12/08/2020 15:26:15
Master Charger - RH - 1st Generation (Remove and Replace)
Correction Code 44100202
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).
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.
Warning
To avoid personal injury, eye protection
must be worn while using compressed air.
Removal
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.
- Remove the HV junction box (refer to procedure).
- Disconnect the low voltage harness.
- Peel back the carpet for access to the bolts.
-
Remove the nuts (x4) that secure the charger to the floor panel (torque 6.5
Nm).
- Remove the bolt that secures the ground strap to the charger casing (torque 6.5 Nm).
- Position the ground strap aside.
-
Clamp both hoses approximately 200 mm from the charger to minimize coolant
loss.
NotePlace suitable absorbent material around the affected area to absorb any possible fluid spillage.
-
Release the locking ring for the inboard coolant hose and carefully slide it
approximately 50 mm away from the nipple on the charger.
- Remove the coolant plug from the inboard side of the replacement charger and have it ready before performing the next step.
-
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.
CAUTIONPlug component open ports and disconnected hoses to prevent coolant loss.CAUTIONThe hoses might be difficult to remove. However, do not use a knife or other sharp object to cut the hoses.
- Repeat steps 8-9 on the outboard coolant hose.
-
Remove the charger from the vehicle.
-
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.
CAUTIONDo 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.