Energy Storage Box (ESB) Internal Signal Harness Replacement

ENERGY STORAGE BOX (ESB) INTERNAL SIGNAL HARNESS 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) intermediate cover.
2. Note the routing of the internal signal harness for ease of reassembly.
3. Disconnect the battery resistor electrical connectors.
4. Disconnect the battery temperature sensor electrical connectors.
5. Remove the energy storage control module (ESCM).
6. Disconnect the ESB fan electrical connectors.
7. Disconnect the battery cut-off switch electrical connector.
8. Disconnect the high current sensor electrical connector.
9. Remove the ground wire screw.
10. Disengage the retainers (1, 2) securing the harness.
11. Remove the internal signal harness from the ESB.

INSTALLATION PROCEDURE




1. Position the internal signal harness to the ESB as noted earlier.
2. Engage the retainers (1, 2) in order to secure the harness.
3. Install the ground wire screw.

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

NOTE: Refer to Fastener Notice in Service Precautions.

4. Connect the high current sensor electrical connector.
5. Connect the battery cut-off switch electrical connector.
6. Connect the ESB fan electrical connectors.
7. Install the ESCM.
8. Connect the battery temperature sensor electrical connectors.
9. Connect the battery resistor electrical connectors.
10. Install the ESB intermediate cover.