08/02/2023 15:41:02
Forward Junction Box (Remove and Replace)
Correction Code 44200702
Remove
- Position the vehicle on a lift, but do not raise the vehicle at this time.
- Disconnect 12V power (refer to procedure).
- Remove the cowl screen panel (refer to procedure).
-
Disconnect the brake fluid level sensor.
-
Release the fir tree clips that secure the 12V harness to the rear of the
fusebox bracket.
-
Remove the screws (x3) that secure the fusebox bracket to the body (torque
7 Nm).
-
Release the battery vent tube by gently pulling it away from the 12V
battery.
NoteThe following image shows the 12V battery ground connection still connected.
- Gently move the fusebox and bracket assembly to the RH side of the vehicle.
- Remove the wiper motor assembly:
-
Release the push clips (x2) that secure the fuse box harness.
-
Remove the bolts (x2) that secure the wiper mount bracket to the
crossmember (torque 20 Nm).
-
Remove the nuts (x2) that secure the wiper mount bracket to the studs on
the bulkhead (torque 20 Nm).
-
If equipped, move the air suspension reservoir out of the working
area:
- Remove the HV battery (refer to procedure).
- Slide battery coolant pump 2 off of the bracket.
- Disconnect the harness from battery coolant pump 2.
-
Remove the bolt that secures the battery coolant heater bracket to the
chassis (torque 7 Nm).
-
Remove the nut that secures the battery coolant heater bracket to the stud
on the bulkhead (torque 7 Nm).
-
Release the barrel clip that secures the HV cable to the DCDC mounting
stud.
- Release the clip that secures the 12V harness to the DCDC mounting stud.
-
Remove the nuts (x3) that secure the DCDC converter bracket to the
bullkhead (torque 6 Nm).
NoteComponents have been removed in this graphic to aid clarity.
-
Gently lower the DCDC and battery coolant heater approximately 1 in (25 mm)
to access the bottom nut that secures the forward junction box to the
bulkhead. Loosen the nut (torque 6 Nm), then reinstall the DCDC and battery
heater onto the retaining studs.
NoteIt is not necessary to remove the nut entirely because the bolt hole is slotted.
1 Lower forward junction box bolt blocked by DCDC converter - Lower the vehicle.
-
Disconnect the upper 4 HV cables from the RH side of the forward junction
box.
- Release the clips that secure the 12V harnesses to the forward junction box and ECU box.
-
Remove the nut that secures
the ground strap to the bulkhead, if equipped (torque 9 Nm).
-
Disconnect the 12V harness from the LH side of the forward junction
box.
-
Remove the screws (x4) that secure the HV cables to the RH side of the
forward junction box (torque 7 Nm). Remove the negative HV cable, then
remove the positive HV cable.
-
Remove the upper 2 nuts that secure the forward junction box to the studs
on the bulkhead (torque 6 Nm). Gently pull the forward junction box toward
the front of the vehicle to allow access to the screws that secure the LH HV
cables.
-
On the LH side of the forward junction box, remove the screw that secures
the top of each HV cable (torque 7 Nm). Do not remove the lower screws at
this time.
- Rotate the forward junction box so that the lower LH HV screws can be accessed once the vehicle is raised.
- Raise the vehicle.
-
On the LH side of the forward junction box, release the screws that secure
the bottom of each HV cable (torque 7 Nm). Do not release the cables at this
time.
- Lower the vehicle.
- Release the HV cables from the forward junction box.
- Remove the forward junction box from the vehicle.
Installation
Installation procedure is the reverse of removal, except for the following:
CAUTION
Replace all patchbolt(s).