31/05/2024 10:33:52

Slave Charger - LH - 2nd Generation (Remove and Replace)

Correction Code 44102102

  • 2023-07-18: Updated charger configuration steps to latest validation.
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Note
This procedure describes how to remove and install the 2nd generation slave charger. If the vehicle is equipped with a 1st generation slave charger, refer to procedure 44101102. See Slave Charger - LH - 1st Generation (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.
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Warning
To avoid personal injury, eye protection must be worn while using compressed air.

Removal

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Note
The slave charger is optional equipment. This procedure describes replacement of a failed slave charger.
  1. Disconnect 12V power. See Disconnect 12V Power.
  2. Remove the 2nd row seat frame:
  3. Perform a vehicle HV disablement procedure at the HVJB. See Vehicle HV Disablement Procedure.
  4. Remove the HVJB cover (refer to procedure).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The previous step contains instructions to check for high voltage inside the HVJB. Do not proceed unless no high voltage is present.
  5. Release the 4 harnesses that connect the HVJB to the chargers.
  6. Release all fasteners inside the High Voltage Junction Box (HVJB) so that it can lifted up in order to replace the charger in a later step:
    1. Dual motor vehicles only: Mark the rear HV cable that leads to the front drive unit as B-, and the forward HV cable that leads to the front drive unit as B+.
      Figure 1. Table 1: HV Cable fasteners inside HVJB
      1 B+ Front Drive Unit (if equipped)
      2 B- Front Drive Unit (if equipped)
      3 B+ battery/drive inverter
      4 B- battery/drive inverter
      5 B+ forward junction box
      6 B- forward junction box
      7 B- charge port
      8 B+ charge port
    2. Release the nuts (x2) that secure the HV cables that lead to the front drive unit (torque 9 Nm).
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      Note
      Refer to Table 1.
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      Note
      It is not necessary to replace the fastener(s) after it is removed. The threaded area has a reusable dry sealant, which looks similar to adhesive patch material.
    3. Mark the rear HV cables that lead to the battery and drive inverter as B‒, and the forward HV cables that lead to the battery and drive inverter as B+.
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      Note
      Refer to Table 1.
    4. Release the nuts (x2) that secure the HV cables that lead to the battery and drive inverter (torque 9 Nm).
      Informational PurposesAn informational icon, calling your attention
      Note
      Refer to Table 1.
      Informational PurposesAn informational icon, calling your attention
      Note
      It is not necessary to replace the fastener(s) after it is removed. The threaded area has a reusable dry sealant, which looks similar to adhesive patch material.
    5. Mark the rear HV cable that leads to the forward junction box as B+ and the forward HV cable that leads to the forward junction box as B‒.
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      Note
      Refer to Table 1.
    6. Release the bolts (x2) that secure the HV cables that lead to the forward junction box (torque 4 Nm).
      Informational PurposesAn informational icon, calling your attention
      Note
      It is not necessary to replace the fastener(s) after it is removed. The threaded area has a reusable dry sealant, which looks similar to adhesive patch material.
    7. Mark the HV cables that lead to the charge port:
      • Single-phase charging: : Mark the forward cable as B- and the rear cable as B+.
      • 3-phase charging: : Starting from the front and working toward the rear of the vehicle, mark the 4 HV cables that lead to the charge port from front to rear as L2, L3, L1, and N.
      Informational PurposesAn informational icon, calling your attention
      Note
      Vehicles equipped with 3-phase charging have 4 charge port cables instead of 2.
      Figure 2. Table 2: 3-Phase charge port cables
      1 B+ N charge port
      2 B- L1 charge port
      3 B+ L3 charge port
      4 B- L2 charge port
    8. Release the bolts that secure the HV cables that lead to the charge port.
      • North America, Japan: 2 bolts (torque 9 Nm).
      • Europe, APAC: 4 bolts (torque 4 Nm).
      Informational PurposesAn informational icon, calling your attention
      Note
      Refer to Table 1.
      Informational PurposesAn informational icon, calling your attention
      Note
      It is not necessary to replace the fastener(s) after it is removed. The threaded area has a reusable dry sealant, which looks similar to adhesive patch material.
  7. Release the bolts (x4) that secure the HVJB to the body (torque 5 Nm).
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    Note
    Do not remove the HVJB from the vehicle. It is only necessary to release the bolts so that the HVJB can be lifted up in a later step.
    Figure 3. HVJB shown removed from vehicle, for clarity.
  8. Disconnect the harnesses (x2) from the side of the master charger in the following order:
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Disconnecting harnesses in the wrong order triggers multiple high-priority alerts.
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    Note
    The master charger must be unplugged in order to configure the slave charger in a later step.
    1. Disconnect the 12-pin harness from the front port.
    2. Disconnect the 10-pin harness from the rear port.
  9. Disconnect the connectors (x2) from the side of the slave charger in the following order:
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Disconnecting harnesses in the wrong order triggers multiple high-priority alerts.
    1. Disconnect the 12-pin harness from the rear port.
    2. Disconnect the 10-pin HVIL loopback connector from the front port.
    1 10-pin HVIL loopback connector
    2 12-pin harness
  10. Release the ground strap from the rear of the charger (torque 7 Nm).
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    Note
    Leave the ground strap secured to the vehicle.
  11. Dual motor vehicles only: Release the bolt that secures the fuse bracket to the slave charger (torque 9 Nm).
  12. Release the bolts (x4) that secure the charger to the body (torque 7 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    It is necessary to lift the front of the HVJB out of the way in order to access the inboard coolant hose. Have an assistant hold up the front of the HVJB 20-30 mm.
  13. Clamp the coolant hoses on both the inboard and outboard sides of the charger, approximately 150 mm from the edge of the charger.
  14. Ensure that all harnesses and cables are protected from any coolant that might be spilled in a later step.
  15. Lift up the inboard side of the charger. Cover the floor of the vehicle with towels or shop rags to catch any coolant that might be spilled in a later step.
  16. Remove the coolant plug from the inboard side of the new charger and have it ready before performing the next step.
  17. Tilt the inboard edge of the charger upwards. Use pliers or a similar tool to release the locking ring from the inboard coolant hose. Slide the locking ring approximately 50 mm away from the tip of the inboard coolant hose. Remove the coolant hose from the new charger and immediately install the coolant plug onto the old charger to stop coolant from spilling out.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The coolant hose might be difficult to remove. However, do not use a knife or other sharp object to cut the hose.
  18. Repeat steps 14-17 for the outboard coolant hose.
  19. Lift the charger out of the vehicle.
  20. If the charger is being shipped or stored, allow the coolant to drain from the charger, then use compressed air lightly to blow out any remaining coolant.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not exceed 25 PSI when using compressed air to blow out any remaining coolant.
  21. Disconnect HV power, but leave 12V power connected. Perform the vehicle HV disablement procedure (refer to procedure), except for the disconnection of the 12V battery ground.
  22. Connect an external charger to the 12V battery.

Installation, Configuration, and Coolant Purge

Fully clean the area before installing the new charger.
  1. Position the new charger over the mounting studs on the base of the vehicle, but do not secure the nuts at this time.
  2. Secure the coolant hoses to the new charger and resecure the locking rings.
    Informational PurposesAn informational icon, calling your attention
    Note
    Have an assistant raise the front of the HVJB 20-30 mm while the coolant hoses are secured to the charger.
  3. Remove the clamps from the coolant hoses.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Clean up any spilled coolant.
  4. Install the nuts (x4) that secure the charger to the body (torque 7 Nm).
  5. Secure the ground strap to the rear of the charger (torque 7 Nm).
  6. Connect the harnesses (x2) to the side of the slave charger in the following order:
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Connecting harnesses in the wrong order triggers multiple high-priority alerts.
    1. Connect the 10-pin HVIL loopback connector to the front port.
    2. Connect the 12-pin harness to the rear port.
    1 10-pin HVIL loopback connector
    2 12-pin harness
  7. If any HV cable terminals have contacted coolant, clean them with alcohol.
  8. Resecure all HV cables inside the HVJB:
    • The 2 cables to the front drive unit (if equipped)
    • The 4 HV cables to the HV battery and drive inverter
    • The 2 HV cables to the DCDC converter
    • The 4 HV cables to the charge port
  9. Reconnect the HVJB harness connections (x4) to the master and slave charger.
  10. Reinstall the bolts (x4) that secure the HVJB (torque 5 Nm).
  11. Reinstall the HVIL bolt, standard bolt, and nuts (x5) that secure the HVJB cover (torque 5 Nm).
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    Note
    The HVIL bolt is a specific length in order to activate the HVIL switch. Ensure that the correct bolt is used during reinstallation.
  12. Connect the 12V battery negative terminal, and then connect a 12V charger to the battery.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not connect the first responder loop at this time.
  13. Configure the new charger, using Toolbox 3 or Toolbox 2:
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    Note
    New chargers come automatically configured as master chargers.
    1. Using Toolbox 3: Unlock the vehicle gateway for diagnostic communication. See Gateway Unlock.
    2. 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).
    3. Configure the new charger as a slave charger: in Toolbox 3, select Actions, then PROC_CHG_X_CHARGER-CONFIG-SET-SLAVEvia Toolbox: (link), click Run, and allow the routine to complete.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not reconnect the master charger until the slave charger is properly configured.
    Or:
    1. Unlock the vehicle gateway for diagnostic communication. See Gateway Unlock.
    2. Using Toolbox 2: Connect a laptop with Toolbox to the diagnostic port and powertrain CAN bus.
    3. Use the Toolbox "Charger Config" panel to configure the new charger as a slave charger.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not reconnect the master charger until the slave charger is properly configured.
  14. Connect the harnesses (x2) to the side of the master charger in the following order:
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Connecting harnesses in the wrong order triggers multiple high-priority alerts.
    1. Connect the 10-pin harness to the rear port.
    2. Connect the 12-pin harness to the front port.
  15. Connect the first responder loop.
  16. Refill and bleed the cooling system (refer to procedure).
    Informational PurposesAn informational icon, calling your attention
    Note
    While the coolant air purge routine is running, check the charger coolant hose connections to make sure there is no leakage.
  17. Reinstall the latest vehicle firmware, or update the firmware if not the latest. See Firmware Reinstall - Touchscreen or Firmware Update.
  18. Disconnect the laptop from the vehicle.
  19. Disconnect the 12V charger from the 12V battery.
  20. Reinstall all components that were removed for access.
  21. If possible, charge the vehicle at above 40A for several minutes and verify that there are no alerts.