NHTSA ID Number: 10044111
Manufacturer Communication Number: SC-390120010
TSB/Document Date: 2012-05-14
Summary
FISKER
: DUE TO INSULATION PROPERTIES OF INSTALLED HARDWARE, INFORMATION IS PROVIDED TO ADDRESS 14 GROUND POINTS IN 12 VOLT SYSTEM WITH HIGH ELECTRICAL RESISTANCE. *PE
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TSB/Document ID: SC-390120010
Replacement Service Bulletin Number:
MFR Communication Date: 2012-01-22
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
SB-10044111-3662
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
TITLE: Ground Connection Rework
PRIORITY:
Vehicles in Operation
APPLICABILITY:
2012 Karma
MARKET REGION:
U.S., Europe
PURPOSE:
Proper grounding is essential for the functionality of the Fisker Karma. This Campaign is to address 14
ground points in the 12 Volt System that have high electrical resistance due to the insulation properties of
the installed hardware. The 14 ground points are to be inspected, cleaned of any paint residue and new
hardware installed. The following instructions will guide the technician through a thorough inspection and
repair of the 14 ground points. In addition, a ground strap is to be installed between the RH A-Post and the
Instrument Panel (IP) which will improve the ground circuit within the IP. Please see the matrix on the
following page that identifies the ground points and related hardware.
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 28
Printed: January 22, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
A1
GD112
A2
GD109
1
1
A3
GD107
1
1
A4
D0205-2
A5
D0205-2
A6
D0205-3
A7
GD110
B1
GD202 C1
B2
GD203 C1
B3
1
1
1
1
1
1
1
1
1
1
B4
GD209
1
1
B5
GD210
1
1
B6
1
1
B7
GD200
1
B8
GD201
1
TOTAL
Heat Shrink Repair
WASHER-STEEL 6.0 X 20.0 X 1.5
WASHER-STAINLESS STEEL M8 X 17.0 X 1.6
GROUND STRAP
NUT-HEX FL PTP M8x1.25 PC8
BOLT-HEX SS M6 X 1.0 X 16.0
BOLT-HEX SS M8 X 1.25 X 25.0
Ground Point / APM Terminal
Location
TITLE: Ground Connection Rework
3
4
1
1
8
4
1
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 28
Printed: January 22, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
TITLE: Ground Connection Rework
PROCESS OVERVIEW:
1. Isolation Procedure for 12 Volt Battery
2. LOCATION A1 – Cylinder Block Ground GD112 – Repair
3. LOCATION A2 & A3 – Bulkhead Ground GD109 and GD107 – Repair
4. LOCATION A4 & A5 – APM Ground D0205-2 – Repair
5. LOCATION A6 – APM Power Wire D0205-3 – Repair
6. LOCATION A7 – A/C Compressor Clutch Ground GD110 – Repair
7. Remove Right-Hand A-Pillar Lower Trim
8. LOCATION B1 – Right-Hand A-Pillar Instrument Panel Ground GD202 C1 – Repair
9. LOCATION B2 – Right-Hand A-Pillar Body Ground GD203 C1 – Repair
10. LOCATION B3 – Right-Hand Instrument Panel Cross Member Bracket Ground – Repair
11. LOCATION B4 & B5 – Grounds GD209 (B4) and GD210 (B5) – Repair
12. Install Right-Hand A-Pillar Lower Trim
13. Remove Left-Hand A-Pillar Lower Trim
14. LOCATION B6 – Left-Hand Instrument Panel Cross Member Bracket Ground – Repair
15. LOCATION B7 and B8 – Left-Hand A-Pillar Body Ground GD200 C1 and Instrument Panel
GD201 C1 – Repair
16. Install Left-Hand A-Pillar Lower Trim
17. Check Security of Both the 12 Volt Positive and Negative Cable
18. Reconnect 12 Volt Battery and Verify Electrical Functions
19. File Technical Support System (TSS) Claim
20. Necessary Hardware (Image)
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 28
Printed: January 22, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
TITLE: Ground Connection Rework
VIN: All vehicles produced prior to VIN# YH4K14AA4CA000852
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 28
Printed: January 22, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
TITLE: Ground Connection Rework
Repair Insufficient Ground Locations
Isolation Procedure for 12 Volt Battery
1a. Open hood.
NOTE: Be sure the Start/Stop Button (SSB) is in the OFF position before going to next step.
1b. Release clip and disconnect 12 volt negative battery connector C104.
12 Volt Battery Negative Connector C104
1c. With the 12 Volt battery disconnected, remove Fuse 27 (25 amp) from the Power Distribution
Center (PDC). This will disable the Solar Panel from powering the 12 Volt battery.
– Let the vehicle sit for 10 minutes to fully discharge the 12 volt system.
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 28
Printed: January 22, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
TITLE: Ground Connection Rework
NOTE: Image below shows locations of ground wire connections to repair located in the engine compartment. Each ground location is designated with a letter for reference of repair steps included in this
document.
● Locations in RED will receive a replacement washer under the head of the ground bolt or ground nut.
● Locations in YELLOW will receive a replacement ground bolt (except where noted).
● Location in BLUE will be checked/repaired if heat shrink tube or its glue is under the head of the bolt.
● Location in Green will receive a replacement nut.
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 28
Printed: January 22, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
TITLE: Ground Connection Rework
LOCATION A1 – Cylinder Block Ground GD112 – Repair
2a. Locate ground GD112 on frame crossmember.
2b. Remove ground wire nut from ground stud.
2c. Remove paint from mating ground surfaces, if present.
2d. Install ground wire (if you removed wire for cleaning mating surfaces) over stud.
2e. Install new replacement Washer (Stainless Steel M8 X 17.0 X 1.6 – PN: C146000907200).
2f. Install ground nut and torque to 10 +/- 5 Nm.
2g. Mark nut with dab of white marking paint to identify this work has been done.
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 28
Printed: January 22, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
TITLE: Ground Connection Rework
LOCATION A2 & A3 – Bulkhead Ground GD109 and GD107 – Repair
3a. Locate grounds GD109 and GD107 from the bulkhead (see image below).
3b. Remove bolts.
3c. Remove paint from mating ground surfaces, if present.
3d. Install ground wires with new replacement Hex-Bolt (SS M6 X 1.0 X 16.0 – PN:
C141900200200) and Washer (Steel 6.0 X 20.0 X 1.5 – PN: C146000007200).
3e. Install ground bolt and torque to 8 +/- 2 Nm (do not overtighten, captured nuts are easily
damaged).
3f. Mark bolt with dab of white marking paint to identify this work has been done.
LOCATION A4 & A5 – APM Ground D0205-2 – Repair
4a. Locate negative ground D0205-2 on APM.
4b. Remove bolt.
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 28
Printed: January 22, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
TITLE: Ground Connection Rework
4c. Examine ground for heat shrink tube or its adhesive improperly located under the ground bolt
washer.
– If heat shrink tube or its adhesive is under ground washer, go to next step.
– If heat shrink tube or its adhesive is not under ground washer, go to step 4e.
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 28
Printed: January 22, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
TITLE: Ground Connection Rework
4d. Trim heat shrink tubing back to red dotted-line (see image below), so that it’s not interfering
with ground washer and then clean off heat shrink adhesive.
Example: Improperly installed heat shrink and incorrect ground bolt.
Example: Corrected heat shrink and proper replacement ground bolt.
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 28
Printed: January 22, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
TITLE: Ground Connection Rework
4e. Install ground wire and new replacement Hex-Bolt (Stainless Steel SS M8 X 1.25 X 25.0 – PN:
C141900100200) (no washer required), then torque to 18 +/- 5 Nm.
4f. Mark bolt with dab of white marking paint to identify this work has been done.
LOCATION A6 – APM Power Wire D0205-3 – Repair
5a. Remove red plastic protective cover from APM power wire junction block (see image below).
5b. Remove nut from APM power wire (see image below).
5c. Install new replacement nut.
5d. Install ground Hex-Nut (FL PTP M8x1.25 PC8 – PN: C144211807200) and torque to 18 +/- 5
Nm.
5e. Mark nut with dab of white marking paint to identify this work has been done.
5f. Re-install red plastic protective cover.
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 28
Printed: January 22, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
TITLE: Ground Connection Rework
LOCATION A7 – A/C Compressor Clutch Ground GD110 – Repair
6a. Locate A/C compressor clutch ground GD110 on driver’s side of engine behind coolant hose
(for specific ground location, see image below).
6b. Remove bolt.
6c. Install ground wire (if you removed wire for cleaning mating surfaces).
6d. Install new replacement Washer (Stainless Steel M8 X 17.0 X 1.6 – PN: C146000907200).
6e. Install ground bolt and torque to 25 Nm.
6f. Mark bolt with dab of white marking paint to identify this work has been done.
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: 12 of 28
Printed: January 22, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
TITLE: Ground Connection Rework
NOTE: Image below shows locations of ground wire connections to repair located in the passenger
compartment. Each ground location is designated with a letter for reference of repair steps included in
this document.
● Locations in RED will receive a replacement washer under the head of the ground nut.
● Locations in YELLOW will receive a replacement ground bolt to improve ground.
● Location in BLACK will receive a ground strap.
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: 13 of 28
Printed: January 22, 2012
CAMPAIGN
FISKER AUTOMOTIVE, INC.
NUMBER: 390120010.01
MODEL: Karma
DATE: January 22, 2012
MODEL YEAR: 2012
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