This operation manual is a proprietary business secret that outlines the successful cloning process for LEAR BCB OBC unit. By following the provided instruction steps, which include text, images, and videos, you will be fully equipped to clone the TC1782 effectively and efficiently
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You can charge this service: 500€ You need 16 labor hours to deploy this repair
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Common causes:
Coolant ingress and HW damage
No communication
Normal Tear&wear
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Errors:
Different alert codes - HVIL Interlock
Current error
Overheat
Different Inverter internal failure errors with BCB preffix
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Part numbers:
296H50132R HW D2.2,
296H50128R HW D2.1,
296H50047R HW D2.1,
296H50130R HW D2.1,
Other 296H5
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Tools needed (prepare it) :
Tricore flasher tool (tool name visible in purchased operation manual)
Soldering iron
OBD2 brakeout cable
12V lab power supply
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Repair operation steps
1- We assume that you took out DRIVETRAIN from vehicle, dissaesmbled everything and you took out Valeo inverter. Remove cover bolts and bolts holding the main inverter tricore board
Before performing any work on the Smart 453, it is mandatory to prepare a controlled and safe working environment in accordance with high-voltage safety protocols. Lvl 3 HV Access license needed.
Read error codes with diagnostic tool and confirm you have same error codes and faults.
Secure the work area – The workspace must be clean, dry, clearly marked as an HV zone, and equipped with proper safety gear (HV gloves, face shield, insulating mat).
Disconnect the 12V system
Perform safe high-voltage system shutdown – Using approved tools and following OEM procedures, disconnect the HV connectors and wait the required cool-down period for capacitor discharge.
Verify absence of voltage (Zero Voltage Verification) – Use an appropriate HV tester to ensure that no voltage is present in the system before proceeding
First thing is to remove 12 V battery by disconnecting (-) terminal
Now disasemble BCB box and locate Tricore TC1782:
And according to this Miniwiggler pinout connect...
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