31/05/2024 10:25:31

Charger (China) (Remove and Replace)

Correction Code 44103012

Special tool(s) required for this procedure:

Part Number Description
1076927-00-A HIOKI MODEL 3541 TESTER 1
1057021-00-A BOLT,PN,SEMS,M6x12,SST,PATCH 2
1083495-00-B BOLT,HF,M6x10,STL[48],ZNNI, PATCH 1
Special tool(s) recommended for this procedure:
Informational PurposesAn informational icon, calling your attention
Note
If the kit is not available, use electrical tape.
Part Number Description
1116814-00-A KIT, DUMMY PLUG, GEN 3 CHARGER
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
To ensure proper torque when replacing an old charger with a new charger, replace all patch bolts with new bolts. However, when reinstalling an old charger, reuse the original patch bolts to avoid an excess buildup of thread locker patch material. Excess patch material requires increased torque to fasten and may result in loose connections.

Removal

  1. Open the LH front door.
  2. Move the driver and front passenger seat fully forward.
  3. Open the hood.
  4. Open the LH and RH rear doors.
  5. Open the liftgate.
  6. Remove the rear underhood apron (refer to procedure).
  7. Remove the LH and RH underhood aprons (refer to procedure).
  8. Remove the inlet HEPA filter duct (refer to procedure).
  9. Remove the outlet HEPA filter duct (refer to procedure).
  10. Disconnect 12V power (refer to procedure).
  11. Check for high voltage at the 3rd generation charger by performing the vehicle HV disablement procedure (refer to procedure).
  12. Remove and discard the bolt that attaches the charge port ground to the charger.
  13. Disconnect the charge port electrical connector from the charger.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the white clip, and then release the tab that faces the charger and the 2 tabs facing away simultaneously.
  14. Remove and discard the bolt that attaches the HV cables to the charger, and then disconnect the HV cables from the charger.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the HV cables from the seat frame area.
  15. Remove the charger ground from the stud on the body.
  16. Disconnect the 12V logic electrical connector from the charger.
  17. Release the barrel clips (x2) that attach the coolant hose to the studs at the rear of the charger.
  18. Remove and discard the bolts (x4) that attach the charger to the body.
  19. Lift up the charger and let it rest on the crossmember.
  20. Place a shop rag or absorbent material underneath the charger.
  21. Remove and discard the bolts (x2) that attach the rapid splitter cables to the charger.
  22. Remove the rapid splitter cables from the charger HV outlet ports, and then set the rapid splitter cables aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the top and bottom clips on the black plastic tabs.
  23. Clamp the coolant hose on the LH side of the charger.
    Informational PurposesAn informational icon, calling your attention
    Note
    Place a shop rag or absorbent material under the coolant hose.
  24. Clamp the coolant hose on the RH side of the charger.
    Informational PurposesAn informational icon, calling your attention
    Note
    Place a shop rag or absorbent material under the coolant hose.
  25. Loosen the clamp, and then remove the coolant hose on the LH side of the charger. Plug the charger port after the coolant hose is removed.
  26. Loosen the clamp, and then remove the coolant hose on the RH side of the charger. Plug the charger port after the coolant hose is removed.
  27. With an assistant, remove the charger from the vehicle.
  28. Remove and discard the mounting bracket bolts (x8) from the charger.

Installation

  1. Install the bolts (x8) that attach mounting brackets onto the new charger (torque 7 Nm).
  2. Clean any coolant residue from the floor of the vehicle.
  3. Put the charger into the vehicle and rest it on the crossmember.
  4. Install the rapid splitter cables into the charger HV outlet ports.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the black plastic tabs are secured.
  5. Install new bolts (x2) that attach the rapid splitter cables to the charger (torque 6 Nm), and then mark the new bolts with a pink/violet paint pen.
  6. Visually inspect the electrical connections for cross threading. Manually wiggle the cables to inspect for movement in the connection.
  7. Set the charger into place, and then install new bolts (x4) that attach the charger to the body (torque 12 Nm).
  8. Connect the 12V logic electrical connector to the charger.
  9. Attach the charger ground to the body stud (torque 9 Nm).
  10. Install new bolt that attaches the charge port HV cables to the charger (torque 6 Nm).
  11. Connect the charge port electrical connector to the charger.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the locking tab is secured.
  12. Install new bolt that attaches the charge port ground to the charger (torque 6 Nm).
  13. Close the orange HV access panel.
  14. Install new bolts (x11) that attach the charger cover panel (torque 2 Nm).
  15. Install the new warranty label onto the charger cover panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean the charger where the warranty label will be applied with an alcohol wipe.
  16. Install the coolant hose onto the LH side of the charger, and then secure the coolant hose with clamp.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The charger must be sealed before disconnecting or reconnecting coolant hoses from the charger. If contaminated by coolant, replace the charger or the charger will be damaged once HV is present.
  17. Install the coolant hose onto the RH side of the charger, and then secure the coolant hose with clamp.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The charger must be sealed before disconnecting or reconnecting coolant hoses from the charger. If contaminated by coolant, replace the charger or the charger will be damaged once HV is present.
  18. Remove the hose clamp pliers from the LH and RH coolant hoses.
  19. Attach the coolant hose clips to the studs on the body.
  20. Install the 2nd row lower seat cushion (refer to procedure).
  21. Reconnect 12V power (refer to procedure).
  22. Reinstall the software (refer to procedure).
  23. Perform the coolant system partial refill and bleed procedure (refer to procedure).
  24. Install the outlet HEPA filter duct (refer to procedure).
  25. Install the inlet HEPA filter duct (refer to procedure).
  26. Install the LH and RH underhood aprons (refer to procedure).
  27. Install the rear underhood apron (refer to procedure).