26/07/2023 16:52:18

Slave Charger - LH - 1st Generation (Remove and Replace)

Correction Code 44101102

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Note
This procedure describes how to remove and install the 1st generation slave charger. If the vehicle is equipped with a 2nd generation slave charger, refer to procedure 44102102 (refer to procedure).
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Warning
Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.
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Warning
To avoid personal injury, eye protection must be worn while using compressed air.

Removal

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Note
The slave charger is optional equipment. This procedure describes replacement of a failed slave charger. To install a slave charger in a vehicle that is only equipped with 1 charger, refer to Service Bulletin SB-12-44-005.
  1. Remove the HV junction box (refer to procedure).
  2. Disconnect the low voltage harness connector from the slave charger.
  3. Remove the nuts (x4) that secure the charger to the body (torque 6.5 Nm).
  4. Remove the bolt that secures the ground strap to the charger case (torque 6.5 Nm).
  5. Position the ground strap aside.
  6. Clamp both coolant hoses near the charger to minimize coolant loss.
  7. Release the locking ring and carefully slide it approximately 50 mm away from the nipple on the charger.
  8. Remove the coolant plug from the inboard side of the replacement charger and have it ready before performing the next step.
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    Note
    Place suitable absorbent material around the affected area to absorb any possible fluid spillage.
  9. Tilt the inboard side of the charger upwards. Release the locking ring and slide the locking ring away from the inboard coolant hose. Remove the coolant hose from the charger and immediately insert the coolant plug into the charger to stop coolant from spilling out. Carefully resecure the locking ring.
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    CAUTION
    The hose might be difficult to remove. However, do not use a knife or other sharp object to cut the hose.
  10. Repeat steps 7-9 on the outboard coolant hose.
  11. Remove the slave charger from the vehicle.
  12. If the charger is being shipped or stored, allow the coolant to drain from the charger, then use compressed air lightly to blow out any remaining coolant.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not exceed 25 PSI when using compressed air to blow out any remaining coolant.

Installation

Installation procedure is the reverse of removal, except for the following:

  1. Install the HV junction box (refer to procedure), but do not connect the master charger at this point.
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    Note
    The master charger must be unplugged in order to configure the slave charger in a later step.
  2. Reconnect 12V and HV power.
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    Note
    Do not reinstall the rear seat cushion yet.
  3. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  4. Unlock the vehicle gateway for diagnostic communication. See Gateway Unlock.
  5. In Toolbox 3, click the Actions tab, type "Set-Slave" into the search field, click PROC_CHG_X_CHARGER-CONFIG-SET-SLAVEvia Toolbox: (link), click Run, and allow the routine to complete.
  6. Reconnect the master charger (refer to procedure).
  7. In Toolbox 3, click the Actions tab, type "Standby Reboot Gateway" into the search field, click Standby Reboot Gateway, click RUN, and allow the routine to complete.
  8. Refill and bleed the cooling system (refer to procedure).
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    Note
    While the coolant air purge routine is running, check the charger coolant hose connections to make sure there is no leakage.
  9. Update the vehicle firmware. See Firmware Update.
  10. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  11. Reinstall and reconnect all components that were removed for access.
  12. If possible, charge the vehicle at above 40A for several minutes and verify that there are no alerts.