HV Header - HV Battery (Remove and Replace)

Correction code 1630630216306302
  • 1140423-00-B Extractor, Battery HV Header, Model 3
  • 1140311-00-ALever Lock, HV Connector, Model 3

SPECIAL TOOLS

Extractor, Battery HV Header, Model 3 (1140423-00-B)
Lever Lock, HV Connector, Model 3 (1140311-00-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.

Parent topic: 1630 - HV Battery Electrical Components

Remove

  1. Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
  2. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  3. Release the clips that attach the RH inner HV battery return hose to the HV battery.
  4. Remove the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
    Torque 10 Nm
  5. Release the locking tab of the rear drive unit HV electrical harness.
  6. Raise the handle, and them disconnect the rear drive unit HV electrical harness from the HV battery connector.
  7. Remove the bolts that attach the HV header to the HV battery.
  8. Insert the extractor tool into the HV header, push the tool handle in, and pull on the header to remove it from the HV battery.
1Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
2Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
3Release the clips that attach the RH inner HV battery return hose to the HV battery.
4Remove the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
Torque 10 Nm
5Release the locking tab of the rear drive unit HV electrical harness.
6Raise the handle, and them disconnect the rear drive unit HV electrical harness from the HV battery connector.
7Remove the bolts that attach the HV header to the HV battery.
8Insert the extractor tool into the HV header, push the tool handle in, and pull on the header to remove it from the HV battery.

Install

  1. Install the HV header onto the HV battery.
    Note: Push and pull on the header to make sure it is secured.
  2. Install and hand-tighten the bolts that attach the HV header to the HV battery
  3. Tighten the bolts to proper torque.
    Torque 10 Nm
  4. Fully raise the handle on the rear drive unit HV electrical harness.
  5. Attach the HV connector lever lock onto the back of the HV electrical harness.
  6. Firmly connect the HV electrical harness to the HV battery connector.
    Caution:
    Make sure that the harness fits the connector squarely and tightly.
  7. While pressing the harness to the connector, remove the HV connector lever lock.
  8. While pressing the harness to the connector, fully lower the handle.
  9. Slide the release to lock the HV electrical harness.
  10. Install the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
    Torque 10 Nm
  11. Fasten the clips that attach the RH inner HV battery return hose to the HV battery.
  12. Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  13. Perform a penthouse air leak test. See Penthouse Air Leak Test.
  14. Connect 12V power. See 12V Power (Disconnect and Connect).
1Install the HV header onto the HV battery.
Note: Push and pull on the header to make sure it is secured.
2Install and hand-tighten the bolts that attach the HV header to the HV battery
3Tighten the bolts to proper torque.
Torque 10 Nm
4Fully raise the handle on the rear drive unit HV electrical harness.
5Attach the HV connector lever lock onto the back of the HV electrical harness.
6Firmly connect the HV electrical harness to the HV battery connector.
Caution:
Make sure that the harness fits the connector squarely and tightly.
7While pressing the harness to the connector, remove the HV connector lever lock.
8While pressing the harness to the connector, fully lower the handle.
9Slide the release to lock the HV electrical harness.
10Install the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
Torque 10 Nm
11Fasten the clips that attach the RH inner HV battery return hose to the HV battery.
12Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
13Perform a penthouse air leak test. See Penthouse Air Leak Test.
14Connect 12V power. See 12V Power (Disconnect and Connect).