Master Charger - RH - 2nd Generation (Remove and Replace)

FRT No: 44102202

Note: This procedure describes how to remove and install the 2nd generation master charger. If the vehicle is equipped with a 1st generation master charger, refer to procedure 44100202 (refer to procedure).
Warning: Only technicians who have been trained in High Voltage Awareness are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 00 (500V) 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: To avoid personal injury, eye protection must be worn while using compressed air.

Removal

  1. Disconnect HV power, but leave 12V power connected. Perform the electrical isolation procedure (refer to procedure), except for the disconnection of the 12V battery ground.
  2. Connect an external charger to the 12V battery.
  3. Remove the 2nd row seat frame:
  4. Disconnect the connectors (x2) from the side of the master charger in the following order:
    Caution: Disconnecting harnesses in the wrong order triggers multiple high-priority alerts.
    1. Disconnect the 12-pin harness from the front port.
    2. Disconnect the 10-pin harness from the rear port.
  5. Remove the HVJB cover (refer to procedure).

Warning: The previous step contains instructions to check for high voltage inside the HVJB. Do not proceed unless no high voltage is present.

  1. Release the 2 harnesses that connect the HVJB to the master charger. If equipped, release the 2 harnesses that connect the HVJB to the slave charger.
  2. Release all fasteners inside the High Voltage Junction Box (HVJB) so that it can lifted up in order to replace the charger in a later step:
    Note: Vehicles equipped with 3-phase charging have 4 charge port cables instead of 2.
    1. Dual motor vehicles only: Mark the rear HV cable that leads to the front drive unit as B-, and the forward HV cable that leads to the front drive unit as B+.

      Table 1: HV Cable fasteners inside HVJB

      1 B+ Front Drive Unit (if equipped)
      2 B- Front Drive Unit (if equipped)
      3 B+ battery/drive inverter
      4 B- battery/drive inverter
      5 B+ forward junction box
      6 B- forward junction box
      7 B- charge port
      8 B+ charge port
    2. Release the 2 nuts that secure the HV cables that lead to the front drive unit (torque 9 Nm).
      Note: Refer to Table 1.
      Note: It is not necessary to replace the fastener(s) after it is removed. The threaded area has a reusable dry sealant, which looks similar to adhesive patch material.
    3. Mark the rear HV cables that lead to the battery and drive inverter as B‒, and the forward HV cables that lead to the battery and drive inverter as B+.
      Note: Refer to Table 1.
    4. Release the 2 nuts that secure the HV cables that lead to the battery and drive inverter (torque 9 Nm).
      Note: Refer to Table 1.
      Note: It is not necessary to replace the fastener(s) after it is removed. The threaded area has a reusable dry sealant, which looks similar to adhesive patch material.
    5. Mark the rear HV cable that leads to the forward junction box as B+ and the forward HV cable that leads to the forward junction box as B‒.
      Note: Refer to Table 1.
    6. Release the 2 bolts that secure the HV cables that lead to the forward junction box (torque 4 Nm).
      Note: It is not necessary to replace the fastener(s) after it is removed. The threaded area has a reusable dry sealant, which looks similar to adhesive patch material.
    7. Mark the HV cables that lead to the charge port:
      • Single-phase charging: : Mark the forward cable as B- and the rear cable as B+.
      • 3-phase charging: : Starting from the front and working toward the rear of the vehicle, mark the 4 HV cables that lead to the charge port from front to rear as L2, L3, L1, and N.
        Note: Refer to Table 2.

      Table 2: 3-Phase charge port cables

      1 B+ N charge port
      2 B- L1 charge port
      3 B+ L3 charge port
      4 B- L2 charge port
    8. Release the bolts that secure the HV cables that lead to the charge port.
      • North America, Japan: 2 bolts (torque 9 Nm).
      • Europe, APAC: 4 bolts (torque 4 Nm).
      Note: Refer to Table 1.
      Note: It is not necessary to replace the fastener(s) after it is removed. The threaded area has a reusable dry sealant, which looks similar to adhesive patch material.
  3. Release the 4 bolts that secure the HVJB to the body (torque 5 Nm).
    Note: Do not remove the HVJB from the vehicle. It is only necessary to release the bolts so that the HVJB can be lifted up in a later step.

    HVJB shown removed from vehicle, for clarity.

  4. Release the ground strap from the rear of the charger (torque 7 Nm).
    Note: Leave the ground strap secured to the vehicle.
  5. Release the 4 bolts that secure the charger to the body (torque 7 Nm).

Note: It is necessary to lift the front of the HVJB out of the way in order to access the inboard coolant hose. Have an assistant hold up the front of the HVJB 20-30 mm.

  1. Clamp the coolant hoses on both the inboard and outboard sides of the charger, approximately 150 mm from the edge of the charger.
  2. Ensure that all harnesses and cables are protected from any coolant that might be spilled in a later step.
  3. Lift up the inboard side of the charger. Cover the floor of the vehicle with towels or shop rags to catch any coolant that might be spilled in a later step.
  4. Remove the coolant plug from the inboard side of the new charger and have it ready before performing the next step.
  5. Tilt the inboard edge of the charger upwards. Use pliers or a similar tool to release the locking ring from the inboard coolant hose. Remove the coolant hose from the new charger and immediately install the coolant plug onto the old charger to stop coolant from spilling out.
  6. Repeat steps 13-15 for the outboard coolant hose.
  7. Lift the charger out of the vehicle.
  8. If the charger is being shipped or stored, allow the coolant to drain from the charger, then use compressed air lightly to blow out any remaining coolant.
    Caution: Do not exceed 25 PSI when using compressed air to blow out any remaining coolant.

Installation, Configuration, and Coolant Purge

Fully clean the area before installing the new charger.

Note: Have an assistant hold up the front of the HVJB 20-30 mm until the coolant hoses have been secured to the charger.

  1. Position the new charger over the mounting studs on the base of the vehicle, but do not secure the nuts at this time.
  2. Secure the coolant hoses to the new charger and resecure the locking rings.
  3. Remove the clamps from the coolant hoses.

Caution: Clean up any spilled coolant.

  1. Install the 4 nuts that secure the charger to the body (torque 7 Nm).
  2. Secure the ground strap to the rear of the charger (torque 7 Nm).
    Note: Do not reconnect the outboard (low voltage) harnesses to the charger yet.
  3. If any HV cable terminals have contacted coolant, clean them with alcohol.
  4. Resecure all HV cables inside the HVJB:
    • The 2 cables to the front drive unit (if equipped)
    • The 4 HV cables to the HV battery and drive inverter
    • The 2 HV cables to the DCDC converter
    • The 4 HV cables to the charge port
  5. Reconnect the 2 HVJB harness connections to the master charger. If the vehicle is equipped with a slave charger, reconnect the 2 harnesses connections that lead from the HVJB to the slave charger.
  6. Reinstall the 4 bolts that secure the HVJB (torque 5 Nm).
  7. Reinstall the HVIL bolt, standard bolt, and 5 nuts that secure the HVJB cover (torque 5 Nm).
    Note: The HVIL bolt is a specific length in order to activate the HVIL switch. Ensure that the correct bolt is used during reinstallation.
  8. Connect the harnesses (x2) to the side of the master charger in the following order:
    Caution: Connecting harnesses in the wrong order triggers multiple high-priority alerts.
    1. Connect the 10-pin harness to the rear port.
    2. Connect the 12-pin harness to the front port.
  9. If the vehicle is equipped with a slave charger, disconnect the connectors (x2) from the side of the slave charger in the following order:
    Caution: Disconnecting harnesses in the wrong order triggers multiple high-priority alerts.
    1. Disconnect the 12-pin harness from the rear port.
    2. Disconnect the 10-pin HVIL loopback connector from the front port.
    1 10-pin HVIL loopback connector
    2 12-pin harness
  10. Use the Toolbox "Charger Config" panel to configure the master charger:
  11. Use the Toolbox "Coolant Air Purge" to purge the coolant system. Monitor the coolant level in the reservoir and fill it as needed. Ensure that there are no coolant leaks in the area around the charger.
  12. Use Toolbox to update or redeploy the firmware:
    Note:
    • If the vehicle is not running the latest firmware, run the "Vehicle Firmware Update" procedure.
    • If the vehicle is running the latest firmware, run the "Firmware Redeploy" procedure.
  13. Reinstall all components that were removed for access.
  14. Reconnect HV power.
  15. Disconnect the 12V float charger.
  16. If possible, charge the vehicle at above 40 A for several minutes and verify that there are no alerts.