07/11/2024 10:22:00

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

Correction code 16010202 FRT 4.98 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 2024-11-07: Added AC harness steps for 3-phase packs.
  • 2024-10-31: Updated HV battery discharge steps.
  • 2024-07-08: Added steps to replace the seat bolt, and remove HV battery bolts below rear end of both LH and RH front seat cushion.
  • 1473522-00-A - KIT, COMPUTER PURGE ADAPTERS, MODEL 3
  • 1129166-02-B - SPARES, HOIST, H-FRAME
  • 1458818-00-B - BOLT PF M10-1 5X36 109 G0310 B SMAT

Torque Specifications

Table 1. Torque Specifications: HV Battery (AWD) \(Remove and Replace\)
Description Torque Value Recommended Tools Reuse/Replace Notes
LH front footwell HV battery bolts
136 Nm (100.3 lbs-ft)
  • Torx Plus EP20 socket
  • Cordless Ratchet/Impact Driver
  • 3/8 in to ½ in adapter
  • 3 in extension
  • Ratchet/torque wrench
 Reuse
Bolts (X2) securing LH front seat to vehicleBolts (X2) securing LH rear seat to vehicle
33.5 Nm (24.7 lbs-ft)
  • Cordless Ratchet/Impact Driver
  • Ratchet/torque wrench
  • ¼ in to 3/8 in adapter
 Replace
Bolt below rear end of LH front seat cushionBolt below rear end of RH front seat cushion
66 Nm (48.7 lbs-ft)
  • Cordless Ratchet/Impact Driver
  • 16 mm deep socket
  • Flex head ratchet/flex head torque wrench
 Reuse
Rear HV battery interior bolts
66 Nm (48.7 lbs-ft)
  • Cordless Ratchet/Impact Driver
  • 16 mm deep socket
  • Flex head ratchet/flex head torque wrench
 Reuse

Bolt that secures the busbar cover access door

Bolts that attach the charge port busbar kit to the HV header
9 Nm (6.6 lbs-ft)
  • Insulated 10 mm 12-point deep socket
  • Insulated Ratchet/torque wrench
  • Insulated 10 in extension
 Reuse
Nut that attaches the positive LV output to the PCS cable
9 Nm (6.6 lbs-ft)
  • 4 in extension
  • Ratchet/torque wrench
  • 13 mm socket
 Replace
Bolts that attach the LH front wheel liner to the skid plate
5 Nm (3.7 lbs-ft)
  • 10 mm deep socket
  • Ratchet/torque wrench
 Reuse
HV battery center bolts
34 Nm (25.1 lbs-ft)
  • Cordless Ratchet/Impact Driver
  • Insulated 6 in extension
  • External Torx Plus EP14
  • Flex head ratchet/flex head torque wrench
 Reuse
Bolts that attach the LH and RH front support brackets to vehicle
110 Nm (81.1 lbs-ft)
  • Cordless Ratchet/Impact Driver
  • 16 mm socket
  • 3 in extension
  • Ratchet/torque wrench
 Reuse
Bolts (x16) that attach the HV battery to vehicle
35 Nm (25.8 lbs-ft)
  • 3 in extension
  • 13 mm socket
  • Cordless Ratchet/Impact Driver
  • Ratchet/torque wrench
 Reuse
Bolts (x2) that attach the center ski cover to the HV battery
34 Nm (25.1 lbs-ft)
  • Ratchet/torque wrench
  • External Torx Plus EP14
 Reuse

Discharge

WARNING: To conform with local laws, High Voltage Lithium Batteries must be discharged before packing for shipment. Additionally, HV batteries must be discharged before being put into storage. HV batteries to be shipped must have a State of Charge (SoC) of less than 30% or 50%, depending on the region. If the method of shipment is unknown or uncertain, or the battery is to be stored, it is recommended to discharge the HV battery to less than 30%.

WARNING: Do not ship or store an HV battery that has a loss of high voltage isolation. Verify HV battery isolation before packing for shipment or storage. Use the HV Battery Communication Tool, described in Toolbox article #41977 or Customer Document CD-21-16-003, to determine if the HV battery parameters are within safe limits for shipment or storage.
Informational PurposesAn informational icon, calling your attention
Note
If possible, perform the discharge procedure before HV battery removal. This method requires less time and user interaction than to use the Battery Discharge Tool after the battery has been removed. The Battery Discharge Tool can only be used by certified technicians..
Informational PurposesAn informational icon, calling your attention
Note
The steps of the discharge procedure are mostly touch time, and can be performed by the Service Advisors/Front of House team as well as Service Technicians..
  1. Enable Service Mode Plus. See Service Mode Plus.
  2. Identify the vehicle's current SOC Max: In the Service Mode Plus menu, touch High Voltage > HV Battery, and then touch the large HV battery diagram to display the HV Battery information window.
    • If the SOC Max is less than the SOC shipping threshold, skip to the Remove section in this procedure.
    • If the SOC Max is greater than the SOC shipping threshold, continue to the next step.
  3. Move the vehicle to a location where the battery can be safely discharged unattended.
  4. In the Service Mode Plus menu, touch High Voltage > HV Battery.
  5. In the Tools section, touch Start HV Discharge, and then in the window that opens, touch Run.
    Informational PurposesAn informational icon, calling your attention
    Note
    The discharge routine starts and will automatically stop when the SOC Max value for surface transport has been attained.
  6. After discharge is complete, move the vehicle to the service bay.

Remove

  1. Remove the LH and RH rocker panel covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).
  2. Open all doors and lower all windows.
  3. Remove all the floor mats. See Kit - Floor Mat - LHD (Remove and Replace).
  4. Partially release the LH front primary door seal.
  5. Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  6. Remove the drive footwell cover. See Cover - Footwell - Driver (Remove and Replace).
  7. Remove and discard LH front seat bolts.
  8. Remove the LH console side panel carpet. See Carpet - Side - Center Console - LH (Remove and Replace).
  9. Remove LH front main cabin carpet clips (x2), and then fold the LH front main cabin carpet aside for access.
    Informational PurposesAn informational icon, calling your attention
    Note
    The number of clips on new vehicles may vary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Dead pedal and foam block are also part of the carpet.
  10. Remove the LH front footwell HV battery bolts (x2).
    Tip: Use of the following tool(s) is recommended:
    • Torx Plus EP20 socket
    • Cordless Ratchet/Impact Driver
    • 3/8 in to ½ in adapter
    • 3 in extension
    • Ratchet/torque wrench
  11. Remove HV battery bolt below rear end of LH front seat cushion.
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 16 mm deep socket
    • Flex head ratchet/flex head torque wrench
  12. Repeat step 4 through step 10 for the RH side.
  13. Remove HV battery bolt below rear end of RH front seat cushion.
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 16 mm deep socket
    • Flex head ratchet/flex head torque wrench
  14. Remove the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  15. Release push clips (x2) and pull back the rear carpet to access the rear HV battery interior bolts.
  16. Remove the rear HV battery interior bolts (x2).
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 16 mm deep socket
    • Flex head ratchet/flex head torque wrench
    Figure 1. LH Shown, RH Similar
  17. Close the LH and RH rear door latches manually.
    Figure 2. LH Shown, RH Similar
  18. Raise and support the vehicle. See GUID-0ECF2493-88F6-48E9-ADBB-9AE1D52E217C.html.
  19. Place the vehicle in Service Mode Plus.
    1. Enter the last six digits of VIN into the Vehicle Ops mobile app.
    2. Select vehicle from the list.
    3. Swipe to the left, and then select Enable Service Mode Plus.
  20. Unlock the vehicle gateway. See Gateway Unlock.
  21. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Coolant Fill/Drain, select Run, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    The Thermal Fill/Drain routine has a 50-minute time limit. After 50 minutes the routine must be performed again.
  22. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  23. Remove the bolt that secures the busbar cover access door.
    Tip: Use of the following tool(s) is recommended:
    • Insulated 10 mm 12-point deep socket
    • Insulated Ratchet/torque wrench
    • Insulated 10 in extension
  24. Remove the bolts (x2) that attach the charge port busbar kit to the HV header.
    Tip: Use of the following tool(s) is recommended:
    • Insulated 10 mm 12-point deep socket
    • Insulated Ratchet/torque wrench
    • Insulated 10 in extension
    Informational PurposesAn informational icon, calling your attention
    Note
    If the vehicle is equipped with a 3-phase HV battery, remove the AC charging interface.
  25. Lift the busbar kit connector to remove it from the HV header.
  26. Remove the HV insulating gloves.
  27. Open the RH rear door.
  28. Disconnect the HVC logic connector and install the logic cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab then push the handle downward to release the connector.
  29. Remove the DCDC busbar. See Harness - Busbar - 12V DCDC (Remove and Replace).
  30. Remove and discard the nut that attaches the positive LV output to the PCS cable, and move the cable aside.
    Tip: Use of the following tool(s) is recommended:
    • 4 in extension
    • Ratchet/torque wrench
    • 13 mm socket
  31. Remove the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  32. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  33. Remove the push clips (x6) that attach the lower rear edge of LH and RH front wheel liners to vehicle for access to the coolant hose.
  34. Remove the bolts (x2) that attach the LH front wheel liner to the skid plate.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Ratchet/torque wrench
    Figure 3. LH Shown, RH Similar
  35. Use bungee strap to pull back the LH and RH front wheel liners and secure them to the subframe.
  36. Position a coolant drain container underneath the LH front of HV battery.
  37. Attach hose extension to the coolant drain hose for extra length.
  38. Connect the battery flush fitting adapter to the coolant cart drain hose.
  39. Disconnect the HV battery return hose at the LH side of vehicle and connect the battery flush fitting to the male side.
  40. Attach the battery drain fitting adapter to the female side of the HV battery return tube.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the valve is set to closed. Perform a push-pull test to verify the adapter is fully engaged.
  41. Attach the battery drain fitting adapter to the coolant cart pressure hose.
  42. Turn the valve knob to vertical position to open the valve on the battery drain fitting adapter.
  43. Slowly open the valve on the pressure regulator and allow the coolant to drain out of the HV battery return tube. Once no coolant is draining, close the valve.
  44. Disconnect the compressed air from the coolant cart.
  45. Set the valve knob to closed position, and then remove the battery drain fitting adapter from the female side of the HV battery return tube.
  46. Remove the battery flush fitting adapter from the male side of the HV battery return tube, and plug the end of fittings as soon as possible.
  47. Position the coolant drain container underneath the RH front of HV battery.
  48. Disconnect the powertrain supply hose from the powertrain supply tube, and plug the ends of fittings as soon as possible to avoid coolant loss.
  49. Disconnect the powertrain return hose from the powertrain return tube, and plug the ends of fittings as soon as possible to avoid coolant loss.
  50. Disconnect the HV battery manifold hose, and plug the ends of fittings as soon as possible to avoid coolant loss.
  51. Remove the front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  52. Remove manifold tube from front of HV battery, and plug the ends of fittings as soon as possible to avoid coolant loss.
  53. Disconnect the A/C compressor HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull back the red tab to unlock the connector, then push the orange lip and pull back, and then push the green lip and pull back to disconnect the connector.
  54. Release the front drive unit ground strap, but do not remove the last bolt that attaches the front drive unit ground strap to the HV battery. See Ground Straps - Front Drive Unit (Remove and Replace).
  55. Remove the rear skid plate enclosure. See Skid Plate - HV Battery - Rear (Remove and Replace).
  56. Perform an ancillary bay coolant leak test. See Ancillary Bay Coolant Leak Test (Inspection).
  57. Disconnect the rear drive unit outlet hose from the PT return tube, and plug the ends of fittings as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    The hose is the lower hose located at the RH rear of HV battery. Use a shop towel to clean any residue coolant if necessary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  58. Remove the LH and RH shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  59. Hand-tighten the bolts (x2) that attach LH and RH sides of subframe to body.
    Figure 4. LH Shown, RH Similar
  60. Remove the support stand from under the vehicle.
  61. Remove the rear drive unit HV harness. See HV Harness - HV Battery to Rear Drive Unit (Remove and Replace).
  62. With assistance, place the HV battery table into position and lower the vehicle to support HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Line up the table so the center 4 bolts are accessible through the opening in table. Adjust the final battery table position using adjustable caster jacks on the table.
  63. Remove the central bolts (x4) that secure the HV battery center ski cover.
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • Insulated 6 in extension
    • External Torx Plus EP14
    • Flex head ratchet/flex head torque wrench
  64. Remove the bolts (x8) that attach the LH and RH front support brackets to vehicle.
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 16 mm socket
    • 3 in extension
    • Ratchet/torque wrench
    Figure 5. LH Shown, RH Similar
  65. Remove the bolts (x16) that attach the HV battery to vehicle.
    Tip: Use of the following tool(s) is recommended:
    • 3 in extension
    • 13 mm socket
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
    Figure 6. LH Shown, RH Similar
  66. With assistance, raise the vehicle free of the HV battery, and then remove the battery from under the vehicle.
  67. Remove and discard the ancillary bay engagement seal from the HV battery pack.
  68. Release the clips (x2) that attach the HV battery return tube to the rear of HV battery.
  69. Release the clips (x5) that attach the HV battery return tube to the LH side of HV battery, then remove all coolant plugs from the hose and allow the hose to fully drain.
  70. Release the clips (x5) that attach the PT supply tube to the RH side of HV battery, then remove all coolant plugs from the hose and allow the hose to fully drain.
  71. Release the clips (x5) that attach the PT return tube to the RH side of HV battery, then remove all coolant plugs from the hose and allow the hose to fully drain.
  72. Attach the HV battery H-frame to gantry and raise into position.
  73. With assistance, position the HV battery under the gantry.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the original pack is RWD and the supplied pack is DM, a center ski transfer will be needed.
  74. Lower the H-frame onto the HV battery and hand-tighten the bolts that attach the H-frame to the battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    The number of fasteners may vary.
  75. Remove the barrel clips (x2) that attach the ancillary harness bracket to the front of HV battery.
  76. Release the red locking tab and rotate the lever arm to disconnect the ancillary harness connector from the RH rear of HV battery.
  77. Raise the HV battery off of the battery table.
  78. With assistance, remove the bolts (x2) that attach the center ski cover to the HV battery, and leave the cover on the battery table.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • External Torx Plus EP14
  79. Position the gantry over pallet, and then lower the battery onto the pallet.
  80. Remove the H-frame from the old HV battery.
  81. Raise the gantry and the H-frame from the old HV battery.
  82. Remove the logic cap from the old battery pack.

Install

  1. With assistance, open the top of the crate with the new high voltage battery pack. Confirm the part number specific to vehicle configuration.
  2. Remove the nuts that attach the new HV battery to crate.
  3. Position the gantry over the new HV battery crate, and hand-tighten the bolts that attach the H-frame to the battery.
  4. Lift the new HV battery out of crate.
  5. With assistance, move the gantry away from the HV battery crate and over the HV battery table.
  6. With assistance, lower the HV battery onto the battery table.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to align the HV battery onto the center ski.
  7. Install the barrel clips (x2) that attach the ancillary harness bracket to the front of HV battery.
  8. Hand-tighten the outer bolts (x2) that attach the center ski cover to the HV battery, and then torque to specification.
    34 Nm (25.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • External Torx Plus EP14
  9. Connect the ancillary harness connector to the RH rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hold the connector level with header and secure the connector with even upward force. Rotate the lever arm and secure the locking tab. Verify that the latch is fully secured and not damaged.
  10. Release the H-frame from the HV battery and raise the gantry.
  11. With assistance, remove the HV battery from under the gantry, and then position the gantry over the old HV battery.
  12. Lower the H-frame onto the old HV battery and hand-tighten the bolts that attach the H-frame to battery.
  13. Raise the old HV battery above the height of the HV battery crate.
  14. Position the HV battery crate underneath the old HV battery, and then lower the old HV battery into the crate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution to align the 4 studs and do not damage the battery.
  15. Remove the H-frame from the old HV battery.
  16. Raise the gantry and the H-frame from the old HV battery.
  17. Lower the gantry and remove the HV battery H-frame from the gantry.
  18. Hand-tighten the 15mm nuts (x4) that attach the HV battery to crate.
  19. With assistance, close the crate top housing of the old HV battery.
  20. Install the logic cap onto the new battery pack.
  21. Secure the clips (x5) to install the HV battery return tube onto the LH side of HV battery.
  22. Remove the plugs on the ends of fittings, and connect the HV battery return tube to the LH and RH rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
    Figure 7. LH Shown, RH Similar
  23. Install the clips (x2) that attach the HV battery return tube onto the rear of HV battery.
  24. Install the clips (x5) that attach the PT supply tube to the RH side of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  25. Install the PT supply tube to the RH rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a shop towel to clean any residue coolant if necessary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  26. Install the clips (x5) that attach the PT return tube to the RH side of HV battery.
  27. Remove the plugs on the ends of fittings, and then install the clips (x4) that attach the manifold tube onto the front of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
  28. Install the ancillary bay engagement seal onto the HV battery pack.
    Informational PurposesAn informational icon, calling your attention
    Note
    This seal is disposable and should be replaced each time a HV battery pack is removed from vehicle or installed onto a new HV battery pack if not equipped.
  29. Install the HV battery alignment rods to the body at front of the vehicle and to the battery near the ancillary bay.
  30. With assistance, position the HV battery under the vehicle.
  31. With assistance, lower the vehicle onto the HV battery and align the holes.
    Informational PurposesAn informational icon, calling your attention
    Note
    Be sure that the coolant hoses do not get caught on the alignment rods. Caution not to damage the HV cable. Do not fully lower vehicle onto battery (this will help with installing battery bolts).
  32. Use cordless impact to set the bolts (x16) that attach the HV battery to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure smooth thread engagement and the bolts are not cross threaded into casting.
    Informational PurposesAn informational icon, calling your attention
    Note
    Flush down the bolts. Do not over tighten bolts. Fully torque at later step.
    Figure 8. LH Shown, RH Similar
  33. Remove the HV battery alignment rods.
  34. Use cordless impact to set the bolts (x8) that attach the LH and RH front support brackets to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure smooth thread engagement and the bolts are not cross threaded into casting.
    Informational PurposesAn informational icon, calling your attention
    Note
    Flush down the bolts. Do not over tighten bolts. Fully torque at later step.
    Figure 9. LH Shown, RH Similar
  35. Use cordless impact to set the central bolts (x4) that secure the HV battery center ski cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure smooth thread engagement and the bolts are not cross threaded into casting.
    Informational PurposesAn informational icon, calling your attention
    Note
    Flush down the bolts. Do not over tighten bolts. Fully torque at later step.
  36. Hand-tighten the bolts (x4) that attach the HV battery to body at the LH and RH shear plate areas.
    Figure 10. LH Shown, RH Similar
  37. Install the rear drive unit HV harness. See HV Harness - HV Battery to Rear Drive Unit (Remove and Replace).
  38. Remove the plugs on the ends of fittings, and then connect the rear drive unit outlet hose to the PT return tube.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use shop towel to clean any coolant residue if necessary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  39. Remove the plugs on the ends of fittings, and then connect the rear drive unit inverter inlet hose to the LH rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  40. Install the rear skid plate enclosure. See Skid Plate - HV Battery - Rear (Remove and Replace).
  41. With assistance, lower the vehicle onto the pack completely.
  42. Torque the bolts (x16) that attach the HV battery to vehicle.
    35 Nm (25.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 3 in extension
    • 13 mm socket
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
    Figure 11. LH Shown, RH Similar
  43. Torque the bolts (x8) that attach the LH and RH front support brackets to vehicle.
    110 Nm (81.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 16 mm socket
    • 3 in extension
    • Ratchet/torque wrench
    Figure 12. LH Shown, RH Similar
  44. Torque the central bolts (x4) that secure the HV battery center ski cover.
    34 Nm (25.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • Insulated 6 in extension
    • External Torx Plus EP14
    • Flex head ratchet/flex head torque wrench
  45. Raise the vehicle to a comfortable working height, and lower the lift onto locks, then remove battery table from under vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION

    Make sure there is an audible click of the locks on both sides before lowering, otherwise the vehicle may tilt to one side.

    Make sure that the doors are clear of surrounding objects.

  46. Use an underhoist stand to support the front portion of the rear subframe.
  47. Remove the smaller fasteners (x4) for the LH and RH shear plates.
    Figure 13. LH Shown, RH Similar
  48. Install the LH and RH shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  49. Install the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  50. Remove the plugs on the ends of fittings, and then connect the HV battery manifold hose.
  51. Remove the plugs on the ends of fittings, and then connect the PT supply hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  52. Remove the plugs on the ends of fittings, and then connect the PT return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  53. Install the front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  54. Release the LH and RH front wheel liners from the bungee straps and remove the straps from the vehicle.
    Figure 14. LH Shown, RH Similar
  55. Install the bolts (x2) that attach the LH and RH front wheel liners to the skid plate.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Ratchet/torque wrench
    Figure 15. LH Shown, RH Similar
  56. Connect the HV battery return hose.
  57. Connect the A/C compressor HV harness connector.
  58. Install the front drive unit ground strap. See Ground Straps - Front Drive Unit (Remove and Replace).
  59. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  60. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill.
  61. Position the busbar kit connector and lower it onto the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Shift the rear end of the busbar assembly upward to help ease installation. If excessive force is required to seat the busbars, they may have been bent. Inspect for damage and replace if necessary.
  62. Install the bolts (x2) that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Insulated 10 mm 12-point deep socket
    • Insulated Ratchet/torque wrench
    • Insulated 10 in extension
    Informational PurposesAn informational icon, calling your attention
    Note
    If the vehicle is equipped with a 3-phase HV battery, install the AC charging interface.
  63. Install the bolt that secures the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Insulated 10 mm 12-point deep socket
    • Insulated Ratchet/torque wrench
    • Insulated 10 in extension
  64. Install the DCDC busbar. See Harness - Busbar - 12V DCDC (Remove and Replace).
  65. Connect the DCDC positive cable to the right body harness.
  66. Remove the logic cap and connect the HVC logic connector. Align the connector then pull the handle to locking position to get the connector fully seated.
  67. Connect the first responder loop but leave the LV battery disconnected.
  68. Connect an LV maintainer. See LV Maintainer (Connect and Disconnect) (Maintenance).
  69. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap High Voltage > HV Battery > Pack Replacement > CAN ECU Redeploy, click Run, and allow the routine to complete.
  70. Select High Voltage Battery Replacement Routine, click Run, and allow the routine to complete.
  71. Disconnect the LV maintainer.
  72. Remove the lift arms from below the vehicle.
  73. On the touchscreen, tap Thermal > Refrigerant System > Stop Thermal Fill Drain, and then allow the routine to complete.
  74. Inspect the coolant level, top off as necessary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the coolant level is at the "Max" line.
  75. On the touchscreen, select Thermal > Coolant System > Coolant Purge, click Run, and then allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    • The routine will last for a while after the stop message displays. The coolant pumps are audible.
    • The test lasts for approximately 10 mins. Do not start another routine during this time.
    • Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
    • The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
    • If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  76. Install the LH and RH rear HV battery interior bolts (x2).
    66 Nm (48.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift up the carpet for access.
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 16 mm deep socket
    • Flex head ratchet/flex head torque wrench
    Figure 16. LH Shown, RH Similar
  77. Install HV battery bolt below rear end of LH and RH front seat cushion.
    66 Nm (48.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 16 mm deep socket
    • Flex head ratchet/flex head torque wrench
    Figure 17. LH Shown, RH Similar
  78. Install the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  79. Close both rear doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the latches before closing if they are manually latched.
  80. Open the LH front door.
  81. Install the LH front footwell HV battery bolts (x2).
    136 Nm (100.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx Plus EP20 socket
    • Cordless Ratchet/Impact Driver
    • 3/8 in to ½ in adapter
    • 3 in extension
    • Ratchet/torque wrench
  82. Install the push clips that attach the LH front main cabin carpet to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Number of clips on new vehicles may vary.
  83. Install the LH console side panel carpet. See Carpet - Side - Center Console - LH (Remove and Replace).
  84. Install the drive footwell cover. See Cover - Footwell - Driver (Remove and Replace).
  85. Install the LH front seat bolts.
    33.5 Nm (24.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
    • ¼ in to 3/8 in adapter
  86. Install the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  87. Install the LH front primary door seal.
  88. Repeat step 80 through step 87.
  89. Install all the floor mats. See Kit - Floor Mat - LHD (Remove and Replace).
  90. Inspect the coolant level, top off as necessary, and then install the coolant bottle cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the coolant level is at the "Max" line.
  91. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  92. Install the LH and RH rocker panel covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).
  93. Exit Service Mode. See Service Mode.
  94. Raise all windows.
  95. Close both front doors.