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BEV POI Oil Type PZ

38899-REV-A01

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REQUIRED MATERIALS
Part Name

Part Number

Quantity

Electrical Contact Cleaner

Commercially available

1

Tool Name

Tool Number

Quantity

Mahle A/C Machine

RTIACX2282

1

A/C Oil Injector

07-J-45037

1

R1234yf A/C Oil Injector Hose

07-GE-50745

1

TOOL INFORMATION

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INSPECTION / REPAIR PROCEDURE
1. Disconnect the 12-volt battery. See Battery Negative Cable Disconnection and Connection.
2. Raise the vehicle. See Lifting and Jacking the Vehicle.
3. Remove the underbody rear air rear deflector. Refer to steps 2–6 of the Removal Procedure in Underbody Rear Air
Rear Deflector – Rear.
4. Locate the body wiring harness to chassis harness connector at the right-rear underside of the vehicle.

5. Disconnect the connector by releasing the red lock tab (A) on the connector, then rotate the release arm (B).

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6. Inspect both connectors for corrosion on the connector terminals.

Is corrosion present on the connector terminals?
YES – Use electrical contact cleaner to remove the surface corrosion, then go to step 7.

Do not use brake or fuel system cleaners as they can damage the connectors.
NOTE: Corrosion on the body harness connector is not expected.
NO – Go to step 8.
7. Was the corrosion successfully removed?
YES – Go to step 8.
NO – Take detailed photos clearly showing presence of corrosion on one or both of the connectors. Then, go to
PARTS INFORMATION to submit a request for the chassis harness, body harness, or both. Once the
harness(es) request is approved and shipped, go to the BODY / CHASSIS HARNESS REPLACEMENT
instructions.
8. Remove the plastic cover from the harness connector.
8.1 Cut off the wire tie securing the cover to the harness.

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8.2 Insert a flat-tipped screwdriver to release the cover lock, then remove the cover.

9

If the large cavity plugs are in place but sitting above the connector body (not fully seated), use a flat screwdriver and
push the cavity plug in until it is fully seated and sitting below the connector.
Cavity Plug Not Fully Seated

Cavity Plug Properly Seated

10 If either of the two large cavity plugs are missing, install a new cavity plug so that it sits flush with the connector body.

11 Reinstall the connector cover onto the connector body and secure it with a new wire tie.
12 Reconnect the harness connectors and return the harness to its original location.
13 Reinstall the underbody rear air rear deflector - rear. Do steps 1–5 of the Installation Procedure in Underbody Rear Air
Rear Deflector – Rear.
14 Lower the vehicle.
15 Connect the 12-volt battery. See Battery Negative Cable Disconnection and Connection.
16 Clear all DTCs.

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BODY / CHASSIS HARNESS REPLACEMENT
IMPORTANT: Complete the repair by following all designated steps in the referenced hyperlinks.
Replacing the Chassis Harness
NOTE: Only replace the chassis harness if the corrosion on the chassis harness terminals cannot be removed with
electrical contact cleaner.
1. Before replacing the chassis harness, take clear photos of the corrosion on the chassis harness connector. These
photos must be submitted with the warranty claim.
2. Disconnect connectors (1) and (2) from the rear electric drive transmission module, then remove the wiring harness
retainers (3).

3. Disconnect the forward lighting leveling position sensor connector (1) and the rear wheel speed sensor connectors (2),
then remove the wiring harness retainers (3, 4, 5).

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4. Remove the wiring harness retainers (1. 2, 3, 4, 5), then remove the rear chassis wiring harness (6).

5. Install the new harness in the reverse order of removal.
6. Reconnect the harness connector and return the harness connector to its original location.
7. Reinstall the underbody rear air rear deflector - rear. Do steps 1–5 of the Installation Procedure in Underbody Rear Air
Rear Deflector – Rear.
8. Lower the vehicle.
9. Connect the 12-volt battery. See Battery Negative Cable Disconnection and Connection.
10. Clear all DTCs.

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Replacing the Body Harness
NOTE:
• Only replace the body harness if the corrosion on the body harness terminals cannot be removed with the electrical
cleaner.
• Refer to PARTS INFORMATION for a list of parts that must be replaced during the body harness replacement.

•

Interior trim panels are attached to the body structure using metal clips. Pulling on the panel can result in damage to
the clips or interior panels.

•

To reduce the risk of damaging the mounting clips or the panels, use a suitable trim/clip removal tool to release the clip
from the body structure.
Panel Removal Tip:
1. Slide the trim/clip tool between where the
trim panel is secured to the body structure.

2. Gently twist the trim/clip tool to release
the metal clip from the body structure.

TIP: Make sure Techline Connect is up to date before proceeding with this repair.
1. Connect the 12-volt battery. See Battery Negative Cable Disconnection and Connection.

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2. Recover the refrigerant:
2.1 Launch the Techline Connect service diagnostic tool to open the system valves. Select the K16 Battery Energy
control module scan tool function.
2.2 Select GDS2.

2.3 Select Module Diagnostics.

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2.4 Select Battery Energy Control Module.

2.5 Select Control Functions.

2.6 Select Air Conditioning Refrigerant Evacuation and Service Fill Request.

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2.7 Select Start.

2.8 Once the valves are open, start recovering the refrigerant.

2.9 Recover the refrigerant using the Mahle machine only, (T/N RTIACX2282). For more information refer to
Refrigerant Recovery and Recharging.
NOTE:
• Do not use the Robinair Machine, it will not output the correct information for recovered POE oil.
• Record the exact amount of refrigerant oil recovered from the vehicle as the same amount of oil recovered will
be needed to recharge the system. Refer to Job Aid Prologue A/C Diagnosis and Leak Check.
3. Unbolt the front seats, removal step 2 only in Front Seat Removal and Installation.
NOTE: Do not disconnect the power seat harness connectors at this time.
4. Disable the SIR system using the negative battery cable method. See SIR Disabling and Enabling.
5. Remove the battery tray. See Battery Tray Replacement.
6. Disable the High Voltage system. See High Voltage Disabling.
7. Remove the right-side front floor carpet panel. See Front Floor Panel Carpet Replacement – Right Side.
8. Remove the left-side front floor carpet panel. See Front Floor Panel Carpet Replacement – Left Side.
9. Remove the rear seat. See Rear Seat Removal and Installation.

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10. Remove the rear floor panel carpet (1).

11. Remove the headliner,
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With Sunroof - See Headlining Trim Panel Replacement

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Without Sunroof – See Headlining Trim Panel Replacement

12. Remove the liftgate lower trim finish panel. See Liftgate Lower Trim Finish Panel Replacement.
13. Remove the headlamps. See Front Headlamp Replacement.
14. Remove the instrument panel assembly:
14.1 Do Removal Procedure steps 2 - 3 and 5 - 81 of the Instrument Panel Assembly Replacement:
NOTE: Do not do steps 4 or 82-90, the instrument panel will be removed as an assembly.
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With Heated Steering Wheel – See Instrument Panel Assembly Replacement (With KI3).

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Without Heated Steering Wheel - See Instrument Panel Assembly Replacement (Without KI3).

During the removal of the turn signal switch on step 69, there are two spring tabs securing the turn signal switch
to the steering column. Gently pry the spring tabs until the turn signal switch releases from the steering column
with light pressure. Excessive pressure can break the spring tabs. If the tabs break the turn signal switch must
be replaced.

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14.2 Disconnect the harness connectors and remove the harness grounds (1) at the kick panels and A-pillars to allow
the instrument panel to be removed.

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14.3 Make sure this left side harness (A) and its connectors (B) are removed before removing the instrument panel.

14.3 Do steps 1 – 18 of Windshield Wiper System Module Replacement.
NOTE: Do not do steps 19 – 21.
14.4 Do Removal Procedure steps 7, 9, and-10 of Instrument Panel Removal and Installation.
NOTE: Do not do step 8, the instrument panel will be removed as an assembly.
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With Heated Steering Wheel – See Instrument Panel Removal and Installation (With KI3).

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Without Heated Steering Wheel – See Instrument Panel Removal and Installation (Without KI3).

14.5 Remove the evaporator and blower module mounting bolts (A).

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14.6 Disconnect the refrigerant auxiliary pipe from the receiver dehydrator and the evaporator and blower module.
14.6.1 Do steps 14 – 35 of Heater and Air Conditioning Evaporator and Blower Module Refrigerant Auxiliary
Pipe Replacement.
14.6.2 Move the auxiliary pipe towards the driver’s side of the engine compartment to provide needed
clearance for the wiring harness removal and installation.

14.6.3 Disconnect the refrigerant pipe (A) from the refrigerant flow valve and discard the seal.
NOTE: Leave the remaining refrigerant lines connected to the refrigerant flow valves.

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14.6.4 Remove the refrigerant flow valve bracket bolts (A).

14.6.5 Remove the refrigerant pipe. Do steps 19 – 37 of Heater and Air Conditioning Evaporator and Blower
Module Refrigerant Pipe Replacement.
14.7 Remove the receiver and dryer tube bolt (1) to allow the tube (2) to be moved for more clearance for the wiring
harness removal and installation.

14.8 Do Removal Procedure steps 20 – 36 of Heater and Air Conditioning Evaporator and Blower Module Refrigerant
Pipe Replacement to disconnect the refrigerant pipe from the receiver dehydrator and the evaporator and blower
module.

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14.9 With the aid of an assistant, lift the instrument panel assembly up and rearward to release the assembly off the
locating pins, then remove it from the vehicle.

15. Remove the body wiring harness. Use Harness Routing Views as a reference.
TIPS:
•

Before removing the wiring harness, take photos to use as a reference during the new wiring harness installation.

•

Marking the old harness before removal can help as a reference with proper harness location during assembly.

16. Install the new body wiring harness.
17. With the aid of an assistant, install the instrument panel:
17.1 Install the new A/C evaporator seals before installing the instrument panel.
17.2 Install the instrument panel so that it is resting on the H pillar tie bar studs, but not fully seated (This provides
needed clearance to install the A/C lines to the evaporator).
17.3 From underneath the vehicle, position the A/C lines over their mounting studs.
17.4 Lower the vehicle and complete the installation of the instrument panel.
18. Replace the receiver dehydrator. See Air Conditioning Receiver and Dehydrator Replacement.
19. Reinstall the remaining parts in the reverse order of removal.

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20. Connect the 12-volt battery. See Battery Negative Cable Disconnection and Connection.
21. Recharge the refrigerant:
21.1 Use the printout from the Mahle machine to determine how much oil to install.

21.2 Current POE bottles do not have level markings to measure fluid. Use an oil injector and calculate how much oil
to install.
Example: If the system needs 39 mL (1.32 oz), (if your oil measurement is in ounces (oz) convert oz to mL).
• 39 mL x 140 mm = 5460
• 5460 / 120 mL = 45.5 mm
• Measure 45.5 mm from the plunger, which is 39 mL

21.3 Launch the Techline Connect service diagnostic tool to open the system valves.
21.4 Follow the instructions on the Mahle machine screen prompts to add the POE oil and refrigerant back into the
system.
NOTE:
• Use the A/C Oil Injector (T/N 07-J-45037) with the R-1234yf A/C Oil Injector Hose (T/N 07-GE-50745).
• Do not use the Honda R-1234yf POE Oil Injector Hose.
• For more information, refer to Refrigerant Recovery and Recharging.
22. Reinstall the underbody rear air rear deflector - rear. Do steps 1–5 of the Installation Procedure in Underbody Rear Air
Rear Deflector – Rear.
23. Reprogram the rear gate control module, do steps 1-3 in Reprogram Control Module in K194 Rear Gate Module:
Programming and Setup.
24. Clear all DTCs. See Diagnostic Repair Verification.
25. Do the liftgate relearn if required. See Liftgate Calibration.
26. Check that the electrical features are operating properly.

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