24/05/2023 18:13:16

Pin Carrier - Charge Port (Remove and Replace)

Correction code 44016102

  • 2023-05-24: Updated procedure to use Charge Port Voltage Check, and not Vehicle Electrical Isolation Procedure.
  • 2023-04-18: Fixed incorrect hyperlink to Vehicle Electrical Isolation Procedure.

Removal

  1. Open the LH front door and lower the window.
  2. Open the liftgate.
  3. Open the charge port door.
  4. Disconnect 12V power. See Disconnect 12V Power.
  5. Perform the charge port voltage check. See Charge Port Voltage Check.
  6. Remove the LH rear trunk side trim, see Trim - Rear Trunk - Side - LH (Remove and Replace).
  7. Release the 12V harness connection from the charge port.
  8. Remove the grounding bracket by releasing the nut that secures it to the body (torque 6 Nm).
  9. Disconnect the harness that connects the taillight to the charge port.
  10. Remove the charge port cover.
  11. Remove the bolts (x3) that attach the HV harness to the charge port in the order shown.
  12. Remove the HV harness from the charge port assembly.
  13. Remove the screws (x2) that attach the pin carrier to the pin carrier cap.
  14. Partially separate the pin carrier from the pin carrier cap near the screw holes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Avoid pinching or damaging any wires inside the charge port.
  15. Fully separate the pin carrier from the pin carrier cap near the screw holes.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position a trim tool below the 2 clear tabs, then separate the pin carrier from the pin carrier cap until the 2 rear tabs disengage.
  16. Remove the screw that attaches the pin housing to the pin carrier.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the screw is corroded, discard the screw and install a new one during reassembly.
  17. Move the pin housing away from the pin carrier.
  18. Release the 3 pins from the pin carrier.
    Informational PurposesAn informational icon, calling your attention
    Note
    Place a shop cloth on top of the trunk floor insulation pad, and then push the pin carrier down onto the shop cloth to release the 3 pins from the pin carrier. Discard the pin carrier.
  19. Inspect the pin carrier cap and pin holder for cracks or damage.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the pin carrier cap or the pin holder was damaged during disassembly, replace the pin carrier cap and/or the pin holder (3x screws, 1 Nm).
  20. Remove and discard the O-rings from all 7 pins.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a pick to remove the O-rings from the pins.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Hold the pins by the pin body, do not hold the pins by the wires.

Installation

Installation procedure is the reverse of removal, except for the following:
  1. Clean all pins with an IPA wipe and allow to dry for at least 1 minute.
  2. Install new O-rings on the 7 pins.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Slide the new O-rings on by hand. Install the smaller O-rings on the 2 data pins, and the larger O-rings on the rest of the pins.
  3. Install a new O-ring onto the new pin carrier.
  4. Insert a new smaller O-ring on the pin carrier screw bore.
  5. Install the screw (torque 0.5 Nm) that attaches the pin housing to the pin carrier.
  6. Apply Krytox lubricant onto the pin O-rings (x3). Do not apply Krytox lubricant on the pins.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a clean shop cloth to remove any lubricant from the pins.
  7. Insert the 2 data pins and the ground pin into the pin carrier ports: partially insert the 2 data pins and the ground pin into the pin carrier ports, and then use a small flat screwdriver or similar tool to fully insert each pin into the pin carrier.
    Informational PurposesAn informational icon, calling your attention
    Note
    Inserting the pins into the pin carrier requires significant force.
  8. Make sure that the pins are fully inserted into the pin carrier.
    Informational PurposesAn informational icon, calling your attention
    Note
    The pins must be inserted at least 2 mm past the edge of the pin bore.
  9. Route the charge port wiring harness in front of the HV cables.
  10. Apply Krytox lubricant onto the remaining pin O-rings (x4). Do not apply Krytox lubricant on the pins.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a clean shop cloth to remove any lubricant from the pins.
  11. Slide the pins (x4) into the pin carrier.
  12. Install the screws (x2) that attach the pin carrier to the pin carrier cap (torque 0.6 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    If the screws are corroded, discard them and install new ones.
  13. Install the bolts (x3) that attach the HV harness to the charge port assembly (torque 5 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    First hand tighten the bolts, then torque the bolts in the order shown.
  14. Make sure that the vehicle's charging system operates appropriately.