2026-08-09

Tube - HV Battery Return (Dual Motor) (Remove and Replace)

Correction code 18302605002 FRT 3.24 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

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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.

Remove

  1. Remove the LH and RH rocker panel lower covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).
  2. Open all four doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    If vehicle is being powered down, latch rear doors to prevent accidental closure.
  3. Lower all four windows.
  4. Move LH front seat backward.
  5. Remove LH front floor mat.
  6. Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  7. Move the LH front seat forward, and then remove and discard the LH front seat rear bolts (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • Torx Plus T45 socket
  8. Move the LH front seat backward, and then remove and discard the LH front seat front bolts (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • Torx Plus T45 socket
  9. Release the driver footwell cover. See Cover - Footwell - Driver (Remove and Replace).
  10. Remove the LH center console side panel. See Carpet - Side - Center Console - LH (Remove and Replace).
  11. Remove the LH front main cabin carpet clips.
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    Note
    2x push clips. Number of clips on new vehicles may vary.
  12. Tilt the LH front seat backward.
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    Note
    It is not necessary to disconnect the LH seat harness from the body controller.
  13. Fold the LH front main cabin carpet aside for access.
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    Note
    Dead pedal and foam block are part of carpet.
  14. Remove the LH front footwell HV battery bolts (x2).
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    Note
    Use of the following tool(s) is recommended:
    • Torx Plus EP20 socket
    • Cordless Ratchet/Impact Driver
  15. Remove the HV battery bolt below the rear end of the LH front seat cushion.
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    Note
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 16 mm socket
  16. Repeat the step 4 to step 15 for the RH front side.
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    Note
    For the front passenger footwell cover removal, see Cover - Footwell - Front Passenger (Remove and Replace).
  17. Remove the 2nd row floor mat from the vehicle.
  18. Release the 2nd row seat cushion and disconnect harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 2x connectors. Press tabs backward and then pull front edge up.
  19. Pull back rear carpet to access rear interior battery bolts.
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    Note
    2x push clips.
  20. Remove LH rear HV battery interior bolt.
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    Note
    1x bolt, 16mm, 66 Nm, Lift up carpet for access.
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    Note
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 16 mm deep socket
  21. Close the LH rear door latch manually.
  22. Remove RH rear HV battery interior bolt.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Lift up carpet for access.
  23. Close the RH rear door latch manually.
  24. Raise and support the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove body plugs and install M3 lift pad adapters to indicated locations .
  25. Place vehicle in Service Mode Plus via the Vehicle Ops mobile app or connecting laptop with Toolbox.
    Informational PurposesAn informational icon, calling your attention
    Note
    Using Vehicle Ops mobile app, enter last six digits of VIN, select vehicle from list, then swipe to the left and select "Enable Service Mode Plus". The Vehicle Ops mobile app can be downloaded at: https://mobile.tesla.com/AppStore/Home/AppDetails?appId=6.
  26. Unlock vehicle gateway.
    Informational PurposesAn informational icon, calling your attention
    Note
    After 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.
  27. Run Thermal Fill Drain (Coolant Only) through the UI: Select Thermal > Coolant System > Coolant Fill/Drain, and touch Run.
    Informational PurposesAn informational icon, calling your attention
    Note
    Close the routine once it's completed. Thermal Fill Drain routine has a 5-hour time limit. After 5 hours, the routine must be performed again.
  28. Disconnect the LV battery power. See LV Power (Disconnect and Connect).
  29. Remove all items from pockets and ensure not wearing metal items.
  30. Perform the Vehicle HV Disablement procedure. See GUID-3C5B5D4F-24A7-4EAE-B382-C93A2DEC1BFA.html.
  31. Remove the fastener securing the busbar cover access door.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 9 Nm.
  32. Remove bolts securing charge port busbar kit to HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm.
  33. Lift busbar kit connector to remove from HV header.
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    Note
    4x guide tabs. Ease removal of aluminum connector housing by shifting rear end of busbar assembly upward.
  34. Remove HV insulating gloves.
  35. Disconnect HVC logic connector and install the logic cap.
  36. Remove the bolt that attaches the DCDC ground busbar to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 12 mm socket
    • 4 in extension
    • Ratchet/torque wrench
  37. Remove and discard the nut that attaches the DCDC ground busbar to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 4 in extension
    • Ratchet/torque wrench
    • 13 mm socket
  38. Remove the DCDC ground busbar.
  39. Remove and discard the nut that secures the positive LV output from PCS cable and move the cable aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 4 in extension
    • Ratchet/torque wrench
    • 13 mm socket
  40. Raise vehicle fully and lower lift onto locks.
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height. Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side. Verify doors are clear of surrounding objects.
  41. Remove LH and RH clips securing rear aero shield to wheel house liner.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips.
  42. Remove the rear aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm.
  43. Remove the outer fasteners securing front aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 10mm, 5 Nm.
  44. Remove remaining nuts and remove front aero shield from vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 15mm, 8 Nm.
  45. Remove push clips securing lower rear edge of LH front wheel liner to vehicle to access the coolant hose.
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    Note
    3x push clips.
  46. Remove bolt securing LH front wheel liner to skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm.
  47. Use bungee strap to pull back LH front wheel liner.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure to subframe.
  48. Repeat step 45 to step 47 for the RH front side.
  49. Position the coolant drain container underneath RH front of HV battery.
  50. Release the FDU inverter inlet hose on the RH side of the vehicle and plug both hose ends.
  51. Disconnect the powertrain supply hose from the powertrain supply tube and plug the hose ends as needed.
  52. Position the coolant drain container underneath LH front of HV battery.
  53. Disconnect the HV battery return tube from the HV battery hose and install plugs on both hose ends.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs. Located on the LH front of the HV battery. Coolant loss greater than 1 L will require a vacuum fill.
  54. Disconnect the HV battery manifold hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs. Plug hoses as required.
  55. Disconnect A/C compressor HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x Red locking tab. 2-stage push-release connector. Unlock it by pulling back the red tab, then push the orange lip and pull back for stage 1. Finally, push the green lip and pull back to disconnect.
  56. Remove the bolt that secures the FDU HV harness to the FDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 mm socket
  57. Disconnect the FDU HV harness connector by releasing the locking tab and rotate the release lever up.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not force the release lever up. Ensure the alignment tabs on the FDU header are not damaged.
  58. Attach hose extension to coolant drain hose for extra length.
  59. Remove the bolt that secures the FDU ground strap to FDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 mm socket
  60. Release the FDU ground strap harness clip from FDU.
  61. Remove the rear skid plate from the HV battery. See GUID-6918CF51-E4C9-41F2-924E-A2A218C5CDD4.html.
  62. Position coolant drain container underneath LH rear of HV battery.
  63. Disconnect LH coolant hose from rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Plug both the coolant hose and passthrough .
  64. Remove fir tree clip securing coolant hose to rear subframe shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip.
  65. Disconnect RDU inverter inlet tube from LH rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill.
  66. Position coolant drain container underneath RH rear of vehicle.
  67. Disconnect rear PT supply hose from rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill.
  68. Support front portion of rear subframe.
  69. Release clips securing coolant hoses to LH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips.
  70. Remove smaller fasteners securing LH shear plate.
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    Note
    2x bolts, 13mm, 35 Nm.
  71. Remove large bolt securing LH shear plate and subframe to body and remove shear plate.
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    Note
    1x bolt, 21mm, 130 Nm, Discard after removal.
  72. Hand tighten bolt securing LH side of subframe to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm.
  73. Release clips securing coolant hoses to RH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips.
  74. Remove smaller fasteners for RH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm.
  75. Remove large bolt securing RH shear plate and subframe to body and remove shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Discard at later step.
  76. Hand tighten bolt securing RH side of subframe to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm.
  77. Remove support stand from under vehicle.
  78. Remove nut securing RDU HV cable bracket to HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm, Number of fasteners may vary.
  79. Disconnect RDU HV cable from HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged.
  80. Place HV battery table into position and lower vehicle to support HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Line up table so center 4 bolts are accessible through opening in table, Adjust final battery table position using adjustable caster jacks on table.
  81. Remove central bolts securing HV battery center ski cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP14, 34 Nm.
  82. Remove bolts securing LH front support bracket to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm.
  83. Remove bolts securing RH front support bracket to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm.
  84. Remove LH bolts securing HV battery to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm.
  85. Remove RH bolts securing HV battery to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm.
  86. Raise vehicle free of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
  87. Remove battery from under vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
  88. Install the penthouse engagement seal (1554330-00-C) onto the HV battery pack.
    Informational PurposesAn informational icon, calling your attention
    Note
    This seal is a one-time-use item and must be replaced each time the HV battery pack is removed from the vehicle, or when installing it onto a new HV battery pack that is not already equipped with the seal.
  89. Release clips securing HV battery return tube from rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips.
  90. Release HV battery return tube from LH side of HV battery and allow hose to fully drain.
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Remove all coolant plugs from hose and allow coolant to fully drain.

Install

  1. Install HV battery return tube onto LH side of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips.
  2. Remove plug and connect HV battery return tube to LH rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x plug, Perform push-pull-push test to make sure hose is fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill.
  3. Install clips securing HV battery return tube onto rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips.
  4. Remove plug and connect HV battery return tube to RH rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x plug, Perform push-pull-push test to make sure hose is fully engaged.Loss of coolant greater than 1L requires coolant vacuum fill.
  5. Install HV battery alignment rods.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x rods to the body at the front of the vehicle. 2x rods to the battery near the ancillary bay.
  6. Position HV battery under vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
  7. Lower vehicle onto HV battery and align holes.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance. Use alignment rods. Be sure coolant hoses do not get caught on alignment rods. Caution not to damage HV cable. Do not fully lower vehicle onto battery (this will help with installing battery bolts).
  8. Set RH bolts (x8) securing HV battery to vehicle with cordless impact.
    35 Nm (25.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure smooth thread engagement and bolts are not cross threaded into casting. Flush down bolts. Do not over tighten bolts. Fully torque at later step.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 3 in extension
    • 13 mm socket
    • Cordless Ratchet/Impact Driver
  9. Set LH bolts (x8) securing HV battery to vehicle with cordless impact.
    35 Nm (25.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure smooth thread engagement and bolts are not cross threaded into casting. Flush down bolts. Do not over tighten bolt. Fully torque at later step.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 3 in extension
    • 13 mm socket
    • Cordless Ratchet/Impact Driver
  10. Remove HV battery alignment rods.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x rods to the body at the front of the vehicle. 2x rods to the battery near the ancillary bay.
  11. Set bolts (x4) securing RH front support bracket to vehicle with cordless impact.
    110 Nm (81.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure smooth thread engagement and bolts are not cross threaded into casting. Flush down bolts. Do not over tighten bolts. Fully torque at later step.
  12. Set bolts (x4) securing LH front support bracket to vehicle with cordless impact.
    110 Nm (81.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure smooth thread engagement and bolts are not cross threaded into casting. Flush down bolts. Do not over tighten bolts. Fully torque at later step.
  13. Set central bolts (x4) securing HV battery center ski cover with cordless impact.
    34 Nm (25.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure smooth thread engagement and bolts are not cross threaded into casting. Flush down bolts. Do not over tighten bolts. Fully torque at later step.
  14. Install the bolts securing the HV battery to the body at the LH shear plate area hand-tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm. Torque at later step.
  15. Install the bolts securing the HV battery to the body at the RH shear plate area hand-tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm. Torque at later step.
  16. Connect RDU HV cable to HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector. Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector. Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position.
  17. Install nut securing RDU HV cable bracket to HV battery.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Number of fasteners may vary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 10 mm socket
    • Ratchet/torque wrench
  18. Remove hose plugs and connect RDU outlet hose to PT return tube.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs. Perform push-pull-push test to make sure hose is fully engaged. Use shop towel to clean any coolant residue if necessary. Loss of coolant greater than 1L requires coolant vacuum fill.
  19. Remove plugs and connect RDU inverter inlet hose to LH rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip. Perform push-pull-push test to make sure hose is fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill.
  20. Position HV battery rear skid plate enclosure onto HV battery for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance if needed.
  21. Install upper bolts securing HV battery rear skid plate enclosure hand-tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm. Torque at later step.
  22. Install upper nut securing HV battery rear skid plate enclosure hand-tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm. Torque at later step.
  23. Install lower bolts (x2) securing HV battery rear skid plate enclosure.
    13 Nm (9.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Earlier vins may be equipped with additional bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 4 in extension
    • External Torx Plus EP10
    • Ratchet/torque wrench
  24. Lower vehicle onto pack completely.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
  25. Torque RH bolts (x8) securing HV battery to vehicle.
    35 Nm (25.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 3 in extension
    • 13 mm socket
    • Flex head ratchet/flex head torque wrench
  26. Torque LH bolts (x8) securing HV battery to vehicle.
    35 Nm (25.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 3 in extension
    • 13 mm socket
    • Flex head ratchet/flex head torque wrench
  27. Torque bolts securing RH front support bracket to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm.
  28. Torque bolts securing LH front support bracket to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm.
  29. Torque central bolts securing HV battery center ski cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP14, 34 Nm.
  30. Torque bolts securing HV battery rear skid plate enclosure to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm.
  31. Torque upper nut securing HV battery rear skid plate enclosure .
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm.
  32. Torque lower bolts securing rear battery enclosure skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm. Earlier vins may be equipped with additional bolts.
  33. Install RH side coolant hose clips to HV battery rear skid plate enclosure .
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips.
  34. Install LH side coolant hose clip to HV battery rear skid plate enclosure.
  35. Raise vehicle and lower onto locks, then remove battery table from under vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance. Set vehicle to comfortable working height. Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
  36. Support front portion of rear subframe.
  37. Remove smaller fasteners for LH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolt, 13mm, 35 Nm.
  38. Remove smaller fasteners for RH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolt, 13mm, 35 Nm.
  39. Install LH front bolt and shear plate to rear subframe hand-tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm. Install new bolt. Torque at later step.
  40. Install bolts securing LH shear plate to HV battery hand-tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm.
  41. Install RH front bolt and shear plate to rear subframe hand-tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm. Install new bolt. Torque at later step.
  42. Install bolts securing RH shear plate to HV battery hand-tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm.
  43. Torque bolts securing shear plates to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm.
  44. Torque bolt securing subframe and LH shear plate to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x front bolt, 21mm, 130 Nm. Mark bolt after torque.
  45. Torque bolt securing subframe and RH shear plate to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x front bolt, 21mm, 130 Nm. Mark bolt after torque.
  46. Remove support stand from under vehicle.
  47. Install clips securing coolant hoses to RH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips.
  48. Install clips securing coolant hoses to LH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips.
  49. lnstall rear aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm. Apply Loctite 222 onto rear aero shield bolts.
  50. Install LH and RH clips securing rear aero shield to wheel house liner.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips.
  51. Connect HV battery manifold hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip. Remove plugs.
  52. Connect PT supply hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip. Remove plugs. Perform push-pull-push test to make sure hose is fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill.
  53. Connect PT return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip. Remove plugs. Perform push-pull test to verify hoses are fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill.
  54. Install front skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP10, 13 Nm, 2x tabs. Position and move backward to installation.
  55. Release RH front wheel liner from bungee strap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove strap from vehicle.
  56. Install bolt securing RH front wheel liner to skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm. Apply Loctite 222 onto front wheel liner bolts.
  57. Install the push clip securing lower edge of RH front wheel liner to vehicle.
  58. Connect HV battery return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip.
  59. Release LH front wheel liner from bungee strap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove strap from vehicle.
  60. Install bolt securing LH front wheel liner to skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm.
  61. Install the push clip securing lower edge of LH front wheel liner to vehicle.
  62. Connect A/C compressor HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector. Engage locking tab.
  63. Secure the FDU ground strap harness clip to FDU.
  64. Install the bolt that secures FDU ground strap to FDU.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 mm socket
  65. Install the FDU HV harness connector to FDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the HV connector lever lock onto the FDU HV cable connector. Align the connector to the FDU, then remove the HV connector lever lock before fully latching the connector. Use one hand to support the connector while using the other hand to latch the locking tab. Once installed, verify that the latch is not damaged and is fully secured in the latched position.
  66. Position front aero shield onto vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 15mm, 5 Nm. Hand-tighten the nuts to temporarily hold the panel in place.
  67. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 10mm, 5 Nm.
  68. Lower vehicle fully.
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
  69. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill (Test/Adjust).
  70. Inspect and put on the HV insulating gloves and leather gloves.
  71. Use alcohol wipe to clean the HV connector contact surface of residual Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute to dry. New busbar comes with penetrox applied to HV connector.
  72. Apply 2 drops of Penetrox A-13, each about 5 mm in diameter, to either side of the hole on both leads. Spread evenly to ensure the contact surface is fully covered.
  73. Position busbar kit connector and lower onto HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x guide tabs. Shift rear end of busbar assembly upward to help ease installation. If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary.
  74. Install bolts securing charge port busbar kit to HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm.
  75. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).
  76. Install fastener securing busbar cover access door.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 9 Nm.
  77. Remove the HV insulating gloves.
  78. Install DCDC ground busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slotted hole goes to body side.
  79. Install bolt securing DCDC ground busbar to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 12mm, 20 Nm.
  80. Install the new nut securing DCDC ground busbar to HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 13mm, 9 Nm.
  81. Connect DCDC positive cable to right body harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector,1x clip. Connect the connector and push in the red locking tab.
  82. Remove logic cap and connect HVC logic connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x cap. Align connector and then pull the handle to locking position to get the connector fully seated.
  83. Connect the LV battery power. See LV Power (Disconnect and Connect).
  84. Remove lift arms from below vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove them from under vehicle.
  85. Move vehicle away from lift.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position to allow easy access to interior.
  86. Unlock the vehicle gateway. See Gateway Unlock.
  87. Run "Stop Thermal Fill/Drain" through UI.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow routine to complete and ensure the routine is successful.
  88. Inspect coolant level and top off as necessary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that fluid level is at Max line.
  89. Select "Start Coolant Air Purge" using the UI.
    Informational PurposesAn informational icon, calling your attention
    Note
    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, 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.
  90. Install RH rear HV battery interior bolt.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm. Lift up carpet for access.
  91. Install LH rear HV battery interior bolt.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm. Lift up carpet for access.
  92. Install rear carpet section.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips. Tuck corners under lower C pillar trim.
  93. Connect 2nd row seat harness and secure cushion.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 2x connectors. Insert buckles through holes. Slide rear inward then align front clips. Perform push-pull-push test.
  94. Close LH and RH rear doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release latch before closing if manually latched.
  95. Install LH front footwell HV battery bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm.
  96. Install HV battery bolt below rear end of LH front seat cushion.
    66 Nm (48.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 16 mm socket
    • Cordless Ratchet/Impact Driver
  97. Install LH front main cabin carpet to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips. Number of clips on new vehicles may vary.
  98. Install LH console side panel carpet.
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x positioning clips, 1x tab. Position side panel and align the front tab. Push the console panel from the front towards the rear.
  99. Install connectors to LH footwell cover .
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x OBDII connector. Ensure tabs engage on OBDII connector.
  100. Install LH footwell cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x magnets,1x guide tab.
  101. Reposition the LH front seat onto the LH front seat risers.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take care when moving seat. Ensure carpet is not damaged.
  102. Move the LH front seat backward.
  103. Install new front bolts securing LH front seat to vehicle.
    33.5 Nm (24.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • Torx T45 socket
    • Flex head ratchet/flex head torque wrench
  104. Move the LH front seat forward.
  105. Install new rear bolts securing LH front seat to vehicle.
    33.5 Nm (24.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • Torx T45 socket
    • Flex head ratchet/flex head torque wrench
  106. Install LH lower A-pillar assembly. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  107. Install the LH front floor mat.
  108. Repeat step 95 to step 107 for the RH front side.
  109. Close RH front door.
  110. Inspect coolant level and top off as necessary.
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    Note
    Ensure that fluid level is at Max line.
  111. Install coolant bottle cap.
  112. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  113. Close hood.
  114. Install the LH and RH rocker panel lower covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace) .
  115. Exit Service Mode through UI: go to Controls > Service Mode > Exit Service Mode, press and hold Exit Service Mode to exit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Exit Service Mode: Controls > Service Mode > Exit Service Mode, Press and hold to exit.
  116. Raise all four windows and close the LH front door.