Energy Storage Box (ESB) Carrier Disassemble/Assemble

ENERGY STORAGE BOX (ESB) CARRIER DISASSEMBLE/ASSEMBLE

TOOLS REQUIRED
J 43679 Battery Removal Handles

DISASSEMBLY PROCEDURE




1. Remove the energy storage box (ESB) carrier.
2. Remove the ESB intermediate cover screws.
3. Remove the ESB intermediate cover.




4. Remove the control module nuts.
5. Lift the control module up off of the studs.
6. Disconnect the control module electrical connectors.
7. Remove the control module.




8. Remove the maxi-fuse cover.




9. Remove the maxi-fuse nuts (1).
10. Remove the maxi-fuse (2).




11. Disconnect the battery resistor electrical connector (1), labeled XR3 from the number 3 battery negative terminal resistor.




12. Remove the power cable nut (2) from the current sensor.
13. Remove the battery 2 to battery 3 power cable nuts (1).
14. Remove the battery resistor (4) from the number 3 battery negative terminal.
15. Cut the tie straps securing the power cables to the ESB.
16. Remove the power cables (3).




17. Disconnect the outlet duct from the ESB duct.
18. Disconnect the battery vent tube that is inside the outlet duct.
19. Disconnect the fan electrical connector.
20. Remove the fan screws.
21. Remove the push pin fasteners.
22. Remove the screws attaching the air duct hose to the ESB.
23. Remove the fan and air duct hose.




24. Remove the receptacle outlet cover screws.
25. Carefully pull the receptacle box out of the ESB.
26. Insert a flat-bladed screwdriver into the openings on top of the receptacle box in order to release the tabs securing the outlet cover.
27. Remove the receptacle outlet cover.




28. Disconnect the battery vent hose(s) from the batteries.
29. Disengage the retainers securing the battery vent hose(s).
30. Remove the battery vent hose(s) from the ESB.




31. Disconnect the battery resistor electrical connector (1), labeled XR1 from the number 1 battery negative terminal.
32. Remove the battery cut-off switch nuts (2).
33. Remove the battery resistor from the number 2 battery terminal.
34. Disconnect the battery cut-off switch electrical connector.
35. Disconnect the high current sensor electrical connector (3).




36. Remove the battery cut-off switch (1) and high current sensor (2).




37. Remove the high current sensor carrier nut.
38. Remove the high current sensor carrier.




39. Disconnect the battery resistor electrical connector (1), labeled XR2 from the number 1 battery positive terminal.




40. Remove the power cable nuts (1) from battery 1 and battery 2.
41. Remove the power cable (3) from battery 1 and battery 2.
42. Remove the battery resistor (2) from the number 1 battery positive terminal.




43. Disconnect the battery resistor electrical connector (1), labeled XR4 from the number 3 battery positive terminal.




44. Remove the power cable nuts (1) from the number 3 battery and high current connector.
45. Remove the battery resistor (3) from the number 3 battery positive terminal.
46. Remove the power cable (2).




47. Remove the service disconnect power cable nuts (1) from the high current connector and the service disconnect switch.
48. Remove the power cable (2).




49. Cut the tie straps securing the power cable to the ESB.
50. Remove the service disconnect power cable nut from the service disconnect switch.
51. Remove the power cable.




52. Remove the 120-volt cable connector screws.




53. Disconnect the retainers securing the 120-volt cable to the ESB.
54. Remove the 120-volt cable.




55. Remove the fuse holder screws.
56. Remove the fuse holder.




57. Remove the high current connector screws.




58. Remove the high current connector.




59. Remove the service disconnect switch nuts.




60. Remove the service disconnect switch screws.




61. Remove the service disconnect switch.




62. Remove the battery hold down bracket nuts.
63. Remove the battery hold down brackets.




64. Remove the battery hold down bolts.




65. Using J 43679 , remove the batteries.




66. Remove the ground wire bolt.
67. Disengage the retainers securing the internal signal harness to the ESB.
68. Remove the internal signal harness from the ESB.
69. If necessary, remove any retainers (1), clips (2), or fasteners (3).

ASSEMBLY PROCEDURE




1. If necessary, install any retainers (1), clips (2), or fasteners (3).
2. Install the internal signal harness from the ESB.
3. Engage the retainers securing the internal signal harness to the ESB.

NOTE: Refer to Fastener Notice in Service Precautions.

4. Install the ground wire bolt.

Tighten the bolt to 2 N.m (18 lb in).




5. Using J 43679 , install the batteries.




6. Ensure that the batteries (1, 2, and 3) have the positive and negative terminals properly oriented.




7. Install the battery hold down bolts.




8. Install the battery hold down brackets.
9. Install the battery hold down bracket nuts.

Tighten the nuts to 10 N.m (89 lb in).




10. Install the service disconnect switch.




11. Install the service disconnect switch screws.

Tighten the screws to 6 N.m (53 lb in).




12. Install the service disconnect switch nuts.

Tighten the nuts to 6 N.m (53 lb in).




13. Install the high current connector.




14. Install the high current connector screws.

Tighten the screws to 5 N.m (44 lb in).




15. Install the fuse holder.
16. Install the fuse holder screws.

Tighten the screws to 2 N.m (18 lb in).




17. Install the 120-volt cable.
18. Connect the retainers securing the 120-volt cable to the ESB.




19. Install the 120-volt cable connector screws.

Tighten the screws to 6 N.m (53 lb in).




20. Install the power cable from the service disconnect switch to the fuse block.
21. Install the service disconnect power cable nut to the service disconnect switch.

Tighten the nut to 10 N.m (89 lb in).

22. Install NEW tie straps securing the power cable to the ESB.




23. Install the power cable (2) to the service disconnect switch and to the high current connector.

IMPORTANT: The power cable must be installed to the negative side of the high current connector.

24. Install the service disconnect power cable nuts (1) to the high current connector and service disconnect switch.

Tighten the nuts to 10 N.m (89 lb in).




25. Install the battery resistor (3) to the number 3 battery positive terminal.
26. Install the power cable (2) to the high current connector and the number 3 battery.
27. Install the power cable nuts (1) to the number 3 battery and high current connector.

Tighten the nuts to 10 N.m (89 lb in).




28. Connect the battery resistor electrical connector (1), labeled XR4 to the number 3 battery positive resistor.




29. Install the battery resistor (2) to the number 1 battery positive terminal.
30. Install the power cable (3) to battery 1 and battery 2.
31. Install the power cable nuts (1) to battery 1 and battery 2.

Tighten the nuts to 10 N.m (89 lb in).

32. Connect the battery resistor electrical connector.




33. Connect the battery resistor electrical connector (1), labeled XR2 to the number 1 battery positive resistor.




34. Install the high current sensor carrier.
35. Install the high current sensor carrier nut.

Tighten the nut to 10 N.m (89 lb in).




36. Install the battery resistor to the number 1 battery negative terminal.

37. Install the high current sensor (2).

IMPORTANT: The high current sensor orientation is VERY important. The sensor wiring MUST be pointed towards the rear of the vehicle, and also the etched numbers on one side of the sensor terminal MUST be on the battery cut-off switch side.

38. Install the battery cut-off switch (1).




39. Connect the battery cut-off switch electrical connector (3).
40. Connect the battery resistor electrical connector (1), labeled XR1 to the number 1 battery negative terminal resistor.
41. Install the battery cut-off switch nuts (2).

Tighten the nuts to 10 N.m (89 lb in).

42. Connect the high current sensor electrical connector.




43. Install the battery vent hose(s) to the ESB.
44. Engage the retainers securing the battery vent hose(s).
45. Connect the battery vent hose(s) to the batteries.




46. Install the receptacle outlet cover.
47. Install the receptacle outlet cover screws.

Tighten the screws to 0.5 N.m (4.4 lb in).




48. Install the fan and air duct hose.
49. Install the screws attaching the air duct hose to the ESB.

Tighten the nuts to 0.5 N.m (4.4 lb in).

50. Install the push pin fasteners.
51. Install the fan screws.

Tighten the nuts to 1 N.m (9 lb in).

52. Connect the fan electrical connector.
53. Connect the ESB vent tube to the outlet duct.
54. Connect the outlet duct to the ESB air duct.




55. Install the battery resistor (4) to the number 3 battery negative terminal.
56. Install NEW tie straps securing the power cables to the ESB.
57. Install the power cables (3).
58. Install the battery 2 to battery 3 power cable nuts (1).
59. Install the power cable nut (2) to the current sensor.

Tighten the nuts to 10 N.m (89 lb in).




60. Connect the battery resistor electrical connector (1), labeled XR3 to the number 3 battery negative terminal resistor.




61. Install the maxi-fuse (2).
62. Install the maxi-fuse nuts (1).

Tighten the nuts to 10 N.m (89 lb in).




63. Install the maxi-fuse cover.




64. Connect the control module electrical connectors.
65. Install the control module.
66. Install the control module nuts.

Tighten the nuts to 6 N.m (53 lb in).




67. Install the ESB intermediate cover.

IMPORTANT: Ensure that the ESB intermediate cover is installed between the ESB metal carrier and the 120-volt receptacle faceplate.

68. Install the ESB intermediate cover screws.

Tighten the screws to 6 N.m (53 lb in).

69. Install the ESB carrier.