HV Battery Assembly (Long Range) (Remove and Replace)

Open all the doors and lower all the windows.

Manually latch all doors to prevent lockout

Note

Engage latch with screwdriver

Place the vehicle into Service Mode. See Service Mode.

Unlock the vehicle Gateway. See Gateway (Unlock).

Run ODIN routine PROC_RCM_DISARMvia Service Mode Plus:

Safety & Restraints ➜ Airbags ➜ Disarm RCM
Safety & Restraints ➜ Seats ➜ Disarm RCM

via Toolbox:(link)

Move vehicle onto lift

Note

Ensure positioning allows rear doors to open, NOTE: If burning odors, popping sounds, flames, or smoke is seen at any time, halt this process and call the fire department immediately! Begin evacuation if vehicle is in the shop.

Move LH front seat backward

Remove bolts securing front of LH front seat tracks to risers

Note

2x patch bolts, T45P, 34 Nm, Discard after removal

Raise and move LH front seat forward

Remove bolts securing rear of LH front seat tracks to floor

Note

2x patch bolts, T45P, 34 Nm, Discard after removal

Adjust position of LH front seat for easy removal

Note

Move seat to middle of track at most upright position with seat fully up off floor

Move RH front seat backward

Remove bolts securing front of RH front seat tracks to risers

Note

2x patch bolts, T45P, 34 Nm, Discard after removal

Move RH front seat forward

Remove bolts securing rear of RH front seat tracks to floor panel

Note

2x patch bolts, T45P, 34 Nm, Discard after removal

Adjust position of RH front seat for easy removal

Note

Move seat to middle of track at most upright position with seat fully up off floor

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 5 hour time limit

Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Install).

Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).

Perform vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (without Terrestrial Armor) (Test/Adjust).

Remove leather over gloves and HV insulating gloves

Note

HV gloves should always be stored in the original packaging and inside a storage box or bag to prevent damage, Make sure that gloves are lying flat not bent or folded

Disconnect EPB harness connector from LH rear brake caliper

Note

1x connector, Release locking tab

Release the LH rear parking brake with EPB release tool

Note

1x connector, Connect EPB release tool to brake caliper then press release button to disengage park brake, Disconnect EPB release tool once complete

Connect LH rear EPB harness

Note

1x connector, Engage locking tab

Disconnect RH rear EPB harness

Note

1x connector, Release locking tab

Release the LH rear parking brake with EPB release tool

Note

1x connector, Connect EPB release tool to brake caliper then press release button to disengage park brake, Disconnect EPB release tool once complete

Connect RH rear EPB harness

Note

1x connector, Engage locking tab

Lower vehicle until tires are touching ground

Note

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

Position wheel chocks fore and aft of RH rear wheel

Remove vehicle from lift

Note

Lower rack arms fully and remove them from under vehicle,

Roll vehicle rearward

Note

Position vehicle so front doors can be fully opened, Chock wheels once vehicle is in desired position

Release LH front seat belt from pretensioner

Note

Unlock linkage by rotating lock screw counterclockwise, audible click when horizontal, do not rotate clockwise to avoid damage

Disconnect LH front seat harness

Note

1x connector, 2 stage locking tab, Release yellow locking tab, then release black lever to disconnect

Remove LH front seat from vehicle

Note

Recommend assistance, Use caution to not damage other components, Lift seat off risers, Rotate sideways and remove out back door opening

Release RH front seat belt from pretensioner

Note

Unlock the linkage by rotating the lock screw counterclockwise A light audible click will be heard, and the screw should remain horizontal Do not rotate clockwise to avoid damage to the mechanism

Disconnect RH seat

Note

1x connector, 2 stage locking tab, Release yellow locking tab, then release black lever to disconnect

Remove RH front seat from vehicle

Note

Recommend assistance, Use caution to not damage other components, Lift seat off risers, Rotate sideways and remove out back door opening

Remove center console front panel

Note

10x clips

Remove front bolts securing center console to riser

Note

4x bolts, 10mm, 5 Nm

Disconnect center console harness connectors

Note

2x connectors

Remove center console back panel

Note

10x clips, 3x connectors, 3x harness clips

Remove rear bolts securing center console to riser

Note

2x bolts, 10mm, 5 Nm

Remove center console

Note

Lift up to release from riser and remove center console from rear right door opening

Remove RH outboard riser bolt cover

Note

Lift from outer edge then pull away

Remove RH seat riser assembly from vehicle

Note

4x bolts, 13mm, 40 Nm, 3x clips, release cabin MV harness and 1x clip air duct from riser assembly

Remove LH outboard riser bolt cover

Note

Lift from outer edge then pull away

Remove LH seat riser assembly from vehicle

Note

4x bolts, 13mm, 40 Nm, 2x clips, release cabin MV harness and air duct from riser assembly

Remove footwell cover

Note

3x clips, 3x magnets, 1x bolt, 10mm, 3 Nm, Bolt is captive to tether

Remove LH front floor mat

Remove LH mid A-pillar trim

Note

1x clip, 3x tabs, Release tabs then slightly bend live hinge and release clip

Remove LH lower A-pillar trim

Note

7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward

Remove LH center floor rail

Note

4x clips, 3x datums, Pull upwards to release

Remove accelerator pedal side trim

Note

3x clips, Lift from forward edge then slide over accelerator pedal

Remove accelerator pedal

Note

2x nuts, 13mm, 10 Nm, 1x connector, Release locking tab

Remove LH front cabin carpet

Note

Plastic portions at rear of carpet need to clear risers, if needed break EPA at line to allow the corner to pass over the risers

Remove LH carpet support foam

Note

Lift up from rear edge

Remove LH front interior HV Battery mounting bolts

Note

3x bolts, 24mm, 160 Nm

Remove RH front floor mat

Remove RH mid A-pillar trim

Note

1x clip, 3x tabs, Release tabs then slightly bend live hinge and release clip

Remove RH lower A-pillar trim

Note

7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward

Remove RH center floor rail

Note

4x clips, 3x datums, Pull upwards to release

Remove center floor trim

Note

17x clips, Release upper section first

Remove RH front cabin carpet

Note

Plastic portions at rear of carpet need to clear risers

Remove RH carpet support foam

Note

Lift up from bottom edge

Remove RH interior front HV battery mounting bolts

Note

3x bolts, 24mm, 160 Nm

Fold up 2nd row 60 seat

Note

Pull tether to release then lift up until locked in place

Remove 2nd row floor mat

Partially release RH lower C-pillar trim

Note

1x clip, 1x datum

Fold up 2nd row 40 seat

Note

Pull tether to release then lift up until locked in place

Partially release RH lower C-pillar trim

Note

1x clip, 1x datum

Remove rear wall lower trim

Note

2x push clips, 4x clips, Remove outermost push clips, then pull straight forward to release inner clips

Remove rear carpet LH duct bezel

Note

4x clips

Remove rear carpet RH duct bezel

Note

4x clips

Remove rear carpet assembly

Note

4x clips, 17x stands, 6x datums, Release stands around LH and RH floor ducts then release stands at center console, Fold back carpet and stands from forward edge, Fold rear carpet and foam forwards then pull center of carpet and foam upwards to remove, Remove clips if they remain on pack side

Remove RH rear interior HV battery mounting bolts

Note

4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts

Remove LH rear interior HV battery mounting bolts

Note

4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts

Remove center floor upper bracket

Note

2x push clips, 2x edge clips, 2x retaining clips, Depress either side of retaining clip then push inward to release upper bracket from duct

Remove center floor lower support bracket

Note

4x clips

Remove center console riser duct

Note

2x clips, Maneuver forward to clear riser assembly

Remove floor jumper duct

Note

Push forward then lift and slide out

Remove 2nd row duct on rails

Note

Pull from the bottom to release

Release connectors from RCM

Note

2x connectors, Release red locking tabs first then depress connecter and slide forward

Remove RCM fasteners

Note

3x nuts, 10mm, 10 Nm, Discard fasteners after removal

Remove RCM from vehicle

Release LH MV controller dry side locking cover

Note

1x bolt, 8mm, 6 Nm, Do not remove locking cover, Loosen until bolt spins freely, Double check that bolt and locking cover are fully released before attempting to release any MV connectors, Plastic Locking CoverUse hand tools on any plastic locking covers, The locking cover may release crooked causing it to get stuck, secure bolt a few turns to loosen the tension then release bolt while assisting plastic locking cover by gently prying on the side that's stuck, Metal Locking CoverYou can use power tools, Quickly disconnecting locking cover helps connectors remove symmetrically, Video uses rear controller for demonstration purposes only

Release floor harness from LH MV controller

Note

1x connector, 1x clip, Depress tabs to release connector housing from locking cover

Release RH MV controller connector lower locking cover

Note

1x bolt, 8mm, 6 Nm, Do not remove locking covers, Loosen until bolts spins freely, Double check that bolts and locking covers are fully released before attempting to release any MV connectorsPlastic Locking Cover Use hand tools on any plastic locking covers, The locking covers may release crooked causing them to get stuck, secure bolts a few turns to loosen the tension then release bolts while assisting plastic locking covers by gently prying on the stuck sidesMetal Locking Cover You can use power tools, Quickly disconnecting locking covers helps connectors remove symmetrically

Release cabin floor and backbone harnesses from RH MV controller

Note

1x connector, 1x backbone cable, 2x edge clipsPull from edges of connector housing, Do not pull backbone cable, Avoid bending cable at a tight radiusDo not remove locking cover, Loosen until bolt spins freely, Double check that bolt and locking cover has fully released before attempting to release any MV connectors, Depress tabs on connector housing to releasePlastic Locking CoverUse hand tools on any plastic locking covers, The locking covers may release crooked causing them to get stuck, Thread bolt a few turns to avoid damage then gently pry stuck edges of locking coverMetal Locking CoverYou can use power tools, Quickly disconnecting locking covers helps connectors release evenly

Disconnect rear display connector from car computer

Note

1x connector

Remove cabin floor harness

Note

4x clips, 2x bolts, 10mm, 10 Nm

Remove RH 2nd row floor duct

Note

1x clip, Lift up then pull away to release duct from Y duct

Remove 2nd row floor Y-Duct

Note

1x clip, Release from passenger side duct then maneuver out of position

Release front section of backbone

Note

3x harness clips, Pass connector under cabin floor harness

Disconnect backbone harness from rear MV controller

Note

1x connector, 1x bolts, 8mm, 6 Nm, Do not remove locking cover, Loosen until bolt spins freely, Double check that bolt and locking cover has fully released before attempting to release any MV connectors, Depress tabs on connector housing to releasePlastic Locking CoverUse hand tools on any plastic locking covers, The locking covers may release crooked causing them to get stuck, Thread bolt a few turns to avoid damage then gently pry stuck edges of locking coverMetal Locking CoverYou can use power tools, Quickly disconnecting locking covers helps connectors release evenly

Remove backbone harness

Note

6x harness clips, Pull harness through to 2nd row then remove

Remove the LH rocker panel assembly. See Rocker Panel Assembly - LH (Remove and Install).

Remove the LH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).

Remove the LH rear rocker step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).

Remove the RH rocker panel assembly. See Rocker Panel Assembly - LH (Remove and Install).

Remove the RH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).

Remove the RH rear rocker step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).

Roll vehicle forward

Note

Remove fore wheel chock, Move vehicle to position necessary to place onto lift

Move vehicle onto lift

Note

Ensure positioning allows rear doors to open, NOTE: If burning odors, popping sounds, flames, or smoke is seen at any time, halt this process and call the fire department immediately! Begin evacuation if vehicle is in the shop.

Install Universal Lift Pad adapters

Note

4x Adapters, Remove original lift pads from lift arms then install respective adapter, Remove plugs from BIW holes, Align pins with lift point holes on body

Raise and support vehicle

Note

If vehicle powered on set air suspension to "Jack Mode", (Cybertruck Rockers Off Step) Align lift adapter pins with lift point holes on body, Slightly lift body but wheels remain touching ground

Remove fastener covers from bed floor assembly

Note

6x covers

Remove bed floor assembly

Note

10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance

Remove bolts securing HV battery to RUB

Note

4x bolts, 21mm, 115 Nm, Break free before using power tools, Tonneau slats must be closed or removed to access forward bolts, Shown without tonneau for clarity

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

Remove bolt securing busbar HV connector lid

Note

1x bolt, EP10, 9 Nm

Remove bolts securing HV connector to DC FC header

Note

2x bolts, 10mm, 9 Nm

Release HV connector from DC FC header

Note

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

Support HV Busbar assembly

Note

1X Bungee, Suspend assembly to maintain clearance, wrap bungee around busbar assembly to achieve required cord length, Connect bungee to tie down hook on bed side

Raise vehicle fully

Note

Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting

Position coolant drain container underneath RH rear of HV battery

Remove the RH rear wheel. See Wheel Assembly (Remove and Install)

Secure RH rear wheel liner aside

Disconnect RDU return hose from PT return hose

Note

1x spring clip, 1x clamp clip, Move wheel liner aside as needed, Plug coolant connections as needed

Disconnect coolant hoses from PCS coolant inlet and outlet couplers

Note

1x spring clip, Plug hoses and let coolant fully drain from PCS HV battery outlets before moving drain container.

Move coolant drain container to front right of HV battery

Remove the RH front wheel. See Wheel Assembly (Remove and Install).

Secure RH front wheel liner aside

Disconnect PT supply and return hoses

Note

2x spring clips, Plug hoses, Hose connections located at RH front side of the vehicle

Disconnect battery coolant supply and return hoses

Note

2x spring clips, Hose connections located in the Front Center of the HV Battery, Use caution with pick near HV harness, Plug Hoses, Position coolant drain as needed

Remove coolant drain container from underneath vehicle

Release A/C compressor HV harness from HV battery

Note

1x locking connector, 4x clips, Pull down red locking tab and disengage the release lever, Do not force the release lever up, Number of connections may vary by vehicle configuration

Release RDU HV harness from HV battery

Note

1x connector, Release locking tab and rotate release lever up, Do not force release lever up, Ensure alignment tabs on header are not damaged, NOTE: During HV battery assembly replacement transfer HV battery dummy plugs to new HV battery pack assembly as needed

Position battery table under vehicle

Note

Ensure table is level, center table to HV battery

Remove front exterior HV Battery mounting bolts and ground strap

Note

6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm, Ensure ground strap is clear of battery

Remove side exterior HV battery mounting bolts from LH and RH side

Note

16x bolts, 15mm, 60 Nm

Raise vehicle away from HV battery

Note

Ensure no coolant hoses, harnesses, or brake lines are caught while lifting, If lift is shorter then remove rear wheels as needed

Remove HV battery from underneath vehicle

Note

Recommend assistance

Connect coolant Drain and Fill Adapter to PCS inlet hose coupling

Note

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

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)

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

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

Open valve on PCS Drain adapter

Connect shop air to regulator

Note

Make sure regulator valve is closed prior to connecting shop air

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

Note

Allow coolant to drain

Close valve on pressure regulator once no more coolant is draining

Close valve on PCS Drain adapter

Remove cart drain hose from PCS Drain adapter

Remove PCS Drain adapter from PCS outlet

Note

1x spring clip

Disconnect coolant hose extension from Drain and Fill adaptor

Note

Press grey button to release hose fitting

Remove PT Flush adapter from PCS inlet coupling

Note

1x spring clip

Attach coolant cart flush hose to HV battery

Note

Remove plugs as required, Verify fully seated, Perform push-pull-push test, Verify regulator valve is closed, Pressure regulator is not adjustable (set at 20 psi), Hose is still attached to cart at this point

Attach PCS drain adapter to HV battery hose coupling using male-to-male adapter

Note

Verify valve is closed, Verify fully seated, Remove plugs as required, Perform push-pull-push test, Connect to coolant drain

Open valve on P2 Battery Drain adapter

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

Note

Allow coolant to drain

Close valve on pressure regulator once no more coolant is draining

Disconnect compressed air from coolant pressure tester

Close valve on P2 Battery drain adapter

Remove cart drain hose and PCS drain adapter from HV battery

Remove cart flush hose and PCS flush adapter from battery

Remove powertrain hose bundle

Note

1x spring clip, 6x clips, Release hose from PCS fitting

Obtain HV battery vitals screenshot

Note

Reference steps in 16018725

Attach HV battery H-frame to gantry and raise into position

Secure the P2 battery sling adapter to H-frame

Note

4x anchor hooks, Install hooks, Verify anchor hooks are fully tightened and secured, Be aware and do not install anchors hooks in a manner which will cause the adapter sling to bind or twist

Remove top housing from new HV battery crate

Note

Recommend assistance

Position gantry over HV battery crate

Note

Recommend assistance

Lower H-frame to HV battery crate

Secure P2 sling adapter to HV battery

Note

6x locking joints, The hoist is color coded and will come with instructions, Verify all the locking joints are fully secured, Perform push and pull test, If not properly secured the top pin will be recessed, Take care to secure properly and safely

Lift new HV battery out of crate

Move gantry away from HV battery crate

Note

Recommend assistance

Position unused HV battery table under gantry

Lower HV battery onto battery table

Release P2 battery sling adapter from HV battery

Note

6x locking joints, Push down on top pin to release

Remove HV battery and table from under gantry

Note

Recommend assistance

Position old HV battery and table under gantry

Note

Recommend assistance

Secure P2 sling adapter to HV battery

Note

6x locking joints, The hoist is color coded and will come with instructions, Verify all the locking joints are fully secured, Perform push and pull test, If not properly secured the top pin will be recessed, Take care to secure properly and safely

Raise HV battery off of battery table

Remove empty HV battery table from under gantry

Position gantry over HV battery crate

Note

Recommend assistance

Lower old HV battery into crate

Note

Recommend assistance, Use caution to align HV battery into crate and do not damage the battery

Remove ancillary HV dummy plugs from old HV battery pack

Note

2x plugs, Release red locking tab then release black lock

Release P2 battery sling adapter from HV battery

Note

6x locking joints, Push down on top pin to release

Raise gantry and H-frame from crate

Secure top housing onto HV battery crate

Note

Recommend assistance, Adhere to proper MRB process

Return gantry to position and remove HV battery H-frame from gantry

Remove FDU HV harness

Note

12x bolts, 10mm, 11 Nm, NOTE: FDU HV harness on new HV battery may not be necessary for vehicle configuration (i.e. RWD) Transfer to new HV battery pack as needed

Apply backbone harness abrasion protection

Note

6x abrasion tape strips, Apply narrow patch to forwardmost position between should bracket ribs, Refer to image for clarity, Skip step if abrasion protection already present and installed correctly, Wide patch dimensions: 50mm wide, 150mm long, Narrow patch dimensions: 25.4mm wide, 235mm long

Install ancillary HV dummy plugs onto new HV battery pack

Note

2x plugs, Secure black lock then secure red locking tab

Install Voss plug into scuba passthrough on new HV battery pack assembly

Note

1x plug, 8Nm, Install as needed

Install powertrain hose bundle

Note

1x spring clip, 6x clips, Perform a push-pull-push test to ensure hose is fully seated

Install HV battery alignment rods into front casting

Note

4x alignment rods, Hand tight, Install 2x larger rods onto front casting, Install 2x smaller rods onto seat stancion mounting holes on pack, New battery packs may not yet have threads in the required holes. Suggest installing bolt to create threads prior to rod installation, It is not recommended to use any holes other than instructed

Lower vehicle onto HV battery

Note

Ensure no coolant hoses, harnesses, or brake lines are caught while lowering, Recommend assistance to ensure good alignment whilst lowering

Install side exterior HV battery mounting bolts onto LH and RH side

Note

16x bolts, 15mm, 60 Nm

Remove HV battery alignment rods from front casting

Note

2x alignment rods

Install front exterior HV Battery mounting bolts and ground strap

Note

6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm

Raise vehicle away from battery table

Note

Set to a comfortable working height, Ensure lift is lowered onto a lock

Remove battery table from under vehicle

Connect FDU HV harness to front Drive Unit

Note

1x connector, 1x bolt, 10mm, 10 Nm, Ensure locking tab engages

Secure A/C compressor HV harness onto battery

Note

1x locking connector, 4x clips, Engage locking tab, Do not force lever up, Number of connections may vary by vehicle configuration

Secure RDU HV harness to HV battery

Note

1x connector, 1x harness clip, Ensure locking tab is engaged, NOTE: During HV battery assembly replacement transfer HV battery dummy plugs to new HV battery pack assembly as needed

Position coolant drain container underneath RH rear of HV battery

Connect RDU return hose to PT return hose

Note

1x spring clip, Remove coolant plugs, Pull back wheel liner as required, Perform a push-pull-push test to ensure hose is engaged, Hose connection located at RH rear of HV Battery

Connect RDU supply hose to HV Battery

Note

1x spring clip, Remove coolant plugs, Perform a push-pull-push test to ensure hose is engaged

Move coolant drain container to front right of HV battery

Connect PT supply and return hoses

Note

2x spring clips, Remove plugs, Perform a push-pull-push test to ensure hose is engaged, Hose connections located at RH front of HV Battery

Connect battery supply and return coolant hoses

Note

2x edge clips, 2x spring clips, Remove plugs, Secure edge clips to casting, Perform a push-pull-push test to ensure hose is engaged, Hose connections located at center of battery front edge

Remove coolant drain container from underneath vehicle

Install the rear skid plate. See Skid Plate - Rear (Remove and Install).

Install the skid plate stamping. See Skid Plate Stamping (Remove and Replace).

Install the skid plate. See Skid Plate (Remove and Install).

Install the RH front and rear wheels. See Wheel Assembly (Remove and Install).

Install bolts securing HV battery to RUB

Note

4x bolts, 21mm, 115 Nm, Tonneau must be closed or removed to access forward bolts, Shown without tonneau for clarity

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. https://service.tesla.com/en-US/documents

Put on HV insulating gloves and leather over gloves

Clean contact surface of HV DC inlet posts

Note

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

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

Apply Penetrox onto HV DC Inlet posts

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

Install busbar onto HV header and install bolts

Note

2x bolts, 10mm, 9 Nm

Connect HV ancillary harness

Note

1x connector, Slide black lever to engage then push in red locking tab, NOTE: Transfer dummy plugs to new HV battery pack as needed.

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 0.005 mΩ (5 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

Install bolt securing busbar HV connector lid

Note

1x bolt, EP10, 9 Nm

Remove leather over gloves and HV insulating gloves

Note

HV gloves should always be stored in the original packaging and inside a storage box or bag to prevent damage, Make sure that gloves are lying flat not bent or folded

Connect ancillary bay MV connector

Note

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

Install bed floor assembly

Note

12x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Recommend assistance

Install fastener covers onto bed floor assembly

Note

14x covers

Position wheel chocks fore and aft of RH rear wheel

Remove vehicle from lift

Note

Lower rack arms fully and remove them from under vehicle,

Roll vehicle rearward

Note

Position vehicle so front doors can be fully opened, Chock wheels once vehicle is in desired position

Install backbone harness

Note

6x harness clips, Push harness through to 1st row

Inspect for presence of backbone harness guide at front casting

Note

Ensure backbone harness guide is installed

Secure front section of backbone

Note

3x clips, Route connector under cabin floor harness

Inspect backbone harness for misalignment near rear ribs

Note

Ensure cable is lying flat without twist, Ensure cable is secured correctly to rib, Apply surface protection at seam of rearmost rib under backbone cable if missing

Install 2nd row floor Y-Duct

Note

1x clip, Maneuver into position then secure to passenger side duct

Connect backbone harness to rear MV controller

Note

1x connector, 1x bolt, 8mm, 6 Nm, Push backbone connector housing into plastic locking cover, Ensure connector housing is secured to locking frame with a push-pull-push test, Ensure connectors are aligned before securing bracket, Secure locking cover bolt by hand initially to prevent thread stripping Plastic Locking Cover Use hand tools on any plastic locking covers, The locking cover may secure crooked causing it to get stuck, release bolt a few turns to loosen the tension then secure bolt while assist plastic locking cover by gently pushing on the side that's stuck, Push connectors too while driving the locking cover bolt to ensure correct seating Metal Locking Cover You can use power tools, Slowly drive locking cover, Ensure locking cover and bolt are seated fully

Install cabin floor harness

Note

2x connectors, 5x clips, 2x bolts, 10mm, 10 Nm, Secure connector housings to seat riser crossmembers, Secure locking levers on RCM connectors

Position RCM for installation

Install RCM to HV battery assembly

Note

3x nuts, 10mm, 10 Nm, Install new nuts

Secure connectors onto RCM

Note

2x connectors, Engage locking tabs

Install RH 2nd row floor duct

Note

1x clip, Align floor duct with Y duct then push inward to engage

Connect rear display connector to car computer

Note

1x connector

Secure cabin floor and backbone harnesses onto RH MV controller

Note

1x connector, 1x backbone cable, 2x edge clips, 3x harness clips, Push from edges of connector housing, Avoid bending ribbon cable at a tight radius

Secure RH MV controller connector locking cover

Note

1x bolt, 8mm, 6 Nm, Ensure connector housing is secured to locking frame with a push-pull-push test, Ensure connectors are aligned before securing bracket, Secure locking cover bolt by hand initially to prevent thread stripping Plastic Locking Cover Use hand tools on any plastic locking covers, The locking cover may secure crooked causing it to get stuck, release bolt a few turns to loosen the tension then secure bolt while assist plastic locking cover by gently pushing on the side that's stuck, Push connectors while driving the locking cover bolt to ensure correct seating Metal Locking Cover You can use power tools, Slowly drive locking cover, Ensure locking cover and bolt

Secure floor harness onto LH MV controller

Note

1x connector, 1x clip, Secure in locking cover

Secure LH MV controller dry side locking cover

Note

1x bolt, 8mm, 6 Nm, Tilt MV controller as needed, Secure locking cover bolt by hand initially to prevent thread stripping, Plastic Locking CoverUse hand tools on any plastic locking covers, The locking cover may secure crooked causing it to get stuck, release bolt a few turns to loosen the tension then secure bolt while assist plastic locking cover by gently pushing on the side that's stuck, Push connectors too while driving the locking cover bolt to ensure correct seating, Metal Locking CoverYou can use power tools, Slowly drive locking cover, Ensure locking cover and bolt are seated fully, Video uses rear controller for demonstration purposes only

Install RH interior front HV battery mounting bolts

Note

3x bolts, 24mm, 160 Nm

Install RH carpet support foam

Note

Seat at rear edge

Install LH front interior HV Battery mounting bolts

Note

3x bolts, 24mm, 160 Nm

Install LH carpet support foam

Note

Seat at rear edge

Install 2nd row dual duct on rails

Note

Maneuver as needed through foam insert

Install floor jumper duct

Note

2x clips

Install center console riser duct

Note

2x clips, Install from front of riser assembly, Replace any missing or damaged clips

Install center floor lower support bracket

Note

4x clips, Replace any missing or damaged clips

Install center floor upper bracket

Note

2x push clips, 4x clips

Install RH front cabin carpet

Note

Plastic portions at rear of carpet need to clear risers

Install LH front cabin carpet

Note

Plastic portions at rear of carpet need to clear risers

Install rear carpet assembly

Note

4x clips, 6x datums, Secure center foams and datums, Secure stands at center console then secure stands around LH and RH floor ducts, Fully tuck carpet under risers and trim, Replace any missing or damaged clips

Install LH seat riser assembly

Note

4x bolts, 13mm, 40 Nm, 8x clips, release cabin MV harness, attach cabin HV outlet harness and air duct to seat riser

Install LH outboard riser bolt cover

Install RH seat riser assembly

Note

4x bolts, 13mm, 40 Nm, 3x clips, Attach cabin MV harness and air duct to riser assembly

Install RH outboard riser bolt cover

Install LH rear carpet duct bezel

Note

4x clips, Replace any missing or damaged clips

Install rear carpet RH duct bezel

Note

4x clips, Replace any missing or damaged clips

Position center console in vehicle

Note

Lower onto riser

Connect center console harness connectors

Note

2x connectorsConnectors located toward the bottom on the front of the center console

Install front bolts securing center console to riser

Note

4x bolts, 10mm, 5 Nm

Install center console front panel

Note

10x clips, Replace any missing or damage clips

Install rear bolts securing center console to riser

Note

2x bolts, 10mm, 5 Nm

Install center console rear panel

Note

10x clips, 3x connectors, 3x harness clips, Replace any missing or damaged clips

Position LH front seat into vehicle

Note

Recommend assistance and position seat through rear seat, Be cautious not to damage surrounding components while lifting the seat into the vehicle, Seat bolts will be installed on a later step

Connect LH front seat harness

Note

1x connector, 2 stage locking tabs, Make connection and engage black lever, then engage yellow locking tab

Position RH front seat into vehicle

Note

Recommend Assistance and position seat through rear door, Be cautious not to damage surrounding components while lifting the seat into the vehicle, Seat bolts will be installed on a later step

Connect RH front seat harness

Note

1x connector, 2 stage locking tabs, Make connection and engage black lever, then engage yellow locking tab

Remove HV battery alignment rods from stancion mounting holes on pack

Note

2x alignment rods

Install RH rear interior HV battery mounting bolts

Note

4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts

Install LH rear interior HV battery mounting bolts

Note

4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts

Install rear wall lower trim

Note

2x push clips, 4x clips

Secure LH lower C-pillar trim

Note

1x clip, 1x datum

Fold down 2nd row 60 seat

Note

Pull tether to release then pivot down until locked in place

Install RH lower C-pillar trim

Note

1x clip, 1x datum

Fold down 2nd row 40 seat

Note

Pull tether to release then pivot down until locked in place

Install 2nd row floor mat

Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).

Select 'High Voltage Procedures

Note

Lighting Bolt Icon > High Voltage > Procedures

Select 'HV Battery Replacement Procedure'

Note

Lightning Bolt Icon > High Voltage > Procedures > High Voltage Battery Replacement

Run ODIN routine UPDATE_CAN-REDEPLOYvia Service Mode Plus:

Drive Inverter Replacement ➜ Drive Inverter DIRE1L Replacement ➜ CAN Redeploy
Drive Inverter Replacement ➜ Drive Inverter DIRE1R Replacement ➜ CAN Redeploy
Drive Inverter Replacement ➜ Drive Inverter DIRE2 Replacement ➜ CAN Redeploy
Drive Inverter ➜ Front Drive Inverter Replacement ➜ CAN Redeploy
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ CAN Redeploy
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ CAN Redeploy
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ CAN Redeploy
Drive Unit ➜ Front Drive Unit Replacement ➜ CAN Redeploy
Drive Unit ➜ Rear Drive Unit Replacement ➜ CAN Redeploy
Thermal ➜ HVAC ➜ CAN Redeploy
chassis ➜ DPB Post Replacement ➜ CAN Redeploy
chassis ➜ ESP Post Replacement ➜ CAN Redeploy
chassis ➜ IDB Post Replacement ➜ CAN Redeploy
chassis ➜ RCU Post Replacement ➜ CAN Redeploy
chassis ➜ ESP Replacement Panel ➜ CAN Redeploy
chassis ➜ IBST Replacement Panel ➜ CAN Redeploy

via Toolbox:(link)

Select 'HV Battery Replacement Procedure'

Note

Lightning Bolt Icon > High Voltage > Procedures > High Voltage Battery Replacement

Remove vehicle from lift

Note

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

Remove Universal Lift Pad adapters

Note

4x Adapters, Install original lift pads, Install plugs back into holes in BIW

Run ODIN routine PROC_EGGRIGHT3_X_THERMAL-FILL-DRAIN-STOPvia Service Mode:

Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain

via Service Mode Plus:

Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain

via Toolbox:(link)

Run ODIN routine PROC_EGGRIGHT3_X_THERMAL-COOLANT-AIR-PURGE-STARTvia Service Mode Plus:

Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge

via Toolbox:(link)

Install the RH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).

Install the RH rear step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).

Install the RH rocker cover to rocker carrier. See Rocker Panel Assembly - LH (Remove and Install)

Secure RH front seat belt to pretensioner

Note

Ensure the lock screw is in the horizonal position. If it is not, unlock it by following the linkage removal instructions.Slide the linkage onto the pretensioner cable, an audible click will be heard, and the screw should rotate to the locked position. Verify there are no twists in the webbing from the upper trim to the pretensioner. Perform a firm pull test with at least 15 pounds of force.

Move RH front seat backward

Install bolts securing RH front seat front tracks to vehicle

Note

2x patch bolts, T45P, 34 Nm, Install new bolts

Install center floor trim

Note

17x clips, Replace any missing or damaged clips, Install lower section first

Install RH center floor rail

Note

4x clips, 3x datums

Install RH lower A-pillar trim

Note

7x clips, 3x datums, 2x tabs

Install RH mid A-pillar trim

Note

1x clip, 3x tabs, Replace any missing or damaged clips

Install RH front floor mat

Move RH front seat forward

Install bolts securing RH front seat rear tracks to vehicle

Note

2x patch bolts, T45P, 34 Nm, Install new bolts

Install the LH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).

Install the LH rear step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).

Install the LH rocker cover to rocker carrier. See Rocker Panel Assembly - LH (Remove and Install)

Secure LH front seat belt to pretensioner

Note

Ensure lock screw is in horizontal position, slide linkage onto pretensioner cable, audible click when screw rotates to locked position, verify no twists in webbing, perform firm pull test with 15 pounds of force