2025-09-11

HV Harness - Charge Port Busbar (Model YL) (Remove and Replace)

Correction code 44500300002 FRT 1.38 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.

Equipment:
  • 1659333-00-A - ZIP TIES
  • 1076927-00-A - HIOKI RM 3548
  • 1076928-00-A - TEST PROBES - HIOKI 9461

Torque Specifications

Table 1. Torque Specifications: HV Harness - Charge Port Busbar (Model YL) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes

Bolt that secures the busbar cover access door

Bolts (x2) that attach the charge port busbar kit to the HV header

Nuts (x2) that attach the charge port busbar leads to the charge port assembly
9 Nm (6.6 lbs-ft)
  • Insulated 10 mm socket
 Reuse

Remove

  1. Remove the trunk tub. See Trunk Tub (Model YL) (Remove and Replace).
  2. Move the LH front seat forward, and adjust the seat back if needed to avoid contacting the headliner.
  3. Remove the 2nd row LH seat. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Install).
  4. Perform the charge port voltage check. See Charge Port Voltage Check.
  5. Remove the trunk side trim assembly. See Trunk Side Trim - LH (Model Y L) (Remove and Replace).
  6. Remove the LH 3rd row duct B section. See Duct - B Section - 3rd Row - Upper - LH (Model YL) (Remove and Replace).
  7. Remove the LH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Model YL) (Remove and Replace).
  8. Install an inflatable air bag to support the LH rear cabin carpet to provide enough space to remove the busbar bolt.
  9. Put on HV insulating gloves and leather over gloves.
  10. Remove the bolt that secures the busbar cover access door.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated 10 mm socket
  11. Remove the bolts (x2) that attach the charge port busbar kit to the HV header.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated 10 mm socket
  12. Release the LH body harness from the rear body, and move it aside.
  13. Lift the busbar kit connector to remove it from the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use an inflatable airbag to suspend the busbar away from the HV header during removal and installation. Hold the busbar firmly, as there is tension on it. Avoid damaging the harness bracket.
  14. Remove the charge port safety cap. See Safety Cap - Charge Port (GB) (Remove and Replace).
  15. Remove the nuts (x2) that attach the charge port busbar leads to the charge port assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    The nuts have captured washers.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated 10 mm socket
  16. With assistance, release the HV busbar assembly from the zip-ties (x2) and clips (x3), and then remove the busbar from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Guide the charge port busbar kit through the body harness, rotating as needed for clearance. Then maneuver it rearward through the trunk.

Install

  1. Use zip-ties and clips to install the HV busbar assembly to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Route the busbar alongside the cable, secure the zip-ties over the white-marked location on the harness.
  2. Verify the charge port studs (x2) (T10) are torqued to proper specification.
    2 Nm (1.5 lbs-ft)
  3. Use IPA wipes to clean the charge port busbar contact surface of residual Penetrox, and allow 1 minute to dry.
  4. Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both busbar leads. Spread it evenly to make sure the contact surface is fully covered.
  5. Install the nuts (x2) that attach the charge port busbar leads to the charge port assembly.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The nuts have captured washers. If excessive force is required to seat the busbars, they may have been bent. Inspect for damage and replace if necessary.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated 10 mm socket
  6. Perform Hioki resistance test at each HV joint from the HV busbar lead to the charge port studs.
    • If the resistance is between 0.050 mΩ (50 μΩ) and 0.270 mΩ (270 μΩ), Hioki test passed, proceed to the next step.
    • If the resistance is greater than 0.270 mΩ (270 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 the next step.
  7. Install the charge port safety cap. See Safety Cap - Charge Port (GB) (Remove and Replace).
  8. Use IPA wipes to clean the HV connector contact surface of residual Penetrox, and allow 1 minute to dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    New busbar comes with penetrox applied to the HV connector.
  9. Use IPA wipes to clean the busbar HV connector contact surface of residual Penetrox, and allow 1 minute to dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is necessary to clean the HV connector during the re-use of the busbar.
  10. Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both HV connector joints. Spread it evenly to make sure the contact surface is fully covered.
  11. Remove the inflatable air bag from under the HV header.
  12. Position the busbar kit connector and lower it onto the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Shift the rear end of the busbar assembly upward to help ease installation. If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary.
  13. Install the bolts (x2) that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the bolts after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated 10 mm socket
  14. Perform Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    • If the resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ), Hioki test passed, proceed to next step.
    • 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.
  15. Install the bolt that secures the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated 10 mm socket
  16. Remove the HV insulating gloves.
  17. Install the LH body harness to the rear of the body.
  18. Remove the inflatable air bag from the LH rear cabin carpet.
  19. Install the LH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Model YL) (Remove and Replace).
  20. Install the LH 3rd row duct B section. See Duct - B Section - 3rd Row - Upper - LH (Model YL) (Remove and Replace).
  21. Install the trunk side trim assembly. See Trunk Side Trim - LH (Model Y L) (Remove and Replace).
  22. Install the 2nd row LH seat. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Install).
  23. Move the RH 2nd row seat to original position.
  24. Raise the RH rear window and close the RH rear door.
  25. Install the trunk tub. See Trunk Tub (Model YL) (Remove and Replace).