26/11/2024 13:53:29

HV Battery (AWD) \(Remove and Install\)

Correction code 16010201 FRT 4.38 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.

2024-11-22: Added warning to NOT skip steps to remove the tonneau slats.
2024-09-18: Updated to latest time study.
2024-08-20: Added steps to install backbone harness guide if the guide is not present.
2024-08-09: Added PN of anti-abrasion tape.
2024-07-15: Updated rear interior HV battery bolt steps: in addition to the 13 mm bolts, some vehicles might also have 15 mm bolts.
2024-06-10: Updated entire procedure according to latest time study.

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

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.

Special tools required for this procedure:

1134523-00-B - Battery Alignment Rods
1065131-00-A - Battery Coolant Drain Kit
1135762-00-A - Coolant Hose Plug Kit
1080568-00-A - Fluid Catcher
1076927-00-A - Hioki tester
1020566-00-F - HV Battery Table
1076928-00-A - Test Probes - Hioki 9461
1936724-00-A - Universal Lift Pad adapters
1050448-00-B - Vacuum Refill Tool
1479505-00-A - Vacuum Fill Adapter -
1879451-99-A - LV ABRASION STICKER,XM,HVB,CTSB

Remove

Open all the doors and lower all the windows.
Use a pocket screwdriver to manually latch all the doors to prevent lockout.
Place the vehicle into Service Mode. See Service Mode.
Unlock the vehicle Gateway. See Gateway (Unlock).
Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
Remove the LH rocker assembly. See Rocker Panel Trim - Rocker Assembly - LH (Remove and Install).
Remove the bolts (x3) that attach the LH front rocker step reinforcement to the vehicle, and then remove the reinforcement from the vehicle.
15 Nm (11.1 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Remove the LH rear rocker step reinforcement. See Rocker Panel Trim - Rear Rocker Step Reinforcement - LH (Remove and Install).
Remove the LH mid A-pillar trim. See A-B-C Post Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
Remove the LH Lower A-pillar trim. See A-B-C Post Interior Trim - A-Pillar Lower Trim - LH (Remove and Install).
Remove the footwell cover. See Dash Support Frame - Footwell Cover (Remove and Install).
Remove the LH front floor mat.
Remove the LH center floor rail. See Passenger Compartment Carpet - Center Floor Rail - LH (Remove and Install).
Remove the accelerator pedal. See Accelerator Pedal (Remove and Install).
Remove the LH carpet support foam.

Note
Lift up from rear edge.
Remove the LH front interior HV battery mounting bolts (x3).
160 Nm (118.0 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 24 mm socket
Temporarily install the accelerator pedal. See Accelerator Pedal (Remove and Install).

Note
Connect the electrical connector and install and hand-tighten the fasteners to allow the vehicle to be driven onto a lift.
Use a flathead screwdriver to rotate the lock mechanism on the front seat belt linkage counterclockwise to release it from the pretensioner, and then slide the linkage off the pretensioner and set it aside.

CAUTION
DO NOT rotate clockwise to avoid damage to the mechanism.

Note
The linkage design may vary, but will function the same.

Note
The lock screw will remain in the horizontal position when released.

Note
A light audible click will be heard when the linkage is released.
Move the LH front seat fully forward.
Remove and discard the bolts (x2) that attach the front of the LH front seat tracks to the risers.
34 Nm (25.1 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- Torx Plus T45 socket
Move the LH front seat fully forward.
Remove and discard the bolts (x2) that attach the rear of the LH front seat tracks to the floor panel.
34 Nm (25.1 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- Torx Plus T45 socket
Move the seat to the middle of track and to the most upright position.
Remove the RH rocker assembly. See Rocker Panel Trim - Rocker Assembly - LH (Remove and Install).
Remove the bolts (x3) that attach the RH front rocker step reinforcement to the vehicle, and then remove the reinforcement from the vehicle.
15 Nm (11.1 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Remove the RH rear rocker step reinforcement. See Rocker Panel Trim - Rear Rocker Step Reinforcement - LH (Remove and Install).
Remove the RH mid A-pillar trim. See A-B-C Post Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
Remove the RH Lower A-pillar trim. See A-B-C Post Interior Trim - A-Pillar Lower Trim - LH (Remove and Install).
Remove the RH front floor mat.
Remove the RH center floor rail. See Passenger Compartment Carpet - Center Floor Rail - LH (Remove and Install).
Remove center floor trim. See Passenger Compartment Carpet - Center Floor Trim (Remove and Install).
Fold back the RH carpet.
Remove the RH carpet support foam.

Note
Lift up from the rear edge.
Remove the RH interior front HV battery mounting bolts (x3).
160 Nm (118.0 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 24 mm socket
Repeat step 18 through step 23 for the RH side of the vehicle.
Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
Select 'Coolant System' to enter coolant circuit screen, Select 'Coolant Fill/Drain' using the UI and
PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT
via 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, Select 'Run'
Note
Verify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 50 minute time limit
Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
Disconnect MV power. See Disconnect MV Power.
Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure.
Remove the front aero shield. See Undertray - Front Aeroshield (Remove and Install).
Remove front skid plate

Note
8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
Remove Mid-aero shield

Note
6x 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

Note
Check 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

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
Remove leather over gloves and HV insulating gloves
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Fold up 2nd row 60 seat

Note
Pull tether to release then lift up until locked in place
Disconnect LH seat

Note
1x connector, 2 stage locking tab, Release yellow locking tab, then release black lever to disconnect
Remove LH front seat from vehicle

Note
Recommend assistance, Use caution to not damage other components, Lift seat off risers, Rotate sideways and remove out back door opening
Remove 2nd row floor mat
Partially release LH lower C-pillar trim

Note
1x clip, 1x datum
Release LH MV controller dry side locking cover

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

Note
1x connector, Depress tabs to release connector housing from locking cover
Fold up 2nd row 40 seat

Note
Pull tether to release then lift up until locked in place
Disconnect RH seat

Note
1x connector, 2 stage locking tab, Release yellow locking tab, then release black lever to disconnect
Remove RH front seat from vehicle

Note
Recommend assistance, Use caution to not damage other components, Lift seat off risers, Rotate sideways and remove out back door opening
Release RH MV controller connector locking cover

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

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
Disconnect rear display connector from car computer

Note
1x connector
Remove center console front panel

Note
10x clips
Release HV outlet from front console panel

Note
2x screws, T20, 1 Nm, 1x clip
Remove front bolts securing center console to riser

Note
4x bolts, 10mm, 5 Nm
Disconnect center console harness connectors

Note
2x connectors
Remove center console back panel

Note
10x clips, 3x connectors, 3x harness clips
Remove rear bolts securing center console to riser

Note
2x bolts, 10mm, 5 Nm
Remove center console

Note
Lift up to release from riser
Partially release RH lower C-pillar trim

Note
1x clip, 1x datum
Remove rear wall lower trim

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

Note
1x 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

Note
4x 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

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

Note
1x 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

Note
4x 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

Note
3x nuts, 10mm, 9 Nm
Remove fastener covers from bed floor assembly

Note
6x covers
Remove bed floor assembly

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

Note
6x 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

Note
Release 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

Note
5x 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

Note
Slide towards center, Ensure busbar clearance during removal to avoid damage to NVH material
Remove bolts securing HV battery to RUB

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
Disconnect ancillary bay MV connector

Note
1x connector, Double locking, Release tab then pivot lever, Release second tab to disengage connector, Wait 1 second between locking tab release to discharge and prevent arcing
Remove bolt securing busbar HV connector lid

Note
1x bolt, EP10, 9 Nm
Remove bolts securing HV connector to DC FC header

Note
2x bolts, 10mm, 9 Nm
Release HV connector from DC FC header

Note
1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly
Support HV Busbar assembly

Note
Suspend assembly to maintain clearance
Disconnect HV ancillary harnesses

Note
2x connectors, Release red locking tab then slide open black lever to remove, Push cabin harness into interior
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Position coolant drain container underneath RH rear of HV battery
Disconnect RDU return hose from PT return hose

Note
1x spring clip, 1x clamp clip, Move wheel liner aside as needed, Plug coolant connections as needed
Disconnect RDU supply hose

Note
1x spring clip, Plug hoses
Move coolant drain container to front right of HV battery
Disconnect PT supply and return hoses

Note
2x spring clips, Plug hoses
Disconnect battery coolant supply and return hoses

Note
2x 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

Note
2x VOSS fittings, 12mm, 8Nm
Release clips securing LH pressurized pack line

Note
3x clips
Release A/C compressor HV harness from HV battery

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

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
Release FDU HV harness

Note
1x connector, 1x bolt, 10mm, 10 Nm, Move harness clear of subframe
Position battery table

Note
Ensure table is level
Remove front exterior HV Battery mounting bolts and ground strap

Note
6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm, Ensure ground strap is clear of battery
Remove side exterior HV battery mounting bolts from LH and RH side

Note
16x bolts, 15mm, 62 Nm
Raise vehicle away from HV battery

Note
Ensure no coolant hoses, harnesses, or brake lines are caught while lifting
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.

Note
Do not allow the grease to contact the busbar HV mating surfaces.

Install

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.

Note
The grease is part number 1089958-00-A and is available from eProcurement.
Install battery alignment rods

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
Position rear carpet section for install

Note
Insert a wheel chock under carpet section to maintain 90 degree angle
Lower vehicle onto HV battery

Note
Ensure no coolant hoses, harnesses, or brake lines are caught while lowering, Recommend assistance to ensure good alignment whilst lowering
Install side exterior HV battery mounting bolts to LH and RH side

Note
16x bolts, 15mm, 60 Nm
Remove exterior battery alignment rods

Note
2x alignment rods
Install front exterior HV Battery mounting bolts and ground strap

Note
6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm
Raise vehicle away from battery table

Note
Set to a comfortable working height, Ensure lift is lowered onto a lock
Remove battery table from under vehicle
Install FDU HV harness

Note
1x connector, 1x bolt, 10mm, 10 Nm, Ensure locking tab engages
Secure A/C compressor HV harness to battery

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

Note
1x connector, 1x harness clip, Ensure locking tab is engaged
Install clips securing pressurized pack line

Note
3x clips
Install pressurized pack lines

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
Position coolant drain container underneath RH rear of HV battery
Connect RDU return hose to PT return hose

Note
1x spring clip, Remove coolant plugs, Pull back wheel liner as required, Perform a push-pull-push test to ensure hose is engaged
Connect RDU supply hose

Note
1x spring clip, Remove coolant plugs, Perform a push-pull-push test to ensure hose is engaged
Move coolant drain container to front right of HV battery
Connect PT supply and return hoses

Note
2x spring clips, Remove plugs, Perform a push-pull-push test to ensure hose is engaged
Connect battery supply and return coolant hoses

Note
2x edge clips, 2x spring clips, Remove plugs, Secure edge clips to casting, Perform a push-pull-push test to ensure hose is engaged
Remove coolant drain container from underneath vehicle
Install Mid-aero shield

Note
6x clips, 3x bolts, 15mm, 70 Nm, 3x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
Install front skid plate

Note
8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
Install front aero shield

Note
11x bolts, 10mm, 6 Nm, Apply loctite 222 to aeroshield fasteners
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Install bolts securing HV battery to RUB

Note
4x bolts, 21mm, 115 Nm, Tonneau must be closed or removed to access forward bolts, Shown without tonneau for clarity
Clean HV connector contact surface of residual Penetrox

Note
Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
Clean busbar HV connector contact surface of residual Penetrox

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

Note
Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
Install busbar onto HV header and install bolts

Note
2x bolts, 10mm, 9 Nm
Connect HV ancillary harnesses

Note
2x connectors, Pull through rear wall opening, Slide black lever to engage then push in red locking tab
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
Put on HV insulating gloves and leather over gloves
Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head

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

Note
1x bolt, EP10, 9 Nm
Connect Ancillary bay MV connector

Note
1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly
Install LH tonneau NVH barrier

Note
2-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

Note
5x bolts, 10mm, 5 Nm
Install RH tonneau NVH barrier

Note
2-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

Note
6x 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

Note
6x bolts, 15mm, 85 Nm, Recommend assistance to lift panel into bed
Install fastener covers to forward bed panel

Note
6x covers
Install interior HV harness bulkhead cover

Note
3x nuts, 10mm, 9 Nm
Inspect for any misalignment at rear ribs

Note
Ensure cable is lying flat without twist, Ensure cable is secured correctly to rib
Connect backbone harness to rear MV controller

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

Note
Ensure backbone harness guide is installed,
Connect rear display connector to car computer

Note
1x connector
Connect cabin floor harness connector and backbone cable to RH MV controller

Note
1x 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

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
Install RH interior front HV battery mounting bolts

Note
3x bolts, 24mm, 160 Nm
Remove temporarily installed accelerator pedal

Note
2x nuts, 13mm, 10 Nm, 1x connector, Release locking tab
Connect cabin floor harness connector to LH MV controller

Note
1x connector, Secure in locking cover
Secure left MV controller connector locking frame

Note
1x bolt, 8mm, 4 Nm, Ensure connectors are aligned before tightening center bolt
Install LH front interior HV Battery mounting bolts

Note
3x bolts, 24mm, 160 Nm
Install LH carpet support foam

Note
Seat at rear edge
Unfold LH front cabin carpet into position
Install accelerator pedal

Note
2x nuts, 13mm, 10 Nm, 1x connector, Secure locking tab
Install center console

Note
Lower onto riser
Connect center console harness connectors

Note
2x connectors
Install front bolts securing center console to riser

Note
4x bolts, 10mm, 5 Nm
Secure HV outlet onto front console panel

Note
2x screws, T20, 1 Nm, 1x clip
Install center console front panel

Note
10x clips, Replace any missing or damage clips
Install LH front seat into vehicle

Note
Recommend Assistance, Be cautious not to damage surrounding components while lifting the seat into the vehicle
Connect LH front seat harness

Note
1x connector, 2 stage locking tabs, Make connection and engage black lever, then engage yellow locking tab
Install RH front seat into vehicle

Note
Recommend Assistance, Be cautious not to damage surrounding components while lifting the seat into the vehicle
Connect RH front seat harness

Note
1x connector, 2 stage locking tabs, Make connection and engage black lever, then engage yellow locking tab
Install rear bolts securing center console to riser

Note
2x bolts, 10mm, 5 Nm
Secure HV outlet onto rear console panel

Note
3x screws, T20, 1 Nm, 2x clips
Install center console rear panel

Note
10x clips, 3x connectors, 3x harness clips, Replace any missing or damaged clips
Remove battery alignment rods

Note
4x alignment rods
Install RH rear interior HV battery mounting bolts

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

Note
1x connector, 2x bolts, 13mm, 8 Nm, Slide towards outside of vehicle to secure port
Install LH rear interior HV battery mounting bolts

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

Note
1x connector, 2x bolts, 13mm, 8 Nm, Slide towards LH of vehicle to secure outer port to body, Engage locking tab
Install rear wall lower trim

Note
2x push clips, 4x clips
Secure LH lower C-pillar trim

Note
1x clip, 1x datum
Fold down 2nd row 60 seat

Note
Pull tether to release then pivot down until locked in place
Secure RH lower C-pillar trim

Note
1x clip, 1x datum
Fold down 2nd row 40 seat

Note
Pull tether to release then pivot down until locked in place
Install 2nd row floor mat
Perform cooling system vacuum fill. See Cooling System (Vacuum Refill).
Slide eCPA to the right and ensure it is seated against the black lever, Connect fireman's loop 20 seconds after eCPA engagement

Note
2x 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
Remove Universal Lift Pad adapters

Note
4x Adapters, Install original lift pads, Install plugs back into holes in BIW
Remove vehicle from lift

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
Select "Stop Thermal Fill Drain" through UI

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

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

Note
3x bolts, 10mm, 15 Nm, 2x datums
Install rear RH step reinforcement

Note
3x bolts, 10mm, 15 Nm
Install RH rocker cover to rocker carrier

Note
11x clips, 1x datum
Install rocker cover fasteners to RH side ski

Note
6x bolts, 10mm, 10 Nm
Install clip securing RH rocker cover to rear wheel liner

Note
1x clip
Install RH rear rocker fastener to step reinforcement

Note
1x bolt, 10mm, 4 Nm
Secure fore section of rear RH fender flare cover

Note
13x clips, 3x datums total, Ensure no clips are damaged, Replace clips as required
Install clip securing RH rocker cover to front wheel liner

Note
1x clip
Install RH front rocker fastener to step reinforcement

Note
1x bolt, 10mm, 4 Nm
Secure aft section of front RH fender flare cover

Note
11x clips, 3x datum, 1x connector total, Ensure no clips are damaged, Replace clips as required
Secure RH front seat belt to pretensioner

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

Note
2x patch bolts, T45P, 34 Nm, Install new bolts
Install RH carpet support foam

Note
Seat at rear edge
Unfold RH front cabin carpet into position
Install center floor trim

Note
17x clips, Replace any missing or damaged clips, Install lower section first
Install RH center floor rail

Note
4x clips, 3x datums
Install RH lower A-pillar trim

Note
7x clips, 3x datums, 2x tabs
Install RH mid A-pillar trim

Note
2x clips, 2x tabs,
Install RH front floor mat
Move RH front seat forward
Install bolts securing RH front seat rear tracks to vehicle

Note
2x patch bolts, T45P, 34 Nm, Install new bolts
Install LH front rocker step reinforcement

Note
3x bolts, 10mm, 15 Nm, 2x datums
Install rear LH step reinforcement

Note
3x bolts, 10mm, 15 Nm
Install LH rocker cover to rocker carrier

Note
11x clips, 1x datum, Replace any missing or damaged clips
Install rocker cover fasteners to LH side ski

Note
6x bolts, 10mm, 10 Nm
Install clip securing LH rocker cover to rear wheel liner

Note
1x clip
Install LH rear rocker fastener to step reinforcement

Note
1x bolt, 10mm, 4 Nm
Secure fore section of rear LH fender flare cover

Note
13x clips, 3x datums total, Replace any missing or damaged clips
Install clip securing LH rocker cover to front wheel liner

Note
1x clip
Install LH front rocker fastener to step reinforcement

Note
1x bolt, 10mm, 4 Nm
Secure aft section of front LH fender flare cover

Note
11x clips, 3x datum, 1x connector total, Replace any missing or damaged clips
Secure LH front seat belt to pretensioner

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

Note
2x patch bolts, T45P, 34 Nm, Install new bolts
Install LH center floor rail

Note
4x clips, 3x datums
Install accelerator pedal side trim

Note
3x clips, Replace any missing or damaged clips
Install footwell cover

Note
3x clips, 3x magnets, 1x bolt, 10mm, 3 Nm, Bolt is captive to tether, Replace any missing or damaged clips or magnets
Install LH Lower A-pillar trim

Note
7x clips, 3x datums, 2x tabs, Replace any missing or damaged clips
Install LH mid A-pillar trim

Note
2x clips, 2x tabs, Replace any missing or damaged clips
Install LH front floor mat
Move LH front seat forward
Install bolts securing LH front seat rear tracks to vehicle

Note
2x patch bolts, T45P, 34 Nm, Install new bolts
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line, Top off fluid as required
Install coolant bottle cap
Install rear underhood apron

Note
9x clips, Adjust windshield seal as required
Close powered front trunk

Note
Via exterior switch or UI
Perform Thermal Performance through the UI

Note
Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow toolbox articles 206000
Position tonneau transfer frame onto tonneau bed rails

Note
Lay 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

Note
Recommend 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
Secure tonneau chain onto motors

Note
Recommend 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

Note
Disconnect air supply, Lower and adjust angle on powertrain table as needed, Frame TPN: 1999662-00-A
Install RH tailgate bumpstop

Note
1x datum, Rotate and secure
Install RH tonneau slip datum bracket
Install RH tonneau hard stop

Note
3x 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

Note
2x clips, 2x datums
Install RH tonneau water management seal

Note
1x clip, Push seal into rail groove
Secure RH sail applique

Note
6x tabs, Remove inflatable air bag, Clean off double sided tape from sail and applique, Clean with IPA wipes and allow 1 minute dry time, Cut same length tape and apply
Secure LH tailgate bumpstop

Note
1x datum, Rotate and secure
Install LH tonneau slip datum bracket
Install LH tonneau hard stop

Note
3x 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

Note
2x clips 2x datums
Install LH tonneau water management seal

Note
1x clip, Push seal into rail groove
Secure rear LH sail applique

Note
6x tabs, 6x tabs, Remove inflatable air bag, Clean off double sided tape from sail and applique, Clean with IPA wipes and allow 1 minute dry time, Cut double sided tape to length and apply
Close tailgate
Run Tonneau Calibration routine

Note
Via Service Mode UI > Closures > Tonneau > Calibrate Tonneau< Allow routine to complete, Tonneau will move while routine running
Close tonneau cover
Exit Service Mode

Note
Via UI > Service > Exit, Press and hold "Exit Service Mode" button
Raise all 4 windows
Close all 4 doors