Module, Power Inverter (PIM): Removal: Removal
On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury. Refer to STANDARD PROCEDURE .
NOTE: When performing any key-on procedure you must charge the 12 volt battery with a setting of 20 amps minimum or the High Voltage Battery could discharge below recommended manufacture specifications and destroy the battery cells.
When performing any repairs that involve contact with high voltage components or systems, the technician performing repairs on the vehicle must verify that the system remains powered down during high voltage repairs.
- This must be done by removing the service disconnect.
- The high voltage check out procedure must also be performed to ensure that the vehicle is properly powered down.
- The technician must know the whereabouts of the service disconnect throughout the repair.
- The technician must ensure that no one reconnects the service disconnect while service is being performed.
- The technician must recheck that the service disconnect has not been reinstalled in cases where the vehicle was unattended.
Perform the High Voltage Power Down procedure. Refer to ELECTRIC VEHICLE CONTROL SYSTEM, STANDARD PROCEDURE .
- Power down the 12-volt system. Refer to ELECTRIC VEHICLE CONTROL SYSTEM, STANDARD PROCEDURE .
- Remove the onboard charging module. Refer to MODULE, ONBOARD CHARGING (OBCM), REMOVAL .
- Remove the 12 volt battery. Refer to BATTERY, REMOVAL .
- Remove the 12 volt battery tray. Refer to TRAY, BATTERY, REMOVAL .
- Raise the vehicle. Refer to HOISTING .
- Disconnect the high-voltage battery cable harness high-voltage electrical connector (1).
- Remove AND DISCARD
the 3 nuts (2 and 3) from the trough guide. The trough guide is located in the underbody tunnel (5) just to the rear of the engine cradle (4). DO NOT REUSE THE NUTS. NOTE:
The guide is constructed of two pieces sandwiched together to protect the wiring under the vehicle.
Prior to cutting the four tie-straps attaching the high-voltage battery cable harness, note the locations to allow new tie-straps to be installed during installation.
- Cut the four tie-straps attaching the PIM high-voltage wiring harness to the vehicle.
- Remove the PIM high-voltage harness bracket bolt (1), and detach the bracket from the harness.
- Detach the two harness retainers (1).
- Disconnect the electric motor high-voltage electrical connector (1), and position the connector upward to allow the PIM to be repositioned.
- Remove the PIM ground strap bolt (1).
- Lower the vehicle.
- Disconnect the PDC harness high-voltage electrical connector (1) at the PIM. Refer to ELECTRIC VEHICLE CONTROL SYSTEM, STANDARD PROCEDURE .
- Detach the negative and positive PIM-to-battery 12-volt battery cable pin-type retainers (1).
- Loosen, but do not completely remove the PIM bracket bolt (1) forward of the cradle front support.
- Remove the four PIM bolts (1).NOTE:
The 12-volt electrical connector must be removed prior to rotating the PIM in order to gain access to the PIM cover and High Voltage cables. Slightly rotate the PIM in order to gain access to the 12-Volt electrical connector. Do not rotate the PIM 180 degrees with the 12-Volt electrical connector attached to the PIM. Doing so will pull the wires out of the connector. .
- Disconnect the PIM 12-volt electrical connector (1).
- Rotate the PIM to gain access to the PIM cover.
- Remove the seven PIM cover screws (1) and the PIM cover (2). THE COVER AND SCREWS MUST BE REPLACED.
- Using a permanent marker, draw a minus symbol (3) on the cable connector surface to match with the minus (negative) symbol on the PIM case (4).
- Using a permanent marker, draw a plus symbol (2) on the cable connector surface to match with the plus (positive) symbol on the PIM case (4).
- Remove and discard the high voltage cable eyelet bolts (1). DO NOT REUSE THE BOLTS.
- Remove the two high-voltage battery cable guide bracket screws (2) at the PIM, and detach the cables from the PIM.
- Once the cables are removed from the PIM note the position of the cable eyelets (2) and the connector face locator (1). When properly installed, the eyelets (2) will have a downward travel to ensure a positive contact with the PIM high voltage contacts. When properly installed, the connector face locator (1) will be in the upper position.
- Remove the PIM from the vehicle with the electric motor high-voltage harness still attached.
- Remove and discard the three electric motor high-voltage harness eyelet connector bolts (1). DO NOT REUSE THE BOLTS.
- Remove the three electric motor high-voltage harness guide bracket screws (2), and detach the harness from the PIM.
- Remove and discard the two PIM 12-volt battery cable nuts (1), and detach the cables from the PIM. DO NOT REUSE THE NUTS.
It is very important that the following steps be performed during the removal process. Failure to identify and label the high voltage cables correctly can result in high voltage battery failure.