nut that attaches the small ground strap to the body (torque 9 Nm).
  26. Remove the DCDC converter from the vehicle.
  27. Remove the fasteners that attach the upper DCDC converter bracket (torque 3 Nm).
  28. Remove the fasteners that attach the lower DCDC converter bracket (torque 3 Nm).
  29. Remove the nut that attaches the large ground strap to the DCDC converter (torque 24.5 Nm).
  30. Remove the nut that attaches small ground strap to the DCDC converter (torque 5.2 Nm).

3rd Generation Dual Motor

Code de correction 44202202

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Seuls les techniciens qui ont été sensibilisés aux dangers de la haute tension et qui ont complété toutes les formations de certification requises (le cas échéant) sont autorisés à effectuer cette procédure. Portez toujours un équipement de protection personnelle et des gants isolants haute tension ayant un classement minimal de 0 (1000 volts) avant de manipuler un câble à haute tension. Se référer à la note technique TN-15-92-003, « Mises en garde relatives à la haute tension » pour obtenir des renseignements supplémentaires sur la sécurité.

Dépose

  1. Remove the forward junction box. See Boîte de jonction avant (Retirer et remplacer).
  2. Release the fastener that attaches the DCDC converter small ground strap to the body (torque 9 Nm).
  3. Release the fastener that attaches the DCDC converter large ground strap to the body (torque 9 Nm).
  4. Release the fastener that attaches the HV cable bracket to the front drive unit (torque 15 Nm).
  5. Release the fastener that attaches the fuse box cable to the DCDC converter (torque 12 Nm).
  6. Disconnect the harnesses from the DCDC converter.
  7. Clamp the DCDC converter coolant hoses.
  8. Place absorbent material beneath the DCDC converter.
  9. Release both coolant hoses from the DCDC converter. Plug the hole as each hose is removed.
  10. Release the 12V harness clip from the battery coolant heater.
  11. Remove the nut that secures the lower DCDC bracket to the bulkhead (torque 22 Nm).
  12. Release the fasteners that attach the DCDC converter to the battery coolant heater (torque 7.7 Nm).
  13. Release the fasteners that attach the upper DCDC converter bracket to the body (torque 22 Nm).
  14. Pull the DCDC converter away from the bulkhead and release the nut that attaches the small ground strap to the body (torque 9 Nm).
  15. Remove the DCDC converter from the vehicle.
  16. Remove the fasteners that attach the upper DCDC converter bracket (torque 3 Nm).
  17. Remove the fasteners that attach the lower DCDC converter bracket (torque 3 Nm).
  18. Remove the nut that attaches the large ground strap to the DCDC converter (torque 24.5 Nm).
  19. Remove the nut that attaches small ground strap to the DCDC converter (torque 5.2 Nm).