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
2WD
• It works as the power distributor for connecting the high voltage battery power and high voltage components (A/C compressor, PTC heater, etc.).
• It is installed in front cross member and includes bus bar, fuse and PTC relay ( + ).
| NO | System | Remark |
| 1 | Battery signal | - |
| 2 | Battery PTC relay | BMU relay control |
| 3 | Battery PTC fuse | 20 A |
| 4 | PTC heater fuse | 30 A |
| 5 | A/C compressor fuse | 30 A |
4WD
• It is the role of power distributor for connecting the high voltage battery power and front high voltage components (Inverter, A/C compressor, PTC heater, etc.).
• It is installed in front inverter assembly and includes bus bar and quick charge relay (+, -).
| NO | System | Remark |
| 1 | Battery PTC relay | BMU relay control |
| 2 | PTC heater fuse | 30 A |
| 3 | Battery PTC fuse | 20 A |
| 4 | A/C compressor fuse | 30 A |
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 (Standard) - “High Voltage Shut-off Procedure”)
2.Remove the front trunk.(Refer to Body - "Front Trunk")
3.Remove the auxiliary 12 V battery tray.(Refer to Electric Power Conversion System - "Auxiliary 12 V Battery")
4.Disconnect the front junction box connector (A).
5.Disconnect the high voltage power cable (A) and battery heater connector (B).
6.Disconnect the PTC heater connector (A).
7.Disconnect the electric A/C compressor connector (A).
8.Remove the front high voltage junction box (A) after removing the nuts.
Tightening torque :6.9 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.1 - 7.2 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.Install in the reverse order of removal.
• Install the front high voltage junction box to the specified torque.
• If the front high voltage junction box is dropped, it may cause internal damage. (Do not reuse)
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 (Standard) - “High Voltage Shut-off Procedure”)
2.Separate the power cable fastener (A) from the body frame.
3.Remove the front trunk.(Refer to Body - "Front Trunk")
4.Disconnect the PTC heater connector (A) and battery heater connector (B).
5.Disconnect the high voltage junction box signal cable connectors (A, B).
6.Separate the wiring protector (A) after removing the bolts.
Tightening torque :6.9 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.1 - 7.2 lb·ft)
7.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)
8.Remove the high voltage junction box ground bolts (A).
Tightening torque :6.9 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.1 - 7.2 lb·ft)
9.Separate the Electric A/C compressor connector (A) and fastener (B).
10.Separate the power cable after separating the fasteners (A).
11.Remove the front high voltage junction box (A).
Tightening torque :6.9 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.1 - 7.2 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 Front High Voltage Junction Box - "Air Tightness")
2.Install in the reverse order of removal.
• Install the front high voltage junction box to the specified torque.
• If the front 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.Disconnect the PTC heater connector (A) and battery heater connector (B).
2.Install the battery heater sealing connector (P008) (A).
3.Install the PTC heater sealing connector (P001) (A).
4.Disconnect the high voltage junction box signal connector (A).
5.Install the high voltage junction box sealing connector (P006) (A).
6.Disconnect the Electric A/C compressor connector (A).
7.Install the Electric A/C compressor sealing connector (P007) (A).
8.Remove the front rear under cover.(Refer to Motor and Reduction Gear System - "Front Under Cover")
9.Install the sealing connector (A) in the high voltage cable.
10.Install the pressure regulator adapters (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.
11.Perform the PE system leak test with the KDS. (S/W Management → Motor Control Unit → PE System leak test)
12.Check the PE system leakage.
| PASS | FAIL |
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