31/05/2024 11:14:18

Charger (Remove and Replace)

Correction Code 44100102

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Warning
Only technicians who have been trained in High Voltage (HV) 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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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 (North America and Japan):

Part Number Description Quantity
1057021-00-A BOLT,PN,SEMS,M6x12,SST,PATCH 2
1083495-00-B BOLT,HF,M6x10,STL[48],ZNNI, PATCH 1

Special tool(s) recommended for this procedure:

Part Number Description
1076927-00-A HIOKI MODEL 3541 TESTER
1116814-00-A KIT, DUMMY PLUG, GEN 3 CHARGER
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Note
If the dummy plug kit is not available, use electrical tape.

Remove

Tip: It is helpful, but not necessary, to have the vehicle on a lift while performing this procedure.
  1. Open both rear doors.
  2. Open the liftgate.
  3. Open the charge port.
  4. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement 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.
  5. Use a dummy plug or electrical tape to cover the opening for the charger access panel.
  6. Remove the LH parcel shelf support (refer to procedure).
  7. Remove the bolts that secure the LH tiedown bracket, then remove the bracket (torque 9 Nm).
  8. Clamp the upper coolant hose.
  9. Remove the mid aero shield (refer to procedure).
  10. Disconnect the electrical connector from the bottom of the charger. Move the harness out of the work area.
  11. Remove the nuts that secure the charger to the body (torque 9 Nm).
  12. Working under the vehicle, clamp the lower coolant hose.
  13. Release the coolant hose from the bottom of the charger.
  14. Lower the vehicle.
  15. If equipped, disconnect the rear PTC heater harness from the charger.
  16. Use a dummy plug or electrical tape to cover the connector on the charger to prevent contamination.
  17. Remove the nut and release the ground strap from the stud on the D-pillar (torque 9 Nm).
  18. Remove and discard the bolt that secures the charge port ground cable to the charger (torque 6 Nm).
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    CAUTION
    Replace all patchbolt(s).
  19. Remove and discard the fasteners that secure the charger bracket to the body (torque 12 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Replace all patchbolt(s).
  20. Gently move the charger to the left and right, then pull it up partially and tilt it toward the center of the vehicle.
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    CAUTION
    Take care not to damage the acoustic padding with the studs on the bottom of the charger.
  21. Remove the bolts that secure the HV harness bracket to the back of the charger (torque 6 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Replace all patchbolt(s).
  22. Remove and discard the fasteners that secure the cables to the HV Battery (torque 6 Nm).
    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, the charger must be replaced. Do not activate high voltage until the charger is replaced.
  23. Use a dummy plug or electrical tape to plug the holes for the HV Battery cables.
  24. Remove the nuts and washers that secure the charge port cables to 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, the charger must be replaced. Do not activate high voltage until the charger is replaced.
  25. Use a flat head screwdriver to release both HV inlet seals from the tabs on the charger inlets.
  26. Pull both charge port cables out from the top of 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 inboard to maneuver it around the tab before completely removing the cable out from the charger.
    Single Phase Markets Three Phase Markets
  27. Use the retained fasteners to temporarily reinstall the charger access panel to prevent contamination.
  28. Plug the holes for the charge port cables.
  29. Position a container in order to catch spilled coolant.
  30. Release the barrel clip that holds the upper coolant hose to the body.
  31. Release the hose from the charger, then plug the hose.
  32. Move the hose out of the working area.
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    Note
    The next step requires an assistant.
  33. Remove the charger from the vehicle.
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    Warning
    The charger weighs approximately 85 pounds (40 kg).

Install

Installation procedure is the reverse of removal, except for the following:
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CAUTION
Replace all patchbolt(s).
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Warning
The HV harness bracket must be reinstalled on the rear of the charger to ensure proper performance in the event of a collision.
  • Clean the charger mounting area on the vehicle before installing the new charger.
  • Ensure that the new charger has a new foam gasket on the bottom of the charger. Do not reuse the foam gasket.
  • The forward HV cables must be inserted into the charger before it is permanently mounted. Place the charger in the approximate mounting position, tilted toward the center of the vehicle, then connect the forward HV cables.
  • The lugs of the forward HV cables must be positioned in front of the busbars.
  • Informational PurposesAn informational icon, calling your attention
    Note
    The charger is difficult to position properly. Position the charger in the approximate position, then check under the vehicle to see the position of the coolant nipple, electrical connector, and studs relative to the holes in the body. Adjust the position of the charger accordingly.
  • 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.
  • 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.
  • Clean the adhesive residue on the charger and charger access panel with an alcohol wipe. Let the alcohol dry before installing a new warranty label.
  • Make sure that the forward HV cable grommet is fully seated on the body.
  • Tip: If the forward HV cable grommet is difficult to insert into the body, apply P-80 emulsion to the edges of the grommet.
  • Update the vehicle firmware. See Firmware Update.
    Tip: Connect 12V power and start the firmware update before reinstalling the components that were removed for access.

  • Refill and bleed the cooling system. See Cooling System - Partial Refill and Bleed.

  • Make sure that the vehicle charges as expected.