HV Header - Inverter - Rear Drive Unit (Remove and Replace)

Correction code 4020630240206302
  • 1142608-00-B Extractor, Drive Unit HV Header, Model 3
  • 1140311-00-ALever Lock, HV Connector, Model 3

SPECIAL TOOLS

Extractor, Drive Unit HV Header, Model 3 (1142608-00-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: 4020 - Rear Drive Inverter

Remove

  1. Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
  2. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  3. Release the clip that attaches the rear drive unit inlet hose to the rear drive unit inverter.
  4. Disconnect the low voltage electrical harness from the inverter connector.
  5. Release the clip that attaches the low voltage electrical harness to the inverter.
  6. Remove the bolt that attaches the HV electrical harness to the inverter.
  7. Slide the release to unlock the HV electrical harness.
  8. Lift the handle on HV electrical harness, and then disconnect the HV electrical harness from the inverter connector.
  9. Remove and discard the bolts that attach the HV header to the inverter.
  10. Insert the extractor tool into the HV header, push the tool handle in, and pull on the header to remove it from the inverter.
  11. Release the clips (x6) that attach the retainer to the inverter, and then remove and discard the retainer from the inverter.
1Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
2Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
3Release the clip that attaches the rear drive unit inlet hose to the rear drive unit inverter.
4Disconnect the low voltage electrical harness from the inverter connector.
5Release the clip that attaches the low voltage electrical harness to the inverter.
6Remove the bolt that attaches the HV electrical harness to the inverter.
7Slide the release to unlock the HV electrical harness.
8Lift the handle on HV electrical harness, and then disconnect the HV electrical harness from the inverter connector.
9Remove and discard the bolts that attach the HV header to the inverter.
10Insert the extractor tool into the HV header, push the tool handle in, and pull on the header to remove it from the inverter.
11Release the clips (x6) that attach the retainer to the inverter, and then remove and discard the retainer from the inverter.

Install

  1. Install a new retainer into the header, and then fasten the clips (x6) that attach the retainer to the header.
  2. Install the HV header onto the inverter.
    Note: Push, pull, and push on the header to make sure it is fully seated.
  3. Install the new bolts (x2) that attach the HV header to the inverter.
    Torque 6 Nm
  4. Perform an inverter air leak test. See Inverter Air Leak Test.
  5. Fully raise the handle on the rear drive unit HV electrical harness.
  6. Attach the HV connector lever lock onto the back of the HV electrical harness.
  7. Firmly connect the HV electrical harness to the inverter connector.
    Caution:
    Make sure that the harness fits the connector squarely and tightly.
  8. While pressing the harness to the connector, remove the HV connector lever lock.
  9. While pressing the harness to the connector, fully lower the handle.
  10. Slide the release to lock the HV electrical harness.
  11. Install the bolt that attaches the HV electrical harness to the inverter.
    Torque 6 Nm
  12. Fasten the clip that attaches the low voltage electrical harness to the inverter.
  13. Connect the low voltage electrical harness to the inverter connector.
  14. Fasten the clip that attaches the rear drive unit inlet hose to the rear drive unit inverter.
  15. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  16. Perform a penthouse air leak test. See Penthouse Air Leak Test.
  17. Connect 12V power. See 12V Power (Disconnect and Connect).
1Install a new retainer into the header, and then fasten the clips (x6) that attach the retainer to the header.
2Install the HV header onto the inverter.
Note: Push, pull, and push on the header to make sure it is fully seated.
3Install the new bolts (x2) that attach the HV header to the inverter.
Torque 6 Nm
4Perform an inverter air leak test. See Inverter Air Leak Test.
5Fully raise the handle on the rear drive unit HV electrical harness.
6Attach the HV connector lever lock onto the back of the HV electrical harness.
7Firmly connect the HV electrical harness to the inverter connector.
Caution:
Make sure that the harness fits the connector squarely and tightly.
8While pressing the harness to the connector, remove the HV connector lever lock.
9While pressing the harness to the connector, fully lower the handle.
10Slide the release to lock the HV electrical harness.
11Install the bolt that attaches the HV electrical harness to the inverter.
Torque 6 Nm
12Fasten the clip that attaches the low voltage electrical harness to the inverter.
13Connect the low voltage electrical harness to the inverter connector.
14Fasten the clip that attaches the rear drive unit inlet hose to the rear drive unit inverter.
15Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
16Perform a penthouse air leak test. See Penthouse Air Leak Test.
17Connect 12V power. See 12V Power (Disconnect and Connect).