2025-10-24

Seal - HV Input Header (Model YL) (Remove and Replace)

Correction code 16300501202 FRT 1.32 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.

Torque Specifications

Table 1. Torque Specifications:Seal - HV Input Header (Model YL) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt securing the busbar cover access door
9 Nm (6.6 lbs-ft)
  • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
 Reuse
Bolts (x2) that attach the charge port busbar kit to the HV header
9 Nm (6.6 lbs-ft)
  • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
 Reuse
Bolts (x4) that attach the input header seal to the ancillary bay
10 Nm (7.4 lbs-ft)
  • Penthouse Socket, 1/4" Dr, 5-Lobe, E-Torx Mag
 Reuse

Remove

  1. Raise and support the vehicle. See Raise Vehicle - 2-Post Lift.
  2. Remove the 2nd row LH and RH seats. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Replace).
  3. Remove the 3rd row LH and RH seat cushion bolsters. See Bolster - Seat Cushion - 3rd Row - LH (Model YL) (Remove and Replace) and Bolster - Seat Cushion - 3rd Row - RH (Model YL) (Remove and Replace).
  4. Remove the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (Model YL) (Remove and Replace).
  5. Remove the clips (x2) that attach the rear cabin carpet harness to the body.
  6. Release the datums (x2), then fold the rear cabin carpet to access the rear inner HV battery ancillary bay.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Pull the carpet out from both side trunk trims, and ensure the 2nd row seat harness is threaded through the carpet.
  7. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (Model YL) (Maintenance).
  8. Put on HV insulating gloves and leather over gloves.
  9. Remove the bolt securing the busbar cover access door.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
  10. 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:
    • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
  11. Use an inflatable air bag to lift the busbar kit connector away from the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    During the process, note the following:
    • Hold the busbar firmly as there is tension on.
    • Avoid damaging the harness bracket.
  12. Remove the bolts (x4) that attach the input header seal to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Penthouse Socket, 1/4" Dr, 5-Lobe, E-Torx Mag
  13. Release the location pins (x2) to remove the input header seal from the ancillary bay.

Replace

  1. Align the location pins (x2) and install the input header seal to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check the sealing ring for damage, and replace the input header seal if necessary.
  2. Install the bolts (x4) that attach the input header seal to the ancillary bay.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Penthouse Socket, 1/4" Dr, 5-Lobe, E-Torx Mag
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the bolts after torque.
  3. Use IPA wipes to clean the HV connector contact surface and the busbar HV connector contact surface of the residual Penetrox. Allow one minute of drying time for each surface.
    Informational PurposesAn informational icon, calling your attention
    Note
    A new busbar comes with Penetrox pre-applied to the HV connector; clean the contact surface of the busbar HV connector when reusing a busbar.
  4. Apply Penetrox onto the HV connector joints. Apply 2 drops of Penetrox A-13 (about 5mm in diameter) on each side of the hole on both leads, and spread evenly to ensure full coverage of the contact surface.
  5. Remove the inflatable air bag from under the HV header.
  6. Position the busbar kit connector, lower it onto the HV header while lifting the rear end of the busbar assembly to ease installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Inspect for damage and replace if excessive force is needed to seat the busbar.
  7. 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
    TIp
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the bolts after torque.
  8. Perform Hioki resistance test at each of the 2 HV joints from HV busbar lead to bolt head; acceptable resistance is 0.050 mΩ (50 μΩ) to 0.195 mΩ (195 μΩ).
    • If above 0.195 mΩ, stop work and escalate to Toolbox session;
    • If below 0.050 mΩ, reposition probes and remeasure;
    • If repeatedly between 0.00 mΩ and 0.050 mΩ, test passed, proceed to next step.
  9. Install the bolt securing 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:
    • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
  10. Align the datums (x2), then fold the rear cabin carpet to its original position.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Insert the carpet under the trunk side trim on both sides, and ensure the 2nd row seat harness is threaded through the carpet.
  11. Install the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (Model YL) (Remove and Replace).
  12. Install the clips (x2) that attach the rear cabin carpet harness to the body.
  13. Install the 3rd row LH and RH seat cushion bolsters. See Bolster - Seat Cushion - 3rd Row - LH (Model YL) (Remove and Replace) and Bolster - Seat Cushion - 3rd Row - RH (Model YL) (Remove and Replace).
  14. Install the 2nd row LH and RH seats. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Replace).
  15. Remove the vehicle from the lift.