Correction code NA NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
2. Open the powered frunk.
3. Open the tailgate.
4. Remove the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
5. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
6. Verify operation of multimeter
   Note

   Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals

   

   

7. Remove the rear skid plate. See Skid Plate - Rear (Remove and Install).
8. Remove all items from pockets and ensure not wearing metal items

   

9. Inspect HV insulating gloves
   Note

   Check gloves for damage prior to use, Refer to service document TN-15-92-003

   

10. Put on HV insulating gloves and leather over gloves

    

11. Verify no HV - Install amp clamp to RDU HV harness
    Note

    Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.Release locking tab and rotate the release lever up to disengage the connector, Release harness clip, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damagedMake sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering

    

    

    

    

    

    

12. Secure RDU header connector to ancillary
    Note

    1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins

    

    

13. Remove pyro fuse access cover
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm

    

14. Remove primary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts

    

    

15. Remove secondary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts

    

    

16. Lower vehicle until tires are touching the ground
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
17. Disconnect ancillary bay MV connector
    Note

    1x connector, Double locking, Release tab then pivot lever, Release second tab to disengage connector, Wait 1 second between locking tab release to discharge and prevent arcing

    

    

    

    

    

18. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

19. Remove bolts securing HV connector to DC FC header
    Note

    2x bolts, 10mm, 9 Nm

    

20. Release HV connector from DC FC header
    Note

    1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly

    

21. Support HV Busbar assembly
    Note

    Suspend assembly to maintain clearance

    

22. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

23. Secure fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

24. Clean HV connector contact surface of residual Penetrox
    Note

    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector

    

25. Clean busbar HV connector contact surface of residual Penetrox
    Note

    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar

    

26. Apply Penetrox onto HV connector joints
    Note

    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered

    

27. Position busbar connector and lower onto HV header
    Note

    Release bungee cord

    

28. Install bolts securing charge port busbar kit to HV Header
    Note

    2x bolts, 10mm, 9 Nm

    

29. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Note

    2x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session.If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step

    

    

30. Install bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

31. Remove leather over gloves and HV insulating gloves
32. Connect Ancillary bay MV connector
    Note

    1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly

    

    

    

    

    

33. Install the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
34. Raise vehicle fully
35. Remove all items from pockets and ensure not wearing metal items
36. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003

    

37. Put on HV insulating gloves and leather over gloves

    

38. Clean mating surface of the pyro
    Note

    Use a non-conductive plastic tool to clean the busbar side, Allow 1 minute for IPA to fully dry, Do not use any other types of cleaner

    

    

    

39. Install secondary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts

    

    

40. Install primary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts

    

    

41. Perform Hioki resistance test at each HV joint from HV busbar lead to pyro fuse busbar
    Note

    4x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session.If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step

    

    

42. Remove leather over gloves and HV insulating gloves
43. Install pyro fuse access cover
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged, If HV pack is being shipped then pyro fuses must be removed

    

    

44. Install rear skid plate. See Skid Plate - Rear (Remove and Install).
45. Lower vehicle until tires are touching the ground
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
46. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
47. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
48. Close the powered frunk.
49. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.