DCDC Converter (Remove and Replace)

FRT No: 44200102

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. Remove the HV battery (refer to procedure).
  2. Remove the screw that secures the coolant pump bracket to the vehicle chassis (torque 5.5 Nm).

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  3. Clamp the top coolant hose between the DCDC converter and the coolant pump.
    Note: Place suitable absorbent material around the affected area to absorb any possible fluid spillage.

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  4. Release the locking ring that secures the upper coolant hose to the DCDC converter. Release the hose from the nipple.
  5. Move the coolant pump and hoses towards the front of the vehicle, out of the working area.
    Note: If the HVAC drain hose is moved out of the working area, ensure that it is moved back to the proper position during installation.
  6. Remove the bolt that secures the 12V positive cable to the RH side of the DCDC converter (torque 12.5 Nm).
    Note: Components have been removed in this graphic to aid clarity.

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  7. Disconnect the 12V logic connector from the RH side of the DCDC converter.
  8. Remove the nut that secures both grounds to the stud on the bulkhead (torque 9 Nm).
    Note: The DCDC converter is removed from the vehicle with both ground cables still attached.

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  9. Disconnect the HV harness connector from the RH side of the DCDC converter.
  10. Release the barrel clip that secures the HV cable to the stud on the bulkhead.

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  11. Remove the nuts (x3) that secure the DCDC converter bracket to the bullkhead (torque 6 Nm).
    Note: Components have been removed in this graphic to aid clarity.

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  12. 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.
  13. Release the locking ring that secures the lower coolant hose on the DCDC converter. Release the hose from the nipple.

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  14. Remove the DCDC converter from the vehicle.

Installation

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

  1. Ensure that the coolant hoses are not kinked.
  2. Perform a push-pull test on all connectors.
  3. Refill and bleed the cooling system (refer to procedure).