31/05/2024 09:56:54

HV Harness - 3rd Generation Charger to Charge Port (Remove and Replace)

Correction Code 44500502

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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 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.

Removal

  1. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure
  2. Remove and discard the bolt that attaches the ground strap to the charger (torque 6 Nm).
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    CAUTION
    Replace all patchbolt(s).
  3. Open the access port on the LH side of the charger, and then loosen the nuts that attach the charge port cables (torque 6 Nm).
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    Note
    It is not necessary to completely remove the nuts.
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    CAUTION
    Do not drop the fasteners inside the charger. If a fastener is dropped inside the charger and not retrieved, the charger must be replaced. Do not activate high voltage until the fastener is retrieved or the charger is replaced.
  4. Remove the charge port cables from 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 upward to maneuver it over the tab before completely removing the cable out from the charger.
    Single Phase Charger Three Phase Charger
  5. Use a dummy plug or electrical tape to cover the holes for the charge port cables to prevent contamination.
  6. Remove the charger ground from the stud on the body (torque 9 Nm).
  7. Remove and discard the bolts (x2) that attach the rapid splitter cables to the charger (torque 6 Nm).
  8. Remove the rapid splitter cables from the charger HV outlet ports, and then set the rapid splitter cables aside.
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    Note
    Release the top and bottom clips on the black plastic tabs.
  9. Remove the grounding bracket by releasing the nut that attaches it to the body.
    • Single phase (North America, Japan): torque 6 Nm
    • 3 phase (Europe, APAC): torque 9 Nm
  10. Remove the cover from the cable connector by using a trim tool or similar non-conductive tool to bend the 3 tabs that secure the cover to the cable connector.
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    Note
    The locations of the tabs are marked by arrows on the face of the cover.
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    CAUTION
    Do not lose or damage the magnet on the outboard side of the cable connector.
  11. Remove the 3 bolts that secure the cable connector to the charge port in the order shown. Remove the cable connector from the charge port.
    • Single phase (North America, Japan): torque 4 Nm
    • 3 phase (Europe, APAC): torque 5 Nm
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    CAUTION
    Even though the HV harness is accessible, do not attempt to remove it at this time.
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    Note
    Before performing the next step, note the locations of the clips that secure the HV harness to the 2nd row seat frame. During installation of the new HV harness, ensure that the harness is clipped to the seat frame in the same locations.
  12. Release the clips that secure the HV cables to the 2nd row seat frame.
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    CAUTION
    Before performing the next step, examine the cable ties on the HV harness. Note that some of the cable ties are mounted to studs on the body.
  13. Release the cable tie mounts (x10) that attach the HV harness to the studs on the body.
  14. Release the cable tie mount that attaches the HV harness to the stud on the body at the lower C-pillar.
  15. Disconnect the charge port HV harness CAN connector near coolant pump.
  16. With an assistant, feed the harness out towards the rear of the vehicle, and then remove the harness from the vehicle.
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    Note
    Folding the second row seat back creates additional room to ease the removal of the harness.

Installation

Installation procedure is the reverse of removal, except for the following:
  • Make sure that the HV harness is clipped to the second row seat frame.
  • When securing the cable connector to the charge port, tighten the bolts in the reverse order of removal.