28/09/2023 00:20:56

Charge Port (China) (Remove and Replace)

Correction code 44012702

  • 1080562-00-A Telescoping Hood Prop
  • 1076921-00-A Fluke 1587
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 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.

Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Proper personal protective equipment (PPE) is required to perform this procedure:

  • High voltage 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.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Make sure that the HV gloves are not expired. 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.

Remove

  1. Open the LH front door and lower the LH front window.
  2. Move both front seats fully forward.
  3. On the touchscreen, touch Controls > Charging > Open Charge Port to open the charge port door.
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Remove the LH and the RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
  6. Remove the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
  7. Remove the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
  8. Disconnect the 12V power. See Disconnect 12V Power.
  9. Perform the charge port voltage check. See Charge Port Voltage Check.
  10. Temporarily lower the seat frame.
  11. Place a protective cover on top of the seat frame to protect the seat back from damage.
  12. Fold the 60 seat in down position.
  13. Remove the parcel shelf.
  14. Remove the LH rear trunk side trim. See Trim - Rear Trunk - Side - LH (Remove and Replace).
  15. Remove the LH side seat back bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
  16. Remove LH C-pillar upper trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  17. Use a clip pry tool to remove the clips that attach the LH C-pillar middle trim to the vehicle and move it aside.
  18. Use a clip pry tool to remove the clips that attach the LH C-pillar lower trim to the vehicle.
  19. Remove the nut that attaches the charge port ground to the body.
    Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 6 in extension
    • 13 mm socket
  20. Release the edge clips (x2) that attach the manual release cables to the charge port assembly.
  21. Remove the screw that attaches the latch release cables at the center of the charge port assembly housing, and then move the cables aside.
    Use of the following tool(s) is recommended:
    • Torx T20 socket
    • 4 in extension
    • Ratchet/torque wrench
  22. Disconnect the latch actuators (x2).
  23. Disconnect the logic connector from the charge port ECU.
  24. Release the clips (x2) that attach the HV harnesses to the body studs.
  25. Remove the bolts (x3) that attach the HV harnesses to the charge port housing, and then move the harnesses aside.
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 in extension
    • 10 mm socket
  26. Release the clips (x6) that attach the HV harnesses to the LH rear of the body.
  27. Release the clips (x3) that attach the charge port assembly to the body along the C-pillar.
  28. Feed the charge port assembly through the trunk area of the vehicle to pass the harnesses through between the seat pivot and body.
  29. Remove the charge port assembly from vehicle

Install

  1. Position the charge port assembly into vehicle and feed it towards the 2nd row seat area.
  2. Pass the HV harnesses through between the seat pivot and body and continue to feed the charge port assembly into position
  3. Fasten the clips (x3) that attach the charge port assembly to the body along the C-pillar.
  4. Fasten the clips (x6) that attach the HV harnesses to the LH rear of the body.
  5. Install the bolts (x3) that attach the HV harnesses to the charge port housing.
    6 Nm (4.4 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Ensure that the cable is not tugged or pulled unnecessarily which can yield the C-clamp strain relief and cause a thermal ignition event at the GB charge port area while attempting to charge.
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 in extension
    • 10 mm socket
  6. Secure the clips (x2) that attach the HV cables to body studs.
  7. Connect the latch actuators (x2).
  8. Connect the logic connector to the charge port ECU.
  9. Install the screw that attaches the latch release cables at the center of the charge port assembly housing.
    1.5 Nm (1.1 lbs-ft)
    Use of the following tool(s) is recommended:
    • Torx T20 socket
    • 4 in extension
    • Ratchet/torque wrench
  10. Fasten the edge clips (x2) that attach the manual release cables to the charge port assembly.
  11. Install the nut that attaches the charge port ground to the body.
    9 Nm (6.6 lbs-ft)
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Ratchet/torque wrench
    • 4 in extension
  12. Install the LH rear trunk side trim. See Trim - Rear Trunk - Side - LH (Remove and Replace).
  13. Install the clips that attach the LH lower C-pillar to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    If any clip is damaged, replace it.
  14. Install the clips (x4) that attach the C-pillar middle trim to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  15. Install the LH C-pillar upper trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  16. Install the LH side seat back bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
  17. Install the parcel shelf.
  18. Return the LH seat back to its original position.
  19. Remove the protection cover from the seat frame.
  20. Connect the 12V power. See Disconnect 12V Power.
  21. Install the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
  22. Install the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
  23. Install the LH and the RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
  24. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  25. Return the LH front seat and LH front window to the original position.
  26. Close the charge port door.
  27. Close the hood and liftgate.
  28. Close all doors.