31/05/2024 10:20:35

Charger - 3rd Generation (Remove and Replace)

Correction Code 44103002

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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.
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Note
In three-phase markets, 4 cables connect the charger to the charge port instead of 2.

Special tool(s) required for this procedure:

Part Number Description
1076927-00-A HIOKI MODEL 3541 TESTER
Special tool(s) recommended for this procedure:
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Note
If the kit is not available, use electrical tape.
Part Number Description
1116814-00-A KIT, DUMMY PLUG, GEN 3 CHARGER
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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.

Removal

  1. Perform the vehicle HV disablement procedure at the 3rd generation charger (refer to procedure).
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    Note
    Retain 2 of the fasteners for the charger access panel; the panel will be temporarily reinstalled in a later step.
  2. Release the fastener that attaches the ground strap to the charger (torque 6 Nm).
  3. Open the access port on the LH side of the charger and loosen the nuts that attach the charge port cables (torque 6 Nm).
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    Note
    It is not necessary to completely remove the nuts.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not drop the fasteners inside the charger. If a fastener is dropped inside the charger and not retrieved, the charger must be replaced. Do not activate high voltage until the fastener is retrieved or the charger is replaced.
  4. Remove the charge port cables from the charger.
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    Note
    The rear HV cable has a slotted lug that surrounds a tab in the charger; use a suitable tool to pry the lug upward to maneuver it over the tab before completely removing the cable out from the charger.
    Figure 1. Single Phase Charger
    Figure 2. Three Phase Charger
  5. Use a dummy plug or electrical tape to cover the holes for the charge port cables to prevent contamination.
  6. Release the fastener that attaches the ground strap to the stud on the body (torque 9 Nm).
  7. Disconnect the low voltage harness from the RH side of the charger.
  8. Use a dummy plug or electrical tape to cover the connector on the charger to prevent contamination.
  9. Remove and discard the fasteners (x4) that attach the charger to the body (torque 12 Nm).
  10. Lift up the front of the charger and rest it on the body crossmember.
  11. Remove and discard the fasteners that attach the cables to the Rapid Splitter (torque 6 Nm). Remove the HV Battery cables from the charger.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Replace all patchbolt(s).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not drop the fasteners inside the charger. If a fastener is dropped inside the charger and not retrieved, the charger must be replaced. Do not activate high voltage until the fastener is retrieved or the charger is replaced.
  12. Use the retained fasteners to temporarily reinstall the charger access panel to prevent contamination.
  13. Plug the holes for the HV Battery cables.
  14. Clamp the coolant hose on the RH side of the charger.
  15. Clamp the coolant hose on the LH side of the charger.
  16. Place absorbent material beneath both coolant hoses to catch any coolant that might spill in a later step.
  17. At the rear of the charger, release the clip that attaches both coolant hoses to the body.
  18. Release both coolant hoses from the charger.
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    Note
    Plug charger hose connections to prevent ingress of dirt.
  19. Move the coolant hoses out of the working area.
  20. Remove the charger from the vehicle.
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    Note
    This step requires an assistant.
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    Warning
    The charger weighs approximately 85 pounds (40 kg).
  21. Remove the charger cover panel. Use a dummy plug or electrical tape to plug the opening.
  22. Remove and discard the fasteners that attach the brackets to the charger (torque 7 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Replace all patchbolt(s).

Installation

  1. Install the brackets to the charger, and install new fasteners to attach the brackets to the charger (torque 7 Nm).
  2. Remove the dummy plug or electrical tape from the charger opening, and install the charger cover panel.
  3. Install the charger into the vehicle, and set it on the body crossmember.
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    Note
    This next step requires an assistant.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The charger weighs approximately 85 pounds (40 kg).
  4. Move the coolant hoses into the working area.
  5. Remove the plugs from the charger hose connections, and then connect both coolant hoses to the charger.
  6. At the rear of the charger, fasten the clip that attaches both coolant hoses to the body.
  7. Remove the absorbent material used to catch any coolant that might spill.
  8. Remove the clamp from the coolant hose on the LH side of the charger.
  9. Remove the clamp from the coolant hose on the RH side of the charger.
  10. Remove the plugs from the holes for the HV Battery cables.
  11. Remove the charger access panel.
  12. Install the HV Battery cables into the charger, and then install new fasteners to attach the cables to the Rapid Splitter (torque 6 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not drop the fasteners inside the charger. If a fastener is dropped inside the charger and not retrieved, the charger must be replaced. Do not activate high voltage until the fastener is retrieved or the charger is replaced.
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    Note
    After reinstalling the HV Battery cables, confirm that there is no cross-threading:
    • Visually inspect the nuts for cross-threading; a cross-threaded nut will not be seated deeply.
    • Visually inspect for cable movement near the stud by pushing and pulling on the cable.
  13. Move the charger to between crossmembers, and align the holes in the brackets with the holes in the crossmembers.
  14. Install new fasteners to attach the charger to the body (torque 12 Nm).
  15. Remove the dummy plug or electrical tape from the connector on the charger.
  16. Connect the low voltage harness to the RH side of the charger.
  17. Install the fastener that attaches the ground strap to the stud on the body (torque 9 Nm).
  18. Remove the dummy plug or electrical tape from the holes for the charge port cables.
  19. Install the charge port cables into the charger.
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    Note
    The rear HV cable has a slotted lug that surrounds a tab in the charger. Make sure that the slotted lug fits under the tab.
    Figure 3. Single Phase Charger
    Figure 4. Three Phase Charger
  20. Tighten the nuts that attaches the charge port cables inside the charger (torque 6 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not drop the fasteners inside the charger. If a fastener is dropped inside the charger and not retrieved, the charger must be replaced. Do not activate high voltage until the fastener is retrieved or the charger is replaced.
    Informational PurposesAn informational icon, calling your attention
    Note
    After reinstalling the charge port cables, confirm that there is no cross-threading:
    • Visually inspect for cable movement near the stud by pushing and pulling on the cable.
    • Visually inspect the nuts for cross-threading; a cross-threaded nut will not be seated deeply.
    • Single Phase only: Use the Hioki Impedance Tester to measure the impedance between the spade connector and the adjacent busbar. The acceptable impedance is between 0.010 mΩ (10 μΩ) and 0.100 mΩ (100 μΩ). If the impedance is outside those bounds, reposition the probes and measure again. If the impedance is repeatedly between 0.00 mΩ and 0.010 mΩ (10 μΩ), the Hioki test passed, proceed with the installation procedure. For more information on Hioki impedance testing, refer to Toolbox article 218200.
  21. Close the access port on the LH side of the charger.
  22. Install a new fastener to attach the ground strap to the charger (torque 6 Nm).
  23. Reconnect 12V power (refer to procedure)
  24. Update the vehicle firmware. See Firmware Update.
  25. Refill and bleed the cooling system (refer to procedure).