03/03/2020 13:18:43
DCDC Converter (Remove and Replace)
Correction Code 44200102
Warning
Only technicians who have been
trained in High Voltage (HV) Awareness and have completed all required
certification courses (if applicable) are permitted to perform this procedure.
Proper Personal Protective Equipment (PPE) and insulating HV gloves with a
minimum rating of class 0 (1000V) must be worn any time a high voltage cable is
handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness
Care Points" for additional safety information.
Removal
- Remove the HV battery (refer to procedure).
-
Remove the screw that secures the coolant pump bracket to the vehicle
chassis (torque 5.5 Nm).
-
Clamp the top coolant hose between the DCDC converter and the coolant
pump.
NotePlace suitable absorbent material around the affected area to absorb any possible fluid spillage.
- Release the locking ring that secures the upper coolant hose to the DCDC converter. Release the hose from the nipple.
-
Move the coolant pump and hoses towards the front of the vehicle, out of
the working area.
NoteIf the HVAC drain hose is moved out of the working area, ensure that it is moved back to the proper position during installation.
-
Remove the bolt that secures the 12V positive cable to the RH side of the
DCDC converter (torque 12.5 Nm).
NoteComponents have been removed in this graphic to aid clarity.
- Disconnect the 12V logic connector from the RH side of the DCDC converter.
-
Remove the nut that secures both grounds to the stud on the bulkhead
(torque 9 Nm).
NoteThe DCDC converter is removed from the vehicle with both ground cables still attached.
- Disconnect the HV harness connector from the RH side of the DCDC converter.
-
Release the barrel clip that secures the HV cable to the stud on the
bulkhead.
-
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.
-
Pull the DCDC converter bracket away from the studs on the bulkhead.
Tip: If necessary, use a trim tool to pry the DCDC converter bracket away from the bulkhead.
-
Release the locking ring that secures the lower coolant hose on the DCDC
converter. Release the hose from the nipple.
- Remove the DCDC converter from the vehicle.
Installation
Installation procedure is the reverse of removal, except for the following:
- Ensure that the coolant hoses are not kinked.
- Perform a push-pull test on all connectors.
- Refill and bleed the cooling system (refer to procedure).