24/05/2023 18:13:23

Charge Port - 3 Phase (Remove and Replace)

FRT No: 44012102

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Note
This procedure describes how to remove and install the 3 phase charge port. If the vehicle is equipped with a single phase charge port, refer to procedure Charge Port - Single Phase - Non-Motorized (Remove and Replace) or Charge Port - Single Phase - Motorized (Remove and Replace).
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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.
  • 2023-05-24: Updated procedure to use Charge Port Voltage Check.

Removal

  1. Open the charge port.
  2. Disconnect 12V power. See Disconnect 12V Power.
  3. Perform the charge port voltage check. See Charge Port Voltage Check.
  4. Remove the LH trunk trim. See Trim - Rear Trunk - Side - LH (Remove and Replace).
  5. Release the 12V harness connection from the charge port.
  6. Remove the grounding bracket by releasing the nut that secures it to the body (torque 6 Nm).
  7. Disconnect the harness that connects the taillight to the charge port.
  8. Remove the cover from the cable connector by using a trim tool or similar non-conductive tool to bend the 3 tabs that secure the cover to the cable connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    The locations of the tabs are marked by arrows on the face of the cover.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not lose or damage the magnet on the outboard side of the cable connector.
  9. Remove the 3 bolts that secure the cable connector to the charge port in the order shown (torque 4 Nm). Remove the cable connector.
  10. Remove the LH taillight assembly. See Taillight Assembly - LH (Remove and Replace).
  11. Remove the bolts in the order shown (torque 3 Nm). Remove the charge port.

Installation

Installation procedure is the reverse of removal, except for the following:
  1. When securing the charge port to the body, install all four bolts loosely, then tighten them in the order shown.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not over-tighten the bolts during installation to prevent water leaks inside the trunk area.
  2. Before installing the cable connector, close the charge port door and verify that it is 0-2 mm underflush to the body. If necessary, turn the screw to adjust the magnet that secures the charge port door.
  3. When reinstalling the cable connector, ensure that the HV cables and data harness do not touch or interfere with the latch on the inside of the charge port.
  4. When securing the cable connector to the charge port, loosely install all 3 bolts, then tighten them in the order shown.
  5. Update the vehicle firmware. See Firmware Update.
  6. Connect a laptop to the diagnostic port of the vehicle, and then use Toolbox 3 to locally connect to the vehicle. See Toolbox 3 (Connect and Disconnect).
  7. Unlock the vehicle gateway for diagnostic communication. See Gateway Unlock.
  8. Using Toolbox 3:
    1. Select the Actions tab and search for "Latch calibration".
    2. Select the ODIN routine PROC_CP_X_LATCH-CALIBRATIONvia Toolbox: (link), and then click the link of the routine.
    3. Click RUN, and allow the routine to complete.
  9. Using Toolbox 3:
    1. Select the Actions tab and search for "Door sensor calibration".
    2. Select the ODIN routine PROC_CP_X_DOOR-SENSOR-CALIBRATIONvia Toolbox: (link), and then click on the link of the routine.
    3. Click RUN, and allow the routine to complete.
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      Note
      If the routine fails with the message "Unmotorized Gen1 charge ports are not supported in this routine", the vehicle might have a non-motorized charge port door with an older revision door sensor that does not require calibration. This is expected behavior and the repair can be considered complete.
  10. Perform a charging session and make sure that charging proceeds as intended.