NHTSA ID Number: 10043626
Manufacturer Communication Number: FC-390120002-02
TSB/Document Date: 2012-04-16
Summary
FISKER: UPON INSPECTION, HV DC GENERATOR POWER CABLE CONNECTOR MAY HAVE BEEN INSTALLED INCORRECTLY OR DAMAGED. *PE
SB-10043626-2409
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120002.02
MODEL: Karma
DATE: February 9, 2012
MODEL YEAR: 2012
TITLE: HV DC Power Cable Inspection
PRIORITY:
Vehicles in Operation
APPLICABILITY:
2012 Karma
MARKET REGION:
U.S., Canada, Europe
PURPOSE:
HV DC Power Cable Connector Inspection – All Fisker Karma vehicles produced prior to VIN#
YH4K16AA0CA001042 may have a damaged or improperly installed HV DC generator power cable
connector.
This Campaign will be used as a reference guide for technicians to perform necessary inspection for a
damaged or improperly seated HV generator cable connector. If connector seal retainer is damaged,
contact Fisker TSS for further instructions.
Low Temperature Electronics Coolant Line Routing – Low temperature coolant lines for electronics may be
incorrectly routed over the rear sway bar, causing unwanted tension and kink the hose.
Low Temperature HV Battery Coolant Line Clearance – HV Battery coolant lines may be coming into
contact with shield under generator motor, which can damage the hose.
PROCESS OVERVIEW:
1. HV DC Power Cable Connector Inspection
2. Low Temperature Electronics Coolant Line Routing
3. Low Voltage Isolation Procedure
4. High Voltage Isolation Procedure - MSD
5. Drain Low Temperature Coolant
6. Remove Rear Diffuser Closing Panel
7. Coolant Hose Rerouting
8. Re-Install Rear Diffuser Panel
9. Refill Low Temp Electronics Cooling System
10. Low Temperature HV Battery Coolant Line Clearance
Fisker Bulletins are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment and a suitable workshop for any procedure
described in this document, we suggest you leave such repairs to an Authorized Fisker Retailer or other qualified shop. See your Fisker Retailer for advice on
whether your vehicle may benefit from the information contained within this document. The information contained in the Fisker Bulletin is accurate at the date of publication. However, Fisker Automotive regularly updates technical information. Please check with your Fisker Retailer that the bulletin you intend to use contains the
latest available information.
Page: 1 of 20
Printed: February 9, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120002.02
MODEL: Karma
DATE: February 9, 2012
MODEL YEAR: 2012
TITLE: HV DC Power Cable Inspection
VIN: All vehicles produced prior to VIN# YH4K16AA0CA001042
Fisker Bulletins are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment and a suitable workshop for any procedure
described in this document, we suggest you leave such repairs to an Authorized Fisker Retailer or other qualified shop. See your Fisker Retailer for advice on
whether your vehicle may benefit from the information contained within this document. The information contained in the Fisker Bulletin is accurate at the date of publication. However, Fisker Automotive regularly updates technical information. Please check with your Fisker Retailer that the bulletin you intend to use contains the
latest available information.
Page: 2 of 20
Printed: February 9, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120002.02
MODEL: Karma
DATE: February 9, 2012
MODEL YEAR: 2012
TITLE: HV DC Power Cable Inspection
1. HV DC Power Cable Connector Inspection
HV Battery Connector Examples
NOTE: Example A is an image of an HV generator battery connector with a properly seated seal
retainer.
Example A
NOTE: Example B is an image of an HV generator battery connector with an improperly seated seal
retainer, compromising the weatherproof seal.
● If the plastic locking tab (see red arrow) is not seated correctly, attempt to re-seat it on connector
housing.
● If the plastic locking tab is broken/missing, contact Fisker TSS for further instructions.
Example B
Fisker Bulletins are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment and a suitable workshop for any procedure
described in this document, we suggest you leave such repairs to an Authorized Fisker Retailer or other qualified shop. See your Fisker Retailer for advice on
whether your vehicle may benefit from the information contained within this document. The information contained in the Fisker Bulletin is accurate at the date of publication. However, Fisker Automotive regularly updates technical information. Please check with your Fisker Retailer that the bulletin you intend to use contains the
latest available information.
Page: 3 of 20
Printed: February 9, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120002.02
MODEL: Karma
DATE: February 9, 2012
MODEL YEAR: 2012
TITLE: HV DC Power Cable Inspection
WARNING!
HIGH VOLTAGE (HV) battery contains lethal voltage.
WARNING: Do not touch any exposed electrical wiring (with hands or tools) if the vehicle is
switched on or running.
1a. Using a lift, elevate the vehicle so that there is full visual access to the HV battery cable
connector attached to the generator.
Fisker Bulletins are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment and a suitable workshop for any procedure
described in this document, we suggest you leave such repairs to an Authorized Fisker Retailer or other qualified shop. See your Fisker Retailer for advice on
whether your vehicle may benefit from the information contained within this document. The information contained in the Fisker Bulletin is accurate at the date of publication. However, Fisker Automotive regularly updates technical information. Please check with your Fisker Retailer that the bulletin you intend to use contains the
latest available information.
Page: 4 of 20
Printed: February 9, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120002.02
MODEL: Karma
DATE: February 9, 2012
MODEL YEAR: 2012
TITLE: HV DC Power Cable Inspection
1b. Inspect the HV DC power cable connector (see arrow in images View 1 and 2). It can be
viewed by looking between the exhaust system and front suspension sub-frame on driver’s side of
vehicle.
NOTE: If the plastic locking tab is broken/missing, contact Fisker TSS for further instructions.
View 1
View 2
Fisker Bulletins are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment and a suitable workshop for any procedure
described in this document, we suggest you leave such repairs to an Authorized Fisker Retailer or other qualified shop. See your Fisker Retailer for advice on
whether your vehicle may benefit from the information contained within this document. The information contained in the Fisker Bulletin is accurate at the date of publication. However, Fisker Automotive regularly updates technical information. Please check with your Fisker Retailer that the bulletin you intend to use contains the
latest available information.
Page: 5 of 20
Printed: February 9, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120002.02
MODEL: Karma
DATE: February 9, 2012
MODEL YEAR: 2012
TITLE: HV DC Power Cable Inspection
For reference only: Complete HV Inverter 3 (Gen.) HV DC power cable harness
Fisker Bulletins are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment and a suitable workshop for any procedure
described in this document, we suggest you leave such repairs to an Authorized Fisker Retailer or other qualified shop. See your Fisker Retailer for advice on
whether your vehicle may benefit from the information contained within this document. The information contained in the Fisker Bulletin is accurate at the date of publication. However, Fisker Automotive regularly updates technical information. Please check with your Fisker Retailer that the bulletin you intend to use contains the
latest available information.
Page: 6 of 20
Printed: February 9, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120002.02
MODEL: Karma
DATE: February 9, 2012
MODEL YEAR: 2012
TITLE: HV DC Power Cable Inspection
2. Low Temperature Electronics Coolant Line Routing
There are 2 versions of coolant hoses for the Low Temperature Electronics Coolant System:
Molded type (shown in image above with curved hoses connected to front of coolant pumps).
Non-molded type (shown in image above with straight hoses connected to front of coolant pumps).
Fisker Bulletins are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment and a suitable workshop for any procedure
described in this document, we suggest you leave such repairs to an Authorized Fisker Retailer or other qualified shop. See your Fisker Retailer for advice on
whether your vehicle may benefit from the information contained within this document. The information contained in the Fisker Bulletin is accurate at the date of publication. However, Fisker Automotive regularly updates technical information. Please check with your Fisker Retailer that the bulletin you intend to use contains the
latest available information.
Page: 7 of 20
Printed: February 9, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120002.02
MODEL: Karma
DATE: February 9, 2012
MODEL YEAR: 2012
TITLE: HV DC Power Cable Inspection
2a. Visually check to confirm hose type (molded or non-molded) by peering through the vents in
the rear diffuser closing panel.
Fisker Bulletins are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment and a suitable workshop for any procedure
described in this document, we suggest you leave such repairs to an Authorized Fisker Retailer or other qualified shop. See your Fisker Retailer for advice on
whether your vehicle may benefit from the information contained within this document. The information contained in the Fisker Bulletin is accurate at the date of publication. However, Fisker Automotive regularly updates technical information. Please check with your Fisker Retailer that the bulletin you intend to use contains the
latest available information.
Page: 8 of 20
Printed: February 9, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120002.02
MODEL: Karma
DATE: February 9, 2012
MODEL YEAR: 2012
TITLE: HV DC Power Cable Inspection
2b. Inspect for proper rear coolant pump line routing for each type of hose (molded and nonmolded).
Proper molded low temperature electronics coolant hose routing (see illustration above).
Proper non-molded low temperature electronics coolant hose routing (see illustration above).
Fisker Bulletins are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment and a suitable workshop for any procedure
described in this document, we suggest you leave such repairs to an Authorized Fisker Retailer or other qualified shop. See your Fisker Retailer for advice on
whether your vehicle may benefit from the information contained within this document. The information contained in the Fisker Bulletin is accurate at the date of publication. However, Fisker Automotive regularly updates technical information. Please check with your Fisker Retailer that the bulletin you intend to use contains the
latest available information.
Page: 9 of 20
Printed: February 9, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120002.02
MODEL: Karma
DATE: February 9, 2012
MODEL YEAR: 2012
TITLE: HV DC Power Cable Inspection
– If rear coolant hoses are non-molded and they are properly routed under the rear sway bar,
go to step 10.
– If rear coolant hoses are non-molded and they are incorrectly installed over the top of the
sway bar (as shown in illustration below), continue with following instructions to reroute
coolant line.
Fisker Bulletins are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment and a suitable workshop for any procedure
described in this document, we suggest you leave such repairs to an Authorized Fisker Retailer or other qualified shop. See your Fisker Retailer for advice on
whether your vehicle may benefit from the information contained within this document. The information contained in the Fisker Bulletin is accurate at the date of publication. However, Fisker Automotive regularly updates technical information. Please check with your Fisker Retailer that the bulletin you intend to use contains the
latest available information.
Page: 10 of 20
Printed: February 9, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120002.02
MODEL: Karma
DATE: February 9, 2012
MODEL YEAR: 2012
TITLE: HV DC Power Cable Inspection
3. Low Voltage Isolation Procedure
3a. Power down the vehicle. Open the hood and disconnect the 12 Volt battery via connector
C104.
12 Volt Battery Negative Connector C104
4. High Voltage Isolation Procedure - MSD
4a. Remove seat cushion - Rear - LH.
4b. Release clips (x2) from seat cushion leading edge by pulling sharply upwards.
Fisker Bulletins are intended for use by experienced and trained Technicians. If you lack the skills, tools, equipment and a suitable workshop for any procedure
described in this document, we suggest you leave such repairs to an Authorized Fisker Retailer or other qualified shop. See your Fisker Retailer for advice on
whether your vehicle may benefit from the information contained within this document. The information contained in the Fisker Bulletin is accurate at the date of publication. However, Fisker Automotive regularly updates technical information. Please check with your Fisker Retailer that the bulletin you intend to use contains the
latest available information.
Page: 11 of 20
Printed: February 9, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
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TSB/Document ID: FC-390120002-02
Replacement Service Bulletin Number:
MFR Communication Date: 2012-02-09
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM:12V/24V/48V BATTERY:CABLES
MFR Component System:
MFR Component Subsystem:
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