04/03/2024 01:43:17
40A Fuse - Front Junction Box (Remove and Replace)
Correction Code 44201102
- 2024-1-24: Added fuse diagram.
Remove
- Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure .
- Remove the wiper motor assembly. See Wiper Module (LHD) (Remove and Replace) .
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Release the clips that attach the fuse box harness to the vehicle.
- Remove the bolts (x2) that attach the wiper mount bracket to the crossmember.
- Remove the nuts (x2) that attach the wiper mount bracket to the bulkhead, and then remove the bracket from the vehicle.
- Release the clips (x3) that attach the cowl screen support to the vehicle, and then remove the support.
- Release the clips that attach the LH front air suspension line to the vehicle.
- Remove the bolts (x4) that attach the air reservoir brackets to the vehicle.
- Carefully move the air reservoir aside.
- Release the clips (x4) that attach the 12V harness to the front junction box and air suspension enclosure.
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Remove the screws (x4) that attach the HV cables to the RH side of the forward junction box.
NoteRemove the negative HV cable first, and then remove the positive HV cable.
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Remove the bolts (x9) that attach the front junction box cover to the front junction box, and then remove the cover.
CAUTIONBe very careful not to drop any fasteners or tools, as the HV battery may need to be removed to retrieve the hardware.
- Inspect the front junction box gasket, and replace the cover if any damage is found.
- Put on HV insulating gloves and leather glove protectors.
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Verify there is no voltage by checking the fuse to the front junction box
ground.
NoteIf there is any voltage present, create a Toolbox session and escalate.
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Remove the blown fuse.
Installation
- Use a digital multimeter to check that the resistance between one end of the fuse and the other end is no greater than 0.3 ohm.
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Install the new fuse in the front junction box.
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Position the front junction box cover on the front junction box, and then install the bolts that attach the cover to the box (torque 4.2 Nm).
NoteA crow's foot socket might help access some fasteners.
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Install the screws (x4) that attach the HV cables to the RH side of the forward junction box (torque 7 Nm).
NoteInstall the positive HV cable first, and then install the negative HV cable.
- Install the clips (x4) that attach the 12V harness to the front junction box and air suspension enclosure.
- 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).
- Install the nuts (x2) that attach the wiper mount bracket to the bulkhead (torque 20 Nm).
- Install the bolts (x2) that attach the wiper mount bracket to the crossmember (torque 20 Nm).
- Install the clips that attach the LH front air suspension line to the vehicle.
- Position the cowl screen support on the vehicle, and then install the clips (x3) that attach the cowl screen support to the vehicle.
- Install the wiper motor assembly. See Wiper Module (LHD) (Remove and Replace)
- Restore vehicle electrical power. See Vehicle HV Disablement Procedure .