Power Distribution Unit (PDU) Inlet Hose Removal And Installation/Replacement

Mobile Repair Possible: No

Special Tools Required:

Hose Spring Clamp Removal Tool - 51012018 (or equivalent)

Vacuum and Fill Machine - 81392152473

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In some Service Instructions, the coolant hoses are shown with a ring pull (1).

This ring pull (1) is only present on a new hose and must be removed after the coolant hose has been installed.

The coolant hoses installed in the vehicle have only spring band clamps (2).

Overview:

Fig 1: Power Distribution Unit (PDU) Inlet Hose Components Location

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WARNING: Electricity hazard
Failure to follow specified procedures may result in death or serious injury from electric shock when working on or near high-voltage components.

Only authorised and appropriately trained persons may carry out work on high-voltage vehicles and components.
Perform High Voltage isolation procedure prior to commencing work
Ensure appropriate Personal Protective Equipment is worn until the system is verified safe

WARNING: Hot surface
Failure to follow specified procedures may result in severe injuries due to burns or scalds.

Do not commence work until components/liquids have sufficiently cooled down.
Always use personal protective equipment (PPE).

NOTE: Contamination
Contamination or moisture entering the cooling system can lead to malfunction or functional failure.

The vehicle cooling system and any removed components should be capped/sealed during work to prevent contamination entry.

Removal Procedure:

Disable High Voltage. Refer to VEHICLE HIGH VOLTAGE ISOLATION AND ENABLING PROCEDURE
Drain cooling system (HV battery and eMotor). Refer to COOLING SYSTEM DRAINING AND FILLING (HV BATTERY AND EMOTOR)

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Remove hose clamp (1) with spring band hose clamp pliers.
Pull PDU inlet hose (2) off the PDU.
NOTE:
Environmental Risk
- Collect and dispose of leaking liquids.
- Observe country-specific disposal regulations.
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Carefully open the hose bracket (1) below the heater for HV coolant with a suitable tool.
Remove the PDU inlet hose (2) from the bracket in arrow direction.
NOTE:
Environmental Risk
- Collect and dispose of leaking liquids.
- Observe country-specific disposal regulations.
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Unhook the PDU inlet hose (1) from the bracket (2) in arrow direction.

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Remove hose clamp (1) with spring band hose clamp pliers.
Pull off PDU inlet hose (2) from HV battery hose in arrow direction.
NOTE:
Environmental Risk
- Collect and dispose of leaking liquids.
- Observe country-specific disposal regulations.
Guide out and remove the PDU inlet hose from the engine compartment.

Installation Procedure:

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Installation note: Use the spring band hose clamp pliers to push the hose on. If replacing with a new hose, you will remove the ring pull (1) to release the clamp. Refer to Figure

Make sure that the spring band clamp is aligned inside the marking on the hose. Refer to HOSE CLAMP REMOVAL AND INSTALLATION/REPLACEMENT GUIDELINES - SPRING TYPE

Installation is the reverse of removal procedure, noting the following.
Fill cooling system (HV battery and eMotor). Refer to COOLING SYSTEM DRAINING AND FILLING (HV BATTERY AND EMOTOR)