10/07/2023 00:09:06

Safety Cap - Charge Port to HV Battery (Remove and Replace)

Correction Code 44015152

  • 1076921-00-A Fluke 1587
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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 at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

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Warning

Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.

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Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
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Warning

Proper Personal Protective Equipment (PPE) is required to perform this procedure:

  • High Voltage (HV) insulating gloves
  • Leather glove protectors
  • High voltage glove tester
  • Safety glasses
  • Electrical hazard rated safety shoes
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

A glove inflator is the only recommended way to test HV gloves. Both HV gloves must pass testing before beginning this procedure. If either glove does not pass the air check, discard the pair.

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Warning
Make sure that the HV gloves are not expired.
  • North America: HV gloves can be used up to 12 months after the testing date printed on the glove, but only 6 months after first use even if the gloves are still within the 12 month period. If the gloves were not put into service during the 12-month period following the testing date, they must be retested before being put into service.
  • Europe: Class 0 (1000V) HV gloves have no expiration date and may be used if they pass the pre-use assessment and the periodic inspection.
  • Asia Pacific: Follow the expiration date stated by the HV glove manufacturer, and:
    • o China only: Test the gloves every 6 months according to GB/T 17622.

Remove

  1. Open the LH front door and lower the LH front window.
  2. Open the hood and the liftgate.
  3. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  4. Remove the RH and the LH underhood apron. See Underhood Apron - LH (Remove and Replace).
  5. Remove the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
  6. Remove the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
  7. Disconnect 12V power. See Disconnect 12V Power.
  8. Remove the LH trunk side trim. See Trim - Rear Trunk - Side - LH (Remove and Replace).
  9. Perform the charge port voltage check. See Charge Port Voltage Check.
  10. Carefully remove the DC charge port connector.
  11. Remove the charge port safety cap from the charge port assembly.

Install

  1. Install the new charge port safety cap on the charge port assembly.
  2. Connect the DC charge port connector.
  3. Install the LH trunk side trim. See Trim - Rear Trunk - Side - LH (Remove and Replace).
  4. Connect 12V power. See Disconnect 12V Power.
  5. Install the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
  6. Install the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
  7. Install the LH and the RH underhood apron. See Underhood Apron - LH (Remove and Replace).
  8. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  9. Raise the LH front window and close all doors and liftgate.