2021-03-10

HVIL Lid Switch - Forward Junction Box (Remove and Replace)

Correction Code 44202402

Remove

  1. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure .
  2. Remove the wiper motor assembly. See Wiper Module (LHD) (Remove and Replace) .
  3. Release the clips that attach the fuse box harness to the vehicle.
  4. Remove the bolts (x2) that attach the wiper mount bracket to the crossmember.
  5. Remove the nuts (x2) that attach the wiper mount bracket to the bulkhead, and then remove the bracket from the vehicle.
  6. Release the clips (x3) that attach the cowl screen support to the vehicle, and then remove the support.
  7. Release the clips that attach the LH front air suspension line to the vehicle.
  8. Remove the bolts (x4) that attach the air reservoir brackets to the vehicle.
  9. Carefully move the air reservoir aside.
  10. Release the clips (x4) that attach the 12V harness to the forward junction box and the air suspension enclosure.
  11. Remove the screws (x4) that attach the HV cables to the RH side of the forward junction box.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the negative HV cable first, and then remove the positive HV cable.
  12. Remove the bolts (x9) that attach the forward junction box cover to the forward junction box, and then remove the cover.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be very careful not to drop any fasteners or tools, as the HV battery may need to be removed to retrieve the hardware.
  13. Inspect the forward junction box gasket, and replace the cover if any damage is found.
  14. Put on HV insulating gloves and leather glove protectors.
  15. Release the HVIL lid switch connector.
  16. Release the HVIL lid switch bracket.
  17. Remove the HVIL lid switch from the forward junction box.

Installation

Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Replace all patchbolt(s).
  1. Install the new HVIL lid switch into the forward junction box.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the pin on the switch is correctly aligned with the forward junction box housing.
  2. Secure the HVIL lid switch with a new HVIL lid switch bracket.
  3. Install the HVIL lid switch connector.
  4. Position the forward junction box cover on the forward junction box, and then install the bolts (x9) that attach the cover to the box (torque 4.2 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    A crow's foot socket might help to access the lower fasteners.
  5. Install the screws (x4) that attach the HV cables to the RH side of the forward junction box (torque 7 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the positive HV cable first, and then install the negative HV cable.
  6. Install the clips (x4) that attach the 12V harness to the forward junction box and the air suspension enclosure.
  7. Position the air reservoir in its mounting location, and then install the bolts (x4) that attach the reservoir brackets to the vehicle (torque 6 Nm).
  8. Install the nuts (x2) that attach the wiper mount bracket to the bulkhead (torque 20 Nm).
  9. Install the bolts (x2) that attach the wiper mount bracket to the crossmember (torque 20 Nm).
  10. Install the clips that attach the LH front air suspension line to the vehicle.
  11. Position the cowl screen support on the vehicle, and then install the clips (x3) that attach the cowl screen support to the vehicle.
  12. Install the wiper motor assembly. See Wiper Module (LHD) (Remove and Replace)
  13. Restore vehicle electrical power. See Vehicle HV Disablement Procedure .