2026-08-09

Ancillary Bay - AC Filter Harness (Remove and Install)

Correction code 1630011401 FRT 1.14 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.

Torque Specifications

Table 1. Torque Specifications:Ancillary Bay - AC Filter Harness (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (X4) securing the Busbar AC input assembly to ancillary bay
10 Nm (7.4 lbs-ft)
  • External Torx E10 5-Lobe
  • RATCHET, 0.25IN SQ DR, HV INSULATED
  • TQRQUE WRENCH, 1/4" DR, INSULATED, 2-10NM. TPN 1785247-00-A
 Replace 1095042-00-C
  • 2025-12-30: Adding missing steps for 8 mm bolts and clip that attach the harness to the fast charge contactor bus bars. Added Hioki test step.

Remove

  1. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  2. Disconnect the AC filter harness from the Power Conversion System (PCS) cover.
    Note
    Release the red locking tab to disconnect the AC filter harness.
  3. Release the clip and remove the bolts (x2) that attach the AC filter harness to the fast charge contactor bus bars, and then remove the harness from the vehicle.
    Note
    Route the harness under the PCS hose during removal. Discard the bolts.

Install

  1. Use IPA wipes to clean the surfaces between the AC filter harness terminals and the fast charge contactor bus bars.
  2. Position the AC filter harness on the vehicle, and then install the clip and bolts (x2) that attach the harness to the ancillary bay.
    4.5 Nm (3.3 lbs-ft)
    Note
    Make sure the harness is routed under the PCS hose. Install new bolts.
  3. Perform a Hioki impedance test at the HV joints (x2) of the AC filter harness.
    Note
    The maximum acceptable resistance is 150μΩ.
    Note
    Test from the negative AC inlet terminal to negative inlet side fast charge busbar, and the positive AC inlet terminal to positive inlet side fast charge busbar.
  4. Install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  5. Move the LH and RH front seats to original position.
  6. Raise all windows and close all doors.