04/06/2024 18:01:38

DC Link - Positive - Ancillary Bay (Remove and Replace)

Correction code 1630010152 FRT 2.76 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.

Warning

This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Raise and support vehicle

Note
Ensure vehicle is not charging
Open all four doors

Note
If vehicle is being powered down, Latch rear doors to prevent accidental closure
Lower all four windows
Move LH front seat forward
Move RH front seat forward
Open hood
Remove rear underhood apron

Note
14x clips
Power off vehicle from center display

Note
Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
Disconnect LV battery and First Responder Loop

Note
2x connectors, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge
Raise vehicle fully and lower lift onto locks

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
Remove LH and RH clips securing rear aero shield to wheel house liner

Note
2x clips
Remove rear aero shield

Note
11x bolts, 10mm, 5 Nm
Release LH side hose clip from rear battery skid plate enclosure

Note
1x fir tree clip
Release RH side hose clips from rear battery skid plate enclosure

Note
2x fir tree clips
Remove lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count
Remove upper nut securing HV battery rear skid plate enclosure

Note
1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles
Remove upper bolts securing HV battery rear skid plate enclosure

Note
4x bolts, 13mm, 35 Nm
Remove HV battery rear skid plate enclosure
Position coolant drain container underneath LH rear of HV battery
Disconnect LH coolant hose from rear of HV battery

Note
1x spring clip, 2x plugs, Plug both the coolant hose and passthrough
Remove fir tree clip securing coolant hose to rear subframe shear plate

Note
1x fir tree clip
Disconnect RDU inverter inlet tube from LH rear of HV battery

Note
1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill
Attach coolant drain hose adapter to PCS outlet hose coupling

Note
Use adapter with 90 degree angle, Make sure locking tab is fully seated
Attach coolant drain hose adapter to coolant hose extension
Attach coolant hose extension to coolant drain hose

Note
Use caution as coolant may spill, Make sure to wear safety glasses
Position coolant drain container underneath RH rear of vehicle
Disconnect rear PT supply hose from rear of HV battery

Note
1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill
Attach coolant pressure tester to PCS inlet hose coupling

Note
This adapter connected to regulated air line adapter, Make sure the locking tab is fully seated
Attach coolant pressure tester to pressure fitting adapter
Connect compressed air to coolant pressure tester
Open regulator valve then slowly adjust regulator to 50 psi

Note
Use caution as coolant may spill, Make sure to wear safety glasses
Open 2nd valve slowly

Note
Use caution as coolant may spill, Make sure to wear safety glasses
Set timer for 1 minutes and select start

Note
Once timer is complete, select Stop Reset
Close regulator valve
Set timer for 1 minutes and select start

Note
Once timer is complete, select Stop Reset
Open regulator valve slowly
Set timer for 1 minutes and select start

Note
Once timer is complete, select Stop Reset
Close regulator valve
Disconnect compressed air from coolant pressure tester
Remove coolant pressure tester from PCS inlet hose coupling
Position coolant drain container underneath LH rear of HV battery
Remove coolant drain adapter with hose from PCS outlet hose coupling

Note
1x spring clip
Attach coolant pressure tester with hose to PCS outlet hose coupling

Note
1x spring clip, Make sure the locking tab is fully seated
Position coolant drain container underneath RH rear of vehicle
Attach coolant drain adapter with hose to PCS inlet hose coupling

Note
1x spring clip, Make sure the locking tab is fully seated
Connect compressed air to coolant pressure tester
Open regulator valve then slowly adjust regulator to 50 psi

Note
Use caution as coolant may spill, Make sure to wear safety glasses
Open 2nd valve slowly

Note
Use caution as coolant may spill, Make sure to wear safety glasses
Set timer for 1 minutes and select start

Note
Once timer is complete, select Stop Reset
Close regulator valve
Set timer for 1 minutes and select start

Note
Once timer is complete, select Stop Reset
Open regulator valve slowly
Set timer for 1 minutes and select start

Note
Once timer is complete, select Stop Reset
Close regulator valve
Disconnect compressed air from coolant pressure tester
Disconnect coolant hose extension from coolant drain hose
Disconnect coolant drain hose adapter from coolant hose extension
Remove coolant drain hose adapter from PCS inlet hose coupling

Note
1x spring clip, Install plug to inlet hose coupling
Position coolant drain container underneath LH rear of HV battery
Remove pressure fitting adapter from coolant pressure tester
Remove coolant pressure tester from PCS outlet hose coupling

Note
1x spring clip, Install plug to outlet hose coupling
Remove coolant drain container from underneath vehicle
Lower vehicle fully

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Release 2nd row seat cushion and disconnect harness

Note
2x clips, 2x connectors, Press tabs backward then pull front edge up
Verify operation of multimeter

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Remove bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
Remove ancillary bay probe lid cover from ancillary bay cover
Verify no high voltage

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover

Note
Confirm no visual damage present,Wipe ancillary bay with IPA to clean surface,Allow to 1 minute dry time
Install bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners
Remove HV insulating gloves
Disconnect HVC logic connector and install logic cap

Note
1x connector, 1x cap, Release locking tab then push the handle downward to release connector
Remove bolts securing ancillary bay cover to HVC

Note
3x bolts, E10, 5 Nm + 30 degrees
Remove bolts securing ancillary bay cover to HV battery

Note
18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Remove ancillary bay cover from HV battery
Inspect ancillary bay for any missing insulators

Note
Install service insulator kit before continuing to next step, The number of bolts on newer vehicles may vary
Remove bolts securing pyro disconnect to ancillary bay

Note
1x insulator, patch bolts, 13mm, 9 Nm, Discard after removal
Remove pyro disconnect from ancillary bay

Note
1x connector from the bottom, Lift pyro disconnect straight up and out of the ancillary bay
Install pyro disconnect dummy
Use bungee to secure HVC in an upwards position

Note
Wrap bungee around RH headrest
Position absorbent sheets below and around PCS coolant inlet hose to avoid excess coolant dripping
Disconnect PCS coolant inlet hose from PCS

Note
2x clips, 2x plugs, Insert the special tool away from the PCS, between the ancillary bay housing and the hose, There is not sufficient room to install the special tool on the PCS side, May cause damage to the tool or the hose retainers, Install plugs to PCS and hose
Disconnect PCS coolant outlet hose from PCS

Note
2x clips, 2x plugs, Use the special tool to release clips, Place absorbent sheet under hose to catch excess coolant, Visually inspect area for any coolant residue, Clean with shop towel if necessary, Install plugs to PCS and hose
Disconnect PCS to DC bus HV connector

Note
1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
Disconnect PCS logic connector from PCS

Note
1x connector
Disconnect PCS LV connector from PCS

Note
1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
Disconnect PCS to AC harness connector

Note
1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
Remove bolts securing PCS to HV battery

Note
5x bolts, 8mm, 18 Nm, Ensure onlythe 8mm fasteners are removed, Do not remove the T30 fasteners
Secure suction cups to PCS

Note
Continue pressing plunger until red line is no longer visible
Lift PCS up and out of ancillary bay area and remove from vehicle

Note
Slightly tilt rear of PCS upward then lift out to remove, Inspect any missing insulators under PCS, Install any missing insulators before continuing to next step, Visually inspect area for any coolant residue, Clean with shop towel if necessary
Install HV joint insulator for positive busbar module 2 to pyro disconnect

Note
1x insulator
Install HV joint insulator for negative busbar module 3 to shunt

Note
1x insulator
Install HV joint insulator for positive DC link to module 4

Note
1x insulator
Disconnect ancillary bay harness connectors from positive pack contactor

Note
2x connectors
Remove ancillary bay harness clip from positive pack contactor

Note
1x clip
Remove HV joint insulators from positive HV switch

Note
2x insulators
Remove bolt securing positive pack contactor to positive busbar

Note
1x patch bolt, 13mm, 9 Nm, Discard after removal
Remove nut securing positive pack contactor to module 4 rear terminal

Note
1x patch nut, 13mm, 9 Nm, Discard after removal
Remove nuts securing positive pack contactor to ancillary bay

Note
3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary
Remove positive pack contactor from ancillary bay

Note
2x guide pins
Release positive LV output cover from PCS cable

Note
1x cover
Remove bolt securing DCDC ground busbar to body

Note
1x bolt, 12mm, 20 Nm
Remove nut securing DCDC ground busbar to HV battery

Note
1x nyloc nut, 13mm, 9 Nm, Discard nut after removal
Remove DCDC ground busbar
Remove nut securing positive LV output from PCS cable and move cable aside

Note
1x nut, 13mm, 15 Nm, Discard after removal
Remove bolts securing DCDC pass through to ancillary bay

Note
2x bolts, E10 5-Lobe, 10 Nm
Remove DCDC pass through from ancillary bay

Note
Electrical Protective Gloves
Remove HV joint insulator for positive DC link to module 4

Note
1x insulator
Remove nut securing DC link to module 4

Note
1x patch nut, 13mm, 9 Nm, Discard after removal
Move positive DC link out to allow access to ancillary bay harness clips
Remove ancillary bay harness clips from positive DC link

Note
3x clips
Remove positive DC link from ancillary bay

Note
2x guide pins
Position the positive DC link for installation

Note
2x guide pins
Install ancillary bay harness clips to positive DC link

Note
3x clips
Install nut securing joint DC link to module 4

Note
1x patch nut, 13mm, 9 Nm, Install new patch bolt, Mark after torque
Perform resistance measurement on DC link to module 4 and busbar

Note
1x HV joint, 60_xD835__xDF07_Ω or less
Install HV joint insulator for positive DC link to module 4

Note
1x insulator
Position DCDC pass through to ancillary bay for installation

Note
Electrical Protective Gloves
Install bolts securing DCDC pass through to ancillary bay

Note
2x bolts, E10 5-Lobe, 10 Nm, Mark the bolts after torque
Install positive LV output

Note
1x nut, 13mm, 9 Nm, Make sure rubber boot is not pinched between cable terminal and pass through
Install positive LV output cover to PCS cable

Note
1x cover
Install DCDC ground busbar

Note
Slotted hole goes to body side
Install bolt securing DCDC ground busbar to body

Note
1x bolt, 12mm, 20 Nm
Install nut securing DCDC ground busbar to HV battery

Note
1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut
Position positive pack contactor to ancillary bay for installation

Note
2x guide pins
Install nuts securing positive pack contactor to ancillary bay

Note
3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs, The number of nuts on newer vehicles may vary
Install bolt securing positive pack contactor to positive busbar

Note
1x patch bolt, 13mm. 9 Nm, Install new patch bolt, Mark after torque
Install nut securing positive pack contactor to HV battery tall terminal to module 4 rear terminal

Note
1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque
Measure resistance from HV joint between HV battery positive contactor and the center of HV battery positive terminal

Note
1x HV joint, 110_xD835__xDF07_Ω or less
Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar

Note
1x HV joint, The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ), If the resistance is greater than 0.060 mΩ (60 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
Install HV joint insulators onto positive pack contactor

Note
2x insulators
Install ancillary bay harness clip to positive pack contactor

Note
1x clip
Connect ancillary bay harness connectors to positive pack contactor

Note
2x connectors
Position the PCS into ancillary bay

Note
Ensure all busbar insulators beneath PCS are present, Slightly tilt rear of PCS upward and lower into position, Align datum into PCS holes, Inspect for any coolant residue inside ancillary bay and clean with absorbent sheets if necessary
Remove suction cups from PCS
Install bolts securing PCS to HV battery

Note
5x bolts, 8mm, 18 Nm
Connect PCS to fastcharge contactor HV harness connector

Note
1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
Connect PCS LV connector to PCS

Note
1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
Connect PCS logic connector to PCS

Note
1x connector
Connect PCS to DC bus HV connector

Note
1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
Replace o-ring on PCS side inlet hose

Note
1x o-ring, Apply light amount of Krytox 203
Connect PCS coolant inlet hose to PCS

Note
2x clips, 1xplug, Remove plug from PCS, Place absorbent sheet under hose to catch excess coolant, Caution when installing this hose, it's difficult to align hose to coupling, Use caution not to damage the o-rings, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated
Replace o-ring on PCS side outlet hose

Note
1x o-ring, Apply light amount of Krytox 203
Connect PCS coolant outlet hose to PCS

Note
2x clips, 1x plug, Remove plug from PCS, Place absorbent sheet under hose to catch excess coolant, Caution not to damage the o-rings, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated, Visually inspect area for any coolant residue, Clean with shop towel if necessary
Lay HVC in original position

Note
Release bungee from back of headrest
Remove pyro disconnect dummy
Clean mating surfaces

Note
Allow to 1 minute dry time,Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect
Set multimeter to "LoZ" (low impedance) mode
Measure voltage between busbar and shunt

Note
While still measuring the voltage, have an assistant position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect, and then press the pyrotechnic battery disconnect down onto the busbars
Position pyro disconnect to ancillary bay for installation

Note
1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way
Install bolts securing pyro disconnect to ancillary bay

Note
2x patch bolts, 13mm, 9 Nm
Measure resistance from module 2 busbar to pyro disconnect

Note
1x HV joint, 48_xD835__xDF07_Ω or less, Perform zero adjust to Hioki meter prior to testing
Measure resistance from pyro disconnect to shunt

Note
1x HV joint, 33_xD835__xDF07_Ω or less, Perform zero adjust to Hioki meter prior to testing
Remove service insulator kit
Inspect ancillary bay walls for damage

Note
Any dent or depression in the seal that causes it to not be flat will result in a leak, and cannot be reused, Any paint that comes off the ancillary bay wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled, It can still be reused
Inspect ancillary bay cover seal to confirm it has no visual damage

Note
Image up close for clarity, Delaminated and torn seals cannot be reused
Position ancillary bay cover to HV battery for installation

Note
Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
Remove HV insulating gloves
Install bolts securing ancillary bay cover to HV battery

Note
18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image
Install bolts securing ancillary bay cover to HVC

Note
3x bolts, E10, 5 Nm + 30 degrees
Remove logic cap and connect HVC logic connector

Note
1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
Connect 2nd row seat harness and secure cushion

Note
2x clips, 2x connectors, Insert buckles through holes, Slide rear inward then align front clips, Perform push-pull-push test
Raise vehicle fully and lower lift onto locks

Note
Set vehicle to comfortable working height, Make sure there's an audible click of locks on both sides before lowering, otherwise vehicle may tilt to side
Position coolant drain container underneath RH rear of vehicle
Install coolant pressure test plug adapter to PCS inlet hose coupling

Note
1x spring clip, 1x plug, Remove plug from inlet hose coupling, Make sure the locking tab is fully seated
Position coolant drain container underneath LH rear of HV battery
Install coolant pressure tester to PCS outlet hose coupling

Note
1x spring clip, 1x plug, Remove plug from outlet hose coupling, Make sure the locking tab is fully seated
Install pressure fitting adapter to coolant pressure tester
Connect compressed air to coolant pressure tester
Open regulator valve then slowly adjust regulator to 50 psi
Slowly open valve on pressure regulator and allow pressure to reach specification
Close the valve and let pressure settle

Note
Wait 2 minutes for pressure to settle, Record the reading
Perform the coolant pressure leak test

Note
Wait for another 4 minutes and record the reading. Max delta 0.35 psi. Check coolant hose to see if it is fully seated or not if pressure test fails
Remove pressure fitting adapter from coolant pressure tester
Remove coolant pressure tester from PCS outlet hose coupling

Note
1x spring clip
Remove plug from HV battery and connect RDU inverter inlet tube

Note
1x spring clip, 1x plug, Perform push-pull-push test to make sure hose is fully engaged
Connect LH coolant hose to rear of HV battery

Note
1x spring clip, 2x plugs, Remove plugs, Perform push-pull-push test to make sure hose is fully seated.Vacuum fill required if > 1L lost during repair
Position coolant drain container underneath RH rear of vehicle
Remove coolant pressure test plug adapter from PCS inlet hose coupling

Note
1x spring clip
Connect rear PT supply hose to rear of HV battery and plug hose

Note
1x spring clip, 1x plugs, Remove plugs, Perform push-pull-push test to make sure hose is fully seated.Vacuum fill required if > 1L lost during repair
Remove coolant drain container from underneath vehicle
Position HV battery rear skid plate enclosure onto HV battery for installation

Note
Recommend assistance if needed
Install upper bolts securing HV battery rear skid plate enclosure hand tight

Note
4x bolts, 13mm, 35 Nm, Torque at later step
Install upper nut securing HV battery rear skid plate enclosure hand tight

Note
1x nut, 10mm, 13 Nm, Torque at later step
Install lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
Torque bolts securing HV battery rear skid plate enclosure to vehicle

Note
4x bolts, 13mm, 35 Nm
Torque upper nut securing HV battery rear skid plate enclosure

Note
1x nut, 10mm, 13 Nm
Install RH side hose clips to HV battery rear skid plate enclosure

Note
2x fir tree clips
Install LH side hose clip to HV battery rear skid plate enclosure

Note
1x clip
lnstall rear aero shield

Note
11x bolts, 10mm, 5 Nm, Apply Loctite 222 onto rear aero shield bolts
Install LH and RH clips securing rear aero shield to wheel house liner

Note
2x clips
Lower vehicle fully

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Remove coolant bottle cap
Place empty coolant container into front storage area
Fill container with at least 15L of coolant
Place filled coolant container into front storage area
Install refill tool cap onto coolant bottle assembly
Setup vacuum refill tool

Note
Verify all valves on refill tool are in the closed position, See image for clarity
Install vacuum refill hose into refill cap on coolant bottle

Note
Perform push-pull-push test to verify hose is fully engaged
Position overflow hose into empty container
Place refill hose inside filled coolant container

Note
Make sure hose end is fully submerged into coolant
Connect shop air supply to coolant refill tool

Note
If not already done, Verify refill valve is set to off
Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve

Note
Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
Slowly open coolant refill valve to allow coolant to be drawn into coolant refill hose, Close valve when hose is full of coolant

Note
This purges trapped air from the hose
Monitor gauge for 30 seconds to verify a vacuum is maintained in cooling system
Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close valve
Slowly open refill valve to allow coolant to be drawn into system

Note
Make sure hose end of refill hose is fully submerged during entire process
Once gauge reads zero, close refill valve
Disconnect shop air supply from coolant refill tool
Remove coolant refill hose from coolant container
Remove coolant overflow hose from coolant container
Remove vacuum refill hose from refill cap on coolant bottle
Remove coolant refill tool from vehicle
Remove both coolant containers from inside underhood area
Connect First Responder Loop and LV battery

Note
2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
Place vehicle in service mode through UI

Note
Select vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box
Unlock vehicle gateway

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
Access Thermal System routines using the UI

Note
Select Service mode > Thermal
Select "Start Coolant Air Purge" using the UI

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.
Inspect coolant level and top off as necessary

Note
Ensure that fluid level is at Max line
Install coolant bottle cap
Install rear underhood apron

Note
14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
Close hood
Move RH front seat to original position
Move LH front seat to original position
Exit Service Mode through UI

Note
Exit Service Mode: Controls > Service Mode > Exit Service Mode, Press and hold to exit
Raise all windows
Close all four doors
Remove lift arms from below vehicle

Note
Lower rack arms fully and remove them from under vehicle

DC Link - Positive - Ancillary Bay (Remove and Replace)

Figure 1

Figure 2

Figure 3