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Module, Power Inverter (PIM): Installation: Installation

WARNING:

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.
NOTE:

Any time the Power Inverter Module (PIM) cover is removed, the cover and the screws MUST BE REPLACED  .

Fig 1: PIM 12-Volt Battery Cable Nuts
GC0157633Courtesy of CHRYSLER GROUP, LLC
  1. Attach the 12-volt battery cables to the studs.Make sure the positive cable (RED) is attached to the stud with the + symbol. Make sure the negative cable (BLACK) is attached to the stud with the - symbol (PIM) case.  Install two NEW  nuts to the studs. Tighten the nuts (1) to 20 N.m (15 ft. lbs.).
    Fig 2: Cable Eyelets & Connector Face Locator
    GC0157645Courtesy of CHRYSLER GROUP, LLC
  2. With the PIM opening upright, position the 2-wire high voltage connector into the PIM with the locator pin (1) at the top of the connector. Make sure the cables are not twisted by ensuring the eyelets (2) have a downward travel to properly align with the PIM contacts.
    Fig 3: Inverted Connector
    GC0157590Courtesy of CHRYSLER GROUP, LLC
  3. If the connector is inverted as shown in illustration, DO NOT ATTEMPT TO INSTALL THE 2-WIRE CONNECTOR. 
  4. Insert the connector into the PIM slot with the positive indicators (1 and 2) and the negative indicators (3 and 4) matched up as shown in illustration.
  5. Fully seat the connector (3) into the slot of the PIM case (4).
  6. Make sure the locator pin (2) is aligned with the locator bore (1). While mating the surfaces, make sure the pin easily seats into the bore.
    Fig 4: High-Voltage Battery Cable Guide Bracket Screws
    GC0157823Courtesy of CHRYSLER GROUP, LLC
  7. Install the NEW  eyelet connector bolts (1)
  8. Tighten the two eyelet connector bolts (1) to 24 N.m (18 ft. lbs.).
  9. Torque the bracket screws (2) to 20 N.m (15 ft. lbs.).
    Fig 5: PIM Cover & Screws
    GC0157863Courtesy of CHRYSLER GROUP, LLC
  10. Install a NEW  PIM cover (2). Install seven NEW  PIM cover screws (1). Tighten the screws to 8 N.m (71 in. lbs.).
    Fig 6: PIM 12-Volt Electrical Connector
    GC0157787Courtesy of CHRYSLER GROUP, LLC
  11. Connect the PIM 12-volt electrical connector.
    Fig 7: PIM Bolts
    GC0157871Courtesy of CHRYSLER GROUP, LLC
  12. Place the PIM in the installed position. Install and tighten the four PIM bolts (1) to 24 N.m (18 ft. lbs).
    Fig 8: PIM Bracket Bolt
    GC0157806Courtesy of CHRYSLER GROUP, LLC
  13. Tighten the PIM bracket bolt (1) forward of the cradle front support to 24 N.m (18 ft. lbs.).
    Fig 9: Negative & Positive PIM-To-Battery 12-Volt Battery Cable Pin-Type Retainers
    GC0157733Courtesy of CHRYSLER GROUP, LLC
  14. Attach the negative and positive PIM-to-battery 12-volt battery cable pin-type retainers (1).
  15. Connect the PIM-to-battery 12-volt battery cable nuts at the 12-volt battery cable terminals.
    Fig 10: Power Distribution Center (PDC) Harness High-Voltage Electrical Connector
    GC0157640Courtesy of CHRYSLER GROUP, LLC
  16. Connect the power distribution center (PDC) harness high-voltage electrical connector (1) at the PIM.
  17. Raise the vehicle. Refer to HOISTING .
    Fig 11: PIM Ground Strap Bolt
    GC0157764Courtesy of CHRYSLER GROUP, LLC
  18. Install and tighten the PIM ground strap bolt (1) to 12 N.m (9 ft. lbs.).
    Fig 12: 3-Phase Wire Harness Connector
    GC0157883Courtesy of CHRYSLER GROUP, LLC
  19. Connect the electric motor high-voltage electrical connector (1).
    Fig 13: Harness Retainers
    GC0157739Courtesy of CHRYSLER GROUP, LLC
  20. Attach the two harness retainers (1).
    Fig 14: PIM High-Voltage Harness Bracket Bolt
    GC0157669Courtesy of CHRYSLER GROUP, LLC
  21. Install the high-voltage battery cable harness bracket, and the high-voltage battery cable harness bracket bolt (1).
  22. Install new tie-straps on the high-voltage battery cable harness in the locations noted during removal.
    Fig 15: Removing/Installing Trough Guide
    GC0158564Courtesy of CHRYSLER GROUP, LLC
  23. Position the trough guide into position over the three underbody studs. Install the NEW  nuts (2 and 3) to secure the trough guide. Tighten the three NEW nuts (2) to 10 N.m (87 in. lbs.).
    Fig 16: High Voltage Connectors
    GC0157857Courtesy of CHRYSLER GROUP, LLC

  24. Connect the high-voltage battery cable harness high-voltage electrical connector (1).

  25. Lower the vehicle.
  26. Attach the two coolant hoses to the PIM, and install the clamps.
  27. Install the battery tray. Refer to TRAY, BATTERY, INSTALLATION .
  28. Install the battery. Refer to BATTERY, INSTALLATION .
  29. Top off the Power Electronics Cooling Reservoir.
  30. Perform the cooling system bleed procedure. Refer to POWER ELECTRONICS COOLING SYSTEM, STANDARD PROCEDURE .
  31. Install the onboard charging module (OBCM). Refer to MODULE, ONBOARD CHARGING (OBCM), INSTALLATION .
  32. Perform the Resolver Relearn procedure. Refer to ELECTRIC VEHICLE CONTROL SYSTEM, STANDARD PROCEDURE .
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