5NP-W9W4Y-12

GROUP
NUMBER
BODY ELECTRICAL
18-BE-018
DATE
Technical Service Bulletin
SUBJECT:
NOVEMBER, 2018
MODEL(S)
IONIQ ELECTRIC (AE EV)
IONIQ PLUG-IN HYBRID
(AE PHEV)
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
Description: Some Ioniq EV (AE EV) and Ioniq Plug-in Hybrid (AE PHEV) vehicles may experience a
charging connector lock/unlock actuator malfunction, which may cause:
 The charging connector to not remain locked when the charger is inserted into the charging port.
 The charging connector to be unable removed from the vehicle charging port.
This bulletin provides part replacement instruction and information on the availability of the inlet locking
actuator as a separate part. If the vehicle exhibits one of the condition described above, it is
recommended to replace the inlet locking actuator only, not the entire quick charge inlet cable wiring
assembly.
Inlet Locking Actuator
Quick Charge Inlet
Cable Wiring Harness
Applicable Vehicles:
All 2017 - 2019 Ioniq Electric (AE EV)
All 2018 - 2019 Ioniq Plug-in Hybrid (AE PHEV)
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
SUBJECT:
Warranty Information:
MODEL
OP. CODE
Ioniq Electric
(AE EV)
91999R00
Ioniq Plug-in
Hybrid
(AE PHEV)
OPERATION
OP. TIME CAUSAL PART NATURE CAUSE
Inlet Locking
Actuator
Replacement
For Causal P/N:
Refer to the
Please
Parts
see
Information for
WEBLTS
the inlet locking
for current
actuator P/N
LTS time.
per applicable
model.
I14
ZZ3
Parts Information:
PART NUMBER
PART
NAME
Inlet
Locking
Actuator
IONIQ
ELECTRIC
(AE EV)
IONIQ PLUG-IN
HYBRID
(AE PHEV)
91999G7310
91999G7110
PART IMAGE
91999G7310
91999G7110
NOTE: The main differences between the two parts
is the length of the tab.
TSB #: 18-BE-018
Page 2 of 14
SUBJECT:
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
Service Procedure:
- Ioniq Electric (AE EV) Inlet Locking Actuator Replacement (pages 3-8)
- Ioniq Plug-in Hybrid (AE PHEV) Inlet Locking Actuator Replacement (pages 9-14)
IONIQ ELECTRIC (AE EV) INLET LOCKING ACTUATOR REPLACEMENT
!
WARNING
Be sure to read and follow the “General Safety Information and Caution” notice before doing
any work related with the high voltage system. Failure to follow the safety guidelines may
result in serious electrical injuries.
1.
Align the vehicle onto the lift. Do not lift the
vehicle up.
2.
If applicable, record the customer’s radio preset
stations for AM/FM/XM.
3.
Open charger door by pressing the release
buttons on the dash.
Open tailgate by pressing the release buttons on
the tailgate.
4.
Pull hood release to open the hood to access
the auxiliary battery.
5.
Disconnect the negative (-) cable on the
auxiliary 12 V battery.
Negative battery terminal tightening torque:
3.0~4.4 lb-ft (4.0~6.0 Nm, 0.4~0.6 kgf.m)
TSB #: 18-BE-018
Page 3 of 14
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
SUBJECT:
6.
Remove the trunk covers.
Remove the safety plug cover by using a Phillips
screwdriver to remove the clip located in the
picture to the right.
7.
Wear insulated protective gloves and disconnect
the high voltage safety plug by following the
illustration steps shown to the right.
!
CAUTION
Per the EV “General Safety Information and
Caution Notice”, wear insulated safety
gloves when working on high voltage
components that have an orange connector
and cable color.
NOTE: Step 2 is pushing the yellow tab inward
and then lift.
Ensure the insulated safety gloves are not
expired by checking the stamped date on the
gloves.
Bosch Part
Number
J-48755-11H
To order a new set of insulated safety gloves,
contact Bosch at 1-866-539-4248. Refer to the
table on the right for the part number
information.
(Medium)
J-48755-12H
(Large)
Description
Image
Insulated
Leather Safety
Gloves
Insulated
Leather Safety
Gloves
Refer to https://www.grainger.com/content/qtelectrical-safety-gloves-inspection-262 for
electrical safety gloves inspection information.
TSB #: 18-BE-018
Page 4 of 14
SUBJECT:
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
8.
Wait 5 minutes to allow the high voltage battery
capacitor to fully discharge.
9.
Remove the three 10mm nuts holding the
charger port and pull the charger port plugs.
Quick charging port mounting bolt
tightening torque:
8.0~10.1 lb-ft (10.8~13.7 Nm, 1.1~1.4 kgf.m)
10. Lift the vehicle to comfortable working height.
11. Remove the rear driver’s side wheel by
removing the 5 lug nuts.
Lug nut tightening torque:
79.6~94.0 lb-ft (107.9~127.5 Nm, 11.0~13.0
kgf.m)
TSB #: 18-BE-018
Page 5 of 14
SUBJECT:
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
12. Remove the wheel well liner by removing the
three types of fasteners located in the picture to
the right.
13. Remove a 10mm bolt and a 10mm nut to loosen
the charging wiring harnesses.
Quick charging port bracket mounting
nut/bolt tightening torque:
7.2~8.7 lb-ft (9.8~11.8 Nm, 1.0~1.2 kgf.m)
Loosen the harnesses by pulling them out of the
body mounting screws.
TSB #: 18-BE-018
Body mounting screw
Page 6 of 14
SUBJECT:
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
14. Carefully pull the charging port away from the
fender and wiggle downward to release the
charging port.
15. Disconnect the connector from the inlet locking
actuator.
16. Use a T15 Torx screwdriver to remove the two
screws holding the inlet locking actuator.
TSB #: 18-BE-018
Page 7 of 14
SUBJECT:
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
17. Detach the cable from the inlet locking actuator
arm.
18. Remove the red rubber seal from the old part
and place it onto the new part.
Rubber Seal
Replace the inlet locking actuator with the new
part.
19. Reinstall all removed parts in reverse order.
20. Confirm if the charging port locks/unlocks and if
the charging function is operating by checking
the vehicle’s charging status.
TSB #: 18-BE-018
Page 8 of 14
SUBJECT:
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
IONIQ PLUG-IN HYBRID (AE PHEV) INLET LOCKING ACTUATOR REPLACEMENT
!
WARNING
Be sure to read and follow the “General Safety Information and Caution” notice before doing
any work related with the high voltage system. Failure to follow the safety guidelines may
result in serious electrical injuries.
1.
Align the vehicle onto the lift. Do not lift the
vehicle up.
2.
If applicable, record the customer’s radio preset
stations for AM/FM/XM.
3.
Open tailgate by pressing the release buttons on
the tailgate.
4.
Remove the battery cover on the rear passenger
side trunk.
Disconnect the negative (-) cable on the
auxiliary 12 V battery.
Negative battery terminal tightening torque:
3.0~4.4 lb-ft (4.0~6.0 Nm, 0.4~0.6 kgf.m)
TSB #: 18-BE-018
Page 9 of 14
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
SUBJECT:
5.
Remove the trunk cover.
Remove the safety plug cover by using a small
flathead screwdriver.
6.
Wear insulated protective gloves and disconnect
the high voltage safety plug by following the
illustration steps shown to the right.
!
CAUTION
Per the EV “General Safety Information and
Caution Notice”, wear insulated safety
gloves when working on high voltage
components that have an orange connector
and cable color.
NOTE: Step 2 is pushing the yellow tab inward
and then lift.
Ensure the insulated safety gloves are not
expired by checking the stamped date on the
gloves.
Bosch Part
Number
J-48755-11H
To order a new set of insulated safety gloves,
contact Bosch at 1-866-539-4248. Refer to the
table on the right for the part number
information.
(Medium)
J-48755-12H
(Large)
Description
Image
Insulated
Leather Safety
Gloves
Insulated
Leather Safety
Gloves
Refer to https://www.grainger.com/content/qtelectrical-safety-gloves-inspection-262 for
electrical safety gloves inspection information.
TSB #: 18-BE-018
Page 10 of 14
SUBJECT:
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
7.
Wait 5 minutes to allow the high voltage battery
capacitor to fully discharge.
8.
Open the charging lid and remove the three
10mm nuts holding the charger port.
Quick charging port mounting bolt
tightening torque:
8.0~10.1 lb-ft (10.8~13.7 Nm, 1.1~1.4 kgf.m)
9.
Remove the charging lid by using a small
flathead screwdriver to unlock the tab as shown
in the picture to the right.
NOTICE
The purpose of removing the charging
lid is to prevent possible scratches
between the contact of the lid and the
body panel.
10. Lift the vehicle to comfortable working height.
TSB #: 18-BE-018
Page 11 of 14
SUBJECT:
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
11. Remove the front driver side wheel by removing
the 5 lug nuts.
Lug nut tightening torque:
79.6~94.0 lb-ft (107.9~127.5 Nm, 11.0~13.0
kgf.m)
12. Remove the wheel well liner by removing the
three types of fasteners located in the picture to
the right.
TSB #: 18-BE-018
Page 12 of 14
SUBJECT:
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
13. Carefully unlock the charging assembly by
unlocking the two lock tabs from behind the front
driver side fender, using a flathead screwdriver
and push outward.
14. Detach the cable from the inlet locking actuator
arm.
TSB #: 18-BE-018
Page 13 of 14
SUBJECT:
CHARGING INLET LOCKING ACTUATOR PART INFORMATION
AND REPLACEMENT PROCEDURE
15. Use a T15 Torx screwdriver to remove the two
screws holding the inlet locking actuator.
16. Disconnect the connector from the inlet locking
actuator.
17. Remove the red rubber seal from the old part
and place it onto the new part.
Rubber Seal
Replace the inlet locking actuator with the new
part.
18. Reinstall all removed parts in reverse order.
19. Confirm if the charging port locks/unlocks and if
the charging function is operating by checking
the vehicle’s charging status.
TSB #: 18-BE-018
Page 14 of 14