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# 01-07 LV Connections Retorque - LionC Gen3

This maintenance procedure covers the retightening of the bolted connections of the following LV components:

  • Ignition solenoid

  • FLEC and PDC fuseboxes

  • Megafuse fusebox and fuse holder busbar

  • Hydraulic brake booster backup pump

  • High current relay

  • Ground busbar

# Table of contents

1 Preliminary steps - Hydraulic Braking System 3

2 Preliminary steps - Pneumatic braking system 8

3 Ignition solenoid connections inspection 10

4 FLEC fusebox connections retorque (if equipped) 12

5 PDC Eaton fusebox retorque (if equipped) 15

6 Megafuse fusebox studs retorque (if equipped) 18

7 Fuse holder busbar retorque (if equipped) 21

8 Hydraulic brake booster connections retorque 23

9 High current relay connections retorque 25

10 Ground busbar connections retorque 26

11 Final validation 28

# Preliminary steps - Hydraulic Braking System

1-A Open the LV battery compartment and ensure that the battery disconnect switch is in the “OFF” position. Lock the red handle with a padlock.

Figure 1 – Battery Disconnect Switch
Figure 1 – Battery Disconnect Switch

1-B Below the battery disconnect switch, locate the fuse holder box.

Figure 2– Fuse holder box
Figure 2– Fuse holder box

1-C Remove the cover and remove the 7.5A fuse from the fuse holder. Other components should remain in place.

Figure 3– 7.5A fuse to remove
Figure 3– 7.5A fuse to remove

1-D With the ignition switch in the OFF position (no key present), press the brake pedal multiple times. The pedal must remain stiff and difficult to depress. The brake booster backup pump should not start.

Figure 4– Depress the brake pedal
Figure 4– Depress the brake pedal

1-E Open the hood. Locate the power and ground passthrough studs on the firewall. Using a multimeter, confirm there is no voltage between the positive and negative studs

Figure 5– Firewall passthrough studs
Figure 5– Firewall passthrough studs

# Preliminary steps - Pneumatic braking system

2-A Open the LV battery compartment and ensure that the battery disconnect switch is in the “OFF” position. Install a padlock on the red handle.

Figure 6– Battery Disconnect Switch.
Figure 6– Battery Disconnect Switch.

2-B Open the hood. Locate the power and ground passthrough studs on the firewall. Using a multimeter, confirm there is no voltage between the positive and negative studs.

Figure 7– Firewall passthrough studs.
Figure 7– Firewall passthrough studs.

# Ignition solenoid connections inspection

3-A On the firewall, locate the ignition solenoid above the steering shaft.

Figure 8– Ignition solenoid location
Figure 8– Ignition solenoid location

3-B Retorque the nuts of the solenoid as presented in the figure below.

Figure 9– Solenoid fasteners torque
Figure 9– Solenoid fasteners torque

3-C Apply Nyogel 760G grease on all the torqued fasteners.

3-D Ensure the ignition solenoid's cables are secured away from the steering shaft; use cable ties.

Figure 10– Required cable tie
Figure 10– Required cable tie

# FLEC fusebox connections retorque (if equipped)

4-A Open the hood, and locate the FLEC fusebox.

Figure 11 – FLEC location
Figure 11 – FLEC location

4-B Remove the protective caps from the top three studs.

Figure 12 – FLEC studs protective caps
Figure 12 – FLEC studs protective caps

4-C Torque the nuts to 15 Nm. Use a ¼” drive torque wrench.

Figure 13 – Stud nuts to retorque.
Figure 13 – Stud nuts to retorque.

# PDC Eaton fusebox retorque (if equipped)

5-A Under the hood, locate the PDC Eaton fusebox.

Figure 14 – Location of the PDC Eaton fusebox
Figure 14 – Location of the PDC Eaton fusebox

5-B Remove the left-hand side cover that protects terminal connections and remove the fusebox cover by rotating the yellow knob.

Figure 15 – Stud nuts to retorque (under the red cover)
Figure 15 – Stud nuts to retorque (under the red cover)

5-C Retorque the two left-hand side nuts on the input studs as shown in the Figure below. Some vehicles have connections on the right side too. Retorque these as well. Use a ¼” drive torque wrench.

Figure 16 – Studs to retorque
Figure 16 – Studs to retorque

# Megafuse fusebox studs retorque (if equipped)

6-A Under the hood, locate the Megafuse fusebox near the steering shaft.

Figure 17 – Megafuse fusebox location.
Figure 17 – Megafuse fusebox location.

6-B Temporarily detach the top cable to gain access to the yellow clips. Unlock the clips and remove the cover.

Figure 18 –Top terminal cable to remove to unlock cover.
Figure 18 –Top terminal cable to remove to unlock cover.

6-C Retorque the four (4) left-hand side nuts as illustrated in the figure below:

Figure 19 – Studs to torque
Figure 19 – Studs to torque

6-F Reinstall the protective cover and close the yellow clips.

6-G Reconnect the top power cable on its stud and torque the nut to 20 Nm.

Figure 20 – Last stud to torque
Figure 20 – Last stud to torque

# Fuse holder busbar retorque (if equipped)

7-A Under the hood, locate the fuse holder busbar near the steering shaft.

Figure 21 – Fuse holder busbar location
Figure 21 – Fuse holder busbar location

7-B Cut the cable tie and move the red protective cover.

7-C Retorque the seven (7) lug nuts on the input studs, as illustrated in the figure below.

Figure 22 – Studs to retorque.
Figure 22 – Studs to retorque.

# Hydraulic brake booster connections retorque

8-A Under the hood, locate the hydraulic brake booster behind the master cylinder.

Figure 23 – Master cylinder with hydraulic brake booster location.
Figure 23 – Master cylinder with hydraulic brake booster location.

8-B Torque the backup pump ground cable screw to 7 Nm.

Figure 24 – Ground cable screw to retorque.
Figure 24 – Ground cable screw to retorque.

8-C Torque the backup pump power stud nut to 2 Nm.

Figure 25 – Power cable fastener to torque.
Figure 25 – Power cable fastener to torque.

# High current relay connections retorque

9-A Under the hood, locate the high current relay on the firewall. It’s positioned on the driver’s side, underneath the power steering fluid reservoir.

Figure 26 – High current relay location.
Figure 26 – High current relay location.

9-B Retorque the two lug nuts on the input studs to 5 Nm.

Figure 27 – Studs to torque.
Figure 27 – Studs to torque.

# Ground busbar connections retorque

10-A Under the hood, locate the ground busbar positioned above the Settima power steering pump, approximately at the center of the firewall.

Figure 28 – Ground busbar location.
Figure 28 – Ground busbar location.

10-B Tighten the stud nuts to 7 Nm.

Figure 29 – Stud nuts to retorque.
Figure 29 – Stud nuts to retorque.

# Final validation

11-A Replace the 7.5A fuse back to its original position (hydraulic braking system only).

Figure 30 – 7.5A fuse to reinstall.
Figure 30 – 7.5A fuse to reinstall.

CAUTION Ensure that the battery disconnect switch is in the “OFF” position.

11-B Hydraulic Braking System: With the start switch in the “OFF” position (no key present), press the brake pedal multiple times. The brake booster pump activation sound must clearly follow each pressing of the pedal.

Figure 31 – Press the brake pedal
Figure 31 – Press the brake pedal

11-C Turn the battery disconnect switch to “ON” position.

11-D Turn the start switch to “START” position to activate the high-voltage system.

11-E Under the hood, locate the power and ground passthrough studs on the firewall. Using a multimeter, measure the voltage between the positive and negative passthrough studs to validate the presence of a stable 12V voltage.

Figure 32 – Voltage measurement on the passthrough studs.
Figure 32 – Voltage measurement on the passthrough studs.

11-D Ensure there are no DTCs (Diagnostic Trouble Codes) displayed on the multifunction screen.

11-E Perform a drive test to validate the vehicle’s functionality:

• Put the drive selector in “D” (Drive) and move the vehicle forward a few meters.

• Select “N” (Neutral).

• Put the drive selector in “R” (Reverse) and move the vehicle rearward a few meters.

11-F Confirm there is no DTC present on the display at the end of the test.

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