Voltage Inverter Module: Service and Repair

Battery Regulation Control Module (J840)

The battery regulation control module is installed into the Connection/conjunction box (SX1) (E-box), on the side of the Hybrid battery unit (AX1).






Removal

Read and follow the High Voltage Electrical System General Warnings. Refer to => [ High Voltage Electrical System General Warnings ] Service Precautions.

The Connection/conjunction box (SX1) (E-box) contains high voltage.

• This can pose health risks for people using electrical medical equipment.

• Danger of serious burns or death.

• Only a high voltage technician is permitted to work on the battery regulation control module.

• Always use insulated tools whenever working on the battery regulation control module.

Hybrid vehicle high voltage in the high voltage system. Danger of electrocution! The following procedure requires working on the high voltage system. Disable the high voltage system now. Refer to => [ High Voltage System, Disabling ] High Voltage System, Disabling.

• Always get the code from the old control module prior to removal if the battery regulation control module is being replaced. Refer to => [ Battery Regulation Control Module (J840), Replacing ] Service and Repair.

- Disable the high voltage system. Refer to => [ High Voltage System, Disabling ] High Voltage System, Disabling.

- Remove the hybrid battery unit. Refer to => [ Hybrid Battery Unit (AX1) ] Service and Repair.

- Remove the 8 bolts - 1 - and remove the cover from the Connection/conjunction box (SX1) (E-box).






- Loosen both bolts - 2 - on the service plug mount.






- Cut the cable tie - arrow -.






- Disconnect the 3 connectors - 1 -, - 2 - and - 3 - from the battery regulation control module.

- Remove both bolts - 3 - from the battery regulation control module using an insulated tool that has a magnet.






- Lift the battery regulation control module and disconnect the connectors - 4 - and - 5 -.






- Remove the battery regulation control module from the E-box.






- Disconnect the connector - 6 - on the battery regulation control module and remove the wiring harness if the battery regulation control module is going to be replaced.

Installation

- Connect the connector - 6 - and install the wiring harness.






- Install the battery regulation control module into the E-box and connect both connectors - 4 - and - 5 -.






- Position the battery regulation control module inside the E-box.

- Attach the ground cable to the battery regulation control module inside the E-box.






- Secure the battery regulation control module and the ground cable with both bolts - 3 -.

- Tighten both bolts - 2 - on the service plug mount.






- Connect the connectors - 1 -, - 2 - and - 3 - into the battery regulation control module until they audibly engage.






- Secure the wire with a new cable tie - arrow -.

- Check the wiring routing for the E-box wiring harness before installing the cover.






• Make sure the rubber grommet for the wiring harness - arrow - is installed correctly in the E-box housing.

- Install the E-box cover and tighten the 8 bolts - 1 -.






- Install the hybrid battery unit. Refer to => [ Hybrid Battery Unit (AX1) ] Service and Repair.

- Restart the high voltage system and complete the required documentation. Refer to => [ High Voltage System, Enabling ] High Voltage System, Enabling.