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.

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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. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
  1. Raise and support vehicle
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    Note
    Ensure vehicle is not charging
  2. Open all four doors
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    Note
    If vehicle is being powered down, Latch rear doors to prevent accidental closure
  3. Lower all four windows
  4. Move LH front seat forward
  5. Move RH front seat forward
  6. Open hood
  7. Remove rear underhood apron
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    Note
    14x clips
  8. Power off vehicle from center display
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    Note
    Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
  9. Disconnect LV battery and First Responder Loop
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    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
  10. Raise vehicle fully and lower lift onto locks
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    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
  11. Remove LH and RH clips securing rear aero shield to wheel house liner
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    Note
    2x clips
  12. Remove rear aero shield
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    Note
    11x bolts, 10mm, 5 Nm
  13. Release LH side hose clip from rear battery skid plate enclosure
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    Note
    1x fir tree clip
  14. Release RH side hose clips from rear battery skid plate enclosure
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    Note
    2x fir tree clips
  15. Remove lower bolts securing HV battery rear skid plate enclosure
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    Note
    2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count
  16. Remove upper nut securing HV battery rear skid plate enclosure
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    Note
    1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles
  17. Remove upper bolts securing HV battery rear skid plate enclosure
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    Note
    4x bolts, 13mm, 35 Nm
  18. Remove HV battery rear skid plate enclosure
  19. Position coolant drain container underneath LH rear of HV battery
  20. Disconnect LH coolant hose from rear of HV battery
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    Note
    1x spring clip, 2x plugs, Plug both the coolant hose and passthrough
  21. Remove fir tree clip securing coolant hose to rear subframe shear plate
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    Note
    1x fir tree clip
  22. Disconnect RDU inverter inlet tube from LH rear of HV battery
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    Note
    1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill
  23. Attach coolant drain hose adapter to PCS outlet hose coupling
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    Note
    Use adapter with 90 degree angle, Make sure locking tab is fully seated
  24. Attach coolant drain hose adapter to coolant hose extension
  25. Attach coolant hose extension to coolant drain hose
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    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  26. Position coolant drain container underneath RH rear of vehicle
  27. 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
  28. Attach coolant pressure tester to PCS inlet hose coupling
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    Note
    This adapter connected to regulated air line adapter, Make sure the locking tab is fully seated
  29. Attach coolant pressure tester to pressure fitting adapter
  30. Connect compressed air to coolant pressure tester
  31. Open regulator valve then slowly adjust regulator to 50 psi
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    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  32. Open 2nd valve slowly
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    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  33. Set timer for 1 minutes and select start
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    Note
    Once timer is complete, select Stop Reset
  34. Close regulator valve
  35. Set timer for 1 minutes and select start
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    Note
    Once timer is complete, select Stop Reset
  36. Open regulator valve slowly
  37. Set timer for 1 minutes and select start
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    Note
    Once timer is complete, select Stop Reset
  38. Close regulator valve
  39. Disconnect compressed air from coolant pressure tester
  40. Remove coolant pressure tester from PCS inlet hose coupling
  41. Position coolant drain container underneath LH rear of HV battery
  42. Remove coolant drain adapter with hose from PCS outlet hose coupling
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    Note
    1x spring clip
  43. Attach coolant pressure tester with hose to PCS outlet hose coupling
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    Note
    1x spring clip, Make sure the locking tab is fully seated
  44. Position coolant drain container underneath RH rear of vehicle
  45. Attach coolant drain adapter with hose to PCS inlet hose coupling
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    Note
    1x spring clip, Make sure the locking tab is fully seated
  46. Connect compressed air to coolant pressure tester
  47. Open regulator valve then slowly adjust regulator to 50 psi
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  48. Open 2nd valve slowly
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    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  49. Set timer for 1 minutes and select start
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    Note
    Once timer is complete, select Stop Reset
  50. Close regulator valve
  51. Set timer for 1 minutes and select start
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    Note
    Once timer is complete, select Stop Reset
  52. Open regulator valve slowly
  53. Set timer for 1 minutes and select start
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    Note
    Once timer is complete, select Stop Reset
  54. Close regulator valve
  55. Disconnect compressed air from coolant pressure tester
  56. Disconnect coolant hose extension from coolant drain hose
  57. Disconnect coolant drain hose adapter from coolant hose extension
  58. Remove coolant drain hose adapter from PCS inlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Install plug to inlet hose coupling
  59. Position coolant drain container underneath LH rear of HV battery
  60. Remove pressure fitting adapter from coolant pressure tester
  61. Remove coolant pressure tester from PCS outlet hose coupling
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    Note
    1x spring clip, Install plug to outlet hose coupling
  62. Remove coolant drain container from underneath vehicle
  63. Lower vehicle fully
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  64. Release 2nd row seat cushion and disconnect harness
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    Note
    2x clips, 2x connectors, Press tabs backward then pull front edge up
  65. Verify operation of multimeter
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    Note
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery
  66. Remove all items from pockets and ensure not wearing metal items
  67. Inspect HV insulating gloves
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    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
  68. Put on HV insulating gloves and leather over gloves
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    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  69. Remove bolts securing ancillary bay probe lid cover to ancillary bay cover
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    Note
    2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
  70. Remove ancillary bay probe lid cover from ancillary bay cover
  71. Verify no high voltage
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    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
  72. Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
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    Note
    Confirm no visual damage present,Wipe ancillary bay with IPA to clean surface,Allow to 1 minute dry time
  73. Install bolts securing ancillary bay probe lid cover to ancillary bay cover
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    Note
    2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners
  74. Remove HV insulating gloves
  75. Disconnect HVC logic connector and install logic cap
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    Note
    1x connector, 1x cap, Release locking tab then push the handle downward to release connector
  76. Remove bolts securing ancillary bay cover to HVC
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    Note
    3x bolts, E10, 5 Nm + 30 degrees
  77. Remove bolts securing ancillary bay cover to HV battery
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    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
  78. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    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
  79. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  80. Remove ancillary bay cover from HV battery
  81. Inspect ancillary bay for any missing insulators
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    Note
    Install service insulator kit before continuing to next step, The number of bolts on newer vehicles may vary
  82. Remove bolts securing pyro disconnect to ancillary bay
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    Note
    1x insulator, patch bolts, 13mm, 9 Nm, Discard after removal
  83. Remove pyro disconnect from ancillary bay
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    Note
    1x connector from the bottom, Lift pyro disconnect straight up and out of the ancillary bay
  84. Install pyro disconnect dummy
  85. Use bungee to secure HVC in an upwards position
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    Note
    Wrap bungee around RH headrest
  86. Position absorbent sheets below and around PCS coolant inlet hose to avoid excess coolant dripping
  87. Disconnect PCS coolant inlet hose from PCS
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    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
  88. Disconnect PCS coolant outlet hose from PCS
    Informational PurposesAn informational icon, calling your attention
    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
  89. Disconnect PCS to DC bus HV connector
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    Note
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  90. Disconnect PCS logic connector from PCS
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    Note
    1x connector
  91. Disconnect PCS LV connector from PCS
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    Note
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  92. Disconnect PCS to AC harness connector
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    Note
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  93. Remove bolts securing PCS to HV battery
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    Note
    5x bolts, 8mm, 18 Nm, Ensure onlythe 8mm fasteners are removed, Do not remove the T30 fasteners
  94. Secure suction cups to PCS
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    Note
    Continue pressing plunger until red line is no longer visible
  95. Lift PCS up and out of ancillary bay area and remove from vehicle
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    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
  96. Install HV joint insulator for positive busbar module 2 to pyro disconnect
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    Note
    1x insulator
  97. Install HV joint insulator for negative busbar module 3 to shunt
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    Note
    1x insulator
  98. Install HV joint insulator for positive DC link to module 4
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    Note
    1x insulator
  99. Disconnect ancillary bay harness connectors from positive pack contactor
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    Note
    2x connectors
  100. Remove ancillary bay harness clip from positive pack contactor
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    Note
    1x clip
  101. Remove HV joint insulators from positive HV switch
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    Note
    2x insulators
  102. Remove bolt securing positive pack contactor to positive busbar
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    Note
    1x patch bolt, 13mm, 9 Nm, Discard after removal
  103. Remove nut securing positive pack contactor to module 4 rear terminal
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    Note
    1x patch nut, 13mm, 9 Nm, Discard after removal
  104. Remove nuts securing positive pack contactor to ancillary bay
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    Note
    3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary
  105. Remove positive pack contactor from ancillary bay
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    Note
    2x guide pins
  106. Release positive LV output cover from PCS cable
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    Note
    1x cover
  107. Remove bolt securing DCDC ground busbar to body
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    Note
    1x bolt, 12mm, 20 Nm
  108. Remove nut securing DCDC ground busbar to HV battery
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    Note
    1x nyloc nut, 13mm, 9 Nm, Discard nut after removal
  109. Remove DCDC ground busbar
  110. Remove nut securing positive LV output from PCS cable and move cable aside
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    Note
    1x nut, 13mm, 15 Nm, Discard after removal
  111. Remove bolts securing DCDC pass through to ancillary bay
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    Note
    2x bolts, E10 5-Lobe, 10 Nm
  112. Remove DCDC pass through from ancillary bay
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    Note
    Electrical Protective Gloves
  113. Remove HV joint insulator for positive DC link to module 4
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    Note
    1x insulator
  114. Remove nut securing DC link to module 4
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    Note
    1x patch nut, 13mm, 9 Nm, Discard after removal
  115. Move positive DC link out to allow access to ancillary bay harness clips
  116. Remove ancillary bay harness clips from positive DC link
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    Note
    3x clips
  117. Remove positive DC link from ancillary bay
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    Note
    2x guide pins
  118. Position the positive DC link for installation
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    Note
    2x guide pins
  119. Install ancillary bay harness clips to positive DC link
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    Note
    3x clips
  120. Install nut securing joint DC link to module 4
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    Note
    1x patch nut, 13mm, 9 Nm, Install new patch bolt, Mark after torque
  121. Perform resistance measurement on DC link to module 4 and busbar
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    Note
    1x HV joint, 60_xD835__xDF07_Ω or less
  122. Install HV joint insulator for positive DC link to module 4
    Informational PurposesAn informational icon, calling your attention
    Note
    1x insulator
  123. Position DCDC pass through to ancillary bay for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    Electrical Protective Gloves
  124. Install bolts securing DCDC pass through to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E10 5-Lobe, 10 Nm, Mark the bolts after torque
  125. Install positive LV output
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 13mm, 9 Nm, Make sure rubber boot is not pinched between cable terminal and pass through
  126. Install positive LV output cover to PCS cable
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    Note
    1x cover
  127. Install DCDC ground busbar
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    Note
    Slotted hole goes to body side
  128. Install bolt securing DCDC ground busbar to body
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    Note
    1x bolt, 12mm, 20 Nm
  129. Install nut securing DCDC ground busbar to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut
  130. Position positive pack contactor to ancillary bay for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    2x guide pins
  131. Install nuts securing positive pack contactor to ancillary bay
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    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
  132. Install bolt securing positive pack contactor to positive busbar
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    Note
    1x patch bolt, 13mm. 9 Nm, Install new patch bolt, Mark after torque
  133. Install nut securing positive pack contactor to HV battery tall terminal to module 4 rear terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque
  134. Measure resistance from HV joint between HV battery positive contactor and the center of HV battery positive terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 110_xD835__xDF07_Ω or less
  135. Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar
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    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.
  136. Install HV joint insulators onto positive pack contactor
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    Note
    2x insulators
  137. Install ancillary bay harness clip to positive pack contactor
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    Note
    1x clip
  138. Connect ancillary bay harness connectors to positive pack contactor
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    Note
    2x connectors
  139. Position the PCS into ancillary bay
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    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
  140. Remove suction cups from PCS
  141. Install bolts securing PCS to HV battery
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    Note
    5x bolts, 8mm, 18 Nm
  142. Connect PCS to fastcharge contactor HV harness connector
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    Note
    1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
  143. Connect PCS LV connector to PCS
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
  144. Connect PCS logic connector to PCS
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    Note
    1x connector
  145. Connect PCS to DC bus HV connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
  146. Replace o-ring on PCS side inlet hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x o-ring, Apply light amount of Krytox 203
  147. Connect PCS coolant inlet hose to PCS
    Informational PurposesAn informational icon, calling your attention
    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
  148. Replace o-ring on PCS side outlet hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x o-ring, Apply light amount of Krytox 203
  149. Connect PCS coolant outlet hose to PCS
    Informational PurposesAn informational icon, calling your attention
    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
  150. Lay HVC in original position
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    Note
    Release bungee from back of headrest
  151. Remove pyro disconnect dummy
  152. Clean mating surfaces
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    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
  153. Set multimeter to "LoZ" (low impedance) mode
  154. Measure voltage between busbar and shunt
    Informational PurposesAn informational icon, calling your attention
    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
  155. Position pyro disconnect to ancillary bay for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way
  156. Install bolts securing pyro disconnect to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, 13mm, 9 Nm
  157. Measure resistance from module 2 busbar to pyro disconnect
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 48_xD835__xDF07_Ω or less, Perform zero adjust to Hioki meter prior to testing
  158. Measure resistance from pyro disconnect to shunt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 33_xD835__xDF07_Ω or less, Perform zero adjust to Hioki meter prior to testing
  159. Remove service insulator kit
  160. Inspect ancillary bay walls for damage
    Informational PurposesAn informational icon, calling your attention
    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
  161. Inspect ancillary bay cover seal to confirm it has no visual damage
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    Note
    Image up close for clarity, Delaminated and torn seals cannot be reused
  162. Position ancillary bay cover to HV battery for installation
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    Note
    Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
  163. Remove HV insulating gloves
  164. Install bolts securing ancillary bay cover to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image
  165. Install bolts securing ancillary bay cover to HVC
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, E10, 5 Nm + 30 degrees
  166. Remove logic cap and connect HVC logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
  167. 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
  168. 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 locks on both sides before lowering, otherwise vehicle may tilt to side
  169. Position coolant drain container underneath RH rear of vehicle
  170. Install coolant pressure test plug adapter to PCS inlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x plug, Remove plug from inlet hose coupling, Make sure the locking tab is fully seated
  171. Position coolant drain container underneath LH rear of HV battery
  172. Install coolant pressure tester to PCS outlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x plug, Remove plug from outlet hose coupling, Make sure the locking tab is fully seated
  173. Install pressure fitting adapter to coolant pressure tester
  174. Connect compressed air to coolant pressure tester
  175. Open regulator valve then slowly adjust regulator to 50 psi
  176. Slowly open valve on pressure regulator and allow pressure to reach specification
  177. Close the valve and let pressure settle
    Informational PurposesAn informational icon, calling your attention
    Note
    Wait 2 minutes for pressure to settle, Record the reading
  178. Perform the coolant pressure leak test
    Informational PurposesAn informational icon, calling your attention
    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
  179. Remove pressure fitting adapter from coolant pressure tester
  180. Remove coolant pressure tester from PCS outlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  181. Remove plug from HV battery and connect RDU inverter inlet tube
    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
  182. Connect LH coolant hose to rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    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
  183. Position coolant drain container underneath RH rear of vehicle
  184. Remove coolant pressure test plug adapter from PCS inlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  185. Connect rear PT supply hose to rear of HV battery and plug hose
    Informational PurposesAn informational icon, calling your attention
    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
  186. Remove coolant drain container from underneath vehicle
  187. Position HV battery rear skid plate enclosure onto HV battery for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance if needed
  188. 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
  189. 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
  190. Install lower bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
  191. Torque bolts securing HV battery rear skid plate enclosure to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  192. Torque upper nut securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm
  193. Install RH side hose clips to HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  194. Install LH side hose clip to HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  195. 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
  196. Install LH and RH clips securing rear aero shield to wheel house liner
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  197. 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
  198. Remove coolant bottle cap
  199. Place empty coolant container into front storage area
  200. Fill container with at least 15L of coolant
  201. Place filled coolant container into front storage area
  202. Install refill tool cap onto coolant bottle assembly
  203. Setup vacuum refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify all valves on refill tool are in the closed position, See image for clarity
  204. Install vacuum refill hose into refill cap on coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to verify hose is fully engaged
  205. Position overflow hose into empty container
  206. Place refill hose inside filled coolant container
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end is fully submerged into coolant
  207. Connect shop air supply to coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, Verify refill valve is set to off
  208. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
    Informational PurposesAn informational icon, calling your attention
    Note
    Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
  209. Slowly open coolant refill valve to allow coolant to be drawn into coolant refill hose, Close valve when hose is full of coolant
    Informational PurposesAn informational icon, calling your attention
    Note
    This purges trapped air from the hose
  210. Monitor gauge for 30 seconds to verify a vacuum is maintained in cooling system
  211. Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close valve
  212. Slowly open refill valve to allow coolant to be drawn into system
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end of refill hose is fully submerged during entire process
  213. Once gauge reads zero, close refill valve
  214. Disconnect shop air supply from coolant refill tool
  215. Remove coolant refill hose from coolant container
  216. Remove coolant overflow hose from coolant container
  217. Remove vacuum refill hose from refill cap on coolant bottle
  218. Remove coolant refill tool from vehicle
  219. Remove both coolant containers from inside underhood area
  220. Connect First Responder Loop and LV battery
    Informational PurposesAn informational icon, calling your attention
    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
  221. Place vehicle in service mode through UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box
  222. 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
  223. Access Thermal System routines using the UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select Service mode > Thermal
  224. 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.
  225. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that fluid level is at Max line
  226. Install coolant bottle cap
  227. Install rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
  228. Close hood
  229. Move RH front seat to original position
  230. Move LH front seat to original position
  231. Exit Service Mode through UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Exit Service Mode: Controls > Service Mode > Exit Service Mode, Press and hold to exit
  232. Raise all windows
  233. Close all four doors
  234. Remove lift arms from below vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove them from under vehicle