Tube - Input - Coolant - Power Conversion System (Remove and Replace)

Correction code 16202002 16202002
  • 1111868-00-B Connector Removal, Coolant, PCS, M3
  • 1135762-00-AKit, Svc Plug, Cooling Hose, Model 3

SPECIAL TOOLS

Connector Removal, Coolant, PCS, M3 (1111868-00-B)
Kit, Svc Plug, Cooling Hose, Model 3 (1135762-00-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: 1620 - HV Battery Cooling System

Remove

  1. Drain the coolant from the power conversion system. See Penthouse Coolant (Drain and Refill).
  2. Remove the pyrotechnic battery disconnect from the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
  3. Remove the high voltage controller. See Controller - High Voltage (Remove and Replace).
  4. Release the clips that attach the harness to the hinge tray and hinges.
  5. Raise the hinge tray and remove the hinge tray from the hinges.
  6. Cut a slit halfway through 2 absorbent pads and surround each coolant input tube fitting with a pad.
  7. Use the coolant connector removal tool to spread the tube fitting clips wider than the barb on the power conversion system.
    Example of Coolant Connector Removal Tool Use
  8. Pull up on the tool and the tube fitting together to disconnect the fitting from the power conversion system.
  9. Repeat step 7 and step 8 for the other tube fitting at the battery flange.
  10. Remove the tube from the vehicle.
  11. Install a plugs into the power conversion system and the battery flange.
  12. Wipe up any spilled coolant.
    Caution:
    Spilled coolant can create an electrical path.
1Drain the coolant from the power conversion system. See Penthouse Coolant (Drain and Refill).
2Remove the pyrotechnic battery disconnect from the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
3Remove the high voltage controller. See Controller - High Voltage (Remove and Replace).
4Release the clips that attach the harness to the hinge tray and hinges.
5Raise the hinge tray and remove the hinge tray from the hinges.
6Cut a slit halfway through 2 absorbent pads and surround each coolant input tube fitting with a pad.
Example of Coolant Connector Removal Tool Use
7Use the coolant connector removal tool to spread the tube fitting clips wider than the barb on the power conversion system.
8Pull up on the tool and the tube fitting together to disconnect the fitting from the power conversion system.
9Repeat step 7 and step 8 for the other tube fitting at the battery flange.
10Remove the tube from the vehicle.
11Install a plugs into the power conversion system and the battery flange.
12Wipe up any spilled coolant.
Caution:
Spilled coolant can create an electrical path.

Install

  1. Wipe up any spilled coolant.
    Caution:
    Spilled coolant can create an electrical path.
  2. Make sure that the o-rings are not damaged and that they are properly seated in the connector groove prior to inserting the tube into the power conversion system. Replace components as necessary.

    O-rings in good condition

    O-ring in poor condition

  3. Lubricate the coolant input tube o-rings with Silaramic lubricant.
  4. Remove the plugs from the power conversion system and the battery flange.
  5. Install the coolant input tube into the power conversion system and the battery flange.
  6. Firmly press down on the tube fittings, to make sure that the fittings are securely connected.
    Caution:
    Verify that both clips have fully engaged the barb on the power conversion system and battery flange, and then pull up on the fittings to check retention.
    Example of a Secure Connection
  7. Remove the absorbent pads from around the coolant input tube fittings, and wipe up any spilled coolant.
    Caution:
    Spilled coolant can create an electrical path.
  8. Perform a penthouse coolant leak test. See Penthouse Coolant Leak Test.
  9. Connect the 12V auxiliary battery negative terminal only.
    Torque 6 Nm
    Caution:
    Do not follow the procedure to connect 12V power at this time.
  10. Connect a 12V charger to the 12V auxiliary battery terminals.
  11. Refill the coolant. See Penthouse Coolant (Drain and Refill).
  12. On the touchscreen, touch Controls > Safety & Security > Vehicle Power > Power Off.
  13. Disconnect the 12V charger from the 12V auxiliary battery terminals.
  14. Disconnect the 12V auxiliary battery negative terminal.
  15. Install the hinge tray into the hinges, and then lower the hinge tray.
  16. Fasten the clips that attach the harness to the hinge tray and hinges.
  17. Install the high voltage controller. See Controller - High Voltage (Remove and Replace).
  18. Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
1Wipe up any spilled coolant.
Caution:
Spilled coolant can create an electrical path.

O-rings in good condition

O-ring in poor condition

2Make sure that the o-rings are not damaged and that they are properly seated in the connector groove prior to inserting the tube into the power conversion system. Replace components as necessary.
3Lubricate the coolant input tube o-rings with Silaramic lubricant.
4Remove the plugs from the power conversion system and the battery flange.
5Install the coolant input tube into the power conversion system and the battery flange.
Example of a Secure Connection
6Firmly press down on the tube fittings, to make sure that the fittings are securely connected.
Caution:
Verify that both clips have fully engaged the barb on the power conversion system and battery flange, and then pull up on the fittings to check retention.
7Remove the absorbent pads from around the coolant input tube fittings, and wipe up any spilled coolant.
Caution:
Spilled coolant can create an electrical path.
8Perform a penthouse coolant leak test. See Penthouse Coolant Leak Test.
9Connect the 12V auxiliary battery negative terminal only.
Torque 6 Nm
Caution:
Do not follow the procedure to connect 12V power at this time.
10Connect a 12V charger to the 12V auxiliary battery terminals.
11Refill the coolant. See Penthouse Coolant (Drain and Refill).
12On the touchscreen, touch Controls > Safety & Security > Vehicle Power > Power Off.
13Disconnect the 12V charger from the 12V auxiliary battery terminals.
14Disconnect the 12V auxiliary battery negative terminal.
15Install the hinge tray into the hinges, and then lower the hinge tray.
16Fasten the clips that attach the harness to the hinge tray and hinges.
17Install the high voltage controller. See Controller - High Voltage (Remove and Replace).
18Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).