Correction code 16300106401 16300106402 2.52 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.

1. Raise and support vehicle
   Note

   Set air suspension to "Jack Mode"

   

   

2. Open powered front trunk
   Note

   Via exterior switch or UI

   

   

3. Place the vehicle into Service Mode. See Service Mode.
4. Unlock the vehicle Gateway. See Gateway (Unlock).
5. Access thermal system routines using the UI
   Note

   Select quick controls > Service mode > Thermal > Actions
6. Select "Coolant Fill/Drain" through Service UI
   Note

   Select 'Coolant System' to enter coolant circuit screen, Select 'Coolant Fill/Drain' and 'PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT' window will appear, Select 'Run', Verify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 50 minute time limit
7. Power off vehicle from center display
   Note

   Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off

   

8. Remove rear underhood apron
   Note

   9x clips

   

   

9. Disconnect first responder loop and MV battery connector
   Note

   2x connectors, Release locking tab then disconnect FRL connector, Slide eCPA to left then lift lever to release MV battery connector, Early production trucks may have black FRL connector, Release eCPA by pushing down to unlock and slide red locking tab, Wait 2 minutes for electrical circuits to discharge before disconnecting modules

   

   

   

10. Verify operation of multimeter
    Note

    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals

    

    

11. Remove fastener covers from bed floor assembly
    Note

    14x covers

    

    

    

    

    

12. Remove bed floor assembly
    Note

    10x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Lift front edge with trim tool then remove panel, Recommend assistance

    

    

    

    

13. Clean all debris from ancillary cover
    Note

    During removal of ancillary cover any debris on top of the cover may be deposited into the ancillary bay

    

14. Raise vehicle fully and lower lift onto locks
    Note

    Set vehicle to comfortable working height, Ensure an audible click of locks on both sides is heard before lowering, Vehicle may tilt to the side if both locks are not engaged

    

    

15. Remove rear skid plate
    Note

    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm

    

    

    

    

    

16. Remove all items from pockets and ensure not wearing metal items

    

17. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.

    

18. Put on HV insulating gloves and leather over gloves
    Note

    Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 R5 for PPE requirements depending on vehicle configuration.

    

19. Verify no HV - Install amp clamp to RDU HV harness
    Note

    Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.Release locking tab and rotate the release lever up to disengage the connector, Release harness clip, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damagedMake sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering

    

    

    

    

    

    

20. Secure RDU header connector to ancillary
    Note

    1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins

    

    

21. Remove pyro fuse access cover
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm

    

22. Remove primary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts

    

    

23. Remove secondary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts

    

    

24. Remove leather over gloves and HV insulating gloves
25. Position coolant drain container underneath RH rear of HV battery

    

26. Disconnect rear PT supply and RDU supply hoses
    Note

    2x spring clip, Plug hoses immediately to prevent excess coolant loss, Allow PCS coolant to drain as much as possible before plugging

    

    

27. Secure PT Flush adapter to PCS inlet hose coupling
    Note

    Remove plugs as required, Verify fully seated, Perform push-pull-push test

    

28. Secure coolant cart flush hose to regulator and PT Flush adapter
    Note

    Verify regulator valve is closed, Pressure regulator is not adjustable (set at 20 psi)

    

    

    

29. Secure PCS Drain adapter to PCS outlet using male-to-male adapter
    Note

    Verify valve is closed, Remove plug as required, Verify fully seated, Perform push-pull-push test

    

30. Secure coolant cart drain hose to PCS drain adapter and coolant drain container

    

    

    

31. Open valve on PCS Drain adapter

    

32. Connect shop air to regulator
    Note

    Make sure regulator valve is closed prior to connecting shop air

    

33. Slowly open valve on pressure regulator and allow coolant to drain out of HV battery
    Note

    Allow coolant to drain

    

34. Close valve on pressure regulator once no more coolant is draining

    

35. Close valve on PCS Drain adapter

    

36. Remove cart drain hose from PCS Drain adapter

    

37. Remove PCS Drain adapter from PCS outlet
    Note

    1x spring clip

    

38. Remove cart flush hose from PT Flush adapter

    

39. Remove PT Flush adapter from PCS inlet coupling
    Note

    1x spring clip

    

40. Remove coolant drain container from underneath vehicle
41. Lower vehicle until tires are touching the ground
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

    

    

42. Disconnect ancillary bay MV connector
    Note

    1x connector, Double locking, Release tab then pivot lever, Release second tab to disengage connector, Wait 1 second between locking tab release to discharge and prevent arcing

    

    

    

    

    

43. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.

    

44. Put on HV insulating gloves and leather over gloves

    

45. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

46. Remove bolts securing HV connector to DC FC header
    Note

    2x bolts, 10mm, 9 Nm

    

47. Release HV connector from DC FC header
    Note

    1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly

    

48. Support HV Busbar assembly
    Note

    Suspend assembly to maintain clearance

    

49. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

50. Release low voltage header
    Note

    2x bolts, EP10, 6 Nm

    

51. Release fasteners securing ancillary cover to HV battery
    Note

    22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order

    

    

    

52. Remove ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

53. Disconnect PCS MV connector
    Note

    1x connector, 1x zip tie, Slide red lock off of lever, Rotate lever to release connector, Remove zip tie as needed

    

    

54. Release PCS MV harness
    Note

    1x bolt, EP10, 6 Nm, 2x clips, Move aside as needed

    

55. Disconnect PCS2 DC HV connector
    Note

    1x connector, Release locking tab, Gently pull up

    

56. Release HV harness to ACJB from PCS
    Note

    1x connector, Release locking tab, Gently pull up

    

57. Release coolant line snap clip zip ties
    Note

    4x zip ties, Cut and discard small and large zip ties from PCS coolant line snap clips

    

    

58. Remove PCS coolant line assembly
    Note

    2x hoses, 1x hose, Insert the special tool away from the PCS

    

    

    

59. Lubricate O-rings on PCS coolant hose bundle
    Note

    2x O-rings, Inspect before installation for any damage and replace as needed, If p-80 is unavailable a water based lubricant can be used.

    

    

    

60. Secure PCS coolant line assembly to new PCS
    Note

    2x Hoses, Use caution not to damage the O-rings, Perform push-pull-push test to make sure coolant hoses are fully latched, Then visually verify clip is fully seated, Rest assembly on edge of flat surface, Do not support assembly on coolant line header

    

    

61. Install coolant line snap clip zip ties
    Note

    4x zip ties, Ensure larger zip tie lands on the metal barn, Tighten large white zip tie to secure clips from warping, Install smaller black zip ties to one of the clips very loosely, Trim excess zip tie once secure Small zip tie

    

    

62. Secure HV harness from ACJB to PCS
    Note

    1x connector, Secure locking tab

    

63. Connect PCS2 DC HV connector
    Note

    1x connector, Secure locking tab

    

64. Secure PCS MV harness
    Note

    1x bolt, EP10, 6 Nm, 2x clips

    

65. Connect PCS MV connector
    Note

    1x connector, 1x zip tie, Install zip tie onto ECPA latch, PCS header not datumed, Ensure correct orientation and polarity of connection, Harness color red for LV+ and black for LV-, Swing down locking lever, Slide lock fully to engage on top of lever

    

    

    

    

66. Remove leather over gloves and HV insulating gloves
67. Raise vehicle fully and lower lift onto locks
    Note

    Set vehicle to comfortable working height, Ensure an audible click of locks on both sides is heard before lowering, Vehicle may tilt to the side if both locks are not engaged

    

    

68. Position coolant drain container underneath RH rear of HV battery

    

69. Remove one PCS coolant header plugs & connect leak test adapters
    Note

    2x spring clips, Leave coolant plugs in supply and return lines, Secure NW22 plug to either coolant header port (Item 6 of kit), Combine NW18 Male testing Couple (Item 5 of kit) to Adapter NW18 180° (Item 1 of kit) and secure to other coolant header port

    

    

    

    

    

70. Attach coolant pressure tester to pressure fitting adapter
    Note

    Confirm hose is securely screwed tight

    

71. Attach coolant pressure tester to compressed air line
    Note

    Make sure valves are closed on pressure regulator

    

    

72. Open the regulator valve then slowly adjust regulator to 50 psi
    Note

    Use caution as coolant may spill, Make sure to wear safety glasses

    

    

73. Open 2nd valve slowly
    Note

    Slowly open valve on pressure regulator and allow pressure to reach specification

    

74. Close the valve and let pressure settle
    Note

    Wait 2 minutes for pressure to settle, Record the reading

    

75. Set timer for 2 minutes and select start
    Note

    Once timer is complete, select Stop Reset

    

76. Perform the coolant pressure leak test
    Note

    Wait for another 4 minutes and record the reading. Max delta 0.35 psi. Check coolant hose to see if it is fully seated or not if pressure test fails
77. Close both valves

    

78. Remove coolant pressure tester from pressure fitting adapter

    

79. Remove coolant pressure tester adapter from PCS coolant header

    

80. Connect rear PT supply and RDU supply hoses
    Note

    2x spring clip, Make sure the locking tabs are fully seated, Perform push-pull-push test

    

81. Remove coolant drain container from underneath vehicle
82. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.

    

83. Put on HV insulating gloves and leather over gloves

    

84. Clean pyro fuse mating surfaces
    Note

    Using an insulated tool wipe all four busbar mating surfaces within pyro fuse bay, Wipe top and bottom mating surfaces of each pyro fuse, Ensure no debris is present on any mating surface, Process shown with device cluster removed for clarity and safety, HV gloves and associated PPE must be worn at all times when cleaning mating surfaces, Allow 1 minute for IPA to dry

    

    

    

85. Install secondary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts, Bolts may be reused

    

    

86. Install primary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts, Bolts may be reused

    

    

87. Perform Hioki resistance test at each HV joint from HV busbar lead to pyro fuse busbar
    Note

    4x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session.If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step

    

    

88. Remove leather over gloves and HV insulating gloves
89. Install pyro fuse access cover
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged, If HV pack is being shipped then pyro fuses must be removed

    

    

90. Install rear skid plate
    Note

    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm, Apply Loctite 222 to mid aero shield bolts and install fasteners

    

    

    

    

    

91. Lower vehicle fully
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

    

    

92. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.

    

93. Put on HV insulating gloves and leather over gloves

    

94. Install ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

95. Secure fasteners of cover to HV battery
    Note

    22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order

    

    

    

96. Secure low voltage header
    Note

    2x bolts, EP10, 6 Nm

    

97. Secure fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

98. Clean HV connector contact surface of residual Penetrox
    Note

    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector

    

99. Clean busbar HV connector contact surface of residual Penetrox
    Note

    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar

    

100. Apply Penetrox onto HV connector joints
     Note

     Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered

     

101. Position busbar connector and lower onto HV header
     Note

     Release bungee cord

     

102. Install bolts securing charge port busbar kit to HV Header
     Note

     2x bolts, 10mm, 9 Nm

     

103. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
     Note

     2x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session.If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step

     

     

104. Install bolt securing busbar HV connector lid
     Note

     1x bolt, EP10, 9 Nm

     

105. Connect Ancillary bay MV connector
     Note

     1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly

     

     

     

     

     

106. Remove leather over gloves and HV insulating gloves
107. Install bed floor assembly
     Note

     10x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Recommend assistance

     

     

     

     

     

108. Install fastener covers onto bed floor assembly
     Note

     14x covers

     

     

     

     

109. Remove coolant bottle cap

     

110. Install coolant reservoir adaptor cap onto coolant bottle assembly

     

     

     

111. Place empty coolant container into front storage area
     Note

     If frunk is not installed take caution, CFM fan shroud assembly cannot support a full coolant container, Ensure overflow container is empty, Place fender cover over FEM and front fascia

     

112. Fill container with at least 15L of coolant

     

113. Place filled coolant container onto coolant drain & fill cart
     Note

     Do not place container with 15L of coolant on top of CFM fan shroud, Position cart as close as possible to front of vehicle

     

114. Setup coolant refill tool
     Note

     Verify all valves on refill tool are in the closed position, See image for clarity

     

     

115. Install vacuum refill hose to refill cap on coolant bottle
     Note

     Perform push-pull-push test to verify hose is fully installed

     

116. Position overflow hose into empty container

     

117. Place refill hose inside filled coolant container
     Note

     Make sure hose end is fully submerged into coolant

     

118. Connect shop air supply to coolant refill tool
     Note

     If not already done, Verify refill valve is set to off

     

119. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
     Note

     Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed

     

     

120. Slowly open the refill valve to allow coolant to be drawn into the system
     Note

     Make sure hose end of refill hose is fully submerged during entire process

     

121. Once the gauge reads zero, close the coolant refill valve

     

     

122. Remove shop air supply to coolant refill tool
     Note

     If not already done, Verify refill valve is set to off

     

123. Remove coolant refill hose from coolant container

     

124. Remove coolant overflow hose from coolant container

     

125. Remove vacuum refill hose from refill cap on coolant bottle

     

126. Remove vacuum refill cap from coolant bottle assembly

     

127. Remove coolant refill tool from vehicle
     Note

     Move coolant drain & fill cart away from vehicle

     

     

128. Remove coolant container from inside underhood area

     

129. Connect first responder loop and MV battery connector
     Note

     2x connectors, Connect FRL connector then secure locking tab, Position lever to secure MV battery connector then slide eCPA to right, Early production trucks may have black FRL connector, If power cycling vehicle then ensure at least 60 seconds has passed since powering down

     

     

     

130. Select "Stop Thermal Fill Drain" through UI
     Note

     Allow routine to complete, ensure routine is successful
131. Select "Start Coolant Air Purge" using the UI
     Note

     Touch time only, wait until coolant pumps stop running (audible noise), Routine Passed will appear, but pumps will run for 10 minutes, If you start next another routine during this time it will fail, Make sure vehicle is not in "Drive", Routine is still running despite the completed message, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, this indicates the pumps are air locked, perform a vacuum fill, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle
132. Inspect coolant level and top off as necessary
     Note

     Ensure that the fluid level is at the Max line, Top off fluid as required

     

133. Install coolant bottle cap

     

134. Perform Thermal Performance through the UI
     Note

     Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow toolbox article 206000
135. Install rear underhood apron
     Note

     9x clips, Adjust windshield seal as required

     

     

136. Close powered front trunk
     Note

     Via exterior switch or UI

     

137. Remove vehicle from lift
     Note

     Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"