Correction code 44000134 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 LH front door and lower the LH front window.
2. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
3. Connect to vehicle using Toolbox. See Toolbox 3 (Connect and Disconnect).
4. In Toolbox, click the Actions tab, and then search for "diagnostic_path_network.HV_isolationCheck".
5. Click HV Isolation Diagnostic Debug, enter the VIN, and then click Run.

   

   

6. Read "HV System Global Check Autodiag", and then click Yes to continue.

   

7. Read the "HV Awareness" warning, and then click Yes to continue.

   

8. Read the interactive procedure instructions, and then click Next to continue.
   Note

   Click Finish Later every time you need to perform a task to prevent timeout error. Click Resume after task has been performed and you are ready to submit input.

   

9. Read the "Vehicle Electrical Isolation Procedure" panel, and then click Finish Later to prevent timeout error.

   

10. Open the powered frunk.
11. Open the tailgate.
12. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
13. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
14. 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

    

    

15. Disconnect Toolbox 3 from vehicle and remove laptop
16. Raise vehicle fully
    Note

    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
17. Remove the rear skid plate. See Skid Plate - Rear (Remove and Install).
18. Remove all items from pockets and ensure not wearing metal items

    

19. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.

    

20. Put on HV insulating gloves and leather over gloves

    

21. Remove clips securing AC compressor HV harness
    Note

    3x clips

    

22. 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

    

    

    

    

    

    

23. Click Resume to continue to "Vehicle Electrical Isolation Procedure" panel.
    Note

    Read panel and select "Yes" to continue

    

    

24. Read "Rear Left DU + HV Harness Isolation Test" panel, and then click Finish Later to prevent timeout error.

    

25. Perform isolation test on LH RDU HV cable at HV battery
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to subframe bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

26. Click Resume to continue to "Rear Left DU + HV Harness Isolation Test" panel.
    Note

    Read panel and submit resistance to continue

    

    

27. Read "Rear Left DU + HV Harness Voltage Check" panel, and then click Continue.

    

28. Read "Rear Right DU + HV Harness Isolation Test" panel, and then click Finish Later to prevent timeout error.

    

29. Disconnect RDU HV harness
    Note

    1x connector, Release locking tab and rotate release lever up, Do not force release lever up, Ensure alignment tabs on header are not damaged

    

30. Perform isolation test on RH RDU HV cable at HV battery
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to subframe bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

31. Click Resume to continue to "Rear Right DU + HV Harness Isolation Test" panel.
    Note

    Read panel and submit resistance to continue

    

    

32. Read "Rear Right DU + HV Harness Voltage Check" panel, and then click Continue.

    

33. Read "Heat Pump A/C Compressor + HV Harness' Isolation Tests" panel, and then click Finish Later to prevent timeout error.

    

34. Release A/C compressor HV harness from HV battery
    Note

    1x locking connector, 4x clips, Pull down red locking tab and disengage the release lever, Do not force the release lever up, Number of connections may vary by vehicle configuration

    

    

    

35. Perform isolation test on ancillary HV harness at rear of HV battery
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to subframe bolt, Position leads then press test button, Amber light will turn on, Test all four terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

36. Click Resume to continue to "Heat Pump A/C Compressor + HV Harness' Isolation Tests" panel.
    Note

    Read panel and submit resistance to continue

    

    

37. Read CP HV Harness FC contactor question and click Yes to continue.

    

38. Read "CP HV Harness Isolation Test" panel, and then click Finish Later to prevent timeout error.

    

    

39. 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
40. Remove the bed floor. See Bed Floor Assembly (Long Range) (Remove and Install).
41. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

43. Release HV connector from DC FC header
    Note

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

    

44. Secure CP busbar connector aside
    Note

    Move connector away from header, Install bags or bungees as needed, Do not open tonneau to prevent damage

    

45. Perform isolation test on CP HV busbar connector
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to door stricker, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

46. Click Resume to continue to "CP HV Harness Isolation Test" panel.
    Note

    Read panel and submit resistance to continue

    

    

47. Read Ancillary certification question, and then click Yes to continue.

    

48. Read "PCS2 DC Isolation Test" panel, and then click Finish Later to prevent timeout error.

    

    

49. Connect HV harness connector to AC compressor
    Note

    1x locking electrical connector, Slide down black lock then push in red locking tab, Perform a push-pull-push test, Ensure red locking tab is fully engaged, Black tab will protrude from red locking tab when engaged correctly, Refer to images and video for clarity

    

    

    

    

50. Install the frunk assembly. See Frunk Assembly (Remove and Install).
51. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
52. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
53. Raise vehicle fully
    Note

    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
54. 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

    

    

    

    

    

    

55. Remove pyro fuse access cover
    Note

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

    

56. Remove primary pyro fuse
    Note

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

    

    

57. Remove secondary pyro fuse
    Note

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

    

    

58. 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
59. Clean all debris from ancillary cover
    Note

    During removal of ancillary cover any debris on top of the cover may be deposited into the ancillary bay

    

60. 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

    

    

    

    

    

61. Support HV Busbar assembly
    Note

    Suspend assembly to maintain clearance

    

62. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

63. Release low voltage header
    Note

    2x bolts, EP10, 6 Nm

    

64. Release fasteners securing ancillary cover to HV battery
    Note

    22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order

    

    

    

65. Remove ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

66. Disconnect PCS2 DC HV connector
    Note

    1x connector, Release locking tab, Gently pull up

    

67. Perform isolation test on PCS2 DC connector at ancillary
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to HV battery chassis bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

68. Click Resume to continue to "PCS2 DC Isolation Test" panel.
    Note

    Read panel and submit resistance to continue

    

    

69. Read "ACJB Isolation Test" panel, and then click Finish Later to prevent timeout error.

    

    

70. Release ancillary bay MV connector header
    Note

    4x tabs, Move aside as needed

    

    

71. Disconnect HVC logic connector
    Note

    1x connector

    

72. Disconnect negative pack contactor sense connectors
    Note

    2x connectors

    

73. Disconnect positive pack contactor sense connectors
    Note

    2x connectors

    

    

74. Disconnect ACJB HV connector
    Note

    1x connector, Release locking tab, Gently pull up

    

75. Perform isolation test on ACJB HV connector
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to HV battery chassis bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

76. Click Resume to continue to "ACJB Isolation Test" panel.
    Note

    Read panel and submit resistance to continue

    

    

77. Read "External Side DC Link Isolation Test" panel, and then click Finish Later to prevent timeout error.

    

78. Perform isolation test on external side of negative and positive pack contactors
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to HV battery chassis bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

    

79. Click Resume to continue to "External Side DC Link Isolation Test" panel.
    Note

    Read panel and submit resistance to continue

    

    

80. Read "Internal Side DC Link Isolation Test" panel, and then click Finish Later to prevent timeout error.

    

    

81. Perform isolation test on internal side of negative and positive pack contactors and pyro disconnect
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to HV battery chassis bolt, Position leads then press test button, Amber light will turn on, Test all four terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

    

    

82. Click Resume to continue to "Internal Side DC Link Isolation Test" panel.
    Note

    Read panel and submit resistance to continue

    

    

83. Read "Warm Heat Pump A/C Compressor Isolation Test" panel, and then click Finish Later to prevent timeout error.

    

84. Connect ACJB HV connector
    Note

    1x connector, Secure locking tab

    

85. Connect positive pack contactor sense connectors
    Note

    2x connectors

    

    

86. Connect negative pack contactor sense connectors
    Note

    2x connectors

    

87. Connect HVC logic connector
    Note

    1x connector

    

88. Secure ancillary bay MV connector header
    Note

    4x tabs

    

89. Connect PCS2 DC HV connector
    Note

    1x connector, Secure locking tab

    

90. Install ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

91. Secure fasteners of cover to HV battery
    Note

    22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order

    

    

    

92. Secure low voltage header
    Note

    2x bolts, EP10, 6 Nm

    

93. Secure fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

94. 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

    

95. 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

    

96. 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

    

97. Position busbar connector and lower onto HV header
    Note

    Release bungee cord

    

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

    2x bolts, 10mm, 9 Nm

    

99. 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

    

    

100. Install bolt securing busbar HV connector lid
     Note

     1x bolt, EP10, 9 Nm

     

101. Connect Ancillary bay MV connector
     Note

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

     

     

     

     

     

102. Raise vehicle fully
     Note

     Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
103. 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

     

     

     

104. Install secondary pyro fuse
     Note

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

     

     

105. Install primary pyro fuse
     Note

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

     

     

106. 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

     

     

107. Remove HV insulating gloves
108. 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

     

     

109. Secure A/C compressor HV harness onto battery
     Note

     1x locking connector, 4x clips, Engage locking tab, Do not force lever up, Number of connections may vary by vehicle configuration

     

     

     

110. Connect RDU HV harness
     Note

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

     

111. Connect LHS RDU HV harness
     Note

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

     

112. Install clips securing AC compressor HV harness
     Note

     3x clips

     

113. Install the rear skid plate. See Skid Plate - Rear (Remove and Install).
114. 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
115. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
116. Remove the frunk assembly. See Frunk Assembly (Remove and Install).
117. Warm up AC compressor via UI
     Note

     Via Climate Control > ON, Set fan speed to 10, Set temperature to HI or LO, Allow 20 minute run time

     

118. Turn off the AC and blower motor

     

119. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
120. Disconnect HV harness connector from AC compressor
     Note

     1x locking electrical connector, Pull red locking tab away from compressor then slide black lock upwards to release

     

     

121. Perform isolation test on AC compressor
     Note

     Move HV harness aside as needed, Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to shock tower brace, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

     

     

     

     

     

122. Click Resume to continue to "Warm Heat Pump A/C Compressor Isolation Test" panel.
     Note

     Read panel and submit resistance to continue

     

123. Read "HV Isolation Diagnostic Debug" results.
     Note

     If this panel is reached then screenshot and escalate a Toolbox session, Select "X" at top right of window to close once complete

     

124. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
125. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
126. Install the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
127. Close the tailgate.
128. Exit Service Mode. See Service Mode.
129. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
130. Raise the LH front window and close the LH front door.