HV Harness - AC Compressor \(Remove and Install\)
Correction code 4450074051 4450074052 FRT 4.14 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.
- 2024-09-18: Updated to latest time study.
- 2024-05-22: Updated connector images and instructions for disconnect/connect.
Remove
- Open all the doors and lower all the windows.
-
Use a pocket screwdriver to manually
latch all the doors to prevent lockout.
-
Place vehicle in service mode
NoteVia UI > Controls > Software, Touch and hold "Cybertruck" for 2 seconds then release, Use screen keyboard to type "service" into dialog box then select OK
-
Unlock vehicle gateway
NoteAfter vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information
-
Open tailgate
NotePress button to release
-
Open tonneau cover
NotePress forward arrow on LH bed rail
- Remove the LH sail applique. See Truck Bed Exterior Trim - Sail Applique Assembly - LH (Remove and Replace).
-
Remove LH tonneau water management
seal
Note1x clip, Pull away from rail to release from groove
-
Release LH tail lamp applique
Note2x clips
-
Remove LH tonneau hard stop
Note3x bolts, 10mm, 9 Nm
-
Remove LH tonneau slip datum
bracket
-
Remove LH tailgate bumpstop
Note1x datum, Rotate and release inboard
- Remove the RH sail applique. See Truck Bed Exterior Trim - Sail Applique Assembly - RH (Remove and Replace).
-
Remove RH tonneau water management
seal
Note1x clip, Pull away from rail to release from groove
-
Release RH tail lamp applique
Note2x clips, 2x datums
-
Remove RH tonneau hard stop
Note3x bolts, 10mm, 9 Nm
-
Remove RH tonneau slip datum
bracket
-
Remove RH tailgate bumpstop
Note1x datum, Rotate and release
-
Install tonneau transfer frame onto
powertrain table
Note4x bolts, 4x nuts, Frame TPN: 1999662-00-A
-
Position tonneau transfer frame onto
tonneau bed rails
NoteConnect air supply, Raise and adjust angle on powertrain table as needed, Frame TPN: 1999662-00-A
-
Align and secure tonneau transfer
frame onto tonneau bed rails
Note2x pins, Frame TPN: 1999662-00-A
-
Run Tonneau Calibration routine
NoteVia Service Mode UI > Closures > Tonneau > Calibrate Tonneau< Allow routine to complete, Tonneau will move while routine running
-
Release tonneau chain from
motors
NoteRecommend assistance, Press close button until both motors have audibly released all links, Frame TPN: 1999662-00-A
-
Manually guide remaining tonneau slats
and chain out of bed rails
NoteRecommend assistance, 2x pins, Remove pins then move powertrain table away from vehicle and guide slats out, Frame TPN: 1999662-00-A
-
Partially release aft section of front
LH fender flare cover
Note11x clips, 3x datum, 1x connector total, Release as needed for clearance, Full removal not required
-
Remove LH front rocker fastener from
step reinforcement
Note1x bolt, 10mm, 4 Nm
-
Remove clip securing LH rocker cover
to front wheel liner
Note1x clip
-
Partially release fore section of rear
LH fender flare cover
Note13x clips, 3x datums total, Release as needed for clearance, Full removal not required
-
Remove LH rear rocker fastener from
step reinforcement
Note1x bolt, 10mm, 4 Nm
-
Remove clip securing LH rocker cover
to rear wheel liner
Note1x clip
-
Remove rocker cover fasteners from LH
side ski
Note6x bolts, 10mm, 10 Nm
-
Release LH rocker cover from rocker
carrier
Note11x clips, 1x datum, Remove any clips that remained on carrier
-
Remove front LH rocker step
reinforcement
Note3x bolts, 10mm, 15 Nm, 2x datums
-
Remove rear LH rocker step
reinforcement
Note3x bolts, 10mm, 15 Nm
-
Partially release LH rear primary door
seal
-
Remove LH mid A-pillar trim
Note2x clips, 2x tabs, Release tabs, Slightly bend live hinge and release clips
-
Remove LH lower A-pillar trim
Note7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward
-
Remove footwell cover
Note3x clips, 3x magnets, 1x bolt, 10mm, 3 Nm, Bolt is captive to tether
-
Remove LH front floor mat
-
Remove LH center floor rail
Note4x clips, 3x datums, Pull upwards to release
-
Remove accelerator pedal side
trim
Note3x clips, Lift from forward edge then slide over accelerator pedal
-
Remove accelerator pedal
Note2x nuts, 13mm, 10 Nm, 1x connector, Release locking tab
-
Remove LH carpet support foam
NoteLift up from rear edge
-
Fold back LH front cabin carpet
-
Remove LH front interior HV Battery
mounting bolts
Note3x bolts, 24mm, 160 Nm
-
Temporarily install accelerator
pedal
Note2x nuts, 13mm, 10 Nm, 1x connector, Secure nuts hand tight to allow vehicle to be driven onto lift
-
Remove LH lower B-pillar trim
Note2x push clips, 11x clips, 4x datums, 4x seal retainers, 2x hooks, Release bottom rear section first
-
Partially release aft section of front
RH fender flare cover
Note11x clips, 3x datum, 1x connector total, Release as needed for clearance, Full removal not required
-
Remove RH front rocker fastener from
step reinforcement
Note1x bolt, 10mm, 4 Nm
-
Remove clip securing RH rocker cover
to front wheel liner
Note1x clip
-
Partially release fore section of rear
RH fender flare cover
Note13x clips, 3x datums total, Release as needed for clearance, Full removal not required
-
Remove RH rear rocker fastener from
step reinforcement
Note1x bolt, 10mm, 4 Nm
-
Remove clip securing RH rocker cover
to rear wheel liner
Note1x clip
-
Remove rocker cover fasteners from RH
side ski
Note6x bolts, 10mm, 10 Nm
-
Release RH rocker cover from rocker
carrier
Note11x clips, 1x datum, Remove any clips that remained on carrier
-
Remove front RH rocker step
reinforcement
Note3x bolts, 10mm, 15 Nm, 2x datums
-
Remove rear RH rocker step
reinforcement
Note3x bolts, 10mm, 15 Nm
-
Remove RH mid A-pillar trim
Note2x clips, 2x tabs, Release tabs, Slightly bend live hinge and release clips
-
Remove RH lower A-pillar trim
Note7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward
-
Remove RH front floor mat
-
Remove RH center floor rail
Note4x clips, 3x datums, Pull upwards to release
-
Remove center floor trim
Note17x clips, Release upper section first
-
Fold back RH carpet
-
Remove RH carpet support foam
NoteLift up from rear edge
-
Remove RH interior front HV battery
mounting bolts
Note3x bolts, 24mm, 160 Nm
-
Remove RH lower B-pillar trim
Note2x push clips, 11x clips, 4x datums, 4x seal retainers, Release bottom rear section first
-
Move vehicle onto lift
NoteEnsure positioning allows rear doors to open
-
Install Universal Lift Pad
adapters
Note4x 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
NoteSet air suspension to "Jack Mode", Align lift adapter pins with lift point holes on body
-
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)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
NoteVerify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 50 minute time limit -
Open powered front trunk
NoteVia exterior switch or UI
-
Power down vehicle via UI
NoteVerify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
-
Remove rear underhood apron
Note9x clips
-
Remove frunk assembly
Note6x bolts, 10mm, 12 Nm, 2x bolt caps, 2x bumpstops, 1x connector, Remove bolt covers from frunk floor, Remove washer fluid cap by gently prying upwards, Rotate bumpstops counter clockwise to release, the 25mm socket from PT Sensor kit can be used, Avoid straining emergency frunk release connector
-
Unlock fireman's loop connector and
disconnect, Slide eCPA to left on the MV battery connector then lift lever to
release
Note2x connectors, Unlock fireman's loop connector and disconnect, Release eCPA by pushing down to unlock and slide red locking tab to left, Wait 2 minutes for electrical circuits to discharge before disconnecting modules
-
Verify operation of multimeter
NoteSet multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
-
Raise vehicle fully
NoteSet to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
-
Remove front aero shield
Note11x bolts, 10mm, 6 Nm
-
Remove front skid plate
Note8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
-
Remove Mid-aero shield
Note6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
-
Remove all items from pockets and
ensure not wearing metal items
-
Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
-
Put on HV insulating gloves and
leather over gloves
-
Verify no HV - Install amp clamp to
RDU HV harness
NoteVerify 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
-
Remove leather over gloves and HV
insulating gloves
-
Lower vehicle until tires are touching
the ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Disconnect HV harness connector from
AC compressor
Note1x locking electrical connector, Pull red locking tab away from compressor then slide black lock upwards to release
-
Fold up 2nd row 60 seat
NotePull tether to release then lift up until locked in place
-
Remove 2nd row floor mat
-
Partially release LH lower C-pillar
trim
Note1x clip, 1x datum
-
Release LH MV controller dry side
locking cover
Note1x 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
-
Disconnect floor harness connector
from LH MV controller
Note1x connector, Depress tabs to release connector housing from locking cover
-
Fold up 2nd row 40 seat
NotePull tether to release then lift up until locked in place
-
Release RH MV controller connector
locking cover
Note1x 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
-
Disconnect center console and backbone
connectors from RH MV controller
Note1x 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
-
Disconnect rear display connector from
car computer
Note1x connector
-
Partially release RH lower C-pillar
trim
Note1x clip, 1x datum
-
Remove rear wall lower trim
Note2x push clips, 4x clips, Remove outermost push clips, then pull straight forward to release inner clips
-
Remove RH subwoofer
Note1x connector, 2x bolts, 13mm, 8 Nm, Slide towards center of vehicle to release outer port from body
-
Remove RH rear interior HV battery
mounting bolts
Note4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
-
Disconnect backbone harness from rear
MV controller
Note1x 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 LH subwoofer
Note1x connector, 2x bolts, 13mm, 8 Nm, Slide towards RH of vehicle to release outer port from body, Release locking tab
-
Remove LH rear interior HV battery
mounting bolts
Note4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
-
Remove interior HV harness bulkhead
cover
Note3x nuts, 10mm, 9 Nm
-
Remove fastener covers from bed floor
assembly
Note6x covers
-
Remove bed floor assembly
Note10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance
-
Release RH tonneau NVH barrier
Note6x bolts, 10mm, 5 Nm, 2-piece NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm
-
Remove RH tonneau NVH barrier
NoteRelease rearward then slide over LH side NVH cover before removing upward, Vehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Maneuver around bed wall then remove
-
Release LH tonneau NVH barrier
Note5x bolts, 10mm, 5 Nm, 2-piece NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal
-
Remove LH tonneau NVH barrier
NoteSlide towards center, Ensure busbar clearance during removal to avoid damage to NVH material
-
Remove bolts securing HV battery to
RUB
Note4x 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
-
Disconnect ancillary bay MV
connector
Note1x 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
Note1x bolt, EP10, 9 Nm
-
Remove bolts securing HV connector to
DC FC header
Note2x bolts, 10mm, 9 Nm
-
Release HV connector from DC FC
header
Note1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly
-
Support HV Busbar assembly
NoteSuspend assembly to maintain clearance
-
Disconnect HV ancillary
harnesses
Note2x connectors, Release red locking tab then slide open black lever to remove, Push cabin harness into interior
-
Raise vehicle fully
NoteSet 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
-
Disconnect RDU return hose from PT
return hose
Note1x spring clip, 1x clamp clip, Move wheel liner aside as needed, Plug coolant connections as needed
-
Disconnect RDU supply hose
Note1x spring clip, Plug hoses
-
Move coolant drain container to front
right of HV battery
-
Disconnect PT supply and return
hoses
Note2x spring clips, Plug hoses
-
Disconnect battery coolant supply and
return hoses
Note2x spring clips, Use caution with pick near HV harness, Plug Hoses, Position coolant drain as needed
-
Remove coolant drain container from
underneath vehicle
-
Disconnect pressurized pack
lines
Note2x VOSS fittings, 12mm, 8Nm
-
Release clips securing LH pressurized
pack line
Note3x clips
-
Release A/C compressor HV harness from
HV battery
Note1x 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
-
Disconnect RDU HV harness
Note1x connector, Release locking tab and rotate release lever up, Do not force release lever up, Ensure alignment tabs on header are not damaged
-
Release FDU HV harness
Note1x connector, 1x bolt, 10mm, 10 Nm, Move harness clear of subframe
-
Position battery table
NoteEnsure table is level
-
Remove front exterior HV Battery
mounting bolts and ground strap
Note6x 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
Note16x bolts, 15mm, 62 Nm
-
Raise vehicle away from HV
battery
NoteEnsure no coolant hoses, harnesses, or brake lines are caught while lifting
-
Remove AC compressor HV harness
Note11x clips
-
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.
NoteDo not allow the grease to contact the busbar HV mating surfaces.
Install
-
Install AC compressor HV harness
Note11x clips, Ensure routing will not cause pinch or rubbing
-
Install battery alignment rods
Note4x 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
-
Position rear carpet section for
install
NoteInsert a wheel chock under carpet section to maintain 90 degree angle
-
Lower vehicle onto HV battery
NoteEnsure 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 to LH and RH side
Note16x bolts, 15mm, 60 Nm
-
Remove exterior battery alignment
rods
Note2x alignment rods
-
Install front exterior HV Battery
mounting bolts and ground strap
Note6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm
-
Raise vehicle away from battery
table
NoteSet to a comfortable working height, Ensure lift is lowered onto a lock
-
Remove battery table from under
vehicle
-
Install FDU HV harness
Note1x connector, 1x bolt, 10mm, 10 Nm, Ensure locking tab engages
-
Secure A/C compressor HV harness to
battery
Note1x locking connector, 4x clips, Engage locking tab, Do not force lever up, Number of connections may vary by vehicle configuration
-
Install RDU HV harness
Note1x connector, 1x harness clip, Ensure locking tab is engaged
-
Install clips securing pressurized
pack line
Note3x clips
-
Install pressurized pack lines
Note2x 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
-
Position coolant drain container
underneath RH rear of HV battery
-
Connect RDU return hose to PT return
hose
Note1x spring clip, Remove coolant plugs, Pull back wheel liner as required, Perform a push-pull-push test to ensure hose is engaged
-
Connect RDU supply hose
Note1x 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
Note2x spring clips, Remove plugs, Perform a push-pull-push test to ensure hose is engaged
-
Connect battery supply and return
coolant hoses
Note2x edge clips, 2x spring clips, Remove plugs, Secure edge clips to casting, Perform a push-pull-push test to ensure hose is engaged
-
Remove coolant drain container from
underneath vehicle
-
Install Mid-aero shield
Note6x clips, 3x bolts, 15mm, 70 Nm, 3x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
-
Install front skid plate
Note8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
-
Install front aero shield
Note11x bolts, 10mm, 6 Nm, Apply loctite 222 to aeroshield fasteners
-
Lower vehicle until tires are touching
the ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Connect HV harness connector to AC
compressor
Note1x 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
-
Install bolts securing HV battery to
RUB
Note4x bolts, 21mm, 115 Nm, Tonneau must be closed or removed to access forward bolts, Shown without tonneau for clarity
-
Clean HV connector contact surface of
residual Penetrox
NoteAllow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
-
Clean busbar HV connector contact
surface of residual Penetrox
NoteAllow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
-
Apply Penetrox onto HV connector
joints
NoteApply 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
Note2x bolts, 10mm, 9 Nm
-
Connect HV ancillary harnesses
Note2x connectors, Pull through rear wall opening, Slide black lever to engage then push in red locking tab
-
Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
-
Put on HV insulating gloves and
leather over gloves
-
Perform Hioki resistance test at each
HV joint from HV busbar lead to bolt head
Note2x 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
-
Remove leather over gloves and HV
insulating gloves
-
Install bolt securing busbar HV
connector lid
Note1x bolt, EP10, 9 Nm
-
Connect Ancillary bay MV
connector
Note1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly
-
Install LH tonneau NVH barrier
Note2-piece NVH assembly order of operations requires LH side to be secured first to allow busbar clearance for RH side installation, Ensure busbar clearance during install to avoid damage to NVH material
-
Secure LH tonneau NVH barrier
Note5x bolts, 10mm, 5 Nm
-
Install RH tonneau NVH barrier
Note2-piece NVH assembly order of operations requires LH side to be secured first to allow busbar clearance for RH side installation, Vehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Maneuver around bed wall then position
-
Secure RH tonneau NVH barrier
Note6x bolts, 10mm, 5 Nm, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm
-
Install forward bed panel
Note6x bolts, 15mm, 85 Nm, Recommend assistance to lift panel into bed
-
Install fastener covers to forward bed
panel
Note6x covers
-
Install interior HV harness bulkhead
cover
Note3x nuts, 10mm, 9 Nm
-
Inspect for any misalignment at rear
ribs
NoteEnsure cable is lying flat without twist, Ensure cable is secured correctly to rib
-
Connect backbone harness to rear MV
controller
Note1x 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
-
Inspect for presence of backbone
harness guide at front casting
NoteEnsure backbone harness guide is installed,
-
Connect rear display connector to car
computer
Note1x connector
-
Connect cabin floor harness connector
and backbone cable to RH MV controller
Note1x connector, 1x backbone cable, 2x edge clips, Push from edges of connector housing, Avoid bending ribbon cable at a tight radius
-
Secure RH MV controller connector
locking cover
Note1x 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
-
Install RH interior front HV battery
mounting bolts
Note3x bolts, 24mm, 160 Nm
-
Remove temporarily installed
accelerator pedal
Note2x nuts, 13mm, 10 Nm, 1x connector, Release locking tab
-
Connect cabin floor harness connector
to LH MV controller
Note1x connector, Secure in locking cover
-
Secure left MV controller connector
locking frame
Note1x bolt, 8mm, 4 Nm, Ensure connectors are aligned before tightening center bolt
-
Install LH front interior HV Battery
mounting bolts
Note3x bolts, 24mm, 160 Nm
-
Install LH carpet support foam
NoteSeat at rear edge
-
Unfold LH front cabin carpet into
position
-
Install accelerator pedal
Note2x nuts, 13mm, 10 Nm, 1x connector, Secure locking tab
- Link to procedure: 664f759f1a55c10019c16205
-
Slide eCPA to the right and ensure it
is seated against the black lever, Connect fireman's loop 20 seconds after eCPA
engagement
Note2x connectors, Slide and secure red locking tab on top of release lever, Lock fireman's loop connection, If power cycling vehicle ensure at least 60 seconds has passed since powering down
-
Select "Stop Thermal Fill Drain"
through UI
NoteAllow routine to complete, ensure routine is successful
-
Remove Universal Lift Pad
adapters
Note4x Adapters, Install original lift pads, Install plugs back into holes in BIW
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Remove vehicle from lift
NoteLower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
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Select "Start Coolant Air Purge" using
the UI
NoteTouch 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
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Remove battery alignment rods
Note4x alignment rods
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Install LH rear interior HV battery
mounting bolts
Note4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
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Install LH subwoofer
Note1x connector, 2x bolts, 13mm, 8 Nm, Slide towards LH of vehicle to secure outer port to body, Engage locking tab
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Install LH lower B-pillar trim
Note2x push clips, 11x clips, 4x datums, 4x seal retainers, 2x hooks, Secure top hooks first
-
Install RH rear interior HV battery
mounting bolts
Note4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
-
Install RH subwoofer
Note1x connector, 2x bolts, 13mm, 8 Nm, Slide towards outside of vehicle to secure port
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Install RH lower B-pillar trim
Note2x push clips, 11x clips, 4x datums, 4x seal retainers
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Install rear wall lower trim
Note2x push clips, 4x clips
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Secure RH lower C-pillar trim
Note1x clip, 1x datum
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Fold down 2nd row 40 seat
NotePull tether to release then pivot down until locked in place
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Secure LH lower C-pillar trim
Note1x clip, 1x datum
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Fold down 2nd row 60 seat
NotePull tether to release then pivot down until locked in place
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Install 2nd row floor mat
-
Install front RH rocker step
reinforcement
Note3x bolts, 10mm, 15 Nm, 2x datums
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Install rear RH step
reinforcement
Note3x bolts, 10mm, 15 Nm
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Install RH rocker cover to rocker
carrier
Note11x clips, 1x datum
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Install rocker cover fasteners to RH
side ski
Note6x bolts, 10mm, 10 Nm
-
Install clip securing RH rocker cover
to rear wheel liner
Note1x clip
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Install RH rear rocker fastener to
step reinforcement
Note1x bolt, 10mm, 4 Nm
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Secure fore section of rear RH fender
flare cover
Note13x clips, 3x datums total, Ensure no clips are damaged, Replace clips as required
-
Install clip securing RH rocker cover
to front wheel liner
Note1x clip
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Install RH front rocker fastener to
step reinforcement
Note1x bolt, 10mm, 4 Nm
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Secure aft section of front RH fender
flare cover
Note11x clips, 3x datum, 1x connector total, Ensure no clips are damaged, Replace clips as required
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Install RH carpet support foam
NoteSeat at rear edge
-
Unfold RH front cabin carpet into
position
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Install center floor trim
Note17x clips, Replace any missing or damaged clips, Install lower section first
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Install RH center floor rail
Note4x clips, 3x datums
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Install RH lower A-pillar trim
Note7x clips, 3x datums, 2x tabs
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Install RH mid A-pillar trim
Note2x clips, 2x tabs,
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Install RH front floor mat
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Install LH front rocker step
reinforcement
Note3x bolts, 10mm, 15 Nm, 2x datums
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Install rear LH step
reinforcement
Note3x bolts, 10mm, 15 Nm
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Install LH rocker cover to rocker
carrier
Note11x clips, 1x datum, Replace any missing or damaged clips
-
Install rocker cover fasteners to LH
side ski
Note6x bolts, 10mm, 10 Nm
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Install clip securing LH rocker cover
to rear wheel liner
Note1x clip
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Install LH rear rocker fastener to
step reinforcement
Note1x bolt, 10mm, 4 Nm
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Secure fore section of rear LH fender
flare cover
Note13x clips, 3x datums total, Replace any missing or damaged clips
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Install clip securing LH rocker cover
to front wheel liner
Note1x clip
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Install LH front rocker fastener to
step reinforcement
Note1x bolt, 10mm, 4 Nm
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Secure aft section of front LH fender
flare cover
Note11x clips, 3x datum, 1x connector total, Replace any missing or damaged clips
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Install LH center floor rail
Note4x clips, 3x datums
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Install accelerator pedal side
trim
Note3x clips, Replace any missing or damaged clips
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Install footwell cover
Note3x clips, 3x magnets, 1x bolt, 10mm, 3 Nm, Bolt is captive to tether, Replace any missing or damaged clips or magnets
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Install LH Lower A-pillar trim
Note7x clips, 3x datums, 2x tabs, Replace any missing or damaged clips
-
Install LH mid A-pillar trim
Note2x clips, 2x tabs, Replace any missing or damaged clips
-
Install LH front floor mat
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Inspect coolant level and top off as
necessary
NoteEnsure that the fluid level is at the Max line, Top off fluid as required
-
Install coolant bottle cap
-
Install frunk assembly
Note6x bolts, 10mm, 12 Nm, 2x bolt caps, 2x bumpstops, 1x connector, Install bolt covers to frunk floor, Install washer fluid cap, Install bumpstops by aligning tabs then turning clockwise, Ensure emergency frunk release functions
-
Install rear underhood apron
Note9x clips, Adjust windshield seal as required
-
Close powered front trunk
NoteVia exterior switch or UI
-
Perform Thermal Performance through
the UI
NoteSelect Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow toolbox articles 206000
-
Position tonneau transfer frame onto
tonneau bed rails
NoteLay tonneau chain on tailgate and secure ends to prevent breakdown or shifting, Use tape or bungees as needed, Connect air supply, Raise and adjust angle on powertrain table as needed, Frame TPN: 1999662-00-A
-
Manually guide remaining tonneau slats
and chain onto bed rails
NoteRecommend assistance, 2x pins, Evenly guide slats in then install pins, Monitor Y reaction clips entering bed rails and ensure clips do not bind, Monitor slats during install and ensure all are squared during install, Adjust as needed, Frame TPN: 1999662-00-A
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Secure tonneau chain onto motors
NoteRecommend assistance, Press open button until both motors have audibly secured all links and cover is fully open, Frame TPN: 1999662-00-A
-
Remove tonneau transfer frame from
tonneau bed rails
NoteDisconnect air supply, Lower and adjust angle on powertrain table as needed, Frame TPN: 1999662-00-A
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Install RH tailgate bumpstop
Note1x datum, Rotate and secure
-
Install RH tonneau slip datum
bracket
-
Install RH tonneau hard stop
Note3x bolts, 10mm, 9 Nm, Hand start center black locating bolt first, Set 2mm space between datum and end of bed rail
-
Secure RH tail lamp applique
Note2x clips, 2x datums
-
Install RH tonneau water management
seal
Note1x clip, Push seal into rail groove
- Install the RH sail applique. See Truck Bed Exterior Trim - Sail Applique Assembly - RH (Remove and Replace).
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Secure LH tailgate bumpstop
Note1x datum, Rotate and secure
-
Install LH tonneau slip datum
bracket
-
Install LH tonneau hard stop
Note3x bolts, 10mm, 9 Nm, Hand start center black locating bolt first, Set 2mm space between datum and end of bed rail
-
Secure LH tail lamp applique
Note2x clips 2x datums
-
Install LH tonneau water management
seal
Note1x clip, Push seal into rail groove
- Install the LH sail applique. See Truck Bed Exterior Trim - Sail Applique Assembly - LH (Remove and Replace).
- Close tailgate
-
Run Tonneau Calibration routine
NoteVia Service Mode UI > Closures > Tonneau > Calibrate Tonneau< Allow routine to complete, Tonneau will move while routine running
- Close tonneau cover
- Exit Service Mode. See Service Mode.
- Raise all the windows and close all the doors.