Sun Country Highway
Intermittent Pilot Signal / Communication Issue
Vehicle shows ‘Charging Paused’ or ‘Unable to Charge’ but charger LEDs indicate ready; no error code displayed.
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Safety Warning
This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.
If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.
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Possible Causes
Loose pilot connection at control board, Intermittent break in pilot conductor within cable, Contaminated pilot pin in J1772 connector, Vehicle inlet contamination or damage
How to Fix / Troubleshooting
Safety first: Turn off power before opening the charger.
- Test with another vehicle: Try a different EV to determine if the issue is vehicle-specific.
- Clean connector and inlet: Use electrical contact cleaner and a soft, lint-free swab to clean the J1772 pins and the vehicle inlet. Do not use abrasives.
- Inspect pilot wiring: Inside the charger, verify that the pilot wire is firmly secured in the control board connector and not pinched.
- Cable flex test: While monitoring a charging attempt, gently move the cable along its length. If charging starts/stops with movement, the pilot conductor is likely broken internally; replace the cable.
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Repair Difficulty
Medium
3/5
Required Part
J1772 Output Cable and Handle Assembly
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