Code de correction 16010103502 5.22 REMARQUE : À moins d’indications explicites contraires dans la procédure, le code de correction et le temps à taux fixe (FRT) connexe représentent tout le travail à accomplir pour cette procédure, y compris les procédures connexes. N’appliquez pas plusieurs codes de correction à la fois, à moins qu’il vous soit explicitement indiqué de le faire. REMARQUE : Consultez Temps forfaitaires pour en apprendre plus à propos des temps forfaitaires et de leur création. NOTE : Consultez Protection individuelle pour vous assurer de porter l’équipement de protection individuelle adéquat lorsque vous effectuez la procédure ci-dessous. REMARQUE : Voir Précautions ergonomiques pour consulter les pratiques de travail sécuritaires et saines.

1. Ouvrez toutes les portes et abaissez toutes les glaces.
2. Manually latch all doors to prevent lockout
   Remarque

   Engage latch with screwdriver

   

3. Mettez le véhicule en mode Entretien. Voir Mode Entretien,
4. Déverrouillez la passerelle du véhicule. Voir Passerelle (déverrouiller),
5. Exécutez la routine ODIN PROC_RCM_DISARMvia Service Mode Plus:
   • Safety & Restraints ➜ Airbags ➜ Disarm RCM
   • Safety & Restraints ➜ Seats ➜ Disarm RCM
   via Toolbox:(link)
6. Move vehicle onto lift
   Remarque

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

   

7. Move LH front seat backward
8. Remove bolts securing front of LH front seat tracks to risers
   Remarque

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

   

9. Raise and move LH front seat forward
10. Remove bolts securing rear of LH front seat tracks to floor
    Remarque

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

    

11. Adjust position of LH front seat for easy removal
    Remarque

    Move seat to middle of track at most upright position with seat fully up off floor
12. Move RH front seat backward
13. Remove bolts securing front of RH front seat tracks to risers
    Remarque

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

    

14. Move RH front seat forward
15. Remove bolts securing rear of RH front seat tracks to floor panel
    Remarque

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

    

16. Adjust position of RH front seat for easy removal
    Remarque

    Move seat to middle of track at most upright position with seat fully up off floor
17. Select "Coolant Fill/Drain" through Service UI
    Remarque

    Select 'Coolant System' to enter coolant circuit screen, Select 'Coolant Fill/Drain' and 'PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT' window will appear, Select 'Run', Verify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 5 hour time limit
18. Retirez le tablier arrière situé sous le capot. Voir Underhood Apron - Rear (Remove and Install),
19. Débranchez l’alimentation MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
20. Perform vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (without Terrestrial Armor) (Test/Adjust).
21. Remove leather over gloves and HV insulating gloves
    Remarque

    HV gloves should always be stored in the original packaging and inside a storage box or bag to prevent damage, Make sure that gloves are lying flat not bent or folded
22. Disconnect EPB harness connector from LH rear brake caliper
    Remarque

    1x connector, Release locking tab

    

23. Release the LH rear parking brake with EPB release tool
    Remarque

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

    

    

24. Connect LH rear EPB harness
    Remarque

    1x connector, Engage locking tab

    

25. Disconnect RH rear EPB harness
    Remarque

    1x connector, Release locking tab

    

26. Release the LH rear parking brake with EPB release tool
    Remarque

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

    

    

27. Connect RH rear EPB harness
    Remarque

    1x connector, Engage locking tab

    

28. Lower vehicle until tires are touching ground
    Remarque

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
29. Position wheel chocks fore and aft of RH rear wheel

    

30. Remove vehicle from lift
    Remarque

    Lower rack arms fully and remove them from under vehicle,
31. Roll vehicle rearward
    Remarque

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

    

    

    

32. Release LH front seat belt from pretensioner
    Remarque

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

    

    

    

33. Disconnect LH front seat harness
    Remarque

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

    

    

    

34. Remove LH front seat from vehicle
    Remarque

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

    

    

    

    

35. Release RH front seat belt from pretensioner
    Remarque

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

    

    

    

36. Disconnect RH seat
    Remarque

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

    

    

    

37. Remove RH front seat from vehicle
    Remarque

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

    

    

    

    

38. Remove center console front panel
    Remarque

    10x clips

    

    

39. Remove front bolts securing center console to riser
    Remarque

    4x bolts, 10mm, 5 Nm

    

40. Disconnect center console harness connectors
    Remarque

    2x connectors

    

41. Remove center console back panel
    Remarque

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

    

    

42. Remove rear bolts securing center console to riser
    Remarque

    2x bolts, 10mm, 5 Nm

    

43. Remove center console
    Remarque

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

    

    

44. Remove RH outboard riser bolt cover
    Remarque

    Lift from outer edge then pull away

    

    

    

45. Remove RH seat riser assembly from vehicle
    Remarque

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

    

    

    

46. Remove LH outboard riser bolt cover
    Remarque

    Lift from outer edge then pull away

    

    

47. Remove LH seat riser assembly from vehicle
    Remarque

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

    

    

    

48. Remove footwell cover
    Remarque

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

    

    

    

    

49. Remove LH front floor mat

    

    

    

50. Remove LH mid A-pillar trim
    Remarque

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

    

    

    

51. Remove LH lower A-pillar trim
    Remarque

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

    

    

    

52. Remove LH center floor rail
    Remarque

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

    

    

53. Remove accelerator pedal side trim
    Remarque

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

    

    

    

54. Remove accelerator pedal
    Remarque

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

    

    

55. Remove LH front cabin carpet
    Remarque

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

    

    

    

    

    

56. Remove LH carpet support foam
    Remarque

    Lift up from rear edge

    

    

57. Remove LH front interior HV Battery mounting bolts
    Remarque

    3x bolts, 24mm, 160 Nm

    

58. Remove RH front floor mat

    

    

    

59. Remove RH mid A-pillar trim
    Remarque

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

    

    

    

60. Remove RH lower A-pillar trim
    Remarque

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

    

    

    

61. Remove RH center floor rail
    Remarque

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

    

    

62. Remove center floor trim
    Remarque

    17x clips, Release upper section first

    

    

    

    

63. Remove RH front cabin carpet
    Remarque

    Plastic portions at rear of carpet need to clear risers

    

    

    

    

64. Remove RH carpet support foam
    Remarque

    Lift up from bottom edge

    

    

65. Remove RH interior front HV battery mounting bolts
    Remarque

    3x bolts, 24mm, 160 Nm

    

66. Fold up 2nd row 60 seat
    Remarque

    Pull tether to release then lift up until locked in place

    

67. Remove 2nd row floor mat

    

    

68. Partially release RH lower C-pillar trim
    Remarque

    1x clip, 1x datum

    

    

69. Fold up 2nd row 40 seat
    Remarque

    Pull tether to release then lift up until locked in place

    

    

70. Partially release RH lower C-pillar trim
    Remarque

    1x clip, 1x datum

    

    

71. Remove rear wall lower trim
    Remarque

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

    

    

    

    

    

    

72. Remove rear carpet LH duct bezel
    Remarque

    4x clips

    

    

    

73. Remove rear carpet RH duct bezel
    Remarque

    4x clips

    

    

    

74. Remove rear carpet assembly
    Remarque

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

    

    

    

    

    

75. Remove RH rear interior HV battery mounting bolts
    Remarque

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

    

    

76. Remove LH rear interior HV battery mounting bolts
    Remarque

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

    

    

77. Remove center floor upper bracket
    Remarque

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

    

    

    

    

    

    

78. Remove center floor lower support bracket
    Remarque

    4x clips

    

    

    

79. Remove center console riser duct
    Remarque

    2x clips, Maneuver forward to clear riser assembly

    

    

80. Remove floor jumper duct
    Remarque

    Push forward then lift and slide out

    

    

81. Remove 2nd row duct on rails
    Remarque

    Pull from the bottom to release

    

    

82. Release connectors from RCM
    Remarque

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

    

    

83. Remove RCM fasteners
    Remarque

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

    

84. Remove RCM from vehicle

    

    

85. Release LH MV controller dry side locking cover
    Remarque

    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

    

86. Release floor harness from LH MV controller
    Remarque

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

    

    

87. Release RH MV controller connector lower locking cover
    Remarque

    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

    

88. Release cabin floor and backbone harnesses from RH MV controller
    Remarque

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

    

    

    

89. Disconnect rear display connector from car computer
    Remarque

    1x connector

    

90. Remove cabin floor harness
    Remarque

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

    

91. Remove RH 2nd row floor duct
    Remarque

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

    

    

92. Remove 2nd row floor Y-Duct
    Remarque

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

    

    

93. Release front section of backbone
    Remarque

    3x harness clips, Pass connector under cabin floor harness

    

94. Disconnect backbone harness from rear MV controller
    Remarque

    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

    

    

95. Remove backbone harness
    Remarque

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

    

    

96. Remove the LH rocker panel assembly. See Rocker Panel Assembly - LH (Remove and Install).
97. Remove the LH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).
98. Remove the LH rear rocker step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).
99. Remove the RH rocker panel assembly. See Rocker Panel Assembly - LH (Remove and Install).
100. Remove the RH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).
101. Remove the RH rear rocker step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).
102. Roll vehicle forward
     Remarque

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

     

     

     

103. Move vehicle onto lift
     Remarque

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

     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

     

     

     

105. Raise and support vehicle
     Remarque

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

     

     

     

     

106. Remove fastener covers from bed floor assembly
     Remarque

     6x covers

     

     

107. Remove bed floor assembly
     Remarque

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

     

     

     

     

108. Remove bolts securing HV battery to RUB
     Remarque

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

     

     

     

109. Disconnect ancillary bay MV connector
     Remarque

     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

     

     

     

     

     

110. Remove bolt securing busbar HV connector lid
     Remarque

     1x bolt, EP10, 9 Nm

     

111. Remove bolts securing HV connector to DC FC header
     Remarque

     2x bolts, 10mm, 9 Nm

     

112. Release HV connector from DC FC header
     Remarque

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

     

113. Support HV Busbar assembly
     Remarque

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

     

     

114. Raise vehicle fully
     Remarque

     Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
115. Position coolant drain container underneath RH rear of HV battery

     

116. Remove the RH rear wheel. See Ensemble de roue (retrait et installation)
117. Secure RH rear wheel liner aside

     

118. Disconnect RDU return hose from PT return hose
     Remarque

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

     

     

119. Disconnect coolant hoses from PCS coolant inlet and outlet couplers
     Remarque

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

     

     

120. Move coolant drain container to front right of HV battery

     

121. Remove the RH front wheel. See Ensemble de roue (retrait et installation).
122. Secure RH front wheel liner aside

     

123. Disconnect PT supply and return hoses
     Remarque

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

     

124. Disconnect battery coolant supply and return hoses
     Remarque

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

     

     

125. Remove coolant drain container from underneath vehicle
126. Release A/C compressor HV harness from HV battery
     Remarque

     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

     

     

     

127. Release RDU HV harness from HV battery
     Remarque

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

     

128. Position battery table under vehicle
     Remarque

     Ensure table is level, center table to HV battery

     

129. Remove front exterior HV Battery mounting bolts and ground strap
     Remarque

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

     

130. Remove side exterior HV battery mounting bolts from LH and RH side
     Remarque

     16x bolts, 15mm, 60 Nm

     

131. Raise vehicle away from HV battery
     Remarque

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

     

132. Remove HV battery from underneath vehicle
     Remarque

     Recommend assistance

     

133. Connect coolant Drain and Fill Adapter to PCS inlet hose coupling
     Remarque

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

     

134. Secure coolant cart flush hose to regulator and PT Flush adapter
     Remarque

     Verify regulator valve is closed, Pressure regulator is not adjustable (set at 20 psi)

     

     

     

135. Secure PCS Drain adapter to PCS outlet using male-to-male adapter
     Remarque

     Verify valve is closed, Remove plug as required, Verify fully seated, Perform push-pull-push test

     

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

     

     

     

137. Open valve on PCS Drain adapter

     

138. Connect shop air to regulator
     Remarque

     Make sure regulator valve is closed prior to connecting shop air

     

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

     Allow coolant to drain

     

140. Close valve on pressure regulator once no more coolant is draining

     

141. Close valve on PCS Drain adapter

     

142. Remove cart drain hose from PCS Drain adapter

     

143. Remove PCS Drain adapter from PCS outlet
     Remarque

     1x spring clip

     

144. Disconnect coolant hose extension from Drain and Fill adaptor
     Remarque

     Press grey button to release hose fitting

     

145. Remove PT Flush adapter from PCS inlet coupling
     Remarque

     1x spring clip

     

146. Attach coolant cart flush hose to HV battery
     Remarque

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

     

     

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

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

     

     

148. Open valve on P2 Battery Drain adapter

     

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

     Allow coolant to drain

     

150. Close valve on pressure regulator once no more coolant is draining

     

151. Disconnect compressed air from coolant pressure tester

     

152. Close valve on P2 Battery drain adapter

     

153. Remove cart drain hose and PCS drain adapter from HV battery

     

     

     

     

154. Remove cart flush hose and PCS flush adapter from battery

     

     

     

155. Remove powertrain hose bundle
     Remarque

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

     

     

     

156. Obtain HV battery vitals screenshot
     Remarque

     Reference steps in 16018725
157. Attach HV battery H-frame to gantry and raise into position

     

158. Secure the P2 battery sling adapter to H-frame
     Remarque

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

     

     

     

     

159. Remove top housing from new HV battery crate
     Remarque

     Recommend assistance

     

160. Position gantry over HV battery crate
     Remarque

     Recommend assistance

     

161. Lower H-frame to HV battery crate

     

162. Secure P2 sling adapter to HV battery
     Remarque

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

     

     

     

     

     

163. Lift new HV battery out of crate

     

     

164. Move gantry away from HV battery crate
     Remarque

     Recommend assistance

     

165. Position unused HV battery table under gantry

     

166. Lower HV battery onto battery table

     

     

167. Release P2 battery sling adapter from HV battery
     Remarque

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

     

     

     

168. Remove HV battery and table from under gantry
     Remarque

     Recommend assistance

     

     

169. Position old HV battery and table under gantry
     Remarque

     Recommend assistance

     

170. Secure P2 sling adapter to HV battery
     Remarque

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

     

     

     

     

     

171. Raise HV battery off of battery table

     

     

     

172. Remove empty HV battery table from under gantry

     

173. Position gantry over HV battery crate
     Remarque

     Recommend assistance

     

174. Lower old HV battery into crate
     Remarque

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

     

     

175. Remove ancillary HV dummy plugs from old HV battery pack
     Remarque

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

     

176. Release P2 battery sling adapter from HV battery
     Remarque

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

     

     

     

177. Raise gantry and H-frame from crate

     

178. Secure top housing onto HV battery crate
     Remarque

     Recommend assistance, Adhere to proper MRB process

     

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

     

     

180. Remove FDU HV harness
     Remarque

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

     

     

     

181. Apply backbone harness abrasion protection
     Remarque

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

     

182. Install ancillary HV dummy plugs onto new HV battery pack
     Remarque

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

     

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

     1x plug, 8Nm, Install as needed

     

     

     

184. Install powertrain hose bundle
     Remarque

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

     

     

     

185. Install HV battery alignment rods into front casting
     Remarque

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

     

     

     

186. Lower vehicle onto HV battery
     Remarque

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

     

187. Install side exterior HV battery mounting bolts onto LH and RH side
     Remarque

     16x bolts, 15mm, 60 Nm

     

188. Remove HV battery alignment rods from front casting
     Remarque

     2x alignment rods

     

189. Install front exterior HV Battery mounting bolts and ground strap
     Remarque

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

     

190. Raise vehicle away from battery table
     Remarque

     Set to a comfortable working height, Ensure lift is lowered onto a lock
191. Remove battery table from under vehicle

     

192. Connect FDU HV harness to front Drive Unit
     Remarque

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

     

     

     

193. Secure A/C compressor HV harness onto battery
     Remarque

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

     

     

     

     

194. Secure RDU HV harness to HV battery
     Remarque

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

     

195. Position coolant drain container underneath RH rear of HV battery

     

196. Connect RDU return hose to PT return hose
     Remarque

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

     

     

197. Connect RDU supply hose to HV Battery
     Remarque

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

     

198. Move coolant drain container to front right of HV battery

     

199. Connect PT supply and return hoses
     Remarque

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

     

200. Connect battery supply and return coolant hoses
     Remarque

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

     

     

201. Remove coolant drain container from underneath vehicle
202. Install the rear skid plate. See Skid Plate - Rear (Remove and Install).
203. Install the skid plate stamping. See Skid Plate Stamping (Remove and Replace).
204. Install the skid plate. See Skid Plate (Remove and Install).
205. Install the RH front and rear wheels. See Ensemble de roue (retrait et installation).
206. Install bolts securing HV battery to RUB
     Remarque

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

     

     

     

207. Inspect HV insulating gloves
     Remarque

     Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.tesla.com/en-US/documents

     

208. Put on HV insulating gloves and leather over gloves

     

209. Clean contact surface of HV DC inlet posts
     Remarque

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

     

210. Clean busbar HV connector contact surface of residual Penetrox
     Remarque

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

     

211. Apply Penetrox onto HV DC Inlet posts
     Remarque

     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

     

212. Install busbar onto HV header and install bolts
     Remarque

     2x bolts, 10mm, 9 Nm

     

     

213. Connect HV ancillary harness
     Remarque

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

     

214. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
     Remarque

     2x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe acceptable resistance is between 0.005 mΩ (5 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session.If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step

     

     

215. Install bolt securing busbar HV connector lid
     Remarque

     1x bolt, EP10, 9 Nm

     

216. Remove leather over gloves and HV insulating gloves
     Remarque

     HV gloves should always be stored in the original packaging and inside a storage box or bag to prevent damage, Make sure that gloves are lying flat not bent or folded
217. Connect ancillary bay MV connector
     Remarque

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

     

     

     

     

     

218. Install bed floor assembly
     Remarque

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

     

     

     

     

     

219. Install fastener covers onto bed floor assembly
     Remarque

     14x covers

     

     

     

     

220. Position wheel chocks fore and aft of RH rear wheel

     

221. Remove vehicle from lift
     Remarque

     Lower rack arms fully and remove them from under vehicle,
222. Roll vehicle rearward
     Remarque

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

     

     

     

223. Install backbone harness
     Remarque

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

     

     

224. Inspect for presence of backbone harness guide at front casting
     Remarque

     Ensure backbone harness guide is installed

     

225. Secure front section of backbone
     Remarque

     3x clips, Route connector under cabin floor harness

     

226. Inspect backbone harness for misalignment near rear ribs
     Remarque

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

     

     

     

227. Install 2nd row floor Y-Duct
     Remarque

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

     

     

228. Connect backbone harness to rear MV controller
     Remarque

     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

     

     

229. Install cabin floor harness
     Remarque

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

     

     

     

230. Position RCM for installation

     

231. Install RCM to HV battery assembly
     Remarque

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

     

232. Secure connectors onto RCM
     Remarque

     2x connectors, Engage locking tabs

     

     

233. Install RH 2nd row floor duct
     Remarque

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

     

234. Connect rear display connector to car computer
     Remarque

     1x connector

     

235. Secure cabin floor and backbone harnesses onto RH MV controller
     Remarque

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

     

     

     

236. Secure RH MV controller connector locking cover
     Remarque

     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

     

237. Secure floor harness onto LH MV controller
     Remarque

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

     

     

238. Secure LH MV controller dry side locking cover
     Remarque

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

     

239. Install RH interior front HV battery mounting bolts
     Remarque

     3x bolts, 24mm, 160 Nm

     

240. Install RH carpet support foam
     Remarque

     Seat at rear edge

     

241. Install LH front interior HV Battery mounting bolts
     Remarque

     3x bolts, 24mm, 160 Nm

     

242. Install LH carpet support foam
     Remarque

     Seat at rear edge

     

243. Install 2nd row dual duct on rails
     Remarque

     Maneuver as needed through foam insert

     

244. Install floor jumper duct
     Remarque

     2x clips

     

     

245. Install center console riser duct
     Remarque

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

     

     

246. Install center floor lower support bracket
     Remarque

     4x clips, Replace any missing or damaged clips

     

     

     

247. Install center floor upper bracket
     Remarque

     2x push clips, 4x clips

     

     

     

     

     

     

248. Install RH front cabin carpet
     Remarque

     Plastic portions at rear of carpet need to clear risers

     

     

     

     

249. Install LH front cabin carpet
     Remarque

     Plastic portions at rear of carpet need to clear risers

     

     

     

     

     

250. Install rear carpet assembly
     Remarque

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

     

     

     

     

     

251. Install LH seat riser assembly
     Remarque

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

     

     

     

     

252. Install LH outboard riser bolt cover

     

     

253. Install RH seat riser assembly
     Remarque

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

     

     

254. Install RH outboard riser bolt cover

     

     

     

255. Install LH rear carpet duct bezel
     Remarque

     4x clips, Replace any missing or damaged clips

     

     

     

256. Install rear carpet RH duct bezel
     Remarque

     4x clips, Replace any missing or damaged clips

     

     

     

257. Position center console in vehicle
     Remarque

     Lower onto riser

     

     

258. Connect center console harness connectors
     Remarque

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

     

259. Install front bolts securing center console to riser
     Remarque

     4x bolts, 10mm, 5 Nm

     

260. Install center console front panel
     Remarque

     10x clips, Replace any missing or damage clips

     

     

261. Install rear bolts securing center console to riser
     Remarque

     2x bolts, 10mm, 5 Nm

     

262. Install center console rear panel
     Remarque

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

     

     

     

263. Position LH front seat into vehicle
     Remarque

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

     

     

     

264. Connect LH front seat harness
     Remarque

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

     

     

     

265. Position RH front seat into vehicle
     Remarque

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

     

     

     

266. Connect RH front seat harness
     Remarque

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

     

     

     

267. Remove HV battery alignment rods from stancion mounting holes on pack
     Remarque

     2x alignment rods

     

268. Install RH rear interior HV battery mounting bolts
     Remarque

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

     

     

     

269. Install LH rear interior HV battery mounting bolts
     Remarque

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

     

     

     

270. Install rear wall lower trim
     Remarque

     2x push clips, 4x clips

     

     

     

     

     

     

271. Secure LH lower C-pillar trim
     Remarque

     1x clip, 1x datum

     

272. Fold down 2nd row 60 seat
     Remarque

     Pull tether to release then pivot down until locked in place

     

     

273. Install RH lower C-pillar trim
     Remarque

     1x clip, 1x datum

     

274. Fold down 2nd row 40 seat
     Remarque

     Pull tether to release then pivot down until locked in place

     

     

275. Install 2nd row floor mat

     

     

276. Branchez l'alimentation électrique MT. Voir Mid-Voltage Power (Disconnect and Connect) (Modify),
277. Select 'High Voltage Procedures
     Remarque

     Lighting Bolt Icon > High Voltage > Procedures

     

     

278. Select 'HV Battery Replacement Procedure'
     Remarque

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

     

279. Exécutez la routine ODIN UPDATE_CAN-REDEPLOYvia Service Mode Plus:
     • Drive Inverter Replacement ➜ Drive Inverter DIRE1L Replacement ➜ CAN Redeploy
     • Drive Inverter Replacement ➜ Drive Inverter DIRE1R Replacement ➜ CAN Redeploy
     • Drive Inverter Replacement ➜ Drive Inverter DIRE2 Replacement ➜ CAN Redeploy
     • Drive Inverter ➜ Front Drive Inverter Replacement ➜ CAN Redeploy
     • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ CAN Redeploy
     • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ CAN Redeploy
     • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ CAN Redeploy
     • Drive Unit ➜ Front Drive Unit Replacement ➜ CAN Redeploy
     • Drive Unit ➜ Rear Drive Unit Replacement ➜ CAN Redeploy
     • Thermal ➜ HVAC ➜ CAN Redeploy
     • chassis ➜ DPB Post Replacement ➜ CAN Redeploy
     • chassis ➜ ESP Post Replacement ➜ CAN Redeploy
     • chassis ➜ IDB Post Replacement ➜ CAN Redeploy
     • chassis ➜ RCU Post Replacement ➜ CAN Redeploy
     • chassis ➜ ESP Replacement Panel ➜ CAN Redeploy
     • chassis ➜ IBST Replacement Panel ➜ CAN Redeploy
     via Toolbox:(link)
280. Select 'HV Battery Replacement Procedure'
     Remarque

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

     

281. Remove vehicle from lift
     Remarque

     Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
282. Remove Universal Lift Pad adapters
     Remarque

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

     

     

     

283. Exécutez la routine ODIN PROC_EGGRIGHT3_X_THERMAL-FILL-DRAIN-STOPvia Service Mode:
     • Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
     • Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
     • Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
     via Service Mode Plus:
     • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
     • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
     • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
     • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
     • Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
     • Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
     via Toolbox:(link)
284. Exécutez la routine ODIN PROC_EGGRIGHT3_X_THERMAL-COOLANT-AIR-PURGE-STARTvia Service Mode Plus:
     • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
     • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
     via Toolbox:(link)
285. Install the RH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).
286. Install the RH rear step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).
287. Install the RH rocker cover to rocker carrier. See Rocker Panel Assembly - LH (Remove and Install)
288. Secure RH front seat belt to pretensioner
     Remarque

     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.

     

     

     

289. Move RH front seat backward
290. Install bolts securing RH front seat front tracks to vehicle
     Remarque

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

     

291. Install center floor trim
     Remarque

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

     

     

     

     

292. Install RH center floor rail
     Remarque

     4x clips, 3x datums

     

     

293. Install RH lower A-pillar trim
     Remarque

     7x clips, 3x datums, 2x tabs

     

     

     

294. Install RH mid A-pillar trim
     Remarque

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

     

     

     

295. Install RH front floor mat

     

     

     

296. Move RH front seat forward
297. Install bolts securing RH front seat rear tracks to vehicle
     Remarque

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

     

298. Install the LH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).
299. Install the LH rear step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).
300. Install the LH rocker cover to rocker carrier. See Rocker Panel Assembly - LH (Remove and Install)
301. Secure LH front seat belt to pretensioner
     Remarque

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

     

     

     

302. Move LH front seat backward
303. Install bolts securing both LH front seat front tracks to vehicle
     Remarque

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

     

304. Install LH center floor rail
     Remarque

     4x clips, 3x datums

     

     

305. Install accelerator pedal
     Remarque

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

     

     

306. Install accelerator pedal side trim
     Remarque

     3x clips, Replace any missing or damaged clips

     

     

     

307. Install footwell cover
     Remarque

     3x clips, 3x magnets, 1x bolt, 10mm, 3 Nm, Bolt is captive to tether, Replace any missing or damaged clips or magnets

     

     

     

     

308. Install LH Lower A-pillar trim
     Remarque

     7x clips, 3x datums, 2x tabs, Replace any missing or damaged clips

     

     

     

309. Install LH mid A-pillar trim
     Remarque

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

     

     

     

310. Install LH front floor mat
311. Move LH front seat forward
312. Install bolts securing LH front seat rear tracks to vehicle
     Remarque

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

     

313. Inspect coolant level and top off as necessary
     Remarque

     Ensure the fluid level is at the Max line, Top off fluid as required

     

314. Install coolant bottle cap

     

315. Installez le tablier sous le capot. Voir Underhood Apron - Rear (Remove and Install),
316. Perform Thermal Performance Test through the UI
     Remarque

     Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow toolbox article 206000

     

     

     

     

317. Close tailgate
318. Exécutez la routine ODIN PROC_RCM_ARMvia Service Mode Plus:
     • Safety & Restraints ➜ Airbags ➜ Re-Arm RCM
     • Safety & Restraints ➜ Seats ➜ Re-Arm RCM
     via Toolbox:(link)
319. Exécutez la routine ODIN PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox:(link)
320. Raise all four windows
321. Close all four doors