2026-10-13

Retrofit PCS1 into Later Revision HV Battery (Retrofit)

Correction code S012616003 FRT 3.12 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated FRT 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.

Note
This procedure is performed on a new HV battery before it is installed into the vehicle.
  • 2026-09-01: Released new procedure.

Remove PCS1 from the Removed HV Battery

  1. Remove the bolts that secure the ancillary bay cover. See Cover - Ancillary Bay (Remove and Install).
  2. Remove the high voltage controller (HVC) logic cap.
  3. Inspect and put on the HV insulating gloves and leather over gloves.
  4. Remove the ancillary bay cover from the HV battery.
  5. Install the HVC logic cap.
  6. Inspect the ancillary bay for any missing insulators.
    Note
    Install service insulator kit before continuing to next step.
  7. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  8. Disconnect the connector X483 - BMB daisy B from the HVC.
  9. Disconnect the connector X482 - BMB daisy A from the HVC.
  10. Disconnect the connector X480 from the HVC.
  11. Disconnect the connector X481 from the HVC.
  12. Disconnect the connector X478 from the HVC.
  13. Disconnect the connector X484 from the HVC.
  14. Disconnect the connector X479 from the HVC.
  15. Remove the megaharness clips (x5) and the tape from the HVC hinge tray.
    Note
    The harness tape needs to be carefully cut with insulating knife.
  16. Release the screws (x2) that attach the HVC tray assembly to the ancillary bay, and then release the wires (x3) routed through the RH hinge.
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 bit
  17. Remove the HVC and hinge tray assembly from the ancillary bay.
  18. Position absorbent sheets below and around the PCS coolant inlet hose to avoid excess coolant dripping.
  19. Disconnect the PCS coolant inlet hose from the PCS (2x clips) and plug the ends of fittings as soon as possible to avoid coolant loss.
    Note
    Insert the special tool from the side opposite the PCS, between the ancillary bay housing and the hose.
    Tip
    Use of the following tool(s) is recommended:
    • 1111868-00-B - CONNECTOR REMOVAL,COOLANT,PCS,M3
  20. Disconnect the PCS coolant outlet hose from the PCS (2x clips) and plug the ends of fittings as soon as possible to avoid coolant loss.
    Note
    Discard the O-ring.
    Note
    Place absorbent sheet under hose to catch excess coolant. Visually inspect the area for any coolant residue. Clean with shop towel if necessary.
    Tip
    Use of the following tool(s) is recommended:
    • 1111868-00-B - CONNECTOR REMOVAL,COOLANT,PCS,M3
  21. Disconnect the PCS to DC bus HV connector.
    Note
    Release the locking tab by pulling upward. May need plastic trim tool to help lift the connector upward.
  22. Disconnect the PCS logic connector from the PCS.
  23. Disconnect the PCS LV connector from the PCS.
    Note
    Release the locking tab by pulling upward. May need plastic trim tool to help lift the connector upward.
  24. Disconnect the AC harness connector from the PCS.
    Note
    Release the locking tab by pulling upward. May need plastic trim tool to help lift the connector upward.
  25. Remove and discard the 8 mm bolts (x5) that attach the PCS to the HV battery.
    Note
    Do not remove the T30 fasteners.
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm socket
  26. Secure suction cups to the PCS.
    Note
    Continue pressing the plunger until the red line is no longer visible. Do not install the suction cups on top of any stickers as this will cause loss of suction.
  27. Lift the PCS up and out of the ancillary bay area and remove it from the vehicle.
    Note
    Slightly tilt the rear of the PCS upward then lift it out. Install any missing insulators under PCS before continuing to the next step. Visually inspect the area for any coolant residue and clean with shop towel if necessary.
  28. Disconnect the ancillary bay harness connectors (x2) from the positive pack contactor.
  29. Remove the ancillary bay harness clip from the positive pack contactor.
  30. Remove the HV joint insulators (x2) from the positive HV switch.
  31. Remove and discard the patch bolt that attaches the positive pack contactor to the positive busbar.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  32. Remove and discard the patch nut that attaches the positive pack contactor to the module 4 rear terminal.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  33. Remove the nuts (x3) that attach the positive pack contactor to the ancillary bay.
    Note
    Use insulated magnet to retrieve the nuts after removal. The number of nuts on newer vehicles may vary.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  34. Remove the positive pack contactor from the ancillary bay.
  35. Remove the HV joint insulator for positive DC link to module 4.
  36. Remove and discard the patch nut that attaches the DC link to module 4.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  37. Remove the ancillary bay harness clips (x3) from the positive DC link.
  38. Remove the positive DC link from the ancillary bay.
    Note
    Be careful not to touch the rear terminal of module 4.
  39. Cut the cable ties (x2) that attach the megaharness to the charger output to DC bus harness.
  40. Remove the protrusion on the ancillary bay harness base.
    Note
    If there is a tab, break off the tab with insulated needle nose pliers. Remove and discard the tab to allow rotation of the coolant inlet hose.
  41. Release the PCS coolant inlet hose from the hose clips (x2).
    Note
    Use plastic trim tool to remove the hose from the card slot, and then rotate 90 degrees counterclockwise.
  42. Disconnect the PCS coolant inlet hose from the ancillary bay (2x clips, 2x plugs).
    Note
    Place absorbent sheet under the hose to catch excess coolant and clean the residual coolant in the hose. Install plugs to the ancillary bay and the hose. If reused, replace both O-rings after disassembly.
  43. Remove the insulators (x2) for the fuse and bolts.
  44. Remove and discard the patch nuts (x4) that secure the fuses (x2).
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm socket
  45. Remove and discard the patch nut that secures the HV battery ancillary positive busbar bracket.
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm socket
  46. Remove and discard the nut that attaches the negative output harness to the negative HV battery DC link busbar.
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm socket
  47. Remove the bolt that secures the RH ancillary bay bus cover.
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 bit
  48. With assistance, lift up the busbar DC link cover (2x clips).
    Note
    Be careful not to damage the cover when lifting.
  49. Remove the charger output to DC Harness outward from the busbar DC link.
    CAUTION
    Do not damage the insulation layer of the harness. If it is damaged, it must be replaced.
  50. Remove the bolts (x2) that attach the DCDC pass through to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  51. Remove the DCDC pass through from the ancillary bay.
    CAUTION
    Avoid metal damage to the cable insulation layer.
  52. Disconnect the ancillary bay harness connectors (x2) from the negative pack contactor.
  53. Remove the HV joint insulators (x2) from the negative pack contactor.
  54. Remove and discard the patch bolt that attaches the negative pack contactor to the DC link busbar joint.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  55. Remove and discard the patch nut that attaches the negative pack contactor to the HV battery tall silicon terminal.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  56. Remove the nuts (x3) that attach the negative pack contactor to the ancillary bay.
    Note
    Use insulated magnet to retrieve the nuts after removal. The number of nuts on newer vehicles may vary.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  57. Remove the negative pack contactor from the ancillary bay.
  58. Disconnect the PCS coolant outlet hose from the ancillary bay (2x clips) and plug the ends of fittings as soon as possible to avoid coolant loss.
    Note
    Place absorbent sheet under the hose to catch excess coolant. If reused, replace both O-rings after disassembly.
    Tip
    Use of the following tool(s) is recommended:
    • 111868-00-B - CONNECTOR REMOVAL,COOLANT,PCS,M3
  59. Release the locking tab and disconnect the AC filter harness connectors (x2) from the fastcharge (FC) contactor cover.
  60. Remove the AC filter harness clips (x2) from the FC contactor cover.
  61. Remove the bolts (x2) that attach the busbar AC input assembly to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  62. Release the 3-phase AC Filter Harness from the 3-phase 4P Header (2x tabs).
    Note
    Lift the connector off the HV battery for access. Inspect the sealing ring, if damaged, it cannot be reused.
  63. Remove the 3-phase AC Filter harness from the vehicle.
    Note
    Harness must be removed through the ancillary bay. PCS2 Lite connector does not fit through the header hole.
  64. Remove the leather over gloves and the HV insulating gloves.

Remove PCS2 from the New Battery

  1. Remove the bolts that secure the ancillary bay cover. See Cover - Ancillary Bay (Remove and Install).
  2. Remove the high voltage controller (HVC) logic cap.
  3. Inspect and put on the HV insulating gloves and leather over gloves.
  4. Remove the ancillary bay cover from the HV battery.
  5. Install the HVC logic cap.
  6. Inspect the ancillary bay for any missing insulators.
    Note
    Install service insulator kit before continuing to next step.
  7. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  8. Disconnect the HVC connectors (x7).
  9. Remove the megaharness clips (x8) from the HVC skylite hinge.
  10. Release the screws (x2) that attach the HVC tray assembly to the ancillary bay, and release the wires (x3) routed through the RH hinge.
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 bit
  11. Remove the HVC and hinge tray assembly from the ancillary bay.
  12. Position absorbent sheets below and around the PCS2 lite coolant inlet hose to avoid excess coolant dripping.
  13. Disconnect the PCS2 lite coolant inlet hose from the PCS2 lite (2x clips) and plug the ends of fittings as soon as possible to avoid coolant loss.
    Note
    Place absorbent sheet under hose to catch excess coolant. Visually inspect the area for any coolant residue and clean with shop towel if necessary.
    Note
    Discard the O-ring.
    Tip
    Use of the following tool(s) is recommended:
    • 1111868-00-B - CONNECTOR REMOVAL,COOLANT,PCS,M3
  14. Disconnect the PCS2 lite coolant outlet hose from PCS2 lite (2x clips) and plug the ends of fittings as soon as possible to avoid coolant loss.
    Note
    Place absorbent sheet under hose to catch excess coolant. Visually inspect the area for any coolant residue and clean with shop towel if necessary.
    Note
    Discard the O-ring.
    Tip
    Use of the following tool(s) is recommended:
    • 1111868-00-B - CONNECTOR REMOVAL,COOLANT,PCS,M3
  15. Disconnect the AC filter harness connector from the PCS2 Lite.
    Note
    First fully release the red lock pin, then press the tab inward and lift the connector upward to remove. May need plastic trim tool to help lift the connector upward.
  16. Disconnect the PCS2 lite HV DC harness HV connector.
    Note
    Release the locking tab by pulling upward. May need plastic trim tool to help lift the connector upward.
  17. Disconnect the PCS2 lite logic connector from the PCS2 lite.
  18. Disconnect the PCS2 lite LV connector from the PCS2 lite.
    Note
    Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  19. Remove and discard the 8 mm bolts (x5) that attach the PCS2 lite to the HV battery.
    Note
    Do not remove the T20 fasteners.
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm socket
  20. Secure the suction cups to the PCS2 lite.
    Note
    Continue pressing the plunger until the red line is no longer visible.
  21. Lift the PCS2 lite up and remove it from the ancillary bay.
    Note
    Slightly tilt the rear of the PCS2 lite upward then lift it out to remove. Install any missing insulators under PCS before continuing to next step. Visually inspect area for any coolant residue and clean with shop towel if necessary.
  22. Remove the ancillary bay harness clip from the positive pack contactor.
  23. Disconnect the ancillary bay harness connectors (x2) from the positive pack contactor.
  24. Remove the HV joint insulators (x2) from the positive pack contactor.
  25. Remove and discard the patch bolt that attaches the positive pack contactor to the positive busbar.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  26. Remove and discard the patch nut that attaches the positive pack contactor to the HV battery tall terminal.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  27. Remove the nuts (x3) that attach the positive pack contactor to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  28. Remove the positive pack contactor from the ancillary bay.
  29. Remove the HV joint insulator for the HV battery DC link positive busbar.
  30. Remove and discard the patch nut that attaches the DC link to the DC link positive busbar.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  31. Remove the ancillary bay harness clips (x3) from the positive DC link.
  32. Remove the DC link extension positive from the ancillary bay.
    Note
    Be careful not to touch the rear terminal of module 4.
  33. Disconnect the PCS2 lite coolant inlet hose from ancillary bay (2x clips) and plug the ends of fittings as soon as possible to avoid coolant loss.
    Note
    Place absorbent sheet under hose to catch excess coolant. Clean the residual coolant inside the hose. Discard the O-ring.
  34. Remove the insulators (x2) for fuse and bolts.
  35. Release the locking tab and disconnect the X421 connector from the DC connection bus.
  36. Remove and discard the nuts (x4) that secure the fuses (x2).
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm socket
  37. Remove and discard the nut that attaches the negative output harness to the negative HV battery DC link busbar.
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm socket
  38. Remove and discard the nut that attaches the ancillary positive busbar bracket to the positive HV battery DC link busbar.
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm socket
  39. Remove the bolt that attaches the RH ancillary bay bus cover.
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 bit
  40. With assistance, lift up the DC link busbar cover (1x clip).
    Note
    Be careful not to damage the cover when lifting.
  41. Remove the PCS2 lite HV DC harness from the ancillary bay (3x harness slots, 1x hook).
    Note
    First remove the terminals from the studs, and then remove the harness outward.
    Note
    Do not damage the insulation layer of the harness. If it is damaged, it must be replaced.
  42. Remove the bolts (x2) that attach the DCDC pass through to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
  43. Remove the LV DC harness of PCS2 lite from the ancillary bay.
    CAUTION
    Avoid metal damage to the cable insulation layer. If damaged, do not reuse the harness.
  44. Remove the RH daisy chain pass through housing from the ancillary bay.
    Note
    Insert the UFO harness removal tool beneath the daisy chain pass through housing, insert the tab release tool to release the bottom 2x clips. Then release the top 3x location pins with trim tool. Pull the daisy chain pass through housing upward to remove.
    CAUTION
    If this part is damaged during disassembly, the PCS2 Lite harness assembly needs to be replaced.
    Tip
    Use of the following tool(s) is recommended:
    • 1475996-00-A - UFO CONNECTOR REMOVAL TOOL - M3 R
  45. Disconnect the ancillary bay harness connectors (x2) from the negative pack contactor.
  46. Disconnect the LV fastcharge contactor connector.
    Note
    Press the tabs on both sides by hand and disconnect the connector upwards.
  47. Remove the HV joint insulators (x2) from the negative pack contactor.
  48. Remove and discard the patch bolt that attaches the negative pack contactor to the DC link busbar joint.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  49. Remove and discard the patch nut that attaches the negative pack contactor to the HV battery tall silicon terminal.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  50. Remove the nuts (x3) that attach the negative pack contactor to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  51. Remove the negative pack contactor from the ancillary bay.
  52. Disconnect the PCS2 Lite coolant outlet hose from the ancillary bay (2x clips) and plug the ends of fittings as soon as possible to avoid coolant loss.
    Note
    Place absorbent sheet under the hose to catch excess coolant.
    Tip
    Use of the following tool(s) is recommended:
    • 2029761-00-A - CONNECTOR REMOVAL, COOLANT , HIGHLAND
  53. Release the locking tab and disconnect the AC filter harness connectors (x2) from the FC contactor cover.
  54. Remove the harness clips (x3) from the FC contactor cover.
    Note
    Move the wiring harness around the FC cover aside.
  55. Remove the harness clip from the left terminals cover.
  56. Remove the ancillary bay left terminals cover (2x tabs).
  57. Remove and discard the patch bolt that attaches the negative fastcharge busbar to the DC link side.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  58. Remove and discard the patch bolt that attaches the positive fastcharge busbar to the DC link side.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  59. Remove the bolts (x4) that attach the DC input header seal to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
  60. Remove the DC input header seal from the ancillary bay.
  61. Remove the bolts (x2) that attach the FC contactor assembly to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  62. Remove the FC contactor assembly from the ancillary bay (1x clip).
    Note
    Tilt upwards to remove the FC contactor assembly.
  63. Remove the bolts (x2) that attach the busbar AC input assembly to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
  64. Release the 3-phase AC Filter harness from the 3-phase 4P Header (2x tabs).
    Note
    Lift the connector off HV battery for access. Inspect the sealing ring, if damaged, it cannot be reused.
  65. Remove the 3-phase AC Filter harness from the vehicle.
    Note
    Harness must be removed through ancillary bay. PCS2 Lite connector does not fit through the header hole.
  66. Remove the LH daisy chain pass through housing from the ancillary bay (3x location pins, 1x harness clip).
    Note
    Insert the UFO harness removal tool beneath the daisy chain pass through housing, insert the tab release tool to release the bottom 2x clips. Then release the top 3x location pins with trim tool. Pull the daisy chain pass through housing upward to remove.
    CAUTION
    If this part is damaged during disassembly, the PCS2 Lite harness assembly needs to be replaced.
    Tip
    Use of the following tool(s) is recommended:
    • 1475996-00-A - UFO CONNECTOR REMOVAL TOOL - M3 R
  67. Remove the X423 connector from the DC link busbar (1x locking tab, 1x clip).
  68. Remove the pyro disconnect dummy.
  69. Remove the pyro disconnect logic connector (1x clip).
  70. Disconnect the shunt assembly connector (1x locking tab, 1x clip).
  71. Remove the HV joint insulator from the DC link busbar.
  72. Remove the X422 connector from the DC link busbar (1x locking tab, 1x clip).
  73. Remove the ancillary bay harness assembly fixing clips (x5) from the DC link.
  74. Remove the tab from the DC link shell.
    Note
    The tab should be broken off along the bottom edge. Do not leave any sharp corners that may damage the wiring harness.
  75. Remove the PCS2 Lite harness assembly from the ancillary bay.
    Note
    First remove the harness from the inlet outlet pipe, and then remove the harness assembly.

Retrofit PCS1 to the New Battery

  1. Position megaharness to the ancillary bay for installation.
  2. Fix the ancillary bay harness assembly to the DC link.
  3. Install the RH daisy chain pass through housing to the ancillary bay (3x clips, 2x bottom clips).
  4. Remove the plugs on the ends of fittings, and then connect the PCS coolant inlet hose to the ancillary bay (2x clips).
    Note
    Place absorbent sheet under the hose to catch excess coolant.
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured, then visually verify the clip is fully seated.
    Note
    Caution not to damage the O-rings. If the hose is reused, install new O-rings to the hose.
  5. Install the charger output to DC harness to the busbar DC link.
    Note
    Do not damage the insulation layer of the harness. If necessary, use a 90 degree hook to assist. Ensure that harness is not pinched.
  6. Install a new nut (1104458-00-B) that attaches the negative output harness to the negative HV battery DC link busbar.
    4.5 Nm (3.3 lbs-ft)
    Note
    Mark the nut after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm socket
  7. Perform Hioki resistance test at the negative output harness terminal to the negative HV battery DC link busbar.
    Note
    Perform zero adjust to Hioki meter prior to testing. The acceptable resistance should be 55 μΩ or less.
  8. Install the busbar DC link cover (2x clips).
  9. Install the bolt that secures the RH ancillary bay bus cover.
    3 Nm (2.2 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 bit
  10. Install a new nut (1104458-00-B) that attaches the HV battery ancillary positive busbar to the RH ancillary bay bus cover.
    4.5 Nm (3.3 lbs-ft)
    Note
    Mark the nut after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm socket
  11. Install new nuts (x2) (1104458-00-B) that attach the PCS output fuse to the RH ancillary bay bus cover.
    4.5 Nm (3.3 lbs-ft)
    Note
    Mark the nut after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm socket
  12. Perform Hioki resistance test at the PCS fuse input joint.
    Note
    Perform zero adjust to Hioki meter prior to testing. The acceptable resistance should be 145μΩ or less.
  13. Perform Hioki resistance test at the PCS fuse output joint.
    Note
    Perform zero adjust to Hioki meter prior to testing. The acceptable resistance should be 105μΩ or less.
  14. Install new patch nuts (x2) (1104458-00-B) that attach the compressor fuse to the RH ancillary bay bus cover.
    4.5 Nm (3.3 lbs-ft)
    Note
    Mark the nut after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm socket
  15. Perform Hioki resistance test at the compressor fuse input joint.
    Note
    Perform zero adjust to Hioki meter prior to testing. The acceptable resistance should be 145μΩ or less.
  16. Perform Hioki resistance test at the compressor fuse output joint.
    Note
    Perform zero adjust to Hioki meter prior to testing. The acceptable resistance should be 105μΩ or less.
  17. Install the insulators (x2) for the fuse and bolts.
  18. Install new cable ties (x2) that attach megaharness to the charger output to DC bus harness, and cut off any excess cable ties.
  19. Position the DC link extension positive for installation (2x guide pins).
  20. Install the ancillary bay harness clips (x3) to the positive DC link.
  21. Install a new patch nut (1104654-00-B) that attaches the DC link to the DC link positive busbar.
    5 Nm (3.7 lbs-ft) + 35 degrees
    Note
    Mark the nut after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  22. Perform Hioki resistance test at the HV joint of positive pack contactor to DC link busbar.
    Note
    Perform zero adjust to Hioki meter prior to testing. The acceptable resistance should be 30μΩ or less.
  23. Install the HV joint insulator for the HV battery DC link positive busbar.
  24. Install the X423 connector onto the DC bus (1x clip).
  25. Install the pyro disconnect logic connector (1x clip).
  26. Install the harness to the shunt insulator (1x clip).
  27. Connect the shunt assembly connector.
  28. Install the X422 connector onto the DC bus.
  29. Install the X421 connector onto the DC bus.
  30. Install the LH daisy chain pass through housing to the ancillary bay.
  31. Install the FC contactor assembly to the ancillary bay (2x guide pins, 1x clip).
  32. Install the bolts (x2) that attach the FC contactor assembly to the ancillary bay.
    5.5 Nm (4.1 lbs-ft)
    Note
    Mark the bolts after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  33. Install the DC input header seal to the ancillary bay (2x location pins).
    Note
    Check if the sealing ring is damaged. Replace the header if necessary.
  34. Install the bolts (x4) that attach the DC input header seal to the ancillary bay.
    10 Nm (7.4 lbs-ft)
    Note
    Mark the bolts after torque.
    Tip
    Use of the following tool(s) is recommended:
    • PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
  35. Install a new patch bolt (1104475-00-F) that secures the positive fastcharge busbar DC link side.
    5 Nm (3.7 lbs-ft) + 60 degrees
    Note
    Mark the bolt after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  36. Perform Hioki resistance test at the positive HV joint fastcharge busbar DC link side.
    Note
    The acceptable resistance should be 25μΩ or less.
  37. Install a new patch bolt (1104475-00-F) that secures the negative fastcharge busbar DC link side.
    5 Nm (3.7 lbs-ft) + 60 degrees
    Note
    Mark the bolt after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  38. Perform Hioki resistance test at the negative HV joint fastcharge busbar DC link side.
    Note
    The acceptable resistance should be 40μΩ or less.
  39. Install the ancillary bay left terminals cover (2x tabs, 1x datum).
  40. Install the harness clip to the left terminals cover.
  41. Remove the plugs on the ends of fittings, and then connect the PCS outlet coolant hose to the ancillary bay (2x clips).
    Note
    Place absorbent sheet under the hose to catch excess coolant.
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured, then visually verify the clip is fully seated.
    Note
    Caution not to damage the O-rings. If the hose is reused, install new O-rings.
  42. Position the negative pack contactor to the ancillary bay for installation (2x guide pins).
  43. Install the nuts (x3) that attach the negative pack contactor to the ancillary bay.
    8 Nm (5.9 lbs-ft)
    Note
    Use insulated magnet as needed to position the nuts onto studs.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  44. Install a new patch nut (1104654-00-B) that attaches the negative pack contactor to the HV battery tall terminal.
    9 Nm (6.6 lbs-ft)
    Note
    Mark the nut after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  45. Install a new patch bolt that attaches the negative pack contactor to the DC link busbar joint.
    9 Nm (6.6 lbs-ft)
    Note
    Mark the bolt after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  46. Perform Hioki impedance test at the HV joint of the negative pack contactor to negative DC link busbar.
    • The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ). If the resistance is within this range, continue to the next step.
    • If the resistance is greater than 0.060 mΩ (60 μΩ), stop work and escalate a Toolbox session.
    • If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
  47. Perform Hioki resistance test at the negative pack contactor to module 1 rear terminal.
    Note
    The acceptable resistance should be 110μΩ or less.
  48. Install the HV joint insulators (x2) to the negative pack contactor.
  49. Connect the ancillary bay harness connectors (x2) to the negative pack contactor.
  50. Use IPA wipes to clean the surface between the 3-phase 4P Header and the ancillary bay, and allow 1 minute to dry.
  51. Route the 3-phase AC filter harness from the ancillary bay up through the HV battery.
  52. Install the 3-phase AC Filter harness to the 3-phase 4P Header (2x tabs).
    Note
    Ensure that the tabs on both sides are properly installed. Inspect the seal on the 3-phase header for any damage and replace as needed.
  53. Install the bolts (x2) that attach the busbar AC input assembly to the ancillary bay.
    10 Nm (7.4 lbs-ft)
    Note
    Mark the bolts after torque.
    Tip
    Use of the following tool(s) is recommended:
    • PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
  54. Install the harness clips (x3) to the FC contactor cover.
  55. Install the AC filter harness to the FC contactor cover and connect the connectors (x2).
  56. Connect the LV fastcharge contactor connector.
  57. Install the positive pack contactor to the ancillary bay (2x guide pins).
  58. Install the nuts (x3) that attach the positive pack contactor to the ancillary bay.
    8 Nm (5.9 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  59. Install a new patch bolt (1104475-00-F) that attaches the positive pack contactor to the positive busbar.
    5 Nm (3.7 lbs-ft) + 60 degress
    Note
    Mark the bolt after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  60. Install a new patch nut (1104654-00-A) that attaches the positive pack contactor to the HV battery tall terminal.
    5 Nm (3.7 lbs-ft) + 35 degress
    Note
    Mark the nut after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  61. Measure the resistance from the HV joint between the HV battery positive contactor and the center of the HV battery positive terminal.
    Note
    The acceptable resistance should be 73μΩ or less.
  62. Perform Hioki resistance test at the HV joint of positive pack contactor to DC link busbar.
    Note
    The acceptable resistance should be 30μΩ or less.
  63. Install the HV joint insulators (x2) to the positive pack contactor.
  64. Install the ancillary bay harness clip to the positive pack contactor.
  65. Connect the ancillary bay harness connectors (x2) to the positive pack contactor.
  66. Install the RH daisy chain pass through housing to the ancillary bay.
  67. Position the DCDC pass through to the ancillary bay for installation.
    Note
    Avoid metal damage to the cable insulation layer.
  68. Install the bolts (x2) that attach the DCDC pass through to the ancillary bay.
    10 Nm (7.4 lbs-ft)
    Note
    Mark the bolts after torque.
    Tip
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  69. Position the PCS into the ancillary bay.
    Note
    Ensure all the busbar insulators beneath the PCS are present. Slightly tilt the rear of the PCS upward and lower it into position. Align the datum into the PCS hole.
  70. Remove the suction cups from the PCS.
  71. Install the bolts (x5) (1115833-00-B) that attach the PCS to the HV battery.
    15 Nm (11.1 lbs-ft)
    Note
    Torque the bolts to 15 Nm, then Minus 180 degrees, and then torque it back to 15 Nm.
    Tip
    Use of the following tool(s) is recommended:
    • 8 mm socket
  72. Connect the PCS to the FC contactor HV harness connector.
    Note
    Push the connector downward then push the locking tab downward to install the connector. Make sure the connector is fully seated.
  73. Connect the PCS LV connector to the PCS.
    Note
    Push the connector downward then push the locking tab downward to install the connector. Make sure the connector is fully seated.
  74. Connect the PCS logic connector to the PCS.
  75. Connect the PCS to DC bus HV connector.
    Note
    Push the connector downward then push the locking tab downward to install the connector. Make sure the connector is fully seated.
  76. Remove the plugs on the ends of fittings, then connect the PCS coolant inlet hose to the PCS (2x clips).
    Note
    Place absorbent sheet under the hose to catch excess coolant.
    Note
    Do not damage the o-rings. If the hose is reused, install new O-rings to the hose.
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured, then visually verify the clip is fully seated.
  77. Replace the O-ring on the PCS side outlet hose, and apply light amount of Krytox 203.
  78. Remove the plugs on the ends of fittings, and then connect the PCS coolant outlet hose to the PCS (2x clips).
    Note
    Place absorbent sheet under the hose to catch excess coolant.
    Note
    Do not damage the o-rings.
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured, then visually verify the clip is fully seated.
  79. Remove the foam pedestal from the bottom of the HVC (3x alignment datums).
  80. Position HVC and hinge tray to the ancillary bay assembly (4x locating pins) and route the wires (x3) through the RH hinge.
  81. Secure the screws (x2) that attach the HVC tray assembly to the ancillary bay.
    2 Nm (1.5 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 bit
  82. Install the megaharness clips (x5) to the HVC hinge tray, and wrap harness tape around the hinge tray again.
  83. Connect the HVC connector X479 to the HVC.
  84. Connect the X484 connector to HVC.
  85. Connect the connector X478 to HVC.
  86. Connect the connector X481 to HVC.
  87. Connect the connector X480 to HVC.
  88. Connect the connector X482 to HVC.
  89. Connect the connector X483 to HVC.
  90. Use IPA wipes to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect, and allow 1 minute to dry.
  91. Set the multimeter to the "LoZ" (low impedance) mode.
    Note
    For Fluke multimeters without "LoZ" mode on the mode selector, see Multimeter (LoZ Setting).
  92. Measure the voltage between the busbar (left) and shunt (right) for at least 10 seconds, so as to balance the voltage across the pyrotechnic battery disconnect mount points.
    Note
    The voltage displayed on the multimeter is not as important as balancing the mount points.
  93. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  94. Measure the resistance at the HV joint between the module 2 busbar to the pyrotechnic disconnect.
    Note
    Perform zero adjust to Hioki meter prior to testing. The acceptable resistance should be 48μΩ or less.
  95. Measure resistance at the HV joint between the pyrotechnic disconnect and the shunt.
    Note
    Perform zero adjust to Hioki meter prior to testing. The acceptable resistance should be 33μΩ or less.
  96. Remove the service insulator kit.
  97. Remove the HVC logic cap.
  98. Install the ancillary bay cover. See Cover - Ancillary Bay (Remove and Install).
  99. Install the HVC logic cap.