DC Input Assembly - HV Battery (Remove and Replace)

Correction code 1630210116302101
  • 1057602-00-ARatchet, 1/4" Sq Dr, HV Insulated
  • 1057606-00-ASkt, 1/4" Sq Dr, 13mm, HV Insulated
  • 1057607-00-AMagnet, Flexible, HV Insulated, 18"
  • 1059330-00-BSkt, 1/4in Dr, 5-Lobe Torx Plus External
  • 1076927-00-AResistance meter, microohm, Hioki RM 3548

SPECIAL TOOLS

Ratchet, 1/4" Sq Dr, HV Insulated (1057602-00-A)
Skt, 1/4" Sq Dr, 13mm, HV Insulated (1057606-00-A)
Magnet, Flexible, HV Insulated, 18" (1057607-00-A)
Skt, 1/4in Dr, 5-Lobe Torx Plus External (1059330-00-B)
Resistance meter, microohm, Hioki RM 3548 (1076927-00-A)
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. Remove the pyrotechnic battery disconnect from the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
  2. Remove the insulator for the DC input assembly.
  3. Remove and discard the bolts that attach the DC input busbars to the fast charge contactor busbars.
  4. Disconnect the electrical harness from the DC input assembly connector.
  5. Remove the bolts that attach the DC input assembly to the penthouse, and then remove the DC input assembly from the vehicle.
1Remove the pyrotechnic battery disconnect from the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
2Remove the insulator for the DC input assembly.
3Remove and discard the bolts that attach the DC input busbars to the fast charge contactor busbars.
4Disconnect the electrical harness from the DC input assembly connector.
5Remove the bolts that attach the DC input assembly to the penthouse, and then remove the DC input assembly from the vehicle.

Install

  1. Install the DC input assembly to the penthouse, install the bolts (x4) that attach the DC input assembly to the penthouse, and then mark the bolts with a paint pen after they are torqued..
    Torque 6 Nm
  2. Install new bolts (x2) to attach the DC input busbars to the fast charge contactor busbars, and then mark the bolts with a paint pen after they are torqued.
    Torque 9 Nm
  3. Use the Hioki resistance meter to measure the resistance at the HV joint between the positive DC input busbar and the positive (LH) fast charge contactor busbar.
    Note: The maximum acceptable resistance is 0.060 mΩ (60 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
    Generic Measurement - Actual busbars and fasteners might appear different
  4. Use the Hioki resistance meter to measure the resistance at the HV joint between the negative DC input busbar and the negative (RH) fast charge contactor busbar.
    Note: The maximum acceptable resistance is 0.060 mΩ (60 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
    Generic Measurement - Actual busbars and fasteners might appear different
  5. Install the insulator for the DC input assembly.
  6. Connect the electrical harness to the DC input assembly connector.
  7. Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
1Install the DC input assembly to the penthouse, install the bolts (x4) that attach the DC input assembly to the penthouse, and then mark the bolts with a paint pen after they are torqued..
Torque 6 Nm
2Install new bolts (x2) to attach the DC input busbars to the fast charge contactor busbars, and then mark the bolts with a paint pen after they are torqued.
Torque 9 Nm
Generic Measurement - Actual busbars and fasteners might appear different
3Use the Hioki resistance meter to measure the resistance at the HV joint between the positive DC input busbar and the positive (LH) fast charge contactor busbar.
Note: The maximum acceptable resistance is 0.060 mΩ (60 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
Generic Measurement - Actual busbars and fasteners might appear different
4Use the Hioki resistance meter to measure the resistance at the HV joint between the negative DC input busbar and the negative (RH) fast charge contactor busbar.
Note: The maximum acceptable resistance is 0.060 mΩ (60 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
5Install the insulator for the DC input assembly.
6Connect the electrical harness to the DC input assembly connector.
7Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).