2026-11-02

HV-Batterie (Hinterradantrieb) (Ausbauen und Einbauen)

Korrekturcodes 16010101 3.72 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 Persönlicher Schutz to make sure wearing proper PPE when performing the below procedure. NOTE: See for safe and healthy working practices.

  • 2026-11-02: Added the removal and installation steps for the 2nd row 60 seats and updates the Vehicle HV Disablement Procedure.
  • 2025-10-10: Changed procedure sequence for cleaning the HV busbar and HV header connector contact surfaces.
  • 2025-01-08: Added images of HV battery alignment rods for clarification.
  • 2024-11-07: Added 3-phase harness disconnect/connect steps.
  • 2024-06-13: Updated lift pad adapter PNs.
  • 2023-11-21: Added new lift pad instructions.
  • 2023-11-02: Added a note to remind of double-checking the charge port busbar connector before removing the HV battery to avoid damage, and added a pain-point video in the same step.
  • 2023-08-23: Updated EPB Service Mode reference.
  • 2023-05-22: Added caution for correct positive DC cable connection.
Equipment:
  • 1936724-00-A – Universal-Hubkissenadapter
  • 1133787-00-A Schlüssel, Sicherheitsgurtfreigabe, Model 3
  • 1020566-00-F BGR, Batteriehubtisch, manuell
  • 1020566-99-A Obere Platte, Batteriehubtisch, manuell
  • 1129166-00-A Hebebühne mit H-Rahmen, EMEA
  • 1134523-00-A Kit, Ausrichtungsstäbe, Batterie, Model 3
  • 1140311-00-A Hebelverriegelung, HV-Steckverbinder, Model 3
  • 1053600-00-B Druckprüfgerät, Antriebseinheit
  • 1130942-00-B Adapter, Kühlmittel-Ausgleichsbehälter, Druckprüfung
  • 1132185-00-B Kit, Kühlmittel-Leckprüfadapter, Model 3
  • 1133843-00-A Kit, Kühlmittel-Ablass- und -Fülladapter, M3
  • 1135762-00-A Kit, Service-Stecker, Kühlschlauch, Model 3
  • GSN-TL-000564 Kit, Batterie-Kühlmittelablass und -füllung
  • 1026636-00-A Packung, Gehäuseleckprüfer, HV-Batterie
  • 1140501-00-A Packungs-Kit, Gehäuse, Leckprüfung, HV-Batterie, Komplett
  • 1144879-00-A Kit, Geh. Leckprüfadapter, HV-Batterie
  • 1108272-00-B Kappe, Logikverbindung, Umr., 3DU
Warning
If installing the HV battery after the vehicle has been in a collision, do not reuse HV battery mounting bolts. Use only new HV battery mounting bolts when reinstalling the HV battery.

Technische Daten zum Drehmoment

Table 1. Technische Daten zum Drehmoment: HV-Batterie (Hinterradantrieb) (Ausbauen und Einbauen)
Beschreibung Drehmomentwert Empfohlene Werkzeuge Wiederverwenden/Ersetzen Hinweise
LH front inner HV battery bolt
136 Nm (100.3 lbs-ft)
  • Torx Plus-Steckschlüssel EP20
Wiederverwenden
LH middle inner HV battery bolt
66 Nm (48.7 lbs-ft)
  • Steckschlüssel, 16 mm
Wiederverwenden
LH rear inner HV battery bolt
66 Nm (48.7 lbs-ft)
  • Steckschlüssel, 16 mm
Wiederverwenden
Bolts that secure the 2nd row 60 seat frame to the body
37 Nm (27.3 lbs-ft)
  • 11 mm socket
  • Cordless 3/8in Dr Impact
  • 6 in extension
Ersetzen 1616775-00-B
Bolt that secures the busbar cover access door
9 Nm (6.6 lbs-ft)
  • Steckschlüssel, 10 mm, tief
Wiederverwenden
Bolts that attach the charge port busbar kit to the HV header
9 Nm (6.6 lbs-ft)
  • Steckschlüssel, 10 mm, tief
Wiederverwenden
Nut that attaches the DCDC ground strap to the HV battery
9 Nm (6.6 lbs-ft)
  • Zwölfkantsteckschlüssel, 13 mm, tief
Ersetzen 1093060-00-A
Nut that attaches the positive 12V output to the PCS cable
9 Nm (6.6 lbs-ft)
  • Steckschlüssel, 13 mm
Ersetzen 1093060-00-A
Bolt that attaches the LH front wheel liner to the HV battery
5 Nm (3.7 lbs-ft)
  • Steckschlüssel, 10 mm
Wiederverwenden
Smaller bolts that attach the LH shear plate to the body
35 Nm (25.8 lbs-ft)
  • Steckschlüssel, 13 mm
Wiederverwenden
Larger bolt that attaches the LH shear plate to the body
130 Nm (95.9 lbs-ft)
  • Steckschlüssel, 21 mm
Ersetzen 1461657-00-A
Nut that attaches the RDU HV electrical harness bracket to the HV battery
10 Nm (7.4 lbs-ft)
  • Steckschlüssel, 10 mm
Wiederverwenden
Center bolts (x4) that attach the HV battery through the HV battery center rail ski cover
35 Nm (25.8 lbs-ft)
  • Außen-Torx Plus EP14
Wiederverwenden
Outer bolts (x2) that attach the center rail ski cover to the HV battery
32 Nm (23.6 lbs-ft)
  • Außen-Torx Plus EP14
Wiederverwenden
Bolts that attach the HV battery LH and RH support brackets to the vehicle
110 Nm (81.1 lbs-ft)
  • Steckschlüssel, 16 mm
Wiederverwenden
Bolts (x16) that attach the HV battery to the vehicle
35 Nm (25.8 lbs-ft)
  • Steckschlüssel, 13 mm
Wiederverwenden

Ausbauen

  1. Remove the LH lower rocker panel cover. See Abdeckung – Trittbrettformteil – Unten – LH (Ausbauen und Ersetzen).
  2. Remove the LH rocker panel carrier. See Träger – Trittbrett – Links (Ausbauen und Ersetzen).
  3. Remove the butyl patches that cover the LH rocker access hole.
  4. Repeat step 1 through step 3 for the RH side of the vehicle.
  5. Install lift pad adapters.
    • For EMEA only, install Adapter, Hubkissen, Model Y (1614078-00-A)
    • For other regions, install Universal Lift Pad Adapters (1936724-00-A)
    Warning
    DO NOT use any other lift pad adapters.
    Note
    Outside of EMEA, Universal Lift Pad Adapters (1936724-00-A) replace Adapter, Hubkissen, Model Y (1614078-00-A). Discard any other versions of lift pad adapters.
    Note
    In EMEA, the Universal Lift Pad Adapters are not yet available. Make sure to use the rubber Model Y lift pads on Model Y and the Model 3 lift pads on Model 3.

    Instructions for Universal Lift Pad Adapters:

    1. Depending on the lift type, install the correct thread adapter onto the lift adapter.
    2. Make sure the thread stop washer is installed and tightened to the bottom of the lift adapter. If the thread stop washer is not installed, do not continue using the lift adapter.
    3. Install the lift adapters onto the lift arms so that the black lift pad is toward the vehicle.
      Warning
      Make sure the adapter is install in the correct orientation.
    4. Position the lift arms so that the lift adapters align with the datum hole on the vehicle.
    5. Lift the lift arms to fully seat the lift pads into the vehicle.
    6. Make sure all 4 adapters are fully seated into the vehicle.
  6. Enable Service Mode. See .
  7. Unlock the vehicle gateway. See .
  8. On the touchscreen, touch Thermal > Coolant System > Coolant Fill/Drain, then touch Run and close once the routine is completed.
    Note
    Thermal Fill Drain routine has a 5 hour time limit. After 5 hours, the routine must be performed again.
  9. Open all the doors and lower all the windows.
  10. Remove the rear underhood apron. See Unterhaubenschürze – Hinten (Ausbauen und Ersetzen).
  11. Remove the HEPA filter assembly. See .
  12. Remove the LH instrument panel end cap. See #GUID-F966829B-F227-486B-9AE8-55F4F733BE58.
  13. Remove the LH middle A-pillar trim. See #GUID-E1DDEA4B-6FBC-438D-997F-B3BD26910740.
  14. Remove the LH lower A-pillar trim. See #GUID-2B48046D-F15C-4E02-B2C9-82D80BB25389.
  15. Move the driver seat fully rearwards.
  16. Remove the driver footwell cover. See #GUID-9E8372EB-55A4-4F04-A950-5D769CD36C14.
  17. Remove the LH center console side panel carpet. See #GUID-F4937396-BA44-41B6-87B7-8A7CFE6939D3.
  18. Remove the clip that attaches the LH front carpet to the vehicle, and then fold the carpet rearward.
  19. Remove the foam plugs in the padding underneath LH front carpet, and then remove the LH front inner HV battery bolts (x2).
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Torx Plus-Steckschlüssel EP20
  20. Raise the LH front seat fully.
  21. Repeat step 10 through step 18 for the RH side of the vehicle.
  22. Remove the 2nd row floor mat from the vehicle.
  23. Lift the flap in the carpet underneath the RH front seat, and then remove the RH middle inner HV battery bolt that attaches the HV battery to the vehicle. Repeat this step for the LH side of the vehicle.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 16 mm
  24. Remove the 2nd row lower seat cushion. See Sitzkissen – Unten – 2. Sitzreihe (Ausbauen und Ersetzen).
  25. Remove the LH lower C-pillar trim. See .
  26. Remove the clip securing the LH lower B-pillar to body.
  27. Repeat steps 23 and 24 for the RH side of the vehicle.
  28. Remove the clips (x3) that attach the rear carpet to the vehicle.
  29. Position a folded shop towel underneath the rear cabin carpet to raise the carpet and allow access to the rear inner HV battery bolts, and then remove the LH and RH bolts.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 16 mm
  30. Disconnect 12V power. See 12-V-/Niederspannungsversorgung (Trennen und Verbinden).
  31. Perform Vehicle HV Disablement Procedure. See HV-Abschaltverfahren des Fahrzeugs.
  32. Disconnect the 2nd row 40 seat connector.
    Note
    There may be a red locking tab on newer models.
  33. Remove and discard the bolts (x5) that attach the 2nd row 60 seat frame to the body.
    Note
    Bottom seat bolts are located behind the main carpet.
    Note
    Use of the following tool(s) is recommended:
    • 11 mm socket
    • Cordless 3/8in Dr Impact
    • 6 in extension
  34. Fold the 2nd row 60 seat back downward.
    Note
    Protect the seat back upholstery if necessary. Do not put weight on seat in folded position without cushion present due to risk of bending locator tab on frame.
  35. Disengage the locking tab and disconnect the 2nd row 60 seat connector.
  36. Release the 2nd row 60 seat connector from the LH seat frame.
    Note
    Pinch tabs on clip to avoid damage.
  37. Remove the 2nd row 60 seat assembly from the vehicle.
    Note
    Recommend assistance. If the seat that is not being replaced does not have the ISOFIX flag for child locks, the seat cover will also require replacement.
  38. Disconnect the logic electrical connector at the LH seat frame.
  39. Release the clip that attaches the logic electrical harness to the LH seat frame.
  40. Remove the bolt that secures the busbar cover access door.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm, tief
  41. Remove the bolts that attach the charge port busbar kit to the HV header, and then lift to remove the kit from the header.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm, tief
  42. If there is a 3-phase (AC) connection between the charge port and HV battery, disconnect it:
    1. Slide the release to unlock the 3-phase connector handle of the charge port to HV battery harness from the secured position.
    2. Fully raise the handle on the 3-phase connector.
    3. Remove the 3-phase connector from the ancillary bay 3-phase header.
  43. Disconnect the HVC logic connector, and then install the logic cap.
  44. Remove and discard the nut that attaches the DCDC ground strap to the HV battery, and then remove the strap from the battery.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Zwölfkantsteckschlüssel, 13 mm, tief
  45. Release the positive 12V output cover from the PCS cable, remove and discard the nut that attaches the positive 12V output to the PCS cable, and then move the cable aside.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 13 mm
  46. Close all doors.
    Note
    Doors will be unlatched at a later step.
  47. Remove the wheel chocks from the wheel.
  48. With assistance, push the vehicle onto the lift, then re-chock the wheels when the vehicle is in position.
    CAUTION
    Only push the vehicle for a very short distance and at less than 1 MPH.
  49. Install lift pad adapters.
    • For EMEA only, install Adapter, Hubkissen, Model Y (1614078-00-A)
    • For other regions, install Universal Lift Pad Adapters (1936724-00-A)
    Warning
    DO NOT use any other lift pad adapters.
    Note
    Outside of EMEA, Universal Lift Pad Adapters (1936724-00-A) replace Adapter, Hubkissen, Model Y (1614078-00-A). Discard any other versions of lift pad adapters.
    Note
    In EMEA, the Universal Lift Pad Adapters are not yet available. Make sure to use the rubber Model Y lift pads on Model Y and the Model 3 lift pads on Model 3.

    Instructions for Universal Lift Pad Adapters:

    1. Depending on the lift type, install the correct thread adapter onto the lift adapter.
    2. Make sure the thread stop washer is installed and tightened to the bottom of the lift adapter. If the thread stop washer is not installed, do not continue using the lift adapter.
    3. Install the lift adapters onto the lift arms so that the black lift pad is toward the vehicle.
      Warning
      Make sure the adapter is install in the correct orientation.
    4. Position the lift arms so that the lift adapters align with the datum hole on the vehicle.
    5. Lift the lift arms to fully seat the lift pads into the vehicle.
    6. Make sure all 4 adapters are fully seated into the vehicle.
  50. Raise and lock the vehicle at a comfortable working height.
    CAUTION
    Verify that the vehicle is stable on the lift.
  51. Remove the front aero shield panel. See Verkleidung – Windabweiser – Vorne (Nicht Strukturpack)(Ausbauen und Ersetzen).
  52. Remove the bolt and clips that attach the LH front wheel liner to the HV battery and lower wheel well area. Repeat this step for the RH side of the vehicle.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm
  53. Remove the front HV battery skid plate. See .
  54. Release the connector lock, and then disconnect the A/C compressor electrical connector from the HV harness.
  55. Install bungee straps to pull the LH and RH front wheel arch liners away from the HV battery and expose the coolant hoses.
  56. Perform a rear powertrain coolant drain. See .
  57. Perform a platter enclosure coolant drain. See .
  58. Remove the mid aero shield panel. See Verkleidung – Windabweiser – Hinten (Ausbauen und Ersetzen).
  59. Position the support stand underneath the front portion of the rear subframe.
  60. Release the fir tree clips that attach the coolant hoses to the LH shear plate.
  61. Remove the smaller bolts that attach the LH shear plate to the body.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 13 mm
  62. Remove and discard the larger bolt that attaches the LH shear plate and rear subframe to the body, and then remove the LH shear plate.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 21 mm
  63. Re-install the larger bolt, and hand-tighten the bolt to the rear subframe.
  64. Repeat step 60through 63 for the RH shear plate.
  65. Remove the support stand from underneath the rear subframe
  66. Remove the rear HV battery skid plate. See #GUID-C28DE945-C6EF-450D-A7A4-98E5CC2C2DA1.
  67. Position the coolant drain under the rear LH side of the HV battery.
  68. Release the clip and disconnect the rear drive unit inverter inlet hose from the rear of the HV battery, and immediately plug the male and female fittings.
  69. Position the coolant drain under the rear RH side of the HV battery.
  70. Release the clip and disconnect the coolant outlet hose to rear powertrain return coupling, and immediately plug the male and female fittings.
  71. Remove the coolant drain from underneath the vehicle.
  72. Remove the nut that attaches the rear drive unit HV electrical harness bracket to the HV battery.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm
  73. Slide the release to unlock the HV battery rear drive unit connector handle of the rear drive unit to HV battery harness from the secured position.
  74. Fully raise the handle on the HV battery rear drive unit connector.
  75. Remove the HV battery rear drive unit connector from the HV battery header.
  76. With an assistant, put the battery table in position, and then lower the vehicle to support the HV battery.
    Note
    Line up the battery table so that the center 4 bolts of the HV battery are accessible through the opening in the battery table.
  77. Remove the center bolts (x4) that attach the HV battery through the HV battery center rail ski cover.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Außen-Torx Plus EP14
  78. Remove the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 16 mm
  79. Remove the bolts (x16) that attach the HV battery to the vehicle.
    Note
    Record the positions of any installed washers, as they will be reinstalled to the same locations during the installation procedure.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 13 mm
  80. With an assistant, raise the vehicle and remove the HV battery from underneath the vehicle.
  81. Remove the ancillary bay perimeter seal from the HV battery pack.

Montieren

  1. Install a new HV battery cover gasket. See #GUID-B23AA3A3-4BCA-4ED3-9785-7F5E2ADA314B.
  2. Inspect the top cover of the HV battery for the presence of NVH pads.
    • If the HV battery already has NVH pads, continue to the next step.
    • If the HV battery does not have NVH pads, install the NVH pads. See .
      Note
      Add correction code 16103101 to the Repair Order separately. The labor time to install the NVH pads is not included in this parent procedure.
  3. Clean the busbar HV connector contact surface of residual Penetrox.
    Note
    Allow one minute of drying time after removing Penetrox.
  4. Clean the HV connector contact surface of residual Penetrox.
    Note
    Allow one minute of drying time after removing Penetrox.
  5. Install the HV battery alignment rods; 2 at the front of the vehicle and 2 at the HV battery near the ancillary bay.
    Figure 1. RH front alignment rod shown; LH similar
    Figure 2. Rear alignment rods
  6. With an assistant, position the HV battery underneath the vehicle.
  7. Lower the vehicle to the HV battery, and with an assistant, align the holes with the alignment rods.
    Note
    Do not fully lower the vehicle onto the HV battery. The battery will still need to slightly move to install the bolts in the following steps.
    CAUTION
    Make sure that the coolant hoses and HV harnesses are not caught on the alignment rods or sandwiched between the HV battery and the vehicle.
  8. Install and hand-tighten the LH and RH bolts (x16) that attach the HV battery to the body.
    Note
    Install the washers to the locations recorded earlier during removal.
  9. Remove HV battery front alignment rods.
  10. Install and hand-tighten the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
  11. Install and hand-tighten the bolts (x4) that attach the center portion of the HV battery through the HV battery center rail ski cover.
  12. Open the LH rear door
  13. Remove the HV battery alignment rod from the LH rear inner bolt location.
  14. Install and hand-tighten the LH rear inner HV battery bolts.
  15. Lift the carpet flap, and then install and hand-tighten the LH middle inner HV battery bolt.
  16. Close the LH rear door and open the LH front door.
  17. Install and hand-tighten both LH front inner HV battery bolts.
  18. Repeat step 12 through step 17 for the RH side of the vehicle.
  19. Fully lower the vehicle onto the HV battery.
  20. Torque the LH and RH bolts (x16) that attach the HV battery to the vehicle.
    35 Nm (25.8 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 13 mm
  21. Torque the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
    110 Nm (81.1 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 16 mm
  22. Torque the bolts (x4) that attach the center portion of the HV battery through the center ski cover.
    35 Nm (25.8 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Außen-Torx Plus EP14
  23. With an assistant, raise the vehicle, and then remove the battery table from underneath the vehicle.
  24. Set the vehicle to a comfortable working height, and then lower the vehicle into locks.
  25. Position the support stand to support the front portion of the rear subframe.
  26. Remove the smaller bolts (x2) and the larger bolt that are used to attach the LH shear plate to the vehicle.
    Figure 3. LH shown, RH similar
  27. Install the LH shear plate, and then install and hand-tighten the larger bolt that attaches the shear plate to the vehicle.
  28. Install and hand-tighten the smaller bolts (x2) that attach the shear plate to the HV battery.
    Figure 4. LH shown, RH similar
  29. Torque the large bolt that attaches the LH shear plate to the body.
    130 Nm (95.9 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 21 mm
  30. Torque the small bolts that attach the LH shear plate to the body.
    35 Nm (25.8 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 13 mm
  31. Repeat step 26 through step 30 for the RH shear plate.
  32. Remove the support stand from underneath the rear subframe
  33. Fasten the fir tree clips that attach the coolant hoses to the LH and RH shear plates.
    Figure 5. LH shown, RH similar
  34. Fully raise the handle on the HV battery rear drive unit connector of the rear drive unit to HV battery harness.
  35. Install the HV connector special tool onto the HV battery rear drive unit connector.
  36. Use both hands to firmly connect the HV battery rear drive unit connector of the rear drive unit to HV battery harness to the HV battery header.
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  37. Remove the HV connector special tool from the HV battery rear drive unit connector.
  38. While pressing the HV battery rear drive unit connector onto the HV battery header, fully lower the handle.
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  39. Slide the release to lock the HV battery rear drive unit connector handle in the secured position.
  40. Verify that the HV battery rear drive unit connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Note
    An improperly seated connector might lead to connector damage and rear drive unit problems later on.
  41. Install the nut that attaches the rear drive unit HV electrical harness bracket to the HV battery.
    10 Nm (7.4 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm
  42. Position the coolant drain beneath the RH rear of the HV battery.
  43. Remove the hose plugs, and then connect coolant outlet hose to rear power train return hose.
    CAUTION
    Perform a push-pull test to verify that the hose is fully seated.
  44. Position the coolant drain underneath the LH rear of the HV battery.
  45. Remove the hose plugs, and then connect rear drive unit inverter inlet hose to the rear of HV battery.
    CAUTION
    Perform a push-pull test to verify that the hose is fully seated.
  46. Remove the coolant drain from underneath the vehicle.
  47. Install the rear HV battery skid plate, but only hand-tighten the fasteners. See #GUID-C28DE945-C6EF-450D-A7A4-98E5CC2C2DA1.
  48. Torque the fasteners that attach the rear skid plate to the vehicle. See #GUID-C28DE945-C6EF-450D-A7A4-98E5CC2C2DA1.
  49. Install the mid aero shield panel. See Verkleidung – Windabweiser – Hinten (Ausbauen und Ersetzen).
  50. Position the coolant drain under the front LH side of the HV battery.
  51. Fasten the clips that attach the HV battery front manifold hose to the body.
  52. Remove the plugs from the chiller to HV battery hose and the manifold at the LH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  53. Remove the plugs from the HV battery return hose at the LH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  54. Position the coolant drain under the front RH side of the HV battery.
  55. Remove the plugs from the rear powertrain supply hose at the RH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  56. Remove the plugs from the powertrain return hose at the RH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  57. Remove the coolant drain from underneath the vehicle.
  58. Remove the plastic bracket that attaches the HV connectors to the HV battery.
  59. Connect the A/C HV connector, and then engage the connector lock.
  60. Install the front HV battery skid plate. See .
  61. Remove the bungee straps from the LH and RH wheel arch liners.
  62. Install the bolt and clips that attach the LH front wheel liner to the HV battery and lower wheel well area. Repeat this step for the RH side of the vehicle.
    5 Nm (3.7 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm
  63. Install the front aero shield panel. See Verkleidung – Windabweiser – Vorne (Nicht Strukturpack)(Ausbauen und Ersetzen).
  64. Lower the vehicle fully.
  65. Remove the chock, and with an assistant, push the vehicle away from the lift to a stall, and then re-chock the wheel.
    CAUTION
    Push the vehicle for a very short distance and at less than 1 MPH.
  66. Install the nut that attaches the positive 12V output to the PCS cable, and then close the cover.
    9 Nm (6.6 lbs-ft)
    CAUTION
    Ensure the rubber boot is not pinched between the cable terminal and pass through.
    CAUTION
    Make sure the positive output cable is positioned properly and in the right direction against the plastic anti-rotation edge on the DCDC passthrough.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 13 mm
  67. Install a new nut that attaches the DCDC ground strap to the HV battery.
    9 Nm (6.6 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Zwölfkantsteckschlüssel, 13 mm, tief
  68. Remove the logic cap, and then connect the HVC logic connector.
  69. Apply a small amount of Penetrox onto the HV connector joints.
  70. Position the busbar kit connector and lower onto the HV header.
  71. Install the bolts that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm, tief
  72. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances. See .
  73. Put on HV insulating gloves and leather over gloves.
  74. At the ancillary bay, use the Hioki resistance meter to measure the resistance between the charge port busbar lead and the ancillary bay HV header bolt head. Also perform this test on the other lead and bolt head.
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again, as appropriate.
    Note
    If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
  75. Remove the HV insulating gloves and leather over gloves.
  76. Install the bolt that secures the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm, tief
  77. If there is a 3-phase (AC) connection between the charge port and HV battery, connect it:
    1. Fully raise the handle on the 3-phase connector of the charge port to HV battery harness.
    2. Use both hands to firmly connect the 3-phase connector of the charge port to HV battery harness to the ancillary bay 3-phase header.
      CAUTION
      Make sure that the connector fits the header squarely and tightly.
    3. While pressing the 3-phase connector onto the 3-phase header, fully lower the handle.
      CAUTION
      Make sure that the handle does not bind as it is lowered.
    4. Slide the release to lock the 3-phase connector handle in the secured position.
    5. Verify that the connector is fully seated, and compare both sides of the connector, that it is properly latched in place.
      Note
      An improperly seated connector might lead to connector damage and charging problems later on.
  78. Install the clip that attaches the logic electrical harness to the LH seat frame.
  79. Connect the logic connector at the LH seat frame.
  80. Connect the 2nd row 40 seat connector.
    Note
    There may be a red locking tab on newer models.
  81. Position the 2nd row 60 seat assembly into the vehicle.
    Note
    Recommend assistance.
  82. Move the 2nd row 60 seat back to vertical position.
  83. Install the new bolts (x5) (1616775-00-B) that attach the 2nd row 60 seat frame to the body, and torque them in the sequence: outboard front → both inboard rear → outboard rear → inboard front.
    37 Nm (27.3 lbs-ft)
    Note
    Bottom seat bolts are located behind the main carpet.
    Note
    Use of the following tool(s) is recommended:
    • 11 mm socket
    • Cordless 3/8in Dr Impact
    • 6 in extension
  84. Connect the 2nd row 60 seat connector and engage the locking tab.
  85. Secure the 2nd row 60 seat connector to the LH seat frame.
  86. Torque the LH and RH rear inner HV battery bolts.
    66 Nm (48.7 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 16 mm
  87. Remove the folded shop towel from underneath the rear cabin carpet.
  88. Install the clips (x3) that attach the rear carpet to the vehicle.
  89. Install the clip securing the LH lower B-pillar to body.
  90. Install the LH lower C-pillar trim. See .
  91. Repeat steps 89 and 90 for the RH side of the vehicle.
  92. Install the 2nd row lower seat cushion. See Sitzkissen – Unten – 2. Sitzreihe (Ausbauen und Ersetzen).
  93. Torque the LH middle inner HV battery bolt, and then fold the carpet to its original position. Repeat this step on the RH side of the vehicle.
    66 Nm (48.7 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 16 mm
  94. Install the 2nd row floor mat into the vehicle.
  95. Torque both RH front inner HV battery bolts, and then install the foam plugs.
    136 Nm (100.3 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Torx Plus-Steckschlüssel EP20
  96. Fold the RH front main cabin carpet forward to its original position, and then install the clip that attaches the LH carpet to the vehicle.
  97. Install the RH lower A-pillar trim. See #GUID-2B48046D-F15C-4E02-B2C9-82D80BB25389.
  98. Install the RH middle A-pillar trim. See #GUID-E1DDEA4B-6FBC-438D-997F-B3BD26910740.
  99. Install the RH instrument panel end cap. See #GUID-F966829B-F227-486B-9AE8-55F4F733BE58.
  100. Install the RH center console side panel carpet. See #GUID-F4937396-BA44-41B6-87B7-8A7CFE6939D3.
  101. Install the RH front floor mat.
  102. Install the front passenger footwell cover. See #GUID-9E8372EB-55A4-4F04-A950-5D769CD36C14.
  103. Repeat step 95 through step 102 for the LH side of the vehicle.
  104. Perform a cooling system vacuum refill. See .
  105. Connect 12V power. See 12-V-/Niederspannungsversorgung (Trennen und Verbinden).
  106. On the vehicle touchscreen, press and hold the park button to release EPB service mode.
  107. Führen Sie die folgende Routine mit dem Service-Modus oder mit Toolbox durch (siehe ): TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Service Mode:
    • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
    • Thermal ➜ Coolant System ➜ Coolant Purge Start
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
    via Toolbox:(link)
  108. Inspect the coolant level and top off as necessary, and then install the coolant bottle cap.
    Note
    Ensure that the coolant level is at the "Max" line.
  109. Führen Sie die folgende Routine mit dem Service-Modus oder mit Toolbox durch (siehe ): TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Service Mode:Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
    via Toolbox:(link)
  110. Install the rear underhood apron. See Unterhaubenschürze – Hinten (Ausbauen und Ersetzen).
  111. Raise all windows and close all doors.
  112. Remove lift pads from the LH rocker.
  113. Install the butyl patch that covers the LH rocker access holes.
  114. Install the LH rocker panel carrier. See Träger – Trittbrett – Links (Ausbauen und Ersetzen).
  115. Install the LH lower rocker panel cover. See Abdeckung – Trittbrettformteil – Unten – LH (Ausbauen und Ersetzen).
  116. Repeat step 112 though step 115 for the RH side of the vehicle.