2026-10-13

Cover - Fast Charge (7-Seat) (Remove and Replace)

Correction code TBD FRT 1.8 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.

  • 2026-10-13: Updated torque values.
  • 2026-02-27: Released new procedure.

Remove

  1. Remove the left terminals cover. See Cover - Left Terminals (7-Seat) (Remove and Replace).
  2. Disconnect the AC filter harness connector from the PCS by pulling the locking tab upward.
  3. Remove the clip and bolts (x2) that attach the AC filter harness to the fast charge cover, then route the harness under the PCS hose to remove it.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 8MM, HV INSULATED
    Note
    Discard the bolts after removal.
  4. Disconnect the LV fast charge contactor connector by pressing the tabs on both sides with your hands and pulling the connector upwards.
  5. Disconnect the mega harness connector from the DC input assembly.
  6. Remove the ancillary bay harness clips (x3) around the negative pack contactor area.
  7. Remove the insulators (x3) for the DC input assembly to both fast charge busbar inlet sides.
  8. Remove and discard the bolts (x2) that attach the positive/negative fast charge busbar inlet sides to the positive/negative DC input assembly busbars.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
  9. Remove the bolts (x2) that attach the fast charge assembly to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
  10. Remove the bolt securing the busbar cover access door.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
  11. Remove the bolts (x2) that attach the charge port busbar kit to the HV header.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
  12. Release the clip that attaches the LH body harness to the rear body, then move the harness aside.
  13. Release the push clip to partially remove the LH B-pillar lower trim, then partially pull out the LH rear body harness.
  14. Use an inflatable air bag to lift the busbar kit connector away from the HV header.
    Note
    During the process, note the following:
    • Hold the busbar firmly as there is tension on.
    • Avoid damaging the harness bracket.
  15. Remove and discard the bolts (x4) that attach the busbar DC 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
  16. Remove the busbar DC input assembly from the ancillary bay.
  17. Release the guide pins (x2) that attach the fast charge assembly to the ancillary bay.
  18. Release the alignment pin and clips (x8) that attach the fast charge insulator cover to the fast charge assembly, then remove and discard the fast charge insulator cover.

Install

  1. Align the alignment pin, install new fast charge insulator cover to the fast charge assembly, then secure the clips (x8).
  2. Align the guide pins (x2), then position the fast charge assembly to the ancillary bay for installation
  3. Install the bolts (x2) that attach the fast charge assembly to the ancillary bay.
    5.5 Nm (4.1 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
    Note
    Mark after torque.
  4. Install the busbar DC input assembly to the ancillary bay.
    Note
    Ensure that the seal is not damaged and seated properly.
  5. Install new bolts (x4) that attach the busbar DC input assembly to the ancillary bay.
    10 Nm (7.4 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
    Note
    Mark after torque.
  6. Install new bolts (x2) that attach the positive/negative fast charge busbar inlet sides to the positive/negative DC input assembly busbars.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Note
    Torque the bolt to the first value, then loosen the bolt by 180 degrees, then torque the bolt to the final value.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
    Note
    Mark after torque.
  7. Perform Hioki resistance test on both HV joints of the DC input assembly busbar making sure that the resistance is 60𝜇Ω or less.
    Note
    Test from the negative fast charge busbar to the negative DC input busbar, and from the positive fast charge busbar to the positive DC input busbar.
  8. Install the insulators (x3) for the DC input assembly to both fast charge busbar inlet sides.
  9. Connect the mega harness connector to the DC input assembly.
  10. Install new bolt securing the negative fast charge busbar.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Note
    Torque the bolt to the first value, then loosen the bolt by 180 degrees, then torque the bolt to the final value.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
    Note
    Mark after torque.
  11. Perform Hioki impedance test on negative HV joint fast charge busbar DC link side
    Note
    1x HV joint, 55μΩ or less
  12. Install new bolt securing the positive fast charge busbar.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Note
    Torque the bolt to the first value, then loosen the bolt by 180 degrees, then torque the bolt to the final value.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
    Note
    Mark after torque.
  13. Perform Hioki impedance test on positive HV joint fast charge busbar DC link side.
    Note
    Resistance must be 25μΩ or less.
  14. Install the ancillary bay harness clips (x3) around the negative pack contactor area.
  15. Connect the LV fast charge contactor connector.
  16. Connect the maga harness connector to the DC input assembly.
  17. Secure the clip, route the AC filter harness under the PCS hose, then install new bolts (x2) that attach the harness to the fast charge cover.
    4.5 Nm (3.3 lbs-ft)
  18. Press down on the red locking tab to connect the AC filter harness connector to the PCS.
  19. 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.
    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.
  20. 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.
  21. Remove the inflatable air bag from under the HV header.
  22. Position the busbar kit connector, lower it onto the HV header while lifting the rear end of the busbar assembly to ease installation.
    Note
    Inspect for damage and replace if excessive force is needed to seat the busbar.
  23. Install the bolts (x2) that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
    Note
    Mark after torque.
  24. 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.
  25. Install the bolt securing the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
  26. Position the LH rear body harness under the LH lower C pillar trim.
  27. Secure the clip that attaches the LH body harness onto the rear body.
  28. Secure the push clip to partially install the LH B-pillar lower trim.
  29. Partially install the lower portion of the LH C-pillar trim.
  30. Install the left terminals cover. See Cover - Left Terminals (7-Seat) (Remove and Replace).