2023-02-08

Forward Junction Box (Remove and Replace)

Correction Code 44200702

Remove

  1. Position the vehicle on a lift, but do not raise the vehicle at this time.
  2. Disconnect 12V power (refer to procedure).
  3. Remove the cowl screen panel (refer to procedure).
  4. Disconnect the brake fluid level sensor.
  5. Release the fir tree clips that secure the 12V harness to the rear of the fusebox bracket.
  6. Remove the screws (x3) that secure the fusebox bracket to the body (torque 7 Nm).
  7. Release the battery vent tube by gently pulling it away from the 12V battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    The following image shows the 12V battery ground connection still connected.
  8. Gently move the fusebox and bracket assembly to the RH side of the vehicle.
  9. Remove the wiper motor assembly:
    • LHD vehicles: Refer to procedure 17502502
    • RHD vehicles: Refer to procedure 17502702
  10. Release the push clips (x2) that secure the fuse box harness.
  11. Remove the bolts (x2) that secure the wiper mount bracket to the crossmember (torque 20 Nm).
  12. Remove the nuts (x2) that secure the wiper mount bracket to the studs on the bulkhead (torque 20 Nm).
  13. If equipped, move the air suspension reservoir out of the working area:
    1. Release the clips that secure the LH front air suspension line.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Replace any broken clips.
    2. Release the clips (x3) that secure the cowl bracket.
    3. Release the clip that secures the air lines to the crossmember.
    4. Release the nuts (x4) that secure the air suspension reservoir (torque 6 Nm).
    5. Slide the air suspension reservoir to the LH side of the vehicle, then move it toward the fusebox to allow access to the front junction box.
  14. Remove the HV battery (refer to procedure).
  15. Slide battery coolant pump 2 off of the bracket.
  16. Disconnect the harness from battery coolant pump 2.
  17. Remove the bolt that secures the battery coolant heater bracket to the chassis (torque 7 Nm).
  18. Remove the nut that secures the battery coolant heater bracket to the stud on the bulkhead (torque 7 Nm).
  19. Release the barrel clip that secures the HV cable to the DCDC mounting stud.
  20. Release the clip that secures the 12V harness to the DCDC mounting stud.
  21. Remove the nuts (x3) that secure the DCDC converter bracket to the bullkhead (torque 6 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Components have been removed in this graphic to aid clarity.
  22. 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is not necessary to remove the nut entirely because the bolt hole is slotted.
    1 Lower forward junction box bolt blocked by DCDC converter
  23. Lower the vehicle.
  24. Disconnect the upper 4 HV cables from the RH side of the forward junction box.
  25. Release the clips that secure the 12V harnesses to the forward junction box and ECU box.
  26. Remove the nut that secures the ground strap to the bulkhead, if equipped (torque 9 Nm).
  27. Disconnect the 12V harness from the LH side of the forward junction box.
  28. 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.
  29. 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.
  30. 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.
  31. Rotate the forward junction box so that the lower LH HV screws can be accessed once the vehicle is raised.
  32. Raise the vehicle.
  33. 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.
  34. Lower the vehicle.
  35. Release the HV cables from the forward junction box.
  36. Remove the forward junction box from the vehicle.

Installation

Installation procedure is the reverse of removal, except for the following:

Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Replace all patchbolt(s).