31/05/2024 11:12:53

Charger (China) (Remove and Replace)

Correction Code 44103012

Special tool(s) required for this procedure:

Part Number Description
1076927-00-A HIOKI MODEL 3541 TESTER
Special tool(s) recommended for this procedure:
Informational PurposesAn informational icon, calling your attention
Note
If the kit is not available, use electrical tape.
Part Number Description
1116814-00-A KIT, DUMMY PLUG, GEN 3 CHARGER
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.
Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Removal

  1. Put the suspension in "Jack" mode on the touchscreen,
  2. Raise and support the vehicle (refer to procedure).
  3. Open the hood, the LH rear door, and the rear liftgate via the touchscreen.
  4. Open the hood fully.
  5. Move the LH 2nd row seat fully forward using the "Easy Entry" mode.
  6. Remove the LH welcome plate (refer to procedure).
  7. Remove the LH and RH side rear trunk garnish (refer to procedure).
  8. Remove the rear trunk sill trim (refer to procedure).
  9. Remove the trunk floor carpet (refer to procedure).
  10. Remove the LH mid C-pillar trim (refer to procedure).
  11. Remove the LH upper C-pillar trim (refer to procedure).
  12. Remove the LH lower C-pillar trim (refer to procedure).
  13. Remove the LH side rear trunk trim (refer to procedure).
  14. Remove the LH mid zone C-pillar bracket (refer to procedure).
  15. Release the push clips (x2) that attach the LH minion bracket to the vehicle.
  16. Remove the HVAC charger duct.
  17. Remove the rear center underhood apron (refer to procedure).
  18. Remove the LH and RH underhood aprons (refer to procedure).
  19. Remove the underhood storage unit (refer to procedure).
  20. Remove the HEPA filter housing (refer to procedure).
  21. Disconnect 12V power (refer to procedure).
  22. Raise the vehicle.
  23. Remove the rear diffuser panel (refer to procedure).
  24. Position the coolant drain underneath the LH rear corner of the vehicle.
  25. Clamp the coolant hose from the charger.
  26. Disconnect the 12V logic electrical connector from the charger.
  27. Remove the nuts that attach the charger to the body.
  28. Lower the vehicle.
  29. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure
  30. Use a dummy plug or electrical tape to cover the opening for the charger access panel.
  31. Unfasten the bolts that attach rapid splitter cables, but do not remove the bolts.
  32. If equipped, disconnect the rear PTC heater harness from the charger.
  33. Connect a dummy plug connector onto the charge rear PTC HV outlet.
  34. Remove and discard the bolt that attaches HV harness to the charger, and then pull the HV harness up from the charger to remove.
  35. Use a dummy plug or electrical tape to plug the ports for the HV battery cables on the charger.
  36. Remove the nut and release the ground strap from the stud on the D-pillar (torque 9 Nm).
  37. Remove and discard the bolt that attaches the charge port ground cable to the charger.
  38. Pinch off the upper coolant hose to the charger.
  39. Release the clamp, and then disconnect the upper coolant hose from the charger.
    Informational PurposesAn informational icon, calling your attention
    Note
    Place absorbent material around the coolant hose to catch any spilled coolant.
  40. Remove the bolts that attach the LH trunk tie down to the body.
  41. Loosen the fasteners (x2) that attach the charger upper mounting brackets to the body.
  42. Pull the charger up, and then remove the bolts that attach the HV cables from the Rapid Mate to the bottom of the charger.
  43. Release the plastic tabs, then remove the HV cables leading to the rapid mate from the outlet of the charger.
  44. With an assistant, remove the charger from the vehicle.

Installation

  1. Install new foam gasket onto the new charger.
  2. Put the new charger near its mounting location so that the electrical connectors can be installed.
  3. Install the HV harness from the Rapid Mate into the HV outlet ports of the charger.
    Informational PurposesAn informational icon, calling your attention
    Note
    The fasteners will be tightened at a later step.
  4. Install the bolts that attach the bracket anchoring the HV cables from the Rapid Mate to the bottom of the charger (torque 6 Nm).
  5. Install the fasteners (x2) that attach the charger onto the upper mounting brackets (torque 12 Nm).
  6. Install new bolts (x2) that attach the ground cables (torque 9 Nm).
  7. If equipped, connect the rear PTC heater harness from the charger.
  8. Install new bolt bolt that attaches the HV harness into the charge port (torque 6 Nm).
  9. Install the fasteners (x2) that attach the HV cables to the rapid splitter (torque 6 Nm).
  10. Install new bolts (x11) that attach the charger access panel to the charger.
  11. Install new warranty sticker to the charger access panel.
  12. Raise the vehicle.
  13. Install the nuts that attach the bottom of the charger to the body (torque 9 Nm).
  14. Connect the 12V logic electrical connector to the charger.
  15. Connect the lower coolant hose, and then remove the hose clamp.
  16. Install the rear diffuser panel (refer to procedure).
  17. Lower the vehicle.
  18. Connect the upper coolant hose, and then remove the hose clamp.
  19. Reconnect 12V power (refer to procedure).
  20. Connect a laptop with Toolbox 3 to the vehicle.
  21. Unlock the gateway. See Gateway Unlock.
  22. In Toolbox 3, click the Actions tab, type "Coolant air purge" into the search field, click PROC_THC_X_COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Coolant Air Purge, click Run, and allow the routine to complete.
  23. Install the bolts (x2) that attach the LH tie down strap to the body (torque 9 Nm).
  24. Install the LH HVAC duct.
  25. Install the clips (x2) that attach the LH minion bracket to the body.
  26. Install the LH mid zone C-pillar bracket (refer to procedure).
  27. Install the LH side rear trunk trim (refer to procedure).
  28. Install the LH lower C-pillar trim (refer to procedure).
  29. Install the LH and RH side rear trunk garnish (refer to procedure).
  30. Install the LH welcome plate (refer to procedure).
  31. Install the LH upper C-pillar trim (refer to procedure).
  32. Install the LH mid C-pillar trim (refer to procedure).
  33. Close the LH rear door.
  34. Install the trunk floor carpet (refer to procedure).
  35. Reinstall the vehicle firmware. See Firmware Reinstall - Touchscreen.
  36. Install the HEPA filter housing (refer to procedure).
  37. Install the underhood storage unit (refer to procedure).
  38. Install the LH and RH underhood aprons (refer to procedure).
  39. Install the rear center underhood apron (refer to procedure).
  40. Close the hood.
  41. Disconnect the laptop from the vehicle.