Pyrotechnic Battery Disconnect (Remove and Replace)

Correction code 1630020016300200
  • 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
  • 1057607-00-AMagnet, Flexible, HV Insulated, 18"
  • 1127845-00-AAsy, Service Cover, Penthouse, Model 3
  • 1131071-00-ADummy Disconnect, Pyro, Safety
  • 1133602-00-A Kit, HV Pyro-disconnect Replacement, BRP
  • 1108272-00-BCap, Logic Conn, Inv, 3DU
  • 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)
Magnet, Flexible, HV Insulated, 18" (1057607-00-A)
Asy, Service Cover, Penthouse, Model 3 (1127845-00-A)
Dummy Disconnect, Pyro, Safety (1131071-00-A)
Kit, HV Pyro-disconnect Replacement, BRP (1133602-00-A )
Cap, Logic Conn, Inv, 3DU (1108272-00-B)
Resistance meter, microohm, Hioki RM 3548 (1076927-00-A)
Warning: Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
Warning: If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
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 penthouse cover. See Cover - Penthouse (Remove and Replace).
    Warning: HV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.
  2. If the logic connector cap is installed on the high voltage controller connector, remove it.
  3. Set the penthouse service cover over the penthouse.
  4. Remove the pyrotechnic battery disconnect shunt insulator(s).
    1st Generation
    2nd Generation
  5. Remove and discard the bolts that attach the pyrotechnic battery disconnect to the HV battery, and then remove the pyrotechnic battery disconnect from the vehicle.
  6. Install the dummy disconnect where the pyrotechnic battery disconnect was removed.
1Remove the penthouse cover. See Cover - Penthouse (Remove and Replace).
Warning: HV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.
2If the logic connector cap is installed on the high voltage controller connector, remove it.
3Set the penthouse service cover over the penthouse.
1st Generation
2nd Generation
4Remove the pyrotechnic battery disconnect shunt insulator(s).
5Remove and discard the bolts that attach the pyrotechnic battery disconnect to the HV battery, and then remove the pyrotechnic battery disconnect from the vehicle.
6Install the dummy disconnect where the pyrotechnic battery disconnect was removed.

Install

  1. Remove the dummy disconnect from where the pyrotechnic battery disconnect will install.
  2. Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pryotechnic battery disconnect.
  3. Position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect.
  4. Install the new bolts that attach the pyrotechnic battery disconnect to the HV battery, and then mark the bolts with a paint pen after they are torqued.
    Torque 9 Nm
  5. Use the Hioki resistance meter to measure the resistance at the HV joint between the newly-installed pyrotechnic battery disconnect and the LH 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.
  6. Use the Hioki resistance meter to measure the resistance at the HV joint between the newly-installed pyrotechnic battery disconnect and the shunt.
    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
  7. Install the pyrotechnic battery disconnect shunt insulator(s).
    1st Generation
    2nd Generation
  8. Remove the penthouse service cover from the penthouse.
  9. Install the penthouse cover. See Cover - Penthouse (Remove and Replace).
1Remove the dummy disconnect from where the pyrotechnic battery disconnect will install.
2Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pryotechnic battery disconnect.
3Position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect.
4Install the new bolts that attach the pyrotechnic battery disconnect to the HV battery, and then mark the bolts with a paint pen after they are torqued.
Torque 9 Nm
5Use the Hioki resistance meter to measure the resistance at the HV joint between the newly-installed pyrotechnic battery disconnect and the LH 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
6Use the Hioki resistance meter to measure the resistance at the HV joint between the newly-installed pyrotechnic battery disconnect and the shunt.
Note: The maximum acceptable resistance is 0.045 mΩ (45 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
1st Generation
2nd Generation
7Install the pyrotechnic battery disconnect shunt insulator(s).
8Remove the penthouse service cover from the penthouse.
9Install the penthouse cover. See Cover - Penthouse (Remove and Replace).