Tech26
Posts: 40
Joined: Sun Dec 25, 2016 7:46 am

Pictures from my onboard charger fuse replacement

I know there were at least a couple people interested in a write up or guide for the onboard charger fuse replacement. I took a fair amount of pictures when I replaced the fuses in my charger, so here you go!

First off, this is what my car was doing when I plugged it in...
https://youtu.be/5Msfjg-_8l0

Basically you can see and hear the known good charge cable attempt to charge the car four times and then it stops.

Now, if you're good at working on cars and you have a fairly complete set of tools... you might be able to pull this off. Have you ever replaced a timing belt and water pump on an ICE car? This is kind of like that job, only with high voltage (HV) components involved. There's very little room for error here. I had 3 large egg cartons worth of nuts and bolts by the time I reached the fuses. Egg cartons are a fantastic way to keep all the nuts and bolts organized in the order that they were removed.

Alright, step one, remove the black cover at the front that is held in by the world's most counter-intuitive clips.
Image

Push down on the center part. Don't worry, it wont fall down behind the panel and be gone forever.

Image

Image


Image

To reset these clips you have to pull out on the legs a little and push it back up through the center hole until a little nub is sticking up through the top of the clip.
Image

Remove the 12V battery:
Image

After removing the 12v battery, remove the HV service disconnect plug under the front passenger seat. I didn't get any pictures of this.

Also remove the black cover for the DC-DC converter / cabin coolant heater and you will see this:
Image

Get your coolant hose pliers in place to stop the flow of coolant and something to catch the spilling coolant in
Image

Image

I left my coolant heater attached on the right side coolant hose and used bungie cords to hold it in place. Be careful to not kink the hose if you can help it.
Image

Alright, moving on to the removal of the DC-DC. More coolant hoses to deal with. You can see here I'm using a small pair of "toothless" vice grips to prevent coolant from spilling everywhere. As long as you can get the end of the hose above the level of coolant inside the reservoir you'll be OK. But if you can't do that... hose pinch pliers are your friends. I should mention here that you will want to go out and buy replacement coolant. It's nearly impossible to not contaminate the coolant that comes out with dust and dirt. Dirt in the coolant pumps is not good.
Image


Whew, alright, I'm tired and going to bed for the night. I'll post more tomorrow.
miimura
Posts: 1914
Joined: Thu Jan 17, 2013 11:13 pm
Location: Los Altos, CA

Re: Pictures from my onboard charger fuse replacement

Your pictures aren't showing up. Stuff posted from googleusercontent usually doesn't work. I use IMGBB to host images to embed in forums.

Like this: {img}https://i.ibb.co/9GrMZZK/RAV4-EV-Shorel ... o.jpg{/img} but with square braces.
Image
2012 Shoreline Blue #1462 w/JdeMO | 2018 Tesla Model 3 LR | 4.32kW Motech/Enphase PV Solar + 2x Powerwall 2 AC| Leviton EVB40 40A & Jesla Home Charging | 2015 e-Golf LE (returned)
Tech26
Posts: 40
Joined: Sun Dec 25, 2016 7:46 am

Re: Pictures from my onboard charger fuse replacement

Ah, OK, thanks for the heads-up. I'll have to put them on my Imgur account and try again.
asavage
Posts: 322
Joined: Mon Aug 07, 2017 4:55 pm
Location: Duvall, Wash.
Contact: Website

Re: Pictures from my onboard charger fuse replacement

You can edit posts here for a fairly long while, so you may be able to "fix" your first post by pasting your Imgur links in place of the malfunctioning ones.

This site is phpBB based. Since 2006 I've hosted a phpBB-based forum myself, and until fairly recently it didn't have file hosting functionality built-in. When I upgraded a couple of years back (a major PITA, due to customisations over the years), my site gained the ability for users to upload images, and that made things so much easier (for them, not for me, as I have to remove images every so often).
Regards,
Al Savage
2014 Rav4 EV, Shoreline Blue Pearl, #2609, first use 04Jun2014, 49k miles (Aug2017), OpenEV-SE 40A. First DU replacement May2018 59k.
2018 Model 3 LR AWD, blue. 9.6kw solar
http://nissandiesel.dyndns.org
alflash
Posts: 164
Joined: Sun Sep 03, 2017 3:46 pm
Location: Ukraine
Contact: Website

Re: Pictures from my onboard charger fuse replacement

Tech26 wrote:I know there were at least a couple people interested in a write up or guide for the onboard charger fuse replacement. I took a fair amount of pictures when I replaced the fuses in my charger, so here you go!
...
Thanks for description.
I add these photo
Image
and again video (viewtopic.php?f=8&t=1196&p=29151#p29151)
https://youtu.be/jMHu2x7RC_I

This is another Reason for the lack of HV Battery Charging
Image

Image
Tech26
Posts: 40
Joined: Sun Dec 25, 2016 7:46 am

Re: Pictures from my onboard charger fuse replacement

Is there a nice step by step guide for the fuse replacement job that anyone else has made? Or a video?
If not, I still have my pictures from when I did mine.
Can anyone see this image?
Image
Can you get it by right clicking and then saying load image or open in new tab?
Image

Here's a link to the whole album on Google pictures that I have shared / made public: https://photos.app.goo.gl/qPgzekFwXkuGFPc99

And trying imgbb too
Image
Dave, AKA The EV Nerd
Silver 2013 RAV4 EV with 40k miles
Blue 2015 Mercedes B-class Electric 10k miles
hokiematt
Posts: 67
Joined: Thu Nov 02, 2017 8:57 pm
Location: Salisbury, NC

Re: Pictures from my onboard charger fuse replacement

Dave, thanks for the fantastic writeup! Unfortunately I'm not seeing any pictures included in your posts (but google album looks great). Perhaps it would be worth putting the text and pics together in a pdf and posting that, which also future-proofs it from any problems with image hosting servers.
asavage
Posts: 322
Joined: Mon Aug 07, 2017 4:55 pm
Location: Duvall, Wash.
Contact: Website

Re: Pictures from my onboard charger fuse replacement

In Dec2020, Google sent me a notification of a change to their data retention policy (all your data is wiped if you don't log in for two years, amongst other things). Tech26, I've put your pics on my server, which won't last forever either, but won't die by the calendar. I've tried to piece the pictures back together with the text, but I'm just guessing, and there's a lot more pictures in that album than you posted back in May2020.

--------------------------------------------------------------------------------------------------------------------------------
by Tech26 » Wed May 20, 2020 12:51 am
I know there were at least a couple people interested in a write up or guide for the onboard charger fuse replacement. I took a fair amount of pictures when I replaced the fuses in my charger, so here you go!

Now, if you're good at working on cars and you have a fairly complete set of tools... you might be able to pull this off. Have you ever replaced a timing belt and water pump on an ICE car? This is kind of like that job, only with high voltage (HV) components involved. There's very little room for error here. I had 3 large egg cartons worth of nuts and bolts by the time I reached the fuses. Egg cartons are a fantastic way to keep all the nuts and bolts organized in the order that they were removed.

Alright, step one, remove the black cover at the front that is held in by the world's most counter-intuitive clips.

Image


Push down on the center part. Don't worry, it wont fall down behind the panel and be gone forever.

Image


Image

To reset these clips you have to pull out on the legs a little and push it back up through the center hole until a little nub is sticking up through the top of the clip.


Image



Remove the 12V battery:

Image

Image


Image


After removing the 12v battery, remove the HV service disconnect plug under the front passenger seat. I didn't get any pictures of this.

Also remove the black cover for the DC-DC converter / cabin coolant heater and you will see this:

Image




Get your coolant hose pliers in place to stop the flow of coolant and something to catch the spilling coolant in


Image


Image


Image


Image


Image


Image


Image


I left my coolant heater attached on the right side coolant hose and used bungie cords to hold it in place. Be careful to not kink the hose if you can help it.


Image


Image




Alright, moving on to the removal of the DC-DC. More coolant hoses to deal with. You can see here I'm using a small pair of "toothless" vice grips to prevent coolant from spilling everywhere. As long as you can get the end of the hose above the level of coolant inside the reservoir you'll be OK. But if you can't do that... hose pinch pliers are your friends. I should mention here that you will want to go out and buy replacement coolant. It's nearly impossible to not contaminate the coolant that comes out with dust and dirt. Dirt in the coolant pumps is not good.

Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image



Whew, alright, I'm tired and going to bed for the night. I'll post more tomorrow.

--------------------------------------------------------------------------------------------------------------
Regards,
Al Savage
2014 Rav4 EV, Shoreline Blue Pearl, #2609, first use 04Jun2014, 49k miles (Aug2017), OpenEV-SE 40A. First DU replacement May2018 59k.
2018 Model 3 LR AWD, blue. 9.6kw solar
http://nissandiesel.dyndns.org

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