09/08/2023 02:12:09

Door Assembly - Charge Port (China) (Remove and Replace)

Correction code 44014302

  • 1080562-00-A Telescoping Hood Prop
  • 1060071-00-A Torque Wrench ¼ in Dr Hexagon
  • 1076921-00-A Fluke 1587
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 at all times a high voltage cable, busbar, or fitting 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
Warning

Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Proper personal protective equipment (PPE) is required to perform this procedure:

  • High voltage insulating gloves
  • Leather glove protectors
  • High voltage glove tester
  • Safety glasses
  • Electrical hazard rated safety shoes
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

A glove inflator is the only recommended way to test HV gloves. Both HV gloves must pass testing before beginning this procedure. If either glove does not pass the air check, discard the pair.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Make sure that the HV gloves are not expired. HV gloves can be used up to 12 months after the testing date printed on the glove, but only 6 months after first use even if the gloves are still within the 12-month period.

Remove

  1. Open the LH front door and lower the LH front window.
  2. Move both front seats fully forward.
  3. Open the rear doors, the liftgate, and the charge port door.
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Remove the LH and the RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
  6. Remove the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
  7. On the touchscreen, tap Controls > Charging > Open Charge Port to open the charge port door.
  8. Perform the charge port voltage check. See Charge Port Voltage Check.
  9. Remove the LH trunk side trims. See Trim - Rear Trunk - Side - LH (Remove and Replace).
  10. Release the clip and the tabs (x6) that attach the painted panel to the charge port door.
    Tip: Release the clip through opening, and then slide the door away from the vehicle.
  11. Remove the nut that attaches the charge port ground to the body.
    Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 6 in extension
    • 13 mm socket
  12. Release the edge clips (x2) that attach the manual release cables to the charge port assembly.
  13. Remove the screw that attaches the latch release cables at the center of the charge port assembly housing, and then move the cables aside.
    Use of the following tool(s) is recommended:
    • Torx T20 socket
    • 4 in extension
    • Ratchet/torque wrench
  14. Disconnect the latch actuators (x2).
  15. Disconnect the logic connector from the charge port ECU.
  16. Release the clips (x2) that attach the HV cables to body studs.
  17. Remove the bolts (x3) that attach the HV harnesses to the charge port housing, and then move the harnesses aside.
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 in extension
    • 10 mm socket
  18. Remove the bolts (x7) to remove the charge port assembly from the vehicle.
    Use of the following tool(s) is recommended:
    • 10 mm socket
    • 4 in extension
    • Ratchet/torque wrench
  19. Disconnect the charge port door connector.
  20. Rotate the charge port door assembly out with charge port door open, release the grommet, and then feed the charge port door harness through the body so that the charge port door may be removed.

Install

  1. Position the charge port door assembly to the vehicle, feed the harness through the body, and then secure the grommet to the body.
    Tip: Ensure the grommet is fully seated all the way around.
  2. Connect the charge port door connector.
  3. Install the bolts (x7) to secure the charge port assembly to the vehicle.
    6 Nm (4.4 lbs-ft)
    Use of the following tool(s) is recommended:
    • 10 mm socket
    • 4 in extension
    • Ratchet/torque wrench
  4. Install the bolts (x3) that attach the HV harnesses to the charge port housing.
    6 Nm (4.4 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Ensure that the cable is not tugged or pulled unnecessarily which can yield the C-clamp strain relief and cause a thermal ignition event at the GB charge port area while attempting to charge.
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 in extension
    • 10 mm socket
    • 4 in extension
  5. Secure the clips (x2) that attach the HV cables to body studs.
  6. Connect the latch actuators (x2).
  7. Connect the logic connector to the charge port ECU.
  8. Install the screw that attaches the latch release cables at the center of the charge port assembly housing.
    1.5 Nm (1.1 lbs-ft)
    Use of the following tool(s) is recommended:
    • Torx T20 socket
    • 4 in extension
    • Ratchet/torque wrench
  9. Secure the edge clips (x2) that attach the manual release cables to the charge port assembly.
  10. Install the nut that attaches the charge port ground to the body.
    9 Nm (6.6 lbs-ft)
    Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 6 in extension
    • 13 mm socket
    • Ratchet/torque wrench
    • 4 in extension
  11. Install the clip and the tabs (x6) that attach the painted panel to the charge port door.
    Tip: Check the orientation of the outer trim prior to the installation (marked on rear of panel).
  12. Install the LH trunk side trims. See Trim - Rear Trunk - Side - LH (Remove and Replace).
  13. Close the liftgate and the charge port door.
  14. Install the new patch bolts (x11) that secure the HV charger access panel cover.
    2 Nm (1.5 lbs-ft)
    Use of the following tool(s) is recommended:
    • Torx T20 socket
    • 2 in extension
    • Electrical Protective Gloves
    • Flex head ratchet/flex head torque wrench
    • Ratchet/torque wrench - 1060071-00-A
  15. Use IPA wipes to clean the charger, and then install the new warranty label onto the charger cover panel.
    Tip: Allow 1 minute for the IPA to dry.
  16. Lower the seat frame into the position, and then secure the harness clips (x8) to the frame.
  17. Install and torque the bolts that attach the seat frame to the vehicle.
    26 Nm (19.2 lbs-ft)
    Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 6 in extension
    • 11 mm socket
  18. Place the NVH padding onto seat frame.
  19. Install the connectors (x7, if equipped) and the clips (x2) that secure the seat bottom cushion.
  20. Connect the 12V battery power. See Disconnect 12V Power.
  21. Install the LH and the RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
  22. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  23. Return both front seats to the original positions.
  24. Raise all windows and close all doors.