ONBOARD CHARGER REMOVAL/INSTALLATION
id304000102000
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Warning
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<<High voltage>>
• If the necessary measures are not taken before servicing an electric vehicle, it could cause electrical shock and result in serious injury or, in the worst case, death. Before servicing the electric vehicle, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and implement the necessary measures. (See
HIGH VOLTAGE SERVICE CAUTIONS.)
High Voltage Part Inspection And Removal/Installation Notes
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Warning
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<<High voltage>>
• If necessary measures such as wearing the correct protective gear are not taken when inspecting or removing/installing the high voltage parts, it could cause electrical shock and result in serious injury or, in the worst case, death.
• Before inspecting or removing/installing the high voltage parts, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and [High Voltage Part Inspection and Removal/Installation Notes] of the high voltage system service cautions and implement the necessary measures and preparations. (See
HIGH VOLTAGE SERVICE CAUTIONS.) (See
HIGH VOLTAGE SYSTEM SERVICE CAUTIONS.)
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Warning
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• The EV system is hot immediately after driving and charging, and can cause severe burns. Turn off the EV system and wait until it is cool before performing the servicing.
• If the cooling system cap is removed while the EV system is hot, hot coolant may be ejected, causing severe burns or injury. Perform the removal of the cooling system cap when the EV system is cool.
• When removing the cooling system cap, cover the cooling system cap with a clean cloth and remove it slowly.
• The cooling fan may suddenly start operating regardless of the main power switch position. Keep hands and tools away from the cooling fan even if the cooling fan is not operating to prevent injury, or damage to the cooling fan. When servicing the cooling fan or parts near the cooling fan, ensure the following.
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― Do not perform normal charging or quick charging
― Do not select high voltage battery cooling on center display after EV system stops
― Do not open/close doors frequently with main power switched OFF
― Access connected vehicle maintenance mode (MyMazda App connected vehicle)
― Cancel climate control timer
― Operate center display and turn off battery heater operation
Onboard Charger Removal Preparation
1. Load the vehicle on the auto lift so that it can be lifted up.
2. Verify that the READY indicator on the instrument cluster is not illuminated.
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• If the READY indicator is turned on, switch the main power OFF.
3. Disconnect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)
4. Partially peel back the cover.
5. Remove the service hole cover.
6. Wear insulating gloves and remove the service plug using the following procedure.
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Warning
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<<High voltage>>
• Touching the terminal on the vehicle side can result in serious injury or death from electric shock. For this reason, after removing the service plug, cover the vehicle-side terminals with insulating tape so that they cannot be touched.
• Do not touch high voltage parts for 10 min after removing service plug. Electric charges may be stored on the condenser for 10 min after the service plug is removed, and touching high voltage parts during that time can result in serious injury or death from electric shock.
• Service plugs must be removed by workers inspecting/removing/installing high voltage parts. Keep the removed service plug on your person until inspection/removal/installation of the high voltage parts is completed to prevent other workers from accidentally installing the service plug.
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Caution
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<<High voltage>>
• After removing the service plug, cover the vehicle side terminals with insulating tape to prevent foreign matter from adhering to them.
• When you are keeping the service plug on your person, cover the service plug terminals with insulating tape to prevent damage to them.
• Do not switch the main power ON (READY on) after removing the service plug. If the main power is switched ON (READY on) after removing the service plug, the vehicle may malfunction.
- (1) Slide the lock in the direction of the arrow shown in the figure. (Do not pull out completely)
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- (2) Raise the lever.
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- (3) Press the area indicated by arrow (1) shown in the figure, release the tabs, and then raise the lever until it is perpendicular.
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- (4) Hold the lever and pull the service plug straight up.
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7. After removing the service plug, leave it for 10 min.
8. Wear insulating gloves and measure the voltage at the high voltage cable connection (junction box No.3 side) using the following procedure.
- (1) Remove the seal cover. (See SEAL COVER REMOVAL/INSTALLATION.)
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Caution
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<<High voltage>>
• Be careful not to allow foreign matter or water droplets to enter the junction box No.3. Since the junction box No.3 has a high voltage circuit, there is a risk of malfunction if foreign matter or water drops enter it.
• Remove the terminal cover by pulling it straight up. The terminal cover is fitted with an interlock switch. This interlock switch may be damaged if the terminal cover is removed while being tilted.
• Do not touch the moisture-proof seal on the terminal cover. If the seal is touched or damaged, replace the terminal cover.
- (2) Remove the terminal cover.
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- (3) Measure the voltage at the high voltage cable connection.
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Note
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• Use a voltmeter with a measurement range of
450 V DC or more.
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― Verify that the voltmeter indicates 0 V and go to the next step.
• Verify that the waterproof rubber on the terminal cover is securely installed.
• Be careful not to damage the interlock, and install it securely.
- (4) Install the terminal cover.
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Coolant draining procedure
1. Place the vehicle onto an auto lift and prepare it so it can be lifted up.
2. Remove the cooling system cap once and then install it.
3. Lift up the vehicle.
4. Remove the rear wheel and tire (RH). (See WHEEL AND TIRE REMOVAL/INSTALLATION.)
5. Connect the plastic hose to the drain port on the rear side and place the other end into the container (volume: approx. 2 L).
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• Plastic hose: Inner diameter approx. 8 mm/length approx. 1 m
6. Open the drain port on the rear side.
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Note
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• Record the amount of drained coolant as a reference when adding coolant.
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Note
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• When the onboard charger water hose is removed, coolant is discharged from the rear side drain port, therefore, install a plastic hose and a container to the rear side drain port and leave them set until the onboard charger water hose is removed.
Onboard Charger Removal/Installation
1. Fold the rear seat backs (RH/LH).
2. Remove the rear package tray. (See REAR PACKAGE TRAY REMOVAL/INSTALLATION.)
3. Remove the trunk mat. (See TRUNK COVERING REMOVAL/INSTALLATION.)
4. Remove the trunk board. (See TRUNK BOARD REMOVAL/INSTALLATION.)
5. Disconnect the onboard charger high voltage connector (3002-403C connector). (See High Voltage Cable Connector Removal Note)
6. Place a clean cloth around the onboard charger water hose so that coolant does not flow out.
7. While slowly loosening the onboard charger water hose (OUT side), allow air to be sucked into the hose.
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Note
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• By allowing air in, the coolant inside of the onboard charger and around the water hose (OUT side) can be slowly drained from the drain plug.
8. Disconnect the high voltage connectors shown in the figure. (See High Voltage Cable Connector Removal Note)
9. Remove using the procedure shown in the figure.
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1
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Bolts A
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2
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Bolts B
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3
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Bolts C
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4
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Bracket (rear)
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5
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On board charger
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6
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Bolts D
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7
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Bracket (front)
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10. Close the rear side drain port and remove the plastic hose.
11. Install in the reverse order of removal.
Coolant Replenishment Procedure
Items to be prepared
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Hand pump
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Hose
Inner diameter: 15 to 16 mm
Length: Approx. 2 m
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1. Remove front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)
2. Install the cooling system cap.
3. Remove the coolant reserve tank installation nuts.
4. Remove the coolant reserve tank outlet hose from the DC-DC converter.
5. Tilt and secure the coolant reserve tank so that the coolant reserve tank outlet hose is pointed upward.
6. Install a commercially-available hose (inner diameter: 15 to 16 mm/length: approx. 2 m) to the DC-DC converter inlet port and set a tray to receive the coolant.
7. Using a commercially-available bottle (volume: approx. 0.5 L), slowly add coolant from the coolant reserve tank outlet hose.
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Note
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• To prevent air infiltration, add approx. 0.5 L for 1 min.
8. When the coolant reserve tank is completely full, stop adding.
9. Install a hand pump to the coolant reserve tank outlet hose.
10. Using the hand pump, pump the coolant in the coolant reserve tank.
11. Repeatedly add coolant and pump the coolant using the hand pump until approx. 0.3 L of coolant is discharged from the DC-DC converter to the tray.
12. When approx. 0.3 L of coolant is discharged, pump the coolant using the hand pump until the coolant reserve tank is empty.
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Note
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• Empty the coolant reserve tank because coolant will overflow when installing the outlet hose.
13. Remove the hand pump.
14. Remove the hose installed to the DC-DC converter inlet port and the tray.
15. Install the coolant reserve tank outlet hose.
16. Install the coolant reserve tank installation nuts.
17. After adding coolant to the F line on the coolant reserve tank, add an additional 0.26 L.
Operation After Onboard Charger Installation
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Caution
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• Before connecting the service plug, check the tightness of the high voltage terminals and the connection status of the connectors.
1. Wear insulating gloves and install the service plug using the following procedure.
- (1) Insert the service plug as far as it will go.
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- (2) Depress the lever completely.
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- (3) Slide the lock in the direction of the arrow shown in the figure until the hook is engaged.
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2. Install the service hole cover.
3. Close the cover.
4. Connect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)
Air Bleeding Procedure
1. Verify that the remaining charge level warning light is not turned on.
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• If it is turned on, charge the battery.
2. Switch to air bleeding mode using the following procedures.
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Caution
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• Verify that the coolant level in the coolant reserve tank changes and that the coolant is flowing while in air bleeding mode.
• If the coolant does not flow, repeat air bleeding mode until the coolant flows.
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Note
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• Electric water pump operates continuously while in air bleeding mode.
• Under the following conditions, air bleeding mode ends and the water pump returns to normal control.
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― Main power is switched OFF
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― Position other than P is shifted
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― 15 min have elapsed
- (1) Switch the main power ON (READY off).
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- (2) Perform the following procedure within 60 s.
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- 1) Release and depress the accelerator pedal 5 times.
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- 2) Release and depress the brake pedal 10 times.
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- (3) Switch the main power ON (READY on).
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3. Listen to the water pump operation sound and vibration sound, and then verify that the water pump transitions to air bleeding mode.
4. Verify the water level in the coolant reserve tank and if the water level is less than the L level, add coolant to the F level.
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Note
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• The status of the air bleeding can be determined by the water level in the coolant reserve tank.
Water level at initial stage of air bleeding:
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― The water pump is operating, but the water flow is weak or there is no water flow.
Water level from after several minutes to within 10 min:
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5. Verify that PCM DTC P2B2A:00 is not stored after 15 min have elapsed from transitioning to air bleeding mode.
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• If PCM DTC P2B2A:00 is stored, repeat the procedure from Step 2 to Step 5.
6. Main power is switched OFF.
7. Inspect to confirm that there is no coolant leakage at any part. (See COOLANT LEAKAGE INSPECTION.)
8. Install front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)
9. Install the trunk board. (See TRUNK BOARD REMOVAL/INSTALLATION.)
10. Install the trunk mat. (See TRUNK COVERING REMOVAL/INSTALLATION.)
11. Install the rear package tray. (See REAR PACKAGE TRAY REMOVAL/INSTALLATION.)
12. Install the rear wheel and tire (RH). (See WHEEL AND TIRE REMOVAL/INSTALLATION.)
13. Lower the vehicle to the ground and adjust the coolant amount to the F line on the coolant reserve tank.
14. Install the seal cover. (See SEAL COVER REMOVAL/INSTALLATION.)
Connector Removal Note
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Caution
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• After disconnecting the connector, protect the terminals from water penetration by wrapping them with tape.
High Voltage Cable Connector Removal Note
1. Wear insulating gloves and disconnect the high voltage cable connectors shown in the figure.
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• After disconnecting the high voltage cable connector, wear insulating gloves and wrap the terminals with electrical tape to insulate them.
- (1) Pull out the lock tab.
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- (2) Pull out the connector while pressing the lock lever.
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