Voltage Converter: Service and Repair
Direct Current/Direct Current (DC/DC) Converter
Removal and Installation
WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage hybrid system utilizes approximately 300 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.
1. Depower the High Voltage Traction Battery (HVTB). For additional information, refer to High Voltage Traction Battery High-Voltage Traction Battery Systems Depowering.
2. Disconnect the 12-volt battery. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.
3. Remove the A/C tube bracket bolt and the 3 DC to DC Converter Control Module (DC/DC) top bracket bolts. Remove the bracket.
- To install, tighten the 3 DC/DC top bracket bolts to 9 Nm (80 lb-in).
- To install, tighten the A/C tube bracket bolt to 6 Nm (53 lb-in).
4. NOTICE: Failure to disconnect high-voltage cable connectors as instructed may result in damage to the connectors.
Disconnect the DC/DC high-voltage and interlock connector as follows:
1. Press the locking tab on the white interlock connector and partially disconnect the connector from the DC/DC.
2. Press the locking tab on the orange high-voltage connector and fully disconnect both connectors from the DC/DC.
5. Disconnect the DC/DC low-voltage connector.
6. WARNING: Always tighten the DC/DC converter low-voltage battery cable fasteners to specification. Loose connections may result in electrical arcing, which increases both the risk of fires and serious personal injury.
Remove the 2 DC/DC low-voltage battery cable nuts and position the low-voltage battery cables aside.
- To install, tighten to 17 Nm (150 lb-in).
7. Clamp the Motor Electronics Cooling System (MECS) hoses to prevent coolant from leaking from the hoses during the repair.
8. Loosen the hose clamps and remove the MECS hoses from the DC/DC.
9. Remove the DC/DC lower RH bracket nut.
- To install, tighten to 22 Nm (16 lb-ft).
10. Detach the wire harness from the lower LH side of the DC/DC.
11. NOTICE: Do not remove the DC to DC Converter Control Module (DC/DC) LH lower bracket from the vehicle rail, as this may degrade the vehicle ground attachment and DC/DC alignment.
NOTE: If a new DC/DC is being installed, the new DC/DC will come with a new LH lower bracket attached. Remove the LH lower bracket from the new DC/DC and discard. Whenever possible, re-use the LH lower bracket which has been left attached to the vehicle. If the a new bracket is being installed, make sure the surfaces between the bracket and side rails are clean and free of grease, dirt and debris.
Remove the 2 lower LH DC/DC bracket bolts and remove the DC/DC.
- To install, tighten to 5 Nm (44 lb-in).
12. To install, reverse the removal procedure.
13. Refill the MECS after installation. Bleed any air from the system. For additional information, refer to Transaxle/Transmission Cooling - Hybrid Motor Electronics Cooling System Draining and Filling.