12/08/2020 15:26:15

Master Charger - RH - 1st Generation (Remove and Replace)

Correction Code 44100202

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Note
This procedure describes how to remove and install the 1st generation master charger. If the vehicle is equipped with a 2nd generation master charger, refer to procedure 44102202 (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 not installed in the vehicle unless it was requested as an option. The graphics may show both options, Master and Slave chargers, during this procedure.
  1. Remove the HV junction box (refer to procedure).
  2. Disconnect the low voltage harness.
  3. Peel back the carpet for access to the bolts.
  4. Remove the nuts (x4) that secure the charger to the floor panel (torque 6.5 Nm).
  5. Remove the bolt that secures the ground strap to the charger casing (torque 6.5 Nm).
  6. Position the ground strap aside.
  7. Clamp both hoses approximately 200 mm from the charger to minimize coolant loss.
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    Note
    Place suitable absorbent material around the affected area to absorb any possible fluid spillage.
  8. Release the locking ring for the inboard coolant hose and carefully slide it approximately 50 mm away from the nipple on the charger.
  9. Remove the coolant plug from the inboard side of the replacement charger and have it ready before performing the next step.
  10. Tilt the inboard side of the charger upwards. Remove the coolant hose from the old charger and immediately insert the coolant plug to stop coolant from spilling out. Carefully resecure the locking ring.
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    CAUTION
    Plug component open ports and disconnected hoses to prevent coolant loss.
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    CAUTION
    The hoses might be difficult to remove. However, do not use a knife or other sharp object to cut the hoses.
  11. Repeat steps 8-9 on the outboard coolant hose.
  12. Remove the charger from the vehicle.
  13. 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:

  • Refill and bleed the cooling system (refer to procedure).
  • Update the vehicle firmware. See Firmware Update.
  • If possible, charge the vehicle at above 40A for several minutes and verify that there are no alerts.