NHTSA ID Number: 10146689
Manufacturer Communication Number: CC-17-20-07
TSB/Document Date: 2018-11-05
Summary
PTC fluid heater replacement procedure for select VINs
Customer Satisfaction Campaign
CC-17-20-07
MODEL: Karma Revero
TITLE: PTC Heater Replacement
DATE: June 2017
First Release
APPLICABILITY: Specified VINs below
MARKET REGION: North America
PURPOSE: Customer Satisfaction Campaign replacement of the PTC Fluid Heater
Air conditioning and heating may not be adequate within the cabin, a new replacement PTC heater is available
to remedy this condition. This affects only a select few vehicles. Confirm the vehicle is on this list before
proceeding.
Vehicle Identification Number
50GK41SA3HA000012
50GK41SA7HA000014
50GK41SA0HA000016
50GK41SA4HA000018
50GK41SA6HA000019
50GK41SA2HA000020
50GK41SA2HA000021
50GK41SA6HA000022
50GK41SA8HA000023
50GK41SAXHA000024
50GK41SA4JA000011
Karma Automotive Bulletins and service documents are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment
and a suitable workshop for any procedure described in this document, we suggest you leave such repairs to a Karma retailer and service provider. See
your service provider for advice on whether your vehicle may benefit from the information contained within this document. The information contained in the
Karma Bulletin is accurate at the date of publication. However, Karma Automotive regularly updates technical information. Please check with your Karma
Automotive Retailer and Karma Automotive service provider that the bulletin you intend to use contains the latest available information.
Page 1 of 10
Published: June 2017
Customer Satisfaction Campaign
CC-17-20-07
MODEL: Karma Revero
TITLE: PTC Heater Replacement
DATE: June 2017
First Release
1. Isolate the 12V battery
a. Note- have vehicle unlocked, open all the windows before disconnecting
b. Remove the 10A solar panel fuse as shown (fig.1a)
c. Disconnect the 12V harness as shown (fig.1b).
fig.1a
fig.1b
2. Disable High Voltage Electrical System - Remove the Manual Service Disconnect
Electrical System - HIGH VOLTAGE
The High Voltage power system supplies 400 volts at 500 amps. In cases of an accident prevention
and recovery, personal protection equipment must be used (as described in the Special Tools list
release 00.01.16.0001 available on the retailer portal).
Karma Automotive Bulletins and service documents are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment
and a suitable workshop for any procedure described in this document, we suggest you leave such repairs to a Karma retailer and service provider. See
your service provider for advice on whether your vehicle may benefit from the information contained within this document. The information contained in the
Karma Bulletin is accurate at the date of publication. However, Karma Automotive regularly updates technical information. Please check with your Karma
Automotive Retailer and Karma Automotive service provider that the bulletin you intend to use contains the latest available information.
Page 2 of 10
Published: June 2017
Customer Satisfaction Campaign
CC-17-20-07
MODEL: Karma Revero
TITLE: PTC Heater Replacement
DATE: June 2017
First Release
2.1. Manual Service Disconnect (MSD) - Removal Instructions
Remove the rear seat cushion to expose the manual service disconnect (MSD). to deactivate the high
voltage supply to the vehicle, open the left rear door, lift the of lower left rear seat cushion to unlatch it.
Under cushion you will find a boxed cover with a locking pin (fig 2a and 2b).
fig.2a
fig.2b
NOTE: The Manual Service Disconnect is a one time use
item, discard the original and refit with a new MSD when the
returning the vehicle to operation
WARNING
HIGH VOLTAGE battery
contains lethal voltage. Do not remove the Manual Service Disconnect
(MSD) if the vehicle is switched on or running. Intentional disconnection of the MSD under load
could potentially damage the battery pack and cause injury to the person performing the act.
Always wear personal protective gear such as insulated gloves and a face shield.
CAUTION
Wait five (5) minutes for high voltage capacitors to discharge after removal of the Manual Service
Disconnect (MSD). Although the battery has been disconnected residual current may still
be present.
Karma Automotive Bulletins and service documents are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment
and a suitable workshop for any procedure described in this document, we suggest you leave such repairs to a Karma retailer and service provider. See
your service provider for advice on whether your vehicle may benefit from the information contained within this document. The information contained in the
Karma Bulletin is accurate at the date of publication. However, Karma Automotive regularly updates technical information. Please check with your Karma
Automotive Retailer and Karma Automotive service provider that the bulletin you intend to use contains the latest available information.
Page 3 of 10
Published: June 2017
Customer Satisfaction Campaign
CC-17-20-07
MODEL: Karma Revero
TITLE: PTC Heater Replacement
DATE: June 2017
First Release
2.1.1 Release the latch pin from the MSD latch (fig.3a,3b,and 3c). Lift cover for access, release clip and
remove the MSD from the HV battery
fig.3a
fig.3b
fig.3c
Karma Automotive Bulletins and service documents are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment
and a suitable workshop for any procedure described in this document, we suggest you leave such repairs to a Karma retailer and service provider. See
your service provider for advice on whether your vehicle may benefit from the information contained within this document. The information contained in the
Karma Bulletin is accurate at the date of publication. However, Karma Automotive regularly updates technical information. Please check with your Karma
Automotive Retailer and Karma Automotive service provider that the bulletin you intend to use contains the latest available information.
Page 4 of 10
Published: June 2017
Customer Satisfaction Campaign
CC-17-20-07
MODEL: Karma Revero
TITLE: PTC Heater Replacement
DATE: June 2017
First Release
3. With the hood open- remove the engine cover and proceed to Disconnect MAF sensor harness
connector (blue in fig.4)
fig.4
4. Remove screws (x3) securing battery low temperature reservoir to PTC mounting bracket
5. Release battery coolant reservoir from mounting and tie aside for access (fig.5)
6. Clamp coolant hoses either side of PTC heater as close to connections as possible
fig.5
Karma Automotive Bulletins and service documents are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment
and a suitable workshop for any procedure described in this document, we suggest you leave such repairs to a Karma retailer and service provider. See
your service provider for advice on whether your vehicle may benefit from the information contained within this document. The information contained in the
Karma Bulletin is accurate at the date of publication. However, Karma Automotive regularly updates technical information. Please check with your Karma
Automotive Retailer and Karma Automotive service provider that the bulletin you intend to use contains the latest available information.
Page 5 of 10
Published: June 2017
Customer Satisfaction Campaign
CC-17-20-07
MODEL: Karma Revero
TITLE: PTC Heater Replacement
DATE: June 2017
First Release
7. Release clips and disconnect coolant hoses from PTC heater
CAUTION
Note: Place suitable absorbent
material around the affected area to
absorb any possible fluid spillage.
Plug all open connections to prevent
ingress of moisture and dirt.
8. Remove screws (x4) securing PTC heater to mounting bracket
9. Raise PTC heater and disconnect the orange high voltage connector and low voltage
harness connectors (fig. 6)
Note: Ensure clean component
mating faces, prior to installation
of the new unit
INSTALLATION
1. Installation procedure is reverse of removal except for the following priming and bleeding procedure
Karma Automotive Bulletins and service documents are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment
and a suitable workshop for any procedure described in this document, we suggest you leave such repairs to a Karma retailer and service provider. See
your service provider for advice on whether your vehicle may benefit from the information contained within this document. The information contained in the
Karma Bulletin is accurate at the date of publication. However, Karma Automotive regularly updates technical information. Please check with your Karma
Automotive Retailer and Karma Automotive service provider that the bulletin you intend to use contains the latest available information.
Page 6 of 10
Published: June 2017
Customer Satisfaction Campaign
CC-17-20-07
MODEL: Karma Revero
TITLE: PTC Heater Replacement
DATE: June 2017
First Release
2. Prime PTC heater with coolant prior to connecting final hose
- Top off the reservoir, leave off the cap then put in Accessory Mode
-Place in Heater and Defrost to allow the air to move through the system
To properly bleed the coolant system the wipers and cowl cover need to be removed.
3. Remove the windshield wipers
a. Mark the fitted position of the wiper arm to reinstall it at the same park location
b. Remove the nut (install torque 25Nm) (fig. 7a)
c. Release clip securing the washer nozzle to wiper arm and release
d. disconnect hose. (note routing for easier install) (fig. 7b)
fig.7a
fig.7b
4. Remove the cowl screen
a. Remove the rear hood seal from the cover
(fig. 8a)
b. Remove the clips (x7) securing the cowl to
the body, disconnect the drain tube on LH side
c. Remove cowl (indicated by arrow)
fig. 8a
Karma Automotive Bulletins and service documents are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment
and a suitable workshop for any procedure described in this document, we suggest you leave such repairs to a Karma retailer and service provider. See
your service provider for advice on whether your vehicle may benefit from the information contained within this document. The information contained in the
Karma Bulletin is accurate at the date of publication. However, Karma Automotive regularly updates technical information. Please check with your Karma
Automotive Retailer and Karma Automotive service provider that the bulletin you intend to use contains the latest available information.
Page 7 of 10
Published: June 2017
Customer Satisfaction Campaign
CC-17-20-07
MODEL: Karma Revero
TITLE: PTC Heater Replacement
DATE: June 2017
First Release
5. Remove the cowl brace and the wiper module -to access the heater hose below.
a. Remove screws (x2) securing plenum chamber brace to bulkhead. Torque - 25 Nm (fig.9a)
b. Disconnect wiper motor connector (fig.9b)
c. Remove screw securing wiper motor to bulkhead. Torque - 25 Nm (fig.9c)
d. Remove screw securing wiper motor to bulkhead brace. Torque - 25 Nm (fig.9d)
e. Remove bulkhead brace (fig.9d)
f. Remove wiper motor assembly, LH mounting screw. Torque - 25 Nm (fig.9e) - there are 2 zipties
and 1 bolt underneath the flip up
g. Install is reverse of removal
fig.9a
fig. 9b
fig. 9c
fig. 9d
NOTE: There is a nut and bolt
here, it is not captured, have
a magnet ready to capture
these as they are loosened.
fig. 9e
Karma Automotive Bulletins and service documents are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment
and a suitable workshop for any procedure described in this document, we suggest you leave such repairs to a Karma retailer and service provider. See
your service provider for advice on whether your vehicle may benefit from the information contained within this document. The information contained in the
Karma Bulletin is accurate at the date of publication. However, Karma Automotive regularly updates technical information. Please check with your Karma
Automotive Retailer and Karma Automotive service provider that the bulletin you intend to use contains the latest available information.
Page 8 of 10
Published: June 2017
Customer Satisfaction Campaign
CC-17-20-07
MODEL: Karma Revero
TITLE: PTC Heater Replacement
DATE: June 2017
First Release
6.Bleeding the system
a.
b.
c.
d.
Remove the clamp from the heater core out hose connection (upper hose not connected to
pump- (fig.10a)
Use a soft pry- or 90 degree tool, and gap the hose end off the connector to allow to burp the
system (fig.10b)
Have the vehicle in Stealth Mode with the heater enabled Maximum heat is not required to run
the pump on high, however max heat periodically will aid in verification that heat is coming out
of the vents (this has been successfully performed with vehicle in ACC Mode with Defrost on)
Make sure PTC hoses get hot, this may take several minutes, to bleed at heater core.
fig. 10a
fig. 10b
NOTE: Coolant may spill on the ground and on the
hot surfaces in the engine compartment. Keep the
vehilce clean as coolant may be smelled in the cabin
after this procedure is complete
7. Check coolant level and top up coolant reservoir as needed
8. Reconnect hose, reassemble wiper motro and cowl
9. Clean the vehicle and return to operation.
Karma Automotive Bulletins and service documents are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment
and a suitable workshop for any procedure described in this document, we suggest you leave such repairs to a Karma retailer and service provider. See
your service provider for advice on whether your vehicle may benefit from the information contained within this document. The information contained in the
Karma Bulletin is accurate at the date of publication. However, Karma Automotive regularly updates technical information. Please check with your Karma
Automotive Retailer and Karma Automotive service provider that the bulletin you intend to use contains the latest available information.
Page 9 of 10
Published: June 2017
Customer Satisfaction Campaign
CC-17-20-07
MODEL: Karma Revero
TITLE: PTC Heater Replacement
DATE: June 2017
First Release
PARTS REQUIRED:
PART NUMBER
C171000000254
C131118002001
Description
PTC Fluid Heater
Manual Service Disconnect
SHOP SUPPLIES:
Description
N/A
SPECIAL TOOLS:
Description
N/A
CAUSAL PART:
PART NUMBER
Description
C131133301002
PTC FLUID HEATER
LABOR CODES:
CODE
20-40-05-01
Description
PTC Fluid Heater Replacement
Bulletin
TIME
DEFECT CODE
1.3
20-40-05-33
SUBLET:
CODE
FLU - FLU002
Description
Coolant
AMOUNT
1 Gal. (3.8 L) max $12.00 (USD)
WARRANTY DISPOSITION: This repair is covered under the New Vehicle Limited Warranty, in effect
for five (5) years from the in-service date with no mileage limitation.
Karma Automotive Bulletins and service documents are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment
and a suitable workshop for any procedure described in this document, we suggest you leave such repairs to a Karma retailer and service provider. See
your service provider for advice on whether your vehicle may benefit from the information contained within this document. The information contained in the
Karma Bulletin is accurate at the date of publication. However, Karma Automotive regularly updates technical information. Please check with your Karma
Automotive Retailer and Karma Automotive service provider that the bulletin you intend to use contains the latest available information.
Page 10 of 10
Published: June 2017
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