| Access the hybrid battery compartment and remove the lid. Be sure to turn the IMA battery circuit breaker off until instructed to turn it on. | |
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Using a trim panel removal tool, remove the four trunk liner pieces in the order listed. There are five clips on the IPU cover trim (#2). The trunk latch cover (#3) is removed by pulling up and foreword (toward the front of the car). There are three clips on the IPU fan cover (#4), two of which are screw clips. Note how the IPU cover trim (#2) interlocks with the IPU fan cover (#4) and left trunk side trim (not removed) at the top corners so that it can be reinstalled properly. |
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Locate the IPU fan on the foreword right corner of the trunk. Remove the factory IPU cooling fan sub-harness from the car by unplugging both ends. Note: The top large white plug can be difficult to remove. Press hard on the locking tab while pulling on the white plug body. See the next step for a photo detailing the locking tab on the white plug. DO NOT PULL EXCESSIVLY ON THE WIRES AS THEY CAN BE PULLED OUT OF THE PLUG AND THE HARNESS WILL NOT BE REUSABLE. This wire sub-harness must be returned in order to receive your core refund! |
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OPTIONAL: If you have trouble removing the factory IPU cooling fan sub-harness from the car with the IPU fan installed, you can remove the three 10mm bolts holding the fan in place and remove the entire fan assembly. The photo at left shows the fan removed from the car (and the white plug locking tab of the factory IPU cooling fan sub-harness). When reinstalling be sure the inlet duct connects properly (seated all the way around the connection) to the IPU compartment output duct. A light coating of WD-40 on the mating surfaces will significantly ease reinstallation of the soft rubber ducting. |
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Install the harness onto the IPU fan. Connect the plugs to the fan motor and chassis wire harness. Anchor the IPU fan controller to the trunk bulkhead using the supplied zip tie as shown. This does not need to be super tight, just enough to hold the IPU fan controller in place so it will not rattle. Trim the excess zip tie material and discard. |
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Route the charge wires (red & black) forward through the passenger side exterior of the IPU compartment and into the IPU compartment through the existing wire harness grommet as shown. |
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The IMA battery does not need to be fully removed from the IPU compartment in order to make the charge connections. If desired, the connections can be made with the battery partially removed, as shown. |
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An alternate method to install the harness is to remove the battery and position it on the rear seat sill as show in this photo. This allows for easier loosening and tightening of the small (fragile) screws that are used to attach the Grid Charger. We used this alternate method for the instructions to show both options. |
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This detail shows the connection points for the charge positive and charge negative wires. Do NOT route the red wire across the negative bus bar as shown in the next photo.Be careful not to strip the small Phillips screws while loosening and tightening. Use firm downward pressure on the screws and turn carefully to loosen. Secure the wires to the IMA battery using the supplied zip tie as shown. It is normal for the red wire to have some black heat shrink tubing on the end as this is protecting the diode that protects the car harness in the event of an electrical short. |
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as shown in this photo.This routing has a very high risk of short if something goes wrong.Don’t do it.
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Route the charge wires as shown and secure using the final two supplied zip ties. |
| Reinstall the hybrid battery. Do not close the IPU compartment until after performing the initial function test as described below. | |
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IMPORTANT – Test the charger before re-assembling the vehicle. Always connect the Grid Charger to the car before plugging it into the wall and unplug it from the wall before disconnecting it from the car.To perform the initial function test: First, make sure all fingers and tools are clear of all wiring and IMA battery components. Plug the Grid Charger into the car and turn the multi-meter on to the 200v DC setting. If your multi-meter has a power switch, turn it on. With the IMA battery circuit breaker still turned off, plug the Grid Charger into the wall. After a few seconds, it should read approx 180 volts on the meter and both the charger and IPU fans should be running. Next, move the IMA battery circuit breaker to the on position. You should see the voltage drop as the charger voltage equalizes with the voltage level of the battery pack. This should happen quickly. The voltage level should be stable and not fluctuating. Both fans should still be running. If anything is wrong, stop and contact us. If the fan is ‘pulsing’ (powering on and off) every few seconds, stop and contact us. This completes the test. Unplug the Grid Charger from the wall, turn the IMA battery circuit breaker off, and disconnect the Grid Charger from the car harness. |
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Cut a 2” x 2” ‘X’ shaped slot in the trunk liner and route the charger harness through the trunk panel as shown. Your trunk will not be fully reassembled as in the photo but that is OK as this will be covered in the next step. |
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Reassemble the trunk liners in the reverse order of removal and reinstall all trim fasteners. |
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Return the IPU cooling fan sub-harness to us at the address given in your shipping confirmation email. This must be received in order to process your core refund. |