Shunt - HV Battery (Remove and Replace)

Correction code 1630360216303602
  • 1057602-00-ARatchet, 1/4" Sq Dr, HV Insulated
  • 1057603-00-AExt Bar, Wobble, 1/4" Dr, HV Insulated
  • 1057606-00-ASkt, 1/4" Sq Dr, 13mm, HV Insulated
  • 1076927-00-AResistance meter, microohm, Hioki RM 3548

SPECIAL TOOLS

Ratchet, 1/4" Sq Dr, HV Insulated (1057602-00-A)
Ext Bar, Wobble, 1/4" Dr, HV Insulated (1057603-00-A)
Skt, 1/4" Sq Dr, 13mm, HV Insulated (1057606-00-A)
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. See Pyrotechnic Battery Disconnect (Remove and Replace).
  2. Disconnect the electrical harness from the shunt connector.
  3. Remove and discard the bolt that attaches the shunt to the busbar.
  4. Remove the shunt from the vehicle.
1Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
2Disconnect the electrical harness from the shunt connector.
3Remove and discard the bolt that attaches the shunt to the busbar.
4Remove the shunt from the vehicle.

Install

  1. Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pryotechnic battery disconnect.
  2. Install the shunt to the busbar, install a new bolt to attach the shunt to the busbar, and then mark the bolt with a paint pen after it is torqued.
    Torque 9 Nm
  3. Use the Hioki resistance meter to measure the resistance between the shunt and the adjacent busbar.
    Note: The maximum acceptable resistance is 0.045 mΩ (45 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
    Generic Measurement - Actual busbars and fasteners might appear different
  4. Connect the electrical harness to the shunt connector.
  5. Install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
1Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pryotechnic battery disconnect.
2Install the shunt to the busbar, install a new bolt to attach the shunt to the busbar, and then mark the bolt with a paint pen after it is torqued.
Torque 9 Nm
Generic Measurement - Actual busbars and fasteners might appear different
3Use the Hioki resistance meter to measure the resistance between the shunt and the adjacent busbar.
Note: The maximum acceptable resistance is 0.045 mΩ (45 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
4Connect the electrical harness to the shunt connector.
5Install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).