2022-09-22

Safety Cap - Busbar - Charge Port to HV Battery (Remove and Replace)

Correction code 44015102 0.30 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and 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 proper PPE is worn when performing the below procedure.

Equipment:
  • 1076921-00-B Insulation Multimeter, Fluke 1507 (NA)
  • 1076921-00-A Insulation Multimeter, Fluke 1587 (EMEA)
  • 1076921-01-B Insulation Multimeter, Fluke 1508 (APAC)
  • 1130480-00-A Test Probes, Slim, Fluke TP38
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Proper Personal Protective Equipment (PPE) is required to perform this procedure:
  • High Voltage (HV) insulating gloves
  • Leather glove protectors
  • High voltage glove tester
  • Safety glasses
  • Electrical hazard rated safety shoes
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional glove and safety information.
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Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
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Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
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Warning
Make sure that the insulation meter and leads are capable of handling at least 500V DC.
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Warning
Make sure that the HV gloves are not expired.
  • North America: HV gloves can be used up to 12 months after the testing date printed on the glove, but only 6 months after first use even if the gloves are still within the 12 month period. If the gloves were not put into service during the 12-month period following the testing date, they must be retested before being put into service.
  • Europe: HV gloves have no expiration date and may be used if they pass the pressure assessment and the periodic inspection.
  • Asia Pacific: Follow the expiration date stated by the HV glove manufacturer, and:
    • o China only: Test the gloves every 6 months according to GB/T 17622.
Informational PurposesAn informational icon, calling your attention
Note
This procedure is for the Original version of this part. An updated/region-specific Global Refresh version of this part is available for newer vehicles and that procedure is here: Safety Cap - Busbar - Charge Port to HV Battery (Global) (Remove and Replace) or Safety Cap - Busbar - Charge Port to HV Battery (EMEA) (Remove and Replace).

Remove

  1. Perform the charge port voltage check. See Charge Port Voltage Check.
  2. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  3. Remove and discard the bolt that attaches the charge port safety cap to the charge port assembly.
  4. Release the tabs (x2) that attach the charge port safety cap to the charge port assembly, and then remove the safety cap from the vehicle.

Install

  1. Position the charge port safety cap on the charge port assembly, and then install the tabs (x2) that attach the safety cap to the charge port assembly.
  2. Install the new bolt that attaches the charge port safety cap to the charge port assembly.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 8 mm socket
    • 4 in extension
    • Flex head ratchet/flex head torque wrench
  3. Install the LH trunk sill trim. See Trim - Side - Trunk - LH (Remove and Replace).
  4. Reconnect LV power. See LV Power (Disconnect and Connect).