2026-04-20

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 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.

  • 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.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 8MM, HV INSULATED
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
    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 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
  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:
    • 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.
    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.
  15. Remove and discard the bolts (x4) that attach the busbar DC input assembly 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
  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)
    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 after torque.
  4. Install the busbar DC input assembly to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    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)
    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 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.
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark after torque.
  7. Perform Hioki resistance test on both HV joints of DC input assembly busbar ensuring 60𝜇Ω or less.
    Informational PurposesAn informational icon, calling your attention
    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.
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark after torque.
  11. Perform Hioki impedance test negative HV joint fast charge busbar DC link side
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 55μΩ or less
  12. Install new bolt securing the positive fast charge busbar.
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark after torque.
  13. Perform Hioki impedance test positive HV joint fast charge busbar DC link side
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 25μΩ or less
  14. Install the ancillary bay harness clips (x3) around the negative pack contactor area.
  15. Secure the locking tabs and connect the LV fast charge contactor connector.
  16. 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.
  17. Press down on the red locking tab to connect the AC filter harness connector to the PCS.
  18. 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.
  19. 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.
  20. Remove the inflatable air bag from under the HV header.
  21. 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.
  22. 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 after torque.
  23. 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.
  24. 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
  25. Position the LH rear body harness under the LH lower C pillar trim.
  26. Secure the clip that attaches the LH body harness onto the rear body.
  27. Secure the push clip to partially install the LH B-pillar lower trim.
  28. Partially install the lower portion of the LH C-pillar trim.
  29. Install the left terminals cover. See Cover - Left Terminals (7-Seat) (Remove and Replace).