HV Junction Box - Cover - 2nd Generation (Remove and Replace)

FRT No: 44301102

Warning: Only technicians who have been trained in High Voltage Awareness are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 00 (500V) 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

  1. Disconnect 12V and HV power:
  2. Remove the 2nd row seat frame:
  3. Remove the HVIL bolt from the HVJB cover. Do not remove the remaining fasteners at this time.
    • North America, Japan (torque 4 Nm)
      Note: In North American and Japanese vehicles, the HVIL bolt is one-time use only. Install a new bolt during reinstallation.
    • Europe, APAC (torque 5 Nm)
      Note: In European and APAC vehicles, the HVIL bolt can be reused during reinstallation.

Warning: Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 00 (500V) must be worn while performing the remainder of this procedure.
Warning: Ensure that the multimeter and leads are capable of handling at least 500V.

  1. Remove the remaining fasteners that secure the HVJB cover.
    • North America, Japan (torque 8 Nm)
      Note: In North American and Japanese vehicles, there are 5 additional fasteners.
    • Europe, APAC (torque 8 Nm)
      Note: In European and APAC vehicles, there are 6 additional fasteners.
  2. Use a multimeter to check voltages across the HV cables and to ground:
    Warning: If any voltage reading is more than 10V, the high voltage contactors are not fully opened. Due to the risk of electrocution, contact Service Engineering before performing any further work.
    Warning: Never use a fastener or an e-coated surface as a path to ground. In this procedure, ensure that the ground strap from the HVJB is secure to the body and use the lug as a path to ground.

    • The 4 HV cables to the HV battery and rear drive unit
    • The 2 HV cables to the forward junction box
    • The 2 HV cables to the charge port
    • Dual Motor vehicles only: The 2 HV cables to the front drive unit
    1 B+ Front Drive Unit (if equipped)
    2 B- Front Drive Unit (if equipped)
    3 B+ battery/drive inverter
    4 B- battery/drive inverter
    5 B+ DCDC converter
    6 B- DCDC converter
    7 B- charge port
    8 B+ charge port
    Note: Vehicles with 3-phase charging have 4 harnesses to the charge port:
    1 B+ N charge port
    2 B- L1 charge port
    3 B+ L3 charge port
    4 B- L2 charge port

North America and Japan only: Inspect the shield collar clamp

  1. Insert the HVIL bolt into the shield collar clamp by 2 threads.
    1 Install HVIL bolt 2 threads
  2. With the HVIL bolt loosely installed, move the bolt from side to side. Note whether there is any free play that might indicate stripped threads in the shield collar clamp.
    • If there is minimal free play, the shield collar clamp does not need to be replaced. Skip to the Installation section of this procedure.
    • If there is significant free play, the shield collar clamp needs to be replaced. Continue to the next step.
  3. Inside the HVJB, mark the 2 wires that lead to the charge port as B+ and B-.
    Caution: Do not reverse the polarity of the cables during reinstallation.
  4. Inside the HVJB, unbolt the 2 cables that lead to the charge port (torque 9 Nm).
    Note: It is not necessary to replace the fastener(s) after it is removed. The threaded area has a reusable dry sealant, which looks similar to adhesive patch material.
  5. Cut the cable ties that secure shield collar clamp
  6. Replace the shield collar clamp.
  7. Inside the HVJB, secure the HV cables that lead to the charge port.
  8. Replace the cable ties that secure the HV cables.

Installation

  1. Position the HVJB cover.
  2. Install the HVIL bolt loosely. Do not tighten it fully at this time.
    • North America, Japan
      Note: In North American and Japanese vehicles, the HVIL bolt is one-time use only. Install a new bolt during reinstallation.
    • Europe and APAC
      Note: In European and APAC vehicles, the HVIL bolt can be reused during reinstallation.
  3. Install the remaining fasteners that secure the HVJB cover in the order shown.
    • North America, Japan (torque 8 Nm)
      Note: In North American and Japanese vehicles, there are 5 additional fasteners.
    • Europe and APAC (torque 8 Nm)
      Note: In European and APAC vehicles, there are 6 additional fasteners.
  4. Fully torque the HVIL bolt:
    • North America and Japan: 4 Nm
    • Europe and APAC: 5 Nm