Controller - High Voltage (Remove and Replace)

Correction code 1630160216301602
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 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Remove

  1. Perform the vehicle isolation procedure. See Vehicle Electrical Isolation Procedure.
  2. If the high voltage controller is being removed as part of another component's replacement procedure, and the same controller will be installed later, go to step 14. Otherwise, continue to the next step.
  3. Remove the RH inner 2nd row rail. See Rail - 2nd Row - Inner - LH (Remove and Replace).
  4. Remove and discard the bolts that attach the high voltage controller internally to the penthouse cover.
    28-Bolt Penthouse Cover
    Retrofit Patch, 18-Bolt, and 16-Bolt Penthouse Covers
  5. Connect the electrical harness to the high voltage controller connector.
    Note: Make sure not to pull up on the high voltage controller connector when connecting the electrical harness or anytime during in the following steps, as this might close the HVIL loop, close the contactors, and cause the high voltage controller backup to fail.
  6. Attach a 12V charger to the 12V auxiliary battery positive terminal and the 12V auxiliary battery negative cable.
  7. Attach the laptop with toolbox to the vehicle.
  8. Verify that the firmware version is 2019.12.1 or later, and update if necessary.
  9. In Toolbox, click Autodiag, and type "backup" into the search field.
  10. Click the arrow next to "HVC clone backup", and then click Run Network.
  11. Record the ID number that is displayed in the Autodiag.
  12. When the Autodiag finishes, disconnect the 12V charger from the 12V auxiliary battery positive terminal and the 12V auxiliary battery negative cable.
  13. Disconnect the electrical harness from the high voltage controller connector.
  14. Remove the penthouse cover. See Cover - Penthouse (Remove and Replace).
  15. Remove the pyrotechnic battery disconnect from the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
  16. Disconnect the penthouse harness from the high voltage controller connectors.
  17. Remove the bolts that attach the high voltage controller to the hinge tray, and then remove the controller from the vehicle.
    Torque 2 Nm
    5-Bolt High Voltage Controller
    4-Bolt High Voltage Controller
1Perform the vehicle isolation procedure. See Vehicle Electrical Isolation Procedure.
2If the high voltage controller is being removed as part of another component's replacement procedure, and the same controller will be installed later, go to step 14. Otherwise, continue to the next step.
3Remove the RH inner 2nd row rail. See Rail - 2nd Row - Inner - LH (Remove and Replace).
28-Bolt Penthouse Cover
Retrofit Patch, 18-Bolt, and 16-Bolt Penthouse Covers
4Remove and discard the bolts that attach the high voltage controller internally to the penthouse cover.
5Connect the electrical harness to the high voltage controller connector.
Note: Make sure not to pull up on the high voltage controller connector when connecting the electrical harness or anytime during in the following steps, as this might close the HVIL loop, close the contactors, and cause the high voltage controller backup to fail.
6Attach a 12V charger to the 12V auxiliary battery positive terminal and the 12V auxiliary battery negative cable.
7Attach the laptop with toolbox to the vehicle.
8Verify that the firmware version is 2019.12.1 or later, and update if necessary.
9In Toolbox, click Autodiag, and type "backup" into the search field.
10Click the arrow next to "HVC clone backup", and then click Run Network.
11Record the ID number that is displayed in the Autodiag.
12When the Autodiag finishes, disconnect the 12V charger from the 12V auxiliary battery positive terminal and the 12V auxiliary battery negative cable.
13Disconnect the electrical harness from the high voltage controller connector.
14Remove the penthouse cover. See Cover - Penthouse (Remove and Replace).
15Remove the pyrotechnic battery disconnect from the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
16Disconnect the penthouse harness from the high voltage controller connectors.
17Remove the bolts that attach the high voltage controller to the hinge tray, and then remove the controller from the vehicle.
Torque 2 Nm
5-Bolt High Voltage Controller
4-Bolt High Voltage Controller

Install

  1. If a new 4-bolt high voltage controller is replacing an old 5-bolt high voltage controller, perform these additional steps to retrofit a 28-bolt penthouse cover with an aluminum retrofit patch. Otherwise go to step 5.
  2. Use an IPA wipe to clean the area around the high voltage controller middle bolt hole on the outside of the penthouse cover, and allow it to completely dry.
  3. Cut a 50mm x 50mm patch of aluminum tape, and apply the patch to the outside of the penthouse cover, centered over the middle bolt hole.
  4. Use a silicon roller to wet out the patch and set the adhesive.
  5. Install the high voltage controller into the penthouse, and then install the bolts that attach the high voltage controller to the hinge tray.
    Torque 2 Nm
  6. Connect the penthouse harness to the high voltage controller connectors.
  7. Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
  8. Use an IPA wipe to clean any residue from the high voltage controller mounting bolt holes and both the inside and outside of the penthouse cover at the bolt holes.
  9. Use IPA wipes to clean the mating surface of the HV battery and the penthouse cover gasket.
  10. Install the penthouse cover on the HV battery, and then hand-tighten the bolts.
    Note: Different penthouse cover revisions have 28, 18, or 16 bolts.
  11. Torque the penthouse cover bolts in the sequence shown, and mark each with a green paint pen as they are torqued.
    Torque 8 Nm
    28-Bolt Penthouse Cover Torque Sequence
    18-Bolt Penthouse Cover Torque Sequence
    16-Bolt Penthouse Cover Torque Sequence
  12. Connect the positive 12V output cable to the DCDC passthrough, install a new nut to attach the cable, and mark the nut with a green paint pen after torque.
    Torque 9 Nm
    Caution:
    Make sure that the rubber boot is not trapped under the cable lug or pinched between the cable lug and nut.
  13. Replace the cover on the positive 12V output cable at the DCDC passthrough, and then press down to attach the cover.
  14. If the high voltage controller being installed was removed earlier, go to step 30. Otherwise, continue to the next step.
  15. Connect the electrical harness to the high voltage controller connector.
    Note: Make sure not to pull up on the high voltage controller connector when connecting the electrical harness or anytime during in the following steps, as this might close the HVIL loop, close the contactors, and cause the high voltage controller restore to fail.
  16. Attach a 12V charger to the 12V auxiliary battery positive terminal and the 12V auxiliary battery negative cable.
  17. Attach the laptop with toolbox to the vehicle.
  18. In Toolbox, click Autodiag, and type "restore" into the search field.
  19. Click the arrow next to "HVBMS clone restore", and then click Run Network.
    Note: Enter the ID number that was recorded earlier.
  20. In Toolbox, click Action, and then type "service-redeploy" into the search field.
  21. Click the arrow next to "UPDATE-SERVICE-REDEPLOY", and then click Run.
  22. In Toolbox, click Autodiag, and type "restore" into the search field.
  23. Click the arrow next to "HVP clone restore", and then click Run Network.
    Note: Enter the ID number that was recorded earlier.
  24. In Toolbox, click Action, and then type "service-redeploy" into the search field.
  25. Click the arrow next to "UPDATE-SERVICE-REDEPLOY", and then click Run.
  26. When the redeploy finishes, perform any firmware updates.
  27. Disconnect the laptop from the vehicle.
  28. Disconnect the 12V charger from the 12V auxiliary battery positive terminal and the 12V auxiliary battery negative cable.
  29. Disconnect the electrical harness from the high voltage controller connector.
  30. Continue the procedure to install the penthouse cover. See Cover - Penthouse (Remove and Replace).
1If a new 4-bolt high voltage controller is replacing an old 5-bolt high voltage controller, perform these additional steps to retrofit a 28-bolt penthouse cover with an aluminum retrofit patch. Otherwise go to step 5.
2Use an IPA wipe to clean the area around the high voltage controller middle bolt hole on the outside of the penthouse cover, and allow it to completely dry.
3Cut a 50mm x 50mm patch of aluminum tape, and apply the patch to the outside of the penthouse cover, centered over the middle bolt hole.
4Use a silicon roller to wet out the patch and set the adhesive.
5Install the high voltage controller into the penthouse, and then install the bolts that attach the high voltage controller to the hinge tray.
Torque 2 Nm
6Connect the penthouse harness to the high voltage controller connectors.
7Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
8Use an IPA wipe to clean any residue from the high voltage controller mounting bolt holes and both the inside and outside of the penthouse cover at the bolt holes.
9Use IPA wipes to clean the mating surface of the HV battery and the penthouse cover gasket.
10Install the penthouse cover on the HV battery, and then hand-tighten the bolts.
Note: Different penthouse cover revisions have 28, 18, or 16 bolts.
28-Bolt Penthouse Cover Torque Sequence
18-Bolt Penthouse Cover Torque Sequence
16-Bolt Penthouse Cover Torque Sequence
11Torque the penthouse cover bolts in the sequence shown, and mark each with a green paint pen as they are torqued.
Torque 8 Nm
12Connect the positive 12V output cable to the DCDC passthrough, install a new nut to attach the cable, and mark the nut with a green paint pen after torque.
Torque 9 Nm
Caution:
Make sure that the rubber boot is not trapped under the cable lug or pinched between the cable lug and nut.
13Replace the cover on the positive 12V output cable at the DCDC passthrough, and then press down to attach the cover.
14If the high voltage controller being installed was removed earlier, go to step 30. Otherwise, continue to the next step.
15Connect the electrical harness to the high voltage controller connector.
Note: Make sure not to pull up on the high voltage controller connector when connecting the electrical harness or anytime during in the following steps, as this might close the HVIL loop, close the contactors, and cause the high voltage controller restore to fail.
16Attach a 12V charger to the 12V auxiliary battery positive terminal and the 12V auxiliary battery negative cable.
17Attach the laptop with toolbox to the vehicle.
18In Toolbox, click Autodiag, and type "restore" into the search field.
19Click the arrow next to "HVBMS clone restore", and then click Run Network.
Note: Enter the ID number that was recorded earlier.
20In Toolbox, click Action, and then type "service-redeploy" into the search field.
21Click the arrow next to "UPDATE-SERVICE-REDEPLOY", and then click Run.
22In Toolbox, click Autodiag, and type "restore" into the search field.
23Click the arrow next to "HVP clone restore", and then click Run Network.
Note: Enter the ID number that was recorded earlier.
24In Toolbox, click Action, and then type "service-redeploy" into the search field.
25Click the arrow next to "UPDATE-SERVICE-REDEPLOY", and then click Run.
26When the redeploy finishes, perform any firmware updates.
27Disconnect the laptop from the vehicle.
28Disconnect the 12V charger from the 12V auxiliary battery positive terminal and the 12V auxiliary battery negative cable.
29Disconnect the electrical harness from the high voltage controller connector.
30Continue the procedure to install the penthouse cover. See Cover - Penthouse (Remove and Replace).