03/12/2024 09:59:05

Power Conversion System (Remove and Replace)

Correction code 1630010081 1630010082 FRT 4.08 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and 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. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 2024-12-03: Restructured procedure to not remove PCS coolant hose bundle, only moving hoses aside.
  • 2024-11-22: Added warning to NOT skip steps to remove the tonneau slats.
  • 2024-08-14: Added/rearranged steps according to latest time study.
  • 2024-07-08: Added step to install zip tie onto PCS MV connector.
  • 2024-05-14: Added install/remove steps for ancillary access bench.
  • 2024-04-10: Updated steps to disconnect and connect the PCS MV connector.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Cybertruck electronics are powered by a 48V "mid voltage" or "MV" architecture that is designed to improve efficiency. Servicing MV components requires extra knowledge and care in order to avoid personal and/or vehicular harm. Read and understand MV precautions in Electrical Precautions and make sure any required MV-related training courses have been completed, as applicable.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
DO NOT SKIP the steps to remove the tonneau slats. Work on or around the ancillary bay REQUIRES the removal of the tonneau slats. Failure to remove the tonneau slats while working on or around the ancillary bay will result in conditions that may cause personal injury.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
  3. Remove the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  4. Remove the tonneau NVH barrier. See Tonneau - Tonneau NVH Barrier Assembly (Remove and Install).
  5. Remove the screws (x8) that attach the tonneau coverbox cross supports.
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Torx T25 socket
  6. Clean all debris from the ancillary cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    During the removal of the ancillary cover, any debris on top of the cover may be deposited into the ancillary bay.
  7. Release the pressurize pack air line from the ancillary.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not release air line to the reservoir. Rapid loss of pressure will result if the wrong air line is released.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 connector
  8. Remove the VOSS fitting from the Pressurize Pack air line to the ancillary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the threaded section back, remove the collet, and then slide the threaded section off of air line. Discard after removal.
  9. Disconnect the electrical connector, and then remove the bolt that attaches the pressurize pack valve block to the air suspension reservoir.
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 clip, x1 zip tie
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the lock before disengaging the connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Cut the zip tie at the reservoir/ancillary air line bundle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the harness clip at the bracket.
  10. Release the air suspension valve block.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 rubber grommets
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate clockwise until the top 2 rubber feet have released from the bracket. Pull upwards at a 45 degree angle to release the bottom rubber foot from the bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Leave all air lines and connections secured, and then set the assembly aside.
  11. Remove the nuts (x2) that attach the air suspension reservoir to the body.
    33 Nm (24.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 fir tree clips
  12. Put the air suspension reservoir in service position, and then install the Ancillary Access Bench (2035746-00-A).
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise and swing the air suspension reservoir to the side of the bed.
  13. Open the powered frunk.
  14. Place the vehicle into Service Mode. See Service Mode.
  15. Unlock the vehicle Gateway. See Gateway (Unlock).
  16. On the vehicle touchscreen, navigate to Service Mode > Thermal > Actions to access the thermal system routines.
  17. Touch Coolant System to enter the coolant circuit screen. Touch Coolant Fill/Drain using the vehicle touchscreen, and then the PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTvia Toolbox: (link)via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Start Coolant Fill/Drain
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Start Coolant Fill/Drain
    window will appear. Touch Run.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify indicator displays green for Coolant readiness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Thermal Fill Drain routine has a 50 minute time limit.
  18. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  19. Disconnect MV power. See Disconnect MV Power.
  20. Verify operation of multimeter
    Informational PurposesAn informational icon, calling your attention
    Note
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
  21. Remove the mid aero shield. See Undertray - Mid Aeroshield (Remove and Install).
  22. Disconnect the pressurized pack lines.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 VOSS fittings, 12 mm, 8 Nm.
  23. Remove the VOSS fitting from pressurized pack air lines.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 VOSS fitting
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the threaded section back, remove the collet, and then slide the threaded section off of air line. Discard after removal.
  24. Remove all items from pockets and ensure not wearing metal items
  25. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
  26. Put on the HV insulating gloves and leather over gloves.
  27. Verify no HV - Install amp clamp to RDU HV harness.
    Informational PurposesAn informational icon, calling your attention
    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 required If 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 damaged Make 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
  28. Secure the RDU header connector to the ancillary.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 connector
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify the lever is in the upright and open position. Carefully seat connector and allow the lever to engage. Fully secure the lever and verify that the red tab is locked.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage any pins.
  29. Remove the pyro access cover. See High Voltage Battery Assembly - Pyro Access Cover, HVB (Remove and Install).
  30. Remove the primary and secondary pyro fuses. See Disconnect, Pyro (Remove and Install).
  31. Remove the leather over gloves and HV insulating gloves.
  32. Position the coolant drain container underneath RH rear of the HV battery.
  33. Remove the spring clips and disconnect the rear PT supply and RDU supply hoses, and then immediately plug all the fittings to prevent excess coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug the coolant connections as needed. If the PCS is being replaced, then allow the coolant to drain.
  34. Secure PT Flush adapter to PCS inlet hose coupling.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove plugs as required. Verify fully seated. Perform push-pull-push test.
  35. Secure coolant cart flush hose to regulator and PT Flush adapter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify regulator valve is closed. Pressure regulator is not adjustable (set at 20 psi).
  36. Secure PCS Drain adapter to PCS outlet using male-to-male adapter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify valve is closed. Remove plug as required. Verify fully seated. Perform push-pull-push test.
  37. Secure coolant cart drain hose to PCS drain adapter and coolant drain container.
  38. Open valve on PCS Drain adapter.
  39. Connect shop air to regulator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure regulator valve is closed prior to connecting shop air.
  40. Slowly open valve on pressure regulator and allow coolant to drain out of HV battery.
  41. Close valve on pressure regulator once no more coolant is draining
  42. Close valve on PCS Drain adapter.
  43. Remove cart drain hose from PCS Drain adapter.
  44. Remove PCS Drain adapter from PCS outlet.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  45. Remove cart flush hose from PT Flush adapter.
  46. Remove PT Flush adapter from PCS inlet coupling.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  47. Remove the coolant drain container from underneath the vehicle.
  48. Lower the vehicle until the tires are touching the ground.
  49. Disconnect the ancillary bay MV electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Double locking. Release the tab, and then pivot the lever. Release the second tab to disengage the electrical connector. Wait 1 second between locking tab release to discharge and prevent arcing.
  50. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
  51. Put on the HV insulating gloves and leather over gloves.
  52. Remove the bolt that attaches the busbar HV connector lid.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  53. Remove the bolts (x2) that attach the HV connector to the DC FC header.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  54. Release the HV connector from the DC FC header, and then use an inflatable airbag to suspend the busbar assembly above the ancillary assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Upon separation, check for grease around the inner perimeter of the DC FC header. If present, additional steps will need to be performed later.
  55. Support the HV busbar assembly to maintain clearance with a bungee cord.
  56. Remove the bolts (x2) that attach the fast charger header doubler.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  57. Remove the bolts (x2) that attach the low voltage header.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  58. Remove the bolts (x22) that attach the ancillary cover to the HV battery.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Informational PurposesAn informational icon, calling your attention
    Note
    Use E10 5-Lobe socket without magnet.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts are captive and will stay attached to the ancillary cover. Follow fastening order.
  59. Remove the ancillary cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a suction cup and maneuver around the busbar and the tonneau cage.
  60. While supporting the harness end of the PCS MV connector, press the release, and then slide the red lock plate away from the black handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not slide the red lock plate without supporting the PCS MV connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    If installed, cut and discard the zip ties before releasing the connector.
  61. Continue to support the harness end of the PCS MV connector, raise the black handle to its vertical position to release, and then pull straight up on the black handle to disconnect the PCS MV connector from the MV header of the PCS.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The MV header can break internally if the PCS MV connector is forced or torqued off center of the MV header. Do not press, twist, or pry the harness end of the PCS MV connector.
  62. Remove the bolt that attaches the PCS MV harness to the vehicle, and then release the harness clips (x2).
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  63. Release the connector lock, and then gently pull the PCS to device cluster HV electrical connector upward to disconnect it.
  64. Release the connector lock, and then gently pull the ACJB to PCS electrical connector upward to disconnect it.
  65. Release coolant hose bundle from PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x hoses, 2x spring clips. Plug coolant connections as needed.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built before December 22, 2023 will have clear collar with zip tie connections. If vehicle has older revision hose then proceed to PCS Coolant Hose Bundle replacement procedure.
  66. Remove bolts securing PCS
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, Bolts are captive and will stay attached, Follow fastening order
  67. Remove PCS from ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x datum, Maneuver PCS around coolant hoses, Remove plugs as needed.
  68. If grease was found around the inner perimeter of the DC FC header, use a disposable towel to wipe the grease off the header and the busbar connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not allow the grease to contact the busbar HV mating surfaces.

Install

  1. Install PCS onto ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x datum, Maneuver PCS around coolant hoses, Plug coolant connections as needed.
  2. Install bolts securing PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, Bolts are captive and will stay attached, Follow fastening order
  3. Lubricate O-rings on PCS coolant hose bundle.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x O-rings, Inspect before installation for any damage and replace as needed
  4. Secure coolant hose bundle onto PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x hoses, 2x spring clips, Remove plugs as needed, Vehicles built before December 22, 2023 will have clear collar with zip tie connections, If vehicle has older revision hose then proceed to PCS Coolant Hose Bundle replacement procedure
  5. Connect the HV electrical harness connector from the ACJB to the PCS, and then engage the connector lock.
  6. Connect the HV electrical connector from the device cluster to the PCS, and then engage the connector lock.
  7. Secure PCS MV harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, EP10, 6 Nm, 2x clips
  8. Raise the black handle of the PCS MV connector so that it is at 90 degrees to the body of the connector.
  9. Position the PCS MV connector over the MV header so that the red positive lead of the connector is closest to the edge of the PCS and over the text "LV+" scribed on the PCS cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    The MV header is symmetrical, and it is possible to connect the PCS MV connector backwards.
  10. Holding only the electrical harness and the black handle, connect the PCS MV connector to the MV header.
  11. Use two fingers centered directly over the pins of the MV header (under the arch of the black handle) to press and hold the PCS MV connector to the MV header, and then carefully lower the black handle until it is flat.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The MV header can break internally if the PCS MV connector is forced or torqued off center of the MV header. Do not press, twist, or pry to the harness end of the PCS MV connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Ensure the correct orientation and polarity of the connection. Harness color red for LV+ and black for LV-.
  12. Install zip ties (x2) onto the PCS MV connector to secure the black lever to the red connector lock.
    Informational PurposesAn informational icon, calling your attention
    Note
    Feed the zip ties under the black lever and through the red connector lock opening, and then fasten the zip tie.
  13. While supporting the harness end of the PCS MV connector, slide the red lock plate to the black handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not slide the red lock plate without supporting the PCS MV connector.
  14. Inspect the PCS MV connector that it is not tilted, but is parallel to the top surface of the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the PCS MV connector is tilted, there may be damage to the MV header inside the PCS. This damage may cause the PCS to go MIA, or deassert the DCDC enable line. Check for respective alerts and faults.
  15. Remove leather over gloves and HV insulating gloves
  16. Fully raise the vehicle.
  17. Position the coolant drain container underneath the RH rear of the HV battery.
  18. Remove one PCS coolant header plugs and connect the leak test adapters from the Coolant Hose Plug Kit (1135762-00-A).
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 spring clips
    Informational PurposesAn informational icon, calling your attention
    Note
    Leave the coolant plugs in supply and return lines. Secure the 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 then secure to other coolant header port.
  19. Attach the coolant pressure tester to the pressure fitting adapter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Confirm the hose is screwed securely tight.
  20. Attach the coolant pressure tester to the compressed air line.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the valves are closed on the pressure regulator.
  21. Open the regulator valve, and then slowly adjust the regulator to 50 psi.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use caution as coolant may spill.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear safety glasses.
  22. Slowly open the second valve.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slowly open the valve on pressure regulator, and then allow the pressure to reach specification.
  23. Close the valve and let pressure settle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wait 2 minutes for the pressure to settle, and then record the reading.
  24. Set timer for 2 minutes and select start.
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset.
  25. Perform the coolant pressure leak test.
    Informational PurposesAn informational icon, calling your attention
    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.
  26. Close both valves.
  27. Remove the coolant pressure tester from the pressure fitting adapter.
  28. Remove the coolant pressure tester adapter from the PCS coolant header.
  29. Secure the rear PT supply and RDU supply hoses to the PCS coolant header.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 spring clips
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the locking tabs are fully seated. Perform a push-pull-push test.
  30. Remove the coolant drain container from underneath vehicle.
  31. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting the HV gloves.
  32. Put on the HV insulating gloves and leather over gloves.
  33. Clean the mating surface of the pyro.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a non-conductive plastic tool to clean the busbar side. Allow 1 minute for the Isopropyl Alcohol (IPA) to fully dry.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use any other types of cleaner.
  34. Install the primary and secondary pyro fuses. See Disconnect, Pyro (Remove and Install).
  35. Remove the leather over gloves and HV insulating gloves.
  36. Install new VOSS fittings and nut to the pyro cover.
    8 Nm (5.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 12 mm 12-point deep socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 VOSS fittings
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the VOSS plastic plug until the pressurized pack line installation.
  37. Install the bolts (x4) that attach the pyro fuse access cover.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the seal is fully seated and undamaged.
  38. Install the pressurized pack lines (x2).
    8 Nm (5.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 12 mm 6 point flare nut wrench
    • 12 mm flare nut crowfoot socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 VOSS fittings
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the plastic caps from the VOSS fittings. Press the air lines into the fitting until the mark aligns with the top of the fitting. Verify the line is properly secured by performing a push-pull test.
  39. Install the mid aero shield. See Undertray - Mid Aeroshield (Remove and Install).
  40. Fully lower the vehicle.
  41. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
  42. Put on HV insulating gloves and leather over gloves
  43. Install the ancillary cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a suction cup.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver around the busbar and tonneau cage.
  44. Install the bolts (x22) that attach the ancillary cover to the HV battery.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Informational PurposesAn informational icon, calling your attention
    Note
    Use E10 5-Lobe socket without magnet.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts are captive and will stay attached to the ancillary cover. Follow fastening order.
  45. Install the bolts (x2) that attach the low voltage header.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  46. Install the bolts (x2) that attach the fast charger header doubler.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  47. If grease was found inside the DC FC header, prepare the grease gun with Mobil XTCE grease, apply a 6 mm diameter continuous bead around the DC FC header inner perimeter, and then use a gloved finger wetted with alcohol to smear the grease up the inner wall to a height of 10 mm.
    Informational PurposesAn informational icon, calling your attention
    Note
    The grease is part number 1089958-00-A and is available from eProcurement.
  48. Clean the HV connector contact surface of residual Penetrox with IPA wipe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox.
  49. Clean the busbar HV connector contact surface of residual Penetrox with IPA wipe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is necessary to clean the HV connector during re-use of the busbar.
  50. Apply Penetrox onto the HV connector joints.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply 2 drops of Penetrox A-13 about 5 mm in diameter to either side of the hole on both leads. Spread evenly to verify the contact surface is fully covered.
  51. Position the busbar connector, and then lower it onto the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the bungee cord.
  52. Install the bolts (x2) that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket (insulated)
  53. Perform a Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 HV joints
    Informational PurposesAn informational icon, calling your attention
    Note
    When using a Hioki tester, verify the meter has been properly adjusted and set prior to usage.
    Informational PurposesAn informational icon, calling your attention
    Note
    The 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), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
    • 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), the Hioki test passed. proceed to the next step.
  54. Install the bolt that attaches the busbar HV connector lid.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Early vehicle builds may be equipped with a 10 mm fastener.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • EP10 socket or
    • 10 mm socket
  55. Connect the ancillary bay MV electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Double locking: Rotate the lever into the second lock. Perform a pull test to ensure the electrical connector is engaged correctly.
  56. Remove leather over gloves and HV insulating gloves
  57. Install the screws (x8) that attach the tonneau coverbox cross supports.
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Torx T25 socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Supports install in the same direction of the fasteners.
  58. Install the tonneau NVH barrier. See Tonneau - Tonneau NVH Barrier Assembly (Remove and Install).
  59. Remove the Ancillary Access Bench, and then put the air suspension reservoir into position for installation.
  60. Install the nuts (x2) that attach the air suspension reservoir.
    33 Nm (24.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 fir tree clips
  61. Secure the air suspension valve block.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 rubber grommets
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate counterclockwise until the top 2 rubber feet are secured onto the bracket. Push downwards at a 45 degree angle to secure the bottom rubber foot into bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position air lines and connections into place for installation.
  62. Install a new VOSS air fitting to the pressurize pack valve block at the ANC circuit.
    8 Nm (5.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 12 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 VOSS fitting
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the VOSS plastic plug until the pressurize pack line install.
  63. Secure the pressurize pack air line from the ancillary to the valve block.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 line
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the plastic cap from the VOSS fittings. Press the air lines into the fitting until the mark aligns with the top of the fitting. Verify the line is properly secured by performing a push-pull test.
  64. Install the bolt that attaches the pressurize pack valve block to the air suspension reservoir, and then connect the electrical connector.
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 clip, x1 zip tie
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the reservoir and ancillary air lines at the white marked sections.
  65. Install the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  66. Perform the cooling system vacuum refill procedure. See Cooling System (Vacuum Refill).
    Informational PurposesAn informational icon, calling your attention
    Note
    Skip steps 1 through 5, Perform step 6 and thereafter.
  67. Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  68. Using Toolbox, click the Actions tab, and then search for "Service-Redeploy".
  69. Click SERVICE CAN REDEPLOY, and then click Run. Allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Click the X at the top right of window to close once complete. Routine will state pass but update will continue to run in the background. UI will show update progress.
  70. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
  71. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.