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.
-
Raise and support vehicle
NoteEnsure vehicle is not charging
-
Open all four doors
NoteIf 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
Note14x clips
-
Power off vehicle from center display
NoteVia Controls > Safety > Power Off, Select Power Off button at warning dialogue box
-
Disconnect LV battery and First Responder Loop
Note2x 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
NoteSet 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
Note2x clips
-
Remove rear aero shield
Note11x bolts, 10mm, 5 Nm
-
Release LH side hose clip from rear battery skid plate enclosure
Note1x fir tree clip
-
Release RH side hose clips from rear battery skid plate enclosure
Note2x fir tree clips
-
Remove lower bolts securing HV battery rear skid plate enclosure
Note2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count
-
Remove upper nut securing HV battery rear skid plate enclosure
Note1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles
-
Remove upper bolts securing HV battery rear skid plate enclosure
Note4x 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
Note1x spring clip, 2x plugs, Plug both the coolant hose and passthrough
-
Remove fir tree clip securing coolant hose to rear subframe shear plate
Note1x fir tree clip
-
Disconnect RDU inverter inlet tube from LH rear of HV battery
Note1x 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
NoteUse 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
NoteUse 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
Note1x 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
NoteThis 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
NoteUse caution as coolant may spill, Make sure to wear safety glasses
-
Open 2nd valve slowly
NoteUse caution as coolant may spill, Make sure to wear safety glasses
-
Set timer for 1 minutes and select start
NoteOnce timer is complete, select Stop Reset
-
Close regulator valve
-
Set timer for 1 minutes and select start
NoteOnce timer is complete, select Stop Reset
-
Open regulator valve slowly
-
Set timer for 1 minutes and select start
NoteOnce 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
Note1x spring clip
-
Attach coolant pressure tester with hose to PCS outlet hose coupling
Note1x 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
Note1x 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
NoteUse caution as coolant may spill, Make sure to wear safety glasses
-
Open 2nd valve slowly
NoteUse caution as coolant may spill, Make sure to wear safety glasses
-
Set timer for 1 minutes and select start
NoteOnce timer is complete, select Stop Reset
-
Close regulator valve
-
Set timer for 1 minutes and select start
NoteOnce timer is complete, select Stop Reset
-
Open regulator valve slowly
-
Set timer for 1 minutes and select start
NoteOnce 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
Note1x 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
Note1x spring clip, Install plug to outlet hose coupling
- Remove coolant drain container from underneath vehicle
-
Lower vehicle fully
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Release 2nd row seat cushion and disconnect harness
Note2x clips, 2x connectors, Press tabs backward then pull front edge up
-
Verify operation of multimeter
NoteSet 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
NoteCheck 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
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
-
Remove bolts securing ancillary bay probe lid cover to ancillary bay cover
Note2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
-
Remove ancillary bay probe lid cover from ancillary bay cover
-
Verify no high voltage
NoteMake 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
NoteConfirm 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
Note2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners
-
Remove HV insulating gloves
-
Disconnect HVC logic connector and install logic cap
Note1x connector, 1x cap, Release locking tab then push the handle downward to release connector
-
Remove bolts securing ancillary bay cover to HVC
Note3x bolts, E10, 5 Nm + 30 degrees
-
Remove bolts securing ancillary bay cover to HV battery
Note18x 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
NoteCheck 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
NoteMake 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
NoteInstall 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
Note1x insulator, patch bolts, 13mm, 9 Nm, Discard after removal
-
Remove pyro disconnect from ancillary bay
Note1x 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
NoteWrap 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
Note2x 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
Note2x 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
Note1x 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
Note1x connector
-
Disconnect PCS LV connector from PCS
Note1x 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
Note1x 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
Note5x bolts, 8mm, 18 Nm, Ensure onlythe 8mm fasteners are removed, Do not remove the T30 fasteners
-
Secure suction cups to PCS
NoteContinue pressing plunger until red line is no longer visible
-
Lift PCS up and out of ancillary bay area and remove from vehicle
NoteSlightly 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
Note1x insulator
-
Install HV joint insulator for negative busbar module 3 to shunt
Note1x insulator
-
Install HV joint insulator for positive DC link to module 4
Note1x insulator
-
Disconnect ancillary bay harness connectors from positive pack contactor
Note2x connectors
-
Remove ancillary bay harness clip from positive pack contactor
Note1x clip
-
Remove HV joint insulators from positive HV switch
Note2x insulators
-
Remove bolt securing positive pack contactor to positive busbar
Note1x patch bolt, 13mm, 9 Nm, Discard after removal
-
Remove nut securing positive pack contactor to module 4 rear terminal
Note1x patch nut, 13mm, 9 Nm, Discard after removal
-
Remove nuts securing positive pack contactor to ancillary bay
Note3x 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
Note2x guide pins
-
Release positive LV output cover from PCS cable
Note1x cover
-
Remove bolt securing DCDC ground busbar to body
Note1x bolt, 12mm, 20 Nm
-
Remove nut securing DCDC ground busbar to HV battery
Note1x 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
Note1x nut, 13mm, 15 Nm, Discard after removal
-
Remove bolts securing DCDC pass through to ancillary bay
Note2x bolts, E10 5-Lobe, 10 Nm
-
Remove DCDC pass through from ancillary bay
NoteElectrical Protective Gloves
-
Remove HV joint insulator for positive DC link to module 4
Note1x insulator
-
Remove nut securing DC link to module 4
Note1x 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
Note3x clips
-
Remove positive DC link from ancillary bay
Note2x guide pins
-
Position the positive DC link for installation
Note2x guide pins
-
Install ancillary bay harness clips to positive DC link
Note3x clips
-
Install nut securing joint DC link to module 4
Note1x patch nut, 13mm, 9 Nm, Install new patch bolt, Mark after torque
-
Perform resistance measurement on DC link to module 4 and busbar
Note1x HV joint, 60_xD835__xDF07_Ω or less
-
Install HV joint insulator for positive DC link to module 4
Note1x insulator
-
Position DCDC pass through to ancillary bay for installation
NoteElectrical Protective Gloves
-
Install bolts securing DCDC pass through to ancillary bay
Note2x bolts, E10 5-Lobe, 10 Nm, Mark the bolts after torque
-
Install positive LV output
Note1x 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
Note1x cover
-
Install DCDC ground busbar
NoteSlotted hole goes to body side
-
Install bolt securing DCDC ground busbar to body
Note1x bolt, 12mm, 20 Nm
-
Install nut securing DCDC ground busbar to HV battery
Note1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut
-
Position positive pack contactor to ancillary bay for installation
Note2x guide pins
-
Install nuts securing positive pack contactor to ancillary bay
Note3x 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
Note1x 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
Note1x 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
Note1x HV joint, 110_xD835__xDF07_Ω or less
-
Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar
Note1x 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
Note2x insulators
-
Install ancillary bay harness clip to positive pack contactor
Note1x clip
-
Connect ancillary bay harness connectors to positive pack contactor
Note2x connectors
-
Position the PCS into ancillary bay
NoteEnsure 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
Note5x bolts, 8mm, 18 Nm
-
Connect PCS to fastcharge contactor HV harness connector
Note1x 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
Note1x 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
Note1x connector
-
Connect PCS to DC bus HV connector
Note1x 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
Note1x o-ring, Apply light amount of Krytox 203
-
Connect PCS coolant inlet hose to PCS
Note2x 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
Note1x o-ring, Apply light amount of Krytox 203
-
Connect PCS coolant outlet hose to PCS
Note2x 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
NoteRelease bungee from back of headrest
-
Remove pyro disconnect dummy
-
Clean mating surfaces
NoteAllow 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
NoteWhile 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
Note1x 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
Note2x patch bolts, 13mm, 9 Nm
-
Measure resistance from module 2 busbar to pyro disconnect
Note1x HV joint, 48_xD835__xDF07_Ω or less, Perform zero adjust to Hioki meter prior to testing
-
Measure resistance from pyro disconnect to shunt
Note1x 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
NoteAny 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
NoteImage up close for clarity, Delaminated and torn seals cannot be reused
-
Position ancillary bay cover to HV battery for installation
NoteEnsure 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
Note18x 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
Note3x bolts, E10, 5 Nm + 30 degrees
-
Remove logic cap and connect HVC logic connector
Note1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
-
Connect 2nd row seat harness and secure cushion
Note2x 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
NoteSet 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
Note1x 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
Note1x 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
NoteWait 2 minutes for pressure to settle, Record the reading
-
Perform the coolant pressure leak test
NoteWait 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
Note1x spring clip
-
Remove plug from HV battery and connect RDU inverter inlet tube
Note1x 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
Note1x 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
Note1x spring clip
-
Connect rear PT supply hose to rear of HV battery and plug hose
Note1x 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
NoteRecommend assistance if needed
-
Install upper bolts securing HV battery rear skid plate enclosure hand tight
Note4x bolts, 13mm, 35 Nm, Torque at later step
-
Install upper nut securing HV battery rear skid plate enclosure hand tight
Note1x nut, 10mm, 13 Nm, Torque at later step
-
Install lower bolts securing HV battery rear skid plate enclosure
Note2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
-
Torque bolts securing HV battery rear skid plate enclosure to vehicle
Note4x bolts, 13mm, 35 Nm
-
Torque upper nut securing HV battery rear skid plate enclosure
Note1x nut, 10mm, 13 Nm
-
Install RH side hose clips to HV battery rear skid plate enclosure
Note2x fir tree clips
-
Install LH side hose clip to HV battery rear skid plate enclosure
Note1x clip
-
lnstall rear aero shield
Note11x 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
Note2x clips
-
Lower vehicle fully
NoteRaise 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
NoteVerify all valves on refill tool are in the closed position, See image for clarity
-
Install vacuum refill hose into refill cap on coolant bottle
NotePerform push-pull-push test to verify hose is fully engaged
-
Position overflow hose into empty container
-
Place refill hose inside filled coolant container
NoteMake sure hose end is fully submerged into coolant
-
Connect shop air supply to coolant refill tool
NoteIf not already done, Verify refill valve is set to off
-
Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
NoteGauge 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
NoteThis 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
NoteMake 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
Note2x 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
NoteSelect vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box
-
Unlock vehicle gateway
NoteAfter 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
NoteSelect Service mode > Thermal
-
Select "Start Coolant Air Purge" using the UI
NoteWait 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
NoteEnsure that fluid level is at Max line
-
Install coolant bottle cap
-
Install rear underhood apron
Note14x 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
NoteExit 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
NoteLower rack arms fully and remove them from under vehicle