DEFA 463211 Inlet cable and Bumper Mounted MiniPlug Instruction Manual
- June 6, 2024
- DEFA
Table of Contents
DEFA 463211 Inlet cable and Bumper Mounted MiniPlug
TECHNICAL INFORMATION / INFORMATION TECHNIQUE
Notes to the Installer:
- Read the entire installation instruction prior to beginning the installation of this accessory.
- Ensure the vehicle is properly protected in the area(s) that the accessory is to be installed.
- To prevent vehicle damage, never place tools on top of painted surfaces, seats, dash pad, console or floor carpet/mats.
- Always wear appropriate safety gear including gloves and eye protection when required.
The diagram below gives an overview of all of the electrical connections in the charger kit.
WARNING:
Disconnect the battery before installation according to the manufacturer’s specifications.
NOTE: This instruction is available for download at: https://www.defa.com/ca/about-defa/download/
INSTALLATION
Inlet cable and Bumper Mounted MiniPlug
NOTE! READ ALL THE INSTRUCTIONS BEFORE PROCEEDING WITH THE INSTALLATION
NOTE! Insure OEM fasteners that require removal and reinstallation are
torqued to specifications.
- Avoid contact between the installed cables to any sharp or moving parts
The MiniPlug can be installed in 1 of 3 possible ways. Bumper trim panel hole method (A) or mounting bracket method (B) or through the grill method (C) using the large mounting discs as shown in the pictures below.
If method A is preferred, drill a
24mm (15/16ths inch) hole in the desired location and make a 3mm groove at
either the 9, 12 or 3 o’clock position depending on if the flap will be opened
vertically or horizontally.
NOTE: There is an index tab on the backside at the top of the MiniPlug
socket that is to engage into the 3mm groove upon installation. A drilling
template is provided in picture 2 on page 7.
NOTE: Make sure there is proper clearance behind the bumper cover before
drilling the hole. 
NOTE: Remove only one of the
plastic drains (the one that will be at the bottom) as pictured below and as
shown in detail picture number 5 on page 7 of these instructions.
Failure to do so may result in corrosion inside the socket. 
Install the Inlet cable through the hole and secure the MiniPlug
socket to the bumper cover using the locking ring (F) and orange O-ring (B) as
shown on pages 6 and 7. 
If using the mounting bracket
in the grill, use the mounting bracket (G) to secure the MiniPlug to the upper
part of the grill opening. Use the small screws (H) to lock the bracket into
position on the MiniPlug housing. Use the self-tapping screws (D) to install
the assembled MiniPlug on the front bumper as shown in the picture below. If
needed, the bracket shim (C) can be used between the bracket and the bumper
cover mounting area to gain extra MiniPlug flap opening clearance.
NOTE: If the vehicle is equipped with active grill shutters, ensure that
the cable does not interfere with the shutter operation. 
If installing the cable through the grill mesh, Install the Inlet
cable through a hole in the grill and secure the MiniPlug socket to the grill
using the assembly ring (A), the 55mm disc (I) and the locking collar (F) to
secure the MiniPlug to the grill in the location indicated in the pictures
below and as shown on pages 6 and 7. 
NOTE:
- Insure the Earth strap on the DEFA inlet cable is attached to a good clean chassis ground that is void of paint to ensure a good ground connection.
This is for safety and for the DEFA system to work correctly.
The MiniPlug may be mounted to various locations in the front bumper that will
retain the aesthetics of the vehicle. It is imperative that the plug be
mounted longitudinally to the vehicle and not transversely or vertically.
NOTE: It is highly recommended to regularly clean the MiniPlug housing during vehicle maintenance or more frequently depending upon weather and road conditions.
Spray the inside of the MiniPlug housing with a suitable aerosol cleaner such as Electronic Parts Cleaner. This will help to flush out any remaining moisture or debris accumulation from regular use.
INSTALLATION – Battery Charger and wire harness
Install the inlet cable up to the location of where the battery charger will be installed. The battery charger can be installed in the engine compartment in a convenient location within reach of the length of the Inlet cable and the charging wire harness to the battery.
NOTE: The charger and cables must not be installed directly next to any
hot or rotating parts.
Assemble the battery charger’s bracket(s) as shown in pictures below. The
optional L bracket can be used if required depending on the installation
location and position.
Install the battery charger and charging wires to the battery. Attach the charger to an available mounting point or original bolt on the inner fender or on the radiator support using the mounting bracket(s) provided as shown in the pictures below.
Attach the yellow/green ground lead
to an original ground point (2) on the chassis. 
Install the battery charging wire harness between the charger and
the battery and secure it along the original wire harnesses using the provided
zip ties. Connect the positive lead of the wire harness to the positive
battery post or clamp and secure the fuse holder with a plastic cable tie. The
red wire can also be connected to the positive power connection of the
underhood fuse panel. Attach the black ground lead to an original ground point
on the chassis.
Any excess wire length can be coiled and zip tied near the charger or other
location away from hot, sharp or other moving parts. 
NOTE!
- Insure OEM fasteners that require removal and reinstallation are torqued to specifications.
- Make sure the charging wire harness is routed away from any hot or sharp or rotating parts of the engine or steering column.
DEFA On-board battery charger KEY checks for good installation and
functionality
BEFORE YOU START THE INSTALLATION
- Read all instructions before proceeding with the installation as procedures may overlap.
- Before installation, disconnect the battery as directed by the manufacturer.
DURING THE INSTALLATION
- Ensure there is sufficient space between components to avoid chaffing or contact with moving parts.
- Ensure the ground wire on the DEFA inlet cable is attached to a good clean chassis ground that is void of paint to ensure a good ground connection.
TEST THE SYSTEM
- The light on the charger will only come on when the battery is at a low state of charge (Below 13.7V) and will not illuminate during the floating/maintaining states.
To test the charger, place a load on the battery such as an open door or headlights on.
MAINTENANCE
- It is highly recommended to regularly clean the MiniPlug housing during vehicle maintenance or more frequently depending upon weather and road conditions.
Spray the inside of the MiniPlug housing with a suitable aerosol cleaner such as Electronic Parts Cleaner. This will help to flush out any remaining moisture or debris accumulation from regular use.
DEFA North America Inc, 15 Allstate Parkway, Markham, ON, L3R5B4 1 888 539-DEFA (3332) or 1 647 660-DEFA (3332)
References
- Downloads • DEFA
- Charger Assembly 1203X • Efficient onboard charger kit • DEFA
- MiniPlug Cord Set • Connection set for the WarmUp system • DEFA
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