Passthrough - DCDC - 12V (Remove and Replace)

Correction code 1630600216306002
  • 1059330-00-BSkt, 1/4in Dr, 5-Lobe Torx Plus External
  • 1076927-00-A Resistance meter, microohm, Hioki RM 3548

SPECIAL TOOLS

Skt, 1/4in Dr, 5-Lobe Torx Plus External (1059330-00-B)
Resistance meter, microohm, Hioki RM 3548 (1076927-00-A)
Parent topic: 1630 - HV Battery Electrical Components

Remove

  1. Remove the high voltage controller. See Controller - High Voltage (Remove and Replace).
  2. Remove the nut that attaches the positive terminal of the DCDC harness to the positive DCDC passthrough busbar.
  3. Remove the nut that attaches the negative terminal of the DCDC harness to the negative DCDC passthrough busbar.
  4. Release the clip and disconnect the DCDC harness from the power conversion system.
  5. Remove the bolts that attaches the DCDC ground busbar to the body.
  6. Remove and discard the nut that attaches the DCDC ground busbar to the HV battery, and remove the DCDC ground busbar from the vehicle.
    Torque 15 Nm
  7. Remove the bolts that attach the 12V DCDC passthrough to the penthouse, and then remove the 12V DCDC passthrough from the penthouse..
1Remove the high voltage controller. See Controller - High Voltage (Remove and Replace).
2Remove the nut that attaches the positive terminal of the DCDC harness to the positive DCDC passthrough busbar.
3Remove the nut that attaches the negative terminal of the DCDC harness to the negative DCDC passthrough busbar.
4Release the clip and disconnect the DCDC harness from the power conversion system.
5Remove the bolts that attaches the DCDC ground busbar to the body.
6Remove and discard the nut that attaches the DCDC ground busbar to the HV battery, and remove the DCDC ground busbar from the vehicle.
Torque 15 Nm
7Remove the bolts that attach the 12V DCDC passthrough to the penthouse, and then remove the 12V DCDC passthrough from the penthouse..

Install

  1. Use an IPA wipe to clean the mating surfaces of the DCDC passthrough, and the DCDC harness.
  2. Install the 12V DCDC passthrough into the penthouse, install the bolts that attach the 12V DCDC passthrough to the penthouse, and then mark the bolts with a paint pen after they are torqued.
    Torque 10 Nm
  3. Install the bolt that attaches the DCDC ground busbar to the body, and then mark the bolt with a paint pen after it is torqued.
    Torque 20 Nm
  4. Install the DCDC ground busbar to the DCDC passthrough, install a new nut to attach the DCDC ground busbar to the DCDC passthrough, and then mark the nut with a paint pen after it is torqued.
    Torque 15 Nm
  5. Connect the DCDC harness to the power conversion system, and then fasten the clip that attaches the DCDC harness to the power conversion system.
  6. Install the nut that attaches the negative terminal of the DCDC harness to the negative DCDC passthrough busbar, and then mark the nut with a paint pen after it is torqued.
    Torque 4.5 Nm
  7. Install the nut that attaches the positive terminal of the DCDC harness to the positive DCDC passthrough busbar, and then mark the nut with a paint pen after it is torqued.
    Torque 4.5 Nm
  8. Use the Hioki resistance meter to measure the resistance between the positive joint of the DCDC harness and the positive terminal of the 12V DCDC passthrough.
    Note: The maximum acceptable resistance is 0.100 mΩ (100 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
    Generic Measurement - Actual busbars and fasteners might appear different
  9. Use the Hioki resistance meter to measure the resistance between the negative joint of the DCDC harness and the negative terminal of the 12V DCDC passthrough.
    Note: The maximum acceptable resistance is 0.100 mΩ (100 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
    Generic Measurement - Actual busbars and fasteners might appear different
  10. Install the high voltage controller. See Controller - High Voltage (Remove and Replace).
  11. Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
1Use an IPA wipe to clean the mating surfaces of the DCDC passthrough, and the DCDC harness.
2Install the 12V DCDC passthrough into the penthouse, install the bolts that attach the 12V DCDC passthrough to the penthouse, and then mark the bolts with a paint pen after they are torqued.
Torque 10 Nm
3Install the bolt that attaches the DCDC ground busbar to the body, and then mark the bolt with a paint pen after it is torqued.
Torque 20 Nm
4Install the DCDC ground busbar to the DCDC passthrough, install a new nut to attach the DCDC ground busbar to the DCDC passthrough, and then mark the nut with a paint pen after it is torqued.
Torque 15 Nm
5Connect the DCDC harness to the power conversion system, and then fasten the clip that attaches the DCDC harness to the power conversion system.
6Install the nut that attaches the negative terminal of the DCDC harness to the negative DCDC passthrough busbar, and then mark the nut with a paint pen after it is torqued.
Torque 4.5 Nm
7Install the nut that attaches the positive terminal of the DCDC harness to the positive DCDC passthrough busbar, and then mark the nut with a paint pen after it is torqued.
Torque 4.5 Nm
Generic Measurement - Actual busbars and fasteners might appear different
8Use the Hioki resistance meter to measure the resistance between the positive joint of the DCDC harness and the positive terminal of the 12V DCDC passthrough.
Note: The maximum acceptable resistance is 0.100 mΩ (100 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
Generic Measurement - Actual busbars and fasteners might appear different
9Use the Hioki resistance meter to measure the resistance between the negative joint of the DCDC harness and the negative terminal of the 12V DCDC passthrough.
Note: The maximum acceptable resistance is 0.100 mΩ (100 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
10Install the high voltage controller. See Controller - High Voltage (Remove and Replace).
11Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).