Energy Storage Box (ESB) Carrier Replacement

ENERGY STORAGE BOX (ESB) CARRIER REPLACEMENT

CAUTION:
- To reduce the risk of severe shock and burns, disable the 42 volt (42V) system anytime you perform service work on or around the energy storage box (ESB). The 42V system will still be active after you have disabled the ESB.
- To reduce the risk of severe shock and burns, always disconnect the 42 volt (42V) energy storage box (ESB) before doing any work to the ESB system. To disconnect the ESB, turn the engine off and turn OFF the service disconnect switch, which is located on the passenger side of the ESB.

REMOVAL PROCEDURE




1. Remove the energy storage box (ESB) trim cover.
2. Disconnect the ESB.
3. Remove the 42-volt positive/negative cable retainer nuts, and retainer.




4. Remove the red connector position assurance (CPA) retainer from the 42-volt connector.
5. Disconnect the 42-volt positive/negative cable electrical connector (4).
6. Disconnect the 120-volt AC electrical connector (3).
7. Remove the ground strap nut (1).
8. Remove the ground straps from the stud (2).
9. Disconnect the 12-volt harness electrical connector on the passenger side.




10. Disconnect the low voltage cable electrical connector (1) on the driver side of the ESB.
11. Remove the retaining clip (2) from ESB carrier.




12. Remove the nuts that retain the ESB carrier to the floor.
13. Reposition the ESB in order to disconnect the HVAC duct from the ESB.
14. With the aid of an assistant, remove the ESB carrier.

INSTALLATION PROCEDURE




1. With the aid of an assistant, install the ESB carrier.
2. Position the ESB in order to connect the HVAC duct to the ESB.
3. Install the ESB carrier nuts.

Tighten the nuts to 47 N.m (35 lb ft).

NOTE: Refer to Fastener Notice in Service Precautions.




4. Connect the low voltage cable electrical connector (1) on the driver side of the ESB.
5. Install the retaining clip (2) to ESB carrier.




6. Connect the 12-volt harness electrical connector on the passenger side.
7. Install the ground straps to the stud (2).
8. Install the ground strap nut (1).

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

9. Connect the 120-volt AC electrical connector (3).
10. Connect the 42-volt positive/negative cable electrical connector (4).
11. Install the red CPA retainer to the 42-volt connector.




12. Install the 42-volt positive/negative cable retainer and nuts.
13. Connect the ESB.
14. Install the ESB trim cover.