2026-08-09

HV Harness - AC Compressor (Remove and Install)

Correction code 4450074051 4450074052 FRT 5.64 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.

  • 2024-09-18: Updated to latest time study.
  • 2024-05-22: Updated connector images and instructions for disconnect/connect.
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.
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
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
Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional glove and safety information.

Remove

  1. Open all the doors and lower all the windows.
  2. Use a pocket screwdriver to manually latch all the doors to prevent lockout.
  3. Place the vehicle into Service Mode. See Service Mode.
  4. Unlock the vehicle Gateway. See Gateway (Unlock).
  5. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
  6. Remove the LH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).
  7. Remove the LH rocker panel assembly. See Rocker Panel Assembly - LH (Remove and Install).
  8. Remove the LH rear rocker step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).
  9. Partially release LH rear primary door seal
  10. Remove the LH mid A-pillar trim. See Trim - A-Pillar - Mid - LH (Remove and Install).
  11. Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Install)
  12. Remove the footwell cover. See Cover - Footwell (Remove and Install).
  13. Remove LH front floor mat.
  14. Remove the LH center floor rail. Seee Rail - Center Floor - LH (Remove and Install).
  15. Remove the accelerator pedal side trim. See Side Trim - Pedal (Remove and Install).
  16. Remove the accelerator pedal. See Accelerator Pedal (Remove and Install).
  17. Remove LH carpet support foam
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift up from rear edge
  18. Fold back LH front cabin carpet
  19. Remove LH front interior HV Battery mounting bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 24mm, 160 Nm
  20. Temporarily install accelerator pedal
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 13mm, 10 Nm, 1x connector, Secure nuts hand tight to allow vehicle to be driven onto lift
  21. Remove the LH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Remove and Install).
  22. Remove the RH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).
  23. Remove the RH rocker panel assembly. See Rocker Panel Assembly - LH (Remove and Install).
  24. Remove the RH rear rocker step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).
  25. Remove the RH mid A-pillar trim. See Trim - A-Pillar - Mid - LH (Remove and Install).
  26. Remove the RH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Install).
  27. Remove RH front floor mat
  28. Remove the RH center floor rail. See Rail - Center Floor - LH (Remove and Install).
  29. Remove the lower center floor trim. See Trim - Center Floor - Lower (Remove and Install).
  30. Fold back RH carpet
  31. Remove RH carpet support foam
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift up from rear edge
  32. Remove RH interior front HV battery mounting bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 24mm, 160 Nm
  33. Remove the RH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Remove and Install).
  34. Move vehicle onto lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure positioning allows rear doors to open
  35. Install Universal Lift Pad adapters
    Informational PurposesAn informational icon, calling your attention
    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
  36. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Set air suspension to "Jack Mode", Align lift adapter pins with lift point holes on body
  37. Select 'Coolant System' to enter coolant circuit screen, Select 'Coolant Fill/Drain' using the UI and PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTvia Toolbox:(link) window will appear, Select 'Run'
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 50 minute time limit
  38. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  39. Remove the frunk assembly. See Frunk Assembly (Remove and Install).
  40. 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
  41. Remove the front aero shield. See Aeroshield - Front (Remove and Install).
  42. Remove the front skid plate stamping. See Skid Plate Stamping (Remove and Replace).
  43. Remove the rear skid plate. See Skid Plate - Rear (Remove and Install).
  44. Remove all items from pockets and ensure not wearing metal items
  45. 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.
  46. Put on HV insulating gloves and leather over gloves
  47. 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 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
  48. Remove leather over gloves and HV insulating gloves
  49. Lower vehicle until tires are touching the ground
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  50. Disconnect HV harness connector from AC compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking electrical connector, Pull red locking tab away from compressor then slide black lock upwards to release
  51. Fold up 2nd row 60 seat
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull tether to release then lift up until locked in place
  52. Remove 2nd row floor mat
  53. Partially release LH lower C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x datum
  54. Release LH MV controller dry side locking cover
    Informational PurposesAn informational icon, calling your attention
    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
  55. Disconnect floor harness connector from LH MV controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Depress tabs to release connector housing from locking cover
  56. Fold up 2nd row 40 seat
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull tether to release then lift up until locked in place
  57. Release RH MV controller connector locking cover
    Informational PurposesAn informational icon, calling your attention
    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
  58. Disconnect center console and backbone connectors from RH MV controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x backbone cable, 2x edge clips, Pull from edges of connector housing, Do not pull backbone cable, Avoid bending cable at a tight radius
  59. Disconnect rear display connector from car computer
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  60. Partially release RH lower C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x datum
  61. Remove rear wall lower trim
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips, 4x clips, Remove outermost push clips, then pull straight forward to release inner clips
  62. Remove RH subwoofer
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2x bolts, 13mm, 8 Nm, Slide towards center of vehicle to release outer port from body
  63. Remove RH rear interior HV battery mounting bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
  64. Disconnect backbone harness from rear MV controller
    Informational PurposesAn informational icon, calling your attention
    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
  65. Remove LH subwoofer
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2x bolts, 13mm, 8 Nm, Slide towards RH of vehicle to release outer port from body, Release locking tab
  66. Remove LH rear interior HV battery mounting bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
  67. Remove interior HV harness bulkhead cover
    Informational PurposesAn informational icon, calling your attention
    Note
    3x nuts, 10mm, 9 Nm
  68. Remove the bed floor assembly. See Bed Floor Assembly (Remove and Install).
  69. Remove the tonneau NVH barrier. See Tonneau NVH Barrier Assembly (Remove and Install).
  70. Remove bolts securing HV battery to RUB
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 21mm, 119 Nm, Break free before using power tools, Tonneau slats must be closed or removed to access forward bolts, Shown without tonneau for clarity
  71. Disconnect ancillary bay MV connector
    Informational PurposesAn informational icon, calling your attention
    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
  72. Remove bolt securing busbar HV connector lid
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, EP10, 9 Nm
  73. Remove bolts securing HV connector to DC FC header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  74. Release HV connector from DC FC header
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly
  75. Support HV Busbar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Suspend assembly to maintain clearance
  76. Disconnect HV ancillary harnesses
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Release red locking tab then slide open black lever to remove, Push cabin harness into interior
  77. Raise vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Note
    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
  78. Position coolant drain container underneath RH rear of HV battery
  79. Disconnect RDU return hose from PT return hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x clamp clip, Move wheel liner aside as needed, Plug coolant connections as needed
  80. Disconnect RDU supply hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug hoses
  81. Move coolant drain container to front right of HV battery
  82. Disconnect PT supply and return hoses
    Informational PurposesAn informational icon, calling your attention
    Note
    2x spring clips, Plug hoses
  83. Disconnect battery coolant supply and return hoses
    Informational PurposesAn informational icon, calling your attention
    Note
    2x spring clips, Use caution with pick near HV harness, Plug Hoses, Position coolant drain as needed
  84. Remove coolant drain container from underneath vehicle
  85. Disconnect pressurized pack lines
    Informational PurposesAn informational icon, calling your attention
    Note
    2x VOSS fittings, 12mm, 8Nm
  86. Release clips securing LH pressurized pack line
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  87. Release A/C compressor HV harness from HV battery
    Informational PurposesAn informational icon, calling your attention
    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
  88. Disconnect RDU HV harness
    Informational PurposesAn informational icon, calling your attention
    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
  89. Release FDU HV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x bolt, 10mm, 10 Nm, Move harness clear of subframe
  90. Position battery table
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure table is level
  91. Remove front exterior HV Battery mounting bolts and ground strap
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm, Ensure ground strap is clear of battery
  92. Remove side exterior HV battery mounting bolts from LH and RH side
    Informational PurposesAn informational icon, calling your attention
    Note
    16x bolts, 15mm, 62 Nm
  93. Raise vehicle away from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure no coolant hoses, harnesses, or brake lines are caught while lifting
  94. Remove AC compressor HV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips
  95. 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 AC compressor HV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, Ensure routing will not cause pinch or rubbing
  2. Install battery alignment rods
    Informational PurposesAn informational icon, calling your attention
    Note
    4x rods, Screw two larger rods in to front casting hand tight, Screw two smaller rods into any of the four seat stancion mounting holes on the HV battery
  3. Position rear carpet section for install
    Informational PurposesAn informational icon, calling your attention
    Note
    Insert a wheel chock under carpet section to maintain 90 degree angle
  4. Lower vehicle onto HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure no coolant hoses, harnesses, or brake lines are caught while lowering, Recommend assistance to ensure good alignment whilst lowering
  5. Install side exterior HV battery mounting bolts to LH and RH side
    Informational PurposesAn informational icon, calling your attention
    Note
    16x bolts, 15mm, 60 Nm
  6. Remove exterior battery alignment rods
    Informational PurposesAn informational icon, calling your attention
    Note
    2x alignment rods
  7. Install front exterior HV Battery mounting bolts and ground strap
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm
  8. Raise vehicle away from battery table
    Informational PurposesAn informational icon, calling your attention
    Note
    Set to a comfortable working height, Ensure lift is lowered onto a lock
  9. Remove battery table from under vehicle
  10. Install FDU HV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x bolt, 10mm, 10 Nm, Ensure locking tab engages
  11. Secure A/C compressor HV harness to battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, 4x clips, Engage locking tab, Do not force lever up, Number of connections may vary by vehicle configuration
  12. Install RDU HV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x harness clip, Ensure locking tab is engaged
  13. Install clips securing pressurized pack line
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  14. Install pressurized pack lines
    Informational PurposesAn informational icon, calling your attention
    Note
    2x VOSS fittings, 12mm, 8 Nm, Remove plastic caps from VOSS fittings if installing new fuse cover, Press air lines into fitting until mark aligns with top of fitting, Verify line is properly secured by performing push and pull test
  15. Position coolant drain container underneath RH rear of HV battery
  16. Connect RDU return hose to PT return hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Remove coolant plugs, Pull back wheel liner as required, Perform a push-pull-push test to ensure hose is engaged
  17. Connect RDU supply hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Remove coolant plugs, Perform a push-pull-push test to ensure hose is engaged
  18. Move coolant drain container to front right of HV battery
  19. Connect PT supply and return hoses
    Informational PurposesAn informational icon, calling your attention
    Note
    2x spring clips, Remove plugs, Perform a push-pull-push test to ensure hose is engaged
  20. Connect battery supply and return coolant hoses
    Informational PurposesAn informational icon, calling your attention
    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
  21. Remove coolant drain container from underneath vehicle
  22. Install the rear skid plate. See Skid Plate - Rear (Remove and Install).
  23. Install skid plate stamping. See Skid Plate Stamping (Remove and Replace).
  24. Install front aeroshield. See Aeroshield - Front (Remove and Install).
  25. Lower vehicle until tires are touching the ground
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  26. Connect HV harness connector to AC compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking electrical connector, Slide down black lock then push in red locking tab, Perform a push-pull-push test, Ensure red locking tab is fully engaged, Black tab will protrude from red locking tab when engaged correctly, Refer to images and video for clarity
  27. Install bolts securing HV battery to RUB
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 21mm, 115 Nm, Tonneau must be closed or removed to access forward bolts, Shown without tonneau for clarity
  28. Clean HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
  29. Clean busbar HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
  30. Apply Penetrox onto HV connector joints
    Informational PurposesAn informational icon, calling your attention
    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
  31. Install busbar onto HV header and install bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  32. Connect HV ancillary harnesses
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Pull through rear wall opening, Slide black lever to engage then push in red locking tab
  33. 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.
  34. Put on HV insulating gloves and leather over gloves
  35. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Informational PurposesAn informational icon, calling your attention
    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
  36. Remove leather over gloves and HV insulating gloves
  37. Install bolt securing busbar HV connector lid
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, EP10, 9 Nm
  38. Connect Ancillary bay MV connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly
  39. Install the tonneau NVH barrier. See Tonneau NVH Barrier Assembly (Remove and Install).
  40. Install the bed floor assembly. See Bed Floor Assembly (Remove and Install).
  41. Install interior HV harness bulkhead cover
    Informational PurposesAn informational icon, calling your attention
    Note
    3x nuts, 10mm, 9 Nm
  42. Inspect for any misalignment at rear ribs
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure cable is lying flat without twist, Ensure cable is secured correctly to rib
  43. Connect backbone harness to rear MV controller
    Informational PurposesAn informational icon, calling your attention
    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
  44. Inspect for presence of backbone harness guide at front casting
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure backbone harness guide is installed,
  45. Connect rear display connector to car computer
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  46. Connect cabin floor harness connector and backbone cable to RH MV controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x backbone cable, 2x edge clips, Push from edges of connector housing, Avoid bending ribbon cable at a tight radius
  47. Secure RH MV controller connector locking cover
    Informational PurposesAn informational icon, calling your attention
    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
  48. Install RH interior front HV battery mounting bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 24mm, 160 Nm
  49. Remove temporarily installed accelerator pedal
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 13mm, 10 Nm, 1x connector, Release locking tab
  50. Connect cabin floor harness connector to LH MV controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Secure in locking cover
  51. Secure left MV controller connector locking frame
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 8mm, 4 Nm, Ensure connectors are aligned before tightening center bolt
  52. Install LH front interior HV Battery mounting bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 24mm, 160 Nm
  53. Install LH carpet support foam
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat at rear edge
  54. Unfold LH front cabin carpet into position
  55. Install the accelerator pedal. See Accelerator Pedal (Remove and Install).
  56. Perform cooling system vacuum refill procedure. See Cooling System (Vacuum Refill).
  57. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  58. Select "Stop Thermal Fill Drain" through UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow routine to complete, ensure routine is successful
  59. Remove Universal Lift Pad adapters
    Informational PurposesAn informational icon, calling your attention
    Note
    4x Adapters, Install original lift pads, Install plugs back into holes in BIW
  60. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  61. Select "Start Coolant Air Purge" using the UI
    Informational PurposesAn informational icon, calling your attention
    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
  62. Remove battery alignment rods
    Informational PurposesAn informational icon, calling your attention
    Note
    4x alignment rods
  63. Install LH rear interior HV battery mounting bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
  64. Install LH subwoofer
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2x bolts, 13mm, 8 Nm, Slide towards LH of vehicle to secure outer port to body, Engage locking tab
  65. Install the LH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Remove and Install).
  66. Install RH rear interior HV battery mounting bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
  67. Install RH subwoofer
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2x bolts, 13mm, 8 Nm, Slide towards outside of vehicle to secure port
  68. Install the RH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Remove and Install).
  69. Install rear wall lower trim
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips, 4x clips
  70. Secure RH lower C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x datum
  71. Fold down 2nd row 40 seat
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull tether to release then pivot down until locked in place
  72. Secure LH lower C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x datum
  73. Fold down 2nd row 60 seat
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull tether to release then pivot down until locked in place
  74. Install 2nd row floor mat
  75. Install the RH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).
  76. Install the RH rear rocker step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).
  77. Install the RH rocker panel. See Rocker Panel Assembly - LH (Remove and Install).
  78. Install RH carpet support foam
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat at rear edge
  79. Unfold RH front cabin carpet into position
  80. Install the lower center floor trim. See Trim - Center Floor - Lower (Remove and Install).
  81. Install the RH center floor rail. See Rail - Center Floor - LH (Remove and Install).
  82. Install the RH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Install).
  83. Install the RH mid A-pillar trim. See Trim - A-Pillar - Mid - LH (Remove and Install).
  84. Install RH front floor mat
  85. Install the LH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).
  86. Install the LH rear rocker step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).
  87. Install the LH rocker panel. See Rocker Panel Assembly - LH (Remove and Install).
  88. Install the LH center floor rail. See Rail - Center Floor - LH (Remove and Install).
  89. Install the accelerator pedal side trim. See Side Trim - Pedal (Remove and Install).
  90. Install the footwell cover. See Cover - Footwell (Remove and Install).
  91. Install the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Install).
  92. Install the LH mid A-pillar trim. See Trim - A-Pillar - Mid - LH (Remove and Install).
  93. Install LH front floor mat
  94. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at the Max line, Top off fluid as required
  95. Install coolant bottle cap
  96. Install the frunk assembly. See Frunk Assembly (Remove and Install).
  97. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
  98. Perform Thermal Performance through the UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow toolbox articles 206000
  99. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
  100. Exit Service Mode. See Service Mode.
  101. Raise all the windows and close all the doors.