Component
2WD
1. Front High Voltage Junction Box
1-a. 6.9 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.1 - 7.2 lb·ft)
2. High Voltage Junction Box Service Cover
2-a. 3.9 - 5.9 N·m (0.4 - 0.6 kgf·m, 2.9 - 4.3 lb·ft, 34.7 - 52.1 lb·in)
2-b. 6.9 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.1 - 7.2 lb·ft)
3. Rear High Voltage Junction Box
3-a. 19.6 - 23.5 N·m (2.0 - 2.4 kgf·m, 14.5 - 17.4 lb·ft)
4WD
1. High Voltage Junction Box Service Cover
1-a. 3.9 - 5.9 N·m (0.4 - 0.6 kgf·m, 2.9 - 4.3 lb·ft, 34.7 - 52.1 lb·in)
1-b. 6.9 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.1 - 7.2 lb·ft)
2. Front High Voltage Junction Box
2-a. 6.9 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.1 - 7.2 lb·ft)
3. High Voltage Junction Box Service Cover
3-a. 3.9 - 5.9 N·m (0.4 - 0.6 kgf·m, 2.9 - 4.3 lb·ft, 34.7 - 52.1 lb·in)
3-b. 6.9 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.1 - 7.2 lb·ft)
4. Rear High Voltage Junction Box
4-a. 19.6 - 23.5 N·m (2.0 - 2.4 kgf·m, 14.5 - 17.4 lb·ft)
Description
• It works as the power distributor that connects high voltage battery power to rear high voltage components.
• It is installed on the top of the rear wheel motor and the front of the multi-inverter assembly, and has a built-in bus bar and fast charging relays (+, -).
| NO | System | Remark |
| 1 | Quick Charge Relay ( + ) | BMU relay control |
| 2 | Quick Charge Relay ( - ) |
Removal
• When working on high voltage system, the work should be performed by technicians who have completed the relevant training. A lack of understanding of the high voltage system can lead to serious accidents due to electric shock or electric leakage.
• When working on high voltage system or related components, make sure that you are familiar and comply with the "Safety Precautions, Cautions and Warnings." If you do not comply with the instructions, serious accidents due to electric shock or leakage may occur.
• When working on high voltage system, make sure to check the Personal Protective Equipment (PPE) and high voltage shut-off procedures.
1.Shut off the high voltage circuit.(Refer to Battery Control System (Long Range) - "High Voltage Shut-off Procedures")
2.Remove the rear motor and reduction gear assembly.(Refer to Motor and Reduction Gear System - "Rear Motor and Reduction Gear Assembly")
3.Separate the high voltage cable (A) from the body after removing the bolts.
Tightening torque :6.9 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.1 - 7.2 lb·ft)
4.Remove the high voltage junction box service cover (A).
Tightening torque :3.9 - 5.9 N·m (0.4 - 0.6 kgf·m, 2.9 - 4.3 lb·ft, 34.7 - 52.1 lb·in)
5.Remove the rear high voltage junction box and inverter bolts (A).
Tightening torque :6.9 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.1 - 7.2 lb·ft)
6.Disconnect the rear high voltage junction box connector (A).
7.Remove the rear high voltage junction box (A) after removing the bolts and nut.
Tightening torque :16.7 - 23.5 N·m (2.0 - 2.4 kgf·m, 14.5 - 17.3 lb·ft)
Installation
• When working on high voltage system, the work should be performed by technicians who have completed the relevant training. A lack of understanding of the high voltage system can lead to serious accidents due to electric shock or electric leakage.
• When working on high voltage system or related components, make sure that you are familiar and comply with the "Safety Precautions, Cautions and Warnings." If you do not comply with the instructions, serious accidents due to electric shock or leakage may occur.
• When working on high voltage system, make sure to check the Personal Protective Equipment (PPE) and high voltage shut-off procedures.
1.Perform the PE system leak test with the KDS.(Refer to Rear High Voltage Junction Box - "Air Tightness")
2.Install in the reverse order of removal.
• Install the rear high voltage junction box to the specified torque.
• If the rear high voltage junction box is dropped, it may cause internal damage. (Do not reuse)
Special Service Tool
| Tool Name | Illustration | Description |
|
Universal Leak Tester GIT air tightness test equipment |
|
Used for inspecting the air tightness of the Battery System Assembly and PE system |
Air Tightness
• During the high voltage junction box and multi inverter assembly (or inverter assembly (4WD)) airtightness inspection, perform it after the motor, inverter, and junction box are all assembled.
• Perform the PE system leak test procedure by using the EV battery pack tool that is for inspecting the air tightness , when working on the high voltage junction box or the inverter assembly.
• Install in the vehicle after completing the PE system leak test procedure, when working in the motor assembly.
1.Install the sealing connector (A) in the rear high voltage junction box.
Tightening torque :7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)
2.Install the sealing connector (A) in the high voltage cable (B).
3.Install the pressure regulator adapter (A) in the pressure regulator.
• Maintain the pressure by pushing the adapter with hands until starting to inspect, when installing the pressure regulator adapter.
• Be careful not to bend the EV battery pack inspection tool hose and the pressure regulator adapter hose.
4.Perform the PE system leak test with the KDS.(S/W Management → Motor Control Unit → PE System Airtightness Inspection)
5.Check the PE system leakage.
| PASS | FAIL |
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