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. Open the tailgate.
2. Open the LH front door and lower the LH front window.
3. Open the powered frunk.
4. Using MCU open charge port door

   

5. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
6. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
7. 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

   

   

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 there is no high voltage present at the charge port
    Note

    Measure B+ to B-, and B+ to Ground and B - to Ground, Place Alligator clip onto body panel

    

    

    

    

12. Remove leather over gloves and HV insulating gloves
13. Remove both LH rear fore and aft fender flares
    Note

    12 clips, 9x tabs

    

14. Remove clips securing LH rear wheel liner to aft fender flare carrier
    Note

    2x clips

    

15. Remove LH rear aft fender flare carrier
    Note

    2x bolts, 10mm, 7 Nm, 2x datum

    

    

16. Remove clips securing LH rear wheel liner to fore fender flare carrier
    Note

    5x clips

    

    

17. Remove LH rear fore fender flare carrier
    Note

    6x bolts, 10mm, 7 Nm, 1x connector, Disconnect BLE module then remove carrier, Release locking tab

    

    

    

18. Remove the LH lower bed side wall. See Wall Assembly - Bed Side - Lower - LH (Long Range) (Remove and Install).
19. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

21. Release HV connector from DC FC header
    Note

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

    

22. Remove connector from chargeport assembly
    Note

    1x connectors, Remove white locking tab, Depress tab to release connection from the charge port, Continue to pull off connector, The charge port connection is intended to disengage safety cap when released, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector

    

23. Remove chargeport door and LV connector
    Note

    2x connector, 1x clip

    

24. Remove bolt securing ground cable to busbar assembly
    Note

    1x bolt, 10mm, 6.5 Nm

    

25. Release chargeport from outer sail
    Note

    1x bolt, 10mm, 6.5 Nm

    

26. Remove bolts securing chargeport assembly onto body
    Note

    2x bolts, 10mm, 6 Nm, Use only hand tools, Risk of galling if power tools used on stainless fasteners

    

27. Remove chargeport and busbar from vehicle

    

    

28. 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

    

29. 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

    

30. Position chargeport busbar assembly onto vehicle

    

    

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

    2x bolts, 10mm, 9 Nm

    

32. 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

    

    

33. Install bolts securing chargeport assembly onto body
    Note

    2x bolts, 10mm, 6 Nm, Use only hand tools, Risk of galling if power tools are used on stainless fasteners

    

34. Install chargeport to outer sail
    Note

    1x bolt, 10mm, 6.5 Nm

    

35. Install busbar ground bolt
    Note

    1x bolt, 10mm, 6.5 Nm

    

36. Install chargeport door and LV connector
    Note

    2x connectors, 1x clip

    

37. Engage charge port connector
    Note

    1x connector, Fully engage connection and white locking tab, The connector is intended to lock the safety cap in place

    

38. Install the LH lower bed side wall. See Wall Assembly - Bed Side - Lower - LH (Long Range) (Remove and Install).
39. Install LH rear fore fender flare carrier
    Note

    6x bolts, 10mm, 7 Nm, 1x connector, Connect BLE then install carrier, Engage locking tab

    

    

    

40. Install clips securing LH rear wheel liner to fore fender flare carrier
    Note

    5x clips

    

    

41. Install clips securing LH rear wheel liner to aft fender flare carrier
    Note

    2x clips

    

42. Install both LH rear fore and aft fender flares
    Note

    12 clips, 9x tabs

    

43. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
44. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
45. Raise the LH front window and close the LH front door.
46. Close the tailgate.