31/05/2024 12:54:01

Charger - 3rd Generation (3 Phase) (Remove and Replace)

Correction Code 44103202

  • 2023-06092: Condensed procedure and substituted Toolbox 2 by Toolbox 3 routines.
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.
Special tools required for this procedure:
  • 1080568-00-A Coolant Catcher
  • 1135762-00-A Coolant Hose Plug Kit

Remove

  1. Open the LH front door and lower the window.
  2. Open both rear doors, the liftgate and the hood.
  3. Prepare the vehicle for lifting, but do not raise it at this time. See Raise Vehicle - 2 Post Lift.
  4. Remove the LH welcome plate. See Welcome Plate - LH (Remove and Replace).
  5. Remove the LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  6. Fold down the LH 3rd row seat.
  7. Remove the rear load floor.
  8. Remove the rear trunk sill trim. See Trim - Rear Trunk - Sill (Remove and Replace).
  9. Remove the trunk board.
  10. Remove the trunk floor carpet.
  11. Remove the rear load floor support
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips, 2x clips
  12. Remove the LH mid C-pillar. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  13. Remove the LH upper C-pillar. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  14. Remove the 3rd row seat LH side cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x tabs. Release bottom section first, then pivot up and release from side of seat.
  15. Remove the LH rear trunk side trim. See Trim - Rear Trunk - Side - LH (Remove and Replace).
  16. Remove the nut, bolt and push clips (x3) that attach the LH C-pillar bracket to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove fasteners, and then release the edge clip that secures the charge port release cable.
  17. Remove the push clips (x2) that attach the LH rear minion bracket.
  18. Remove the HVAC charger duct.
  19. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  20. Remove the HEPA filter.
  21. Disconnect 12V power. See Disconnect 12V Power.
  22. Raise vehicle fully and lower onto locks.
  23. Remove the LH and RH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x screws, 1x bolt, 2x push clips and 1x nylon nut per side. Discard the nyloc nut after removal.
    Figure 1. LH side shown, RH side similar
  24. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  25. Remove the rear diffuser panel. See Diffuser Panel - Rear (Remove and Replace).
  26. Position the coolant drain underneath the LH rear corner of the vehicle.
  27. Install a coolant hose clamp onto the coolant outlet hose.
  28. Remove the coolant hose from the charger, allow the coolant to drain, and then plug the charger opening.
    Informational PurposesAn informational icon, calling your attention
    Note
    Protect the 12V logic connector and harness from potential coolant ingress.
  29. Disconnect the 12V logic connector from the charger.
  30. Remove the nuts (x2) that attach the charger to the vehicle.
  31. Remove the coolant drain from underneath vehicle, and then lower the vehicle.
  32. Perform the vehicle HV disablement procedure at the charger. See Vehicle HV Disablement Procedure.
  33. Remove and discard the bolts (x2) that attach the rapid splitter cables to the charger.
  34. Release the tabs (x3), and then open the large access door.
  35. Remove the nuts (x4) that attach the charge port cables.
  36. Close the large access door.
  37. Close the small access door.
  38. Use a dummy plug or tape to cover the opening for the charger access panel.
  39. Release the tabs (x4), and then remove the rear pair of HV cables from the charger.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the tabs, and then pull the cables up and out of the charger. Cables may have to be turned slightly to release them from the charger.
  40. Release the tabs (x4), and then remove the front pair of HV cables from the charger.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the tabs, and the pull the cables up and out of the charger. Cables may have to be turned slightly to release them from the charger.
  41. Plug the holes on top of the charger where the HV cables were installed.
  42. Disconnect the rear PTC heater connector.
  43. Install KET dummy plug connector onto the charger's rear PTC HV outlet.
  44. Release the PTC harness barrel clips (x2) from the D-pillar and charger bolt studs.
  45. Remove the bolt that attaches the ground strap to the D-pillar.
  46. Remove the bolt that attaches the ground strap to the charger.
  47. Install coolant hose clamp pliers onto the coolant inlet hose.
  48. Disconnect the coolant inlet hose from the top of the charger.
    Informational PurposesAn informational icon, calling your attention
    Note
    Put absorbent material around the hose to catch any spilled coolant.
  49. Remove the bolts (x2) that attach the LH trunk tie down bracket to the body.
  50. Remove and discard the bolts (x2) that attach the charger upper mounting brackets to the body.
  51. Lift the charger up, and then remove and discard the bolts (x2) that attach the HV cables to the rapid splitter at the bottom of the charger.
  52. Release the black plastic tabs (x2), and then remove the rapid splitter cables from the charger HV outlet ports and set them aside.
  53. Remove the charger from vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance. Use a shop towel to clean any coolant spilled.
  54. Remove and discard the bolts that attach the mounting bracket to the charger.

Install

  1. Install new bolts (x4) that attach the mounting bracket onto the new charger (torque 7 Nm).
  2. Install a new foam gasket onto the charger.
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean the mating surface with IPA.
  3. Put the charger into the vehicle so that HV cables can be installed.
  4. Install the rapid splitter cables into the charger HV outlet.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the black tabs (x2) are tight. Insert the cables into the correct cavity on the charger: the shorter positive cable closest to the access panel, the longer negative cable furthest away from the access panel.
  5. Install new bolts (x2) that attach the rapid splitter cables to the charger (torque 6 Nm).
  6. Install the charger onto the upper mounting brackets and torque the bolts (x2) to 12 Nm.
  7. Install the bolts that attach the LH trunk tie down bracket to the body (torque 9 Nm).
  8. Install the bolt that attaches the ground strap to the charger (torque 6 Nm).
  9. Install the bolt that attaches the ground strap to the D-pillar (torque 9 Nm).
  10. Remove the PTC KET dummy plug, and then connect the PTC heater connector.
  11. Attach the PTC harness barrel clips (x2) to the D-pillar and charger bolt studs.
  12. Release the tabs (x2), and then open the small access door.
  13. Release the tabs (x3), and then open the large access door.
  14. Install the front pair of HV cables into the charger and secure the tabs.
    Informational PurposesAn informational icon, calling your attention
    Note
    Cables may have to be turned slightly to fit then into the charger.
  15. Install the rear pair of HV cables into the charger and secure the tabs.
    Informational PurposesAn informational icon, calling your attention
    Note
    Cables may have to be turned slightly to fit into the charger.
  16. Install the nuts (x4) that attach the charge port cables to the charger (torque 6 Nm).
  17. Install new bolts (x2) that attach the HV cables from the rapid splitter (torque 6 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the cable end terminals before tightening the bolts.
  18. Close the large and small access door.
  19. Install new bolts (x11) that attach the charger access panel to the charger (torque 2 Nm).
  20. Clean the area around the charger access panel with an IPA wipe prior to installation of a new warranty label.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow IPA to dry for at least 1 minute.
  21. Install a new warranty label.
  22. Install the coolant inlet hose onto the charger and then remove the hose clamp pliers from the hose.
  23. Raise the vehicle fully and lower onto locks.
  24. Install the nuts (x2) that attach the bottom of the charger to the body (torque 9 Nm).
  25. Connect the 12V logic connector to the charger.
  26. Install the coolant outlet hose onto the charger, and then remove the hose clamp pliers from the hose.
  27. Install the rear diffuser panel. See Diffuser Panel - Rear (Remove and Replace).
  28. Hand start the bolts that attach the mid aero shield bolts (x20) and install the clips (x2)
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque the bolts at a later step.
  29. Install the LH and RH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x screws, T25, torque 6 Nm; 1x bolt, 10mm, torque 4 Nm; 2x push clips. Install a new nyloc nut 15mm, torque to 35 Nm.
    Figure 2. LH side shown, RH side similar
  30. Torque the mid aero shield bolts (x20) to 4 Nm.
  31. Lower the vehicle.
  32. Reconnect 12V power. See Disconnect 12V Power.
  33. Perform a coolant air purge. See the "Bleed" section in Cooling System - Partial Refill and Bleed.
  34. Reinstall the LH rear charger HVAC duct.
  35. Install the push clips (x2) that attach the LH rear minion bracket.
  36. Install the LH rear C-pillar bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 8mm, torque 1.25 Nm; 1x bolt, 10mm, torque 2.5 Nm; 3x push clips, 1x edge clip. Secure the edge clip for charge port release cable, then position and install the fasteners.
  37. Install the LH trunk carpet panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips. Slide the panel down into position, and then connect the 12V outlet. Attach the clips at the top of the panel. Position the rear edge of the panel and feed the trunk tie down hook through, then fully seat the carpet surrounding the trunk nub.
  38. Install the calamari trim onto the LH rear side trunk trim.
    Informational PurposesAn informational icon, calling your attention
    Note
    6x tabs. Seat outboard tabs first, then front and back, then inboard for easiest installation.
  39. Install the 3rd row seat LH side cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x tabs. Position the top section next to seat, then secure the lower tabs.
  40. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  41. Install the LH C-pillar mid trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  42. Install the rear load floor support.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips, 2x clips
  43. Reinstall the front lower carpet trim panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    Attach the 3rd row seat wiring harnesses to the panel.
  44. Install the trunk board.
  45. Install the rear trunk sill trim. See Trim - Rear Trunk - Sill (Remove and Replace).
  46. Install the LH and RH trunk sill side garnish. See Garnish - Rear Trunk - Side - LH (Remove and Replace).
  47. Install the rear load floor.
  48. Install the LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  49. Install the LH welcome plate. See Welcome Plate - LH (Remove and Replace).
  50. Perform a firmware update. See Firmware Update.
  51. Install the HEPA filter.
  52. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  53. Verify correct charging system operation.