25/07/2024 10:45:29

Harness - Ancillary Bay

Correction code 1630010322 3.72 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
  3. Lower all four windows
  4. Move LH front seat forward
  5. Move RH front seat forward
  6. 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
  7. Open hood
  8. Remove rear underhood apron
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    Note
    14x clips
  9. Place vehicle in service mode
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    Note
    Via UI > Controls > Software, Touch and hold "Model 3" for 4 seconds then release, Use screen keyboard to type "service" into dialog box then select OK
  10. Unlock vehicle gateway
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    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
  11. Run Thermal Fill Drain (Coolant Only) through the UI
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    Note
    Select Thermal > Coolant System > Coolant Fill/Drain, click Run, close once routine is completed, Thermal Fill Drain routine has 50 minutes time limit, After 50 minutes routine must be performed again
  12. Power off vehicle from center display
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    Note
    Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
  13. 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
  14. 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
  15. Remove all items from pockets and ensure not wearing metal items
  16. Inspect HV insulating gloves
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    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
  17. 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
  18. 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
  19. Remove ancillary bay probe lid cover from ancillary bay cover
  20. Verify no high voltage
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    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
  21. Inspect ancillary bay probe lid cover gasket then position onto 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
  22. Install bolts securing ancillary bay probe lid cover to ancillary bay cover
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    Note
    2x bolts, EP10 5-Lobe, 6 Nm, Install new fasteners
  23. Fold 2nd row 60 seat back down
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    Note
    Pull release, Fold down, Protect seat cushion if necessary
  24. Remove LH side bolster
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    Note
    1x locator clip, 3x guide tabs, Pull outward then slightly upward to remove
  25. Remove bolster plastic bracket from LH side body
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    Note
    2x clips, If necessary, Depress clips from behind, this bracket may come out with bolster, Discard after removal
  26. Move 2nd row 60 seat back into vertical position
  27. Partially release LH front primary door seal
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    Note
    Release lower section of LH front primary door seal
  28. Remove LH IP end cap
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    Note
    5x clips, 2x guide tabs
  29. Remove clip securing LH lower A-pillar assembly
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    Note
    1x push clip
  30. Remove LH lower A-pillar assembly
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    Note
    4x clips, 2x guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet
  31. Remove LH lower B-pillar assembly
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    Note
    7x clips, 4x locator clips, Pull the trim panel outward in the direction of the arrow to release clip from lower B-pillar
  32. Remove bolts securing sadface bracket to vehicle
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    Note
    2x bolts, 10mm, 10 Nm
  33. Remove sadface bracket from vehicle
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    Note
    1x Positioning clip
  34. Remove fastener securing busbar cover access door
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    Note
    1x bolt, 10mm, 9 Nm
  35. Remove bolts securing charge port busbar kit to HV header
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    Note
    2x bolts, 10mm, 9 Nm. If 3PH vehicles are involved, please remove the AC charging interface
  36. Remove AC chargeport inlet harness clip
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    Note
    1x clip
  37. Lift busbar kit connector to remove from HV header
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    Note
    4x guide tabs, Ease removal of aluminum connector housing by shifting rear end of busbar assembly upward
  38. Position chargeport busbar connector for access below
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    Note
    Rest on cross-member in front of penthouse
  39. Remove HV insulating gloves
  40. 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
  41. Remove bolts securing ancillary bay cover to HVC
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    Note
    3x bolts, E10, 5 Nm + 30 degrees
  42. 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
  43. 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
  44. 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
  45. Remove ancillary bay cover from HV battery
  46. 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
  47. Remove bolts securing pyro disconnect to ancillary bay
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    Note
    1x insulator, patch bolts, 13mm, 9 Nm, Discard after removal
  48. 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
  49. Install pyro disconnect dummy
  50. Use bungee to secure HVC in an upwards position
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    Note
    Wrap bungee around RH headrest
  51. 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
  52. Remove rear aero shield clips
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    Note
    2x clips, One clip on LH side wheel liner, One clip on RH side wheel liner
  53. Remove rear aero shield
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    Note
    11x bolts, 10mm, 5 Nm
  54. Release LH side hose clip from rear battery skid plate enclosure
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    Note
    1x fir tree clip
  55. Release RH side hose clips from rear battery skid plate enclosure
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    Note
    2x fir tree clips
  56. 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
  57. 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
  58. Remove upper bolts securing HV battery rear skid plate enclosure
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    Note
    4x bolts, 13mm, 35 Nm
  59. Remove HV battery rear skid plate enclosure
  60. Position coolant drain container underneath LH rear of HV battery
  61. Remove fir tree clip securing coolant hose to rear subframe shear plate
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    Note
    1x fir tree clip
  62. 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
  63. 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
  64. Attach coolant drain hose adapter to coolant hose extension
  65. 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
  66. Position coolant drain container underneath RH rear of vehicle
  67. Disconnect rear PT supply hose from rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill
  68. 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
  69. Attach coolant pressure tester to pressure fitting adapter
  70. Connect compressed air to coolant pressure tester
  71. 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
  72. Open 2nd valve slowly
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    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  73. Set timer for 1 minutes and select start
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    Note
    Once timer is complete, select Stop Reset
  74. Close regulator valve
  75. Set timer for 1 minutes and select start
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    Note
    Once timer is complete, select Stop Reset
  76. Open regulator valve slowly
  77. Set timer for 1 minutes and select start
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    Note
    Once timer is complete, select Stop Reset
  78. Close regulator valve
  79. Disconnect compressed air from coolant pressure tester
  80. Remove coolant pressure tester from PCS inlet hose coupling
  81. Position coolant drain container underneath LH rear of HV battery
  82. Remove coolant drain adapter with hose from PCS outlet hose coupling
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    Note
    1x spring clip
  83. 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
  84. Position coolant drain container underneath RH rear of vehicle
  85. 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
  86. Connect compressed air to coolant pressure tester
  87. 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
  88. Open 2nd valve slowly
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    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  89. Set timer for 1 minutes and select start
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    Note
    Once timer is complete, select Stop Reset
  90. Close regulator valve
  91. Set timer for 1 minutes and select start
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    Note
    Once timer is complete, select Stop Reset
  92. Open regulator valve slowly
  93. Set timer for 1 minutes and select start
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    Note
    Once timer is complete, select Stop Reset
  94. Close regulator valve
  95. Disconnect compressed air from coolant pressure tester
  96. Disconnect coolant hose extension from coolant drain hose
  97. Disconnect coolant drain hose adapter from coolant hose extension
  98. Remove coolant drain hose adapter from PCS inlet hose coupling
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    Note
    1x spring clip
  99. Position coolant drain container underneath LH rear of HV battery
  100. Remove pressure fitting adapter from coolant pressure tester
  101. Remove coolant pressure tester from PCS outlet hose coupling
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    Note
    1x spring clip
  102. Remove coolant drain container from underneath vehicle
  103. 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
  104. Position absorbent sheets below and around PCS coolant inlet hose to avoid excess coolant dripping
  105. 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
  106. Disconnect PCS coolant outlet hose from PCS
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    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
  107. 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
  108. Disconnect PCS logic connector from PCS
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    Note
    1x connector
  109. 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
  110. 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
  111. Remove bolts securing PCS to HV battery
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    Note
    5x bolts, 8mm, 18 Nm, Ensure only the 8mm fasteners are removed, Do not remove the T30 fasteners
  112. Secure suction cups to PCS
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    Note
    Continue pressing plunger until red line is no longer visible
  113. 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
  114. Install HV joint insulator for positive busbar module 2 to pyro disconnect
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    Note
    1x insulator
  115. Install HV joint insulator for negative busbar module 3 to shunt
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    Note
    1x insulator
  116. Install HV joint insulator for positive DC link to module 4
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    Note
    1x insulator
  117. Remove HV joint insulator for negative busbar module 3 to shunt
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    Note
    1x insulator
  118. Disconnect ancillary bay harness connectors from positive pack contactor
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    Note
    2x connectors
  119. Remove ancillary bay harness clip from positive pack contactor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  120. Remove HV joint insulators from positive HV switch
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    Note
    2x insulators
  121. Remove bolt securing positive pack contactor to positive busbar
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    Note
    1x patch bolt, 13mm, 9 Nm, Discard after removal
  122. Remove nut securing positive pack contactor to module 4 rear terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch nut, 13mm, 9 Nm, Discard after removal
  123. 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
  124. Remove positive pack contactor from ancillary bay
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    Note
    2x guide pins
  125. Release positive LV output cover from PCS cable
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    Note
    1x cover
  126. Remove bolt securing DCDC ground busbar to body
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    Note
    1x bolt, 12mm, 20 Nm
  127. Remove nut securing DCDC ground busbar to HV battery
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    Note
    1x nyloc nut, 13mm, 9 Nm, Discard nut after removal
  128. Remove DCDC ground busbar
  129. Remove nut securing positive LV output from PCS cable and move cable aside
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    Note
    1x nut, 13mm, 9 Nm, Discard after removal
  130. Remove bolts securing DCDC pass through to ancillary bay
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    Note
    2x bolts, E10 5-Lobe, 10 Nm
  131. Remove DCDC pass through from ancillary bay
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    Note
    Electrical Protective Gloves
  132. Remove HV joint insulator for positive DC link to module 4
    Informational PurposesAn informational icon, calling your attention
    Note
    1x insulator
  133. Remove AC filter harness from FC contactor cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab, 1x harness clip
  134. Disconnect megaharness connector from DC input assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  135. Remove the bolts securing the busbar AC input assembly to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E10 5-Lobe, 10 Nm, Discard after removal
  136. Release 3PH AC Filter Harness from 3PH 4P Header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, Lift connector off HV battery for access
  137. Remove the 3PH AC Filter harness from the vehicle
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    Note
    Harness must be removed through the ancillary bay, PCS connector does not fit through the header hole
  138. Remove insulator for DC input assembly to both fast charge busbar inlet side
    Informational PurposesAn informational icon, calling your attention
    Note
    1x insulator
  139. Remove bolt securing negative fast charge busbar inlet side and negative DC input assembly busbar
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    Note
    1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Discard after removal
  140. Remove bolt securing positive fast charge busbar inlet side and positive DC input assembly busbar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Discard after removal
  141. Remove bolts securing busbar DC input assembly to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, E10 5-Lobe, 10 Nm, Discard after removal
  142. Remove Busbar DC input assembly from ancillary bay
  143. Disconnect ancillary bay harness connectors from negative pack contactor
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    Note
    2x connectors
  144. Disconnect LV fast charge contactor connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Press tabs on both sides by hand and disconnect the connector upwards
  145. Remove harness clips from FC contactor cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  146. Remove harness clips from FC contactor cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Move the wiring harness around the FC cover aside
  147. Remove ancillary bay left terminals cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, 1x datum
  148. Remove bolt securing negative fast charge busbar DC link side
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Discard after removal, 0300_007
  149. Remove bolt securing positive fast charge busbar DC link side
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Discard after removal, 0300_006
  150. Remove bolts and nut securing FC assembly to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 5.5 Nm
  151. Remove the FC assembly from ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x guide pins
  152. Remove the LH daisy chain pass through housing from ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x harness clip, Insert UFO harness removal tool beneath daisy chain pass through housing, Insert tab release tool to release bottom 2x clips, Release top 3x clips with trim tool, Pull daisy chain pass through housing upward to remove
  153. Disconnect HV controller connector X483 - BMB daisy B at HVC from HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  154. Disconnect HV controller connector X482 - BMB daisy A at HVC from HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  155. Disconnect HV controller connector X480 – Shunt at HVC from HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  156. Disconnect HV controller connector X481 – Negative contactor sense at HVC from HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  157. Disconnect HV controller connector X478 – Positive contactor sense at HVC from HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  158. Disconnect HV controller connector X484 – Pyro disconnect at HVC from HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  159. Disconnect HV controller connector X479 –Main HVC connector from HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  160. Remove megaharness clips from HV controller hinge tray
    Informational PurposesAn informational icon, calling your attention
    Note
    5x harness clips,1x tape, The harness tape needs to be carefully cut with insulating knife
  161. Remove screws securing HVC tray assembly to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 2 Nm, 3x wires routed through RH hinge, Pull slightly forward on HVC at ~45 degree angle to access fastener between hinge and tray
  162. Remove the HVC and tray assembly from ancillary bay
  163. Remove X423 connector from DC link busbar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab1x clip
  164. Remove the pyro disconnect logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x clip
  165. Disconnect shunt assembly connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab
  166. Release harness from shunt insulator
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  167. Remove X422 connector from DC link busbar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab
  168. Remove the X421 connector from the DC connection bus
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab
  169. Remove RH daisy chain pass through housing from ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, Insert UFO harness removal tool beneath daisy chain pass through housing, Insert tab release tool to release bottom 2x clips, Release top 3x clips with trim tool, Pull daisy chain pass through housing upward to remove
  170. Remove nut securing DC link to module 4
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch nut, 13mm, 9 Nm, Discard after removal
  171. Move positive DC link out to allow access to ancillary bay harness clips
  172. Remove ancillary bay harness clips from positive DC link
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  173. Remove positive DC link from ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x guide pins
  174. Cut cable ties securing the megaharness to charger output to DC bus harness
    Informational PurposesAn informational icon, calling your attention
    Note
    2x cable ties
  175. Remove the Ancillary bay harness assembly fixing clip from the DC link
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips
  176. Remove the tab from the DC link shell
    Informational PurposesAn informational icon, calling your attention
    Note
    1x tab, When removing a tab,it should break off along the bottom edge, Do not leave any sharp corners that may damage the wiring harness.
  177. Remove megaharness from ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    1x harness
  178. Position megaharness to ancillary bay for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    1x harness
  179. Fix the Ancillary bay harness assembly to the DC link
  180. Install new cable ties securing the megaharness to charger output to DC bus harness
    Informational PurposesAn informational icon, calling your attention
    Note
    2x cable tie, cut off any excess cable ties
  181. Install the RH daisy chain pass through housing to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 2x bottom clips
  182. Position the positive DC link for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    2x guide pins
  183. Install ancillary bay harness clips to positive DC link
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  184. Install nut securing joint DC link to module 4
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch nut, 13mm, 9 Nm, Install new patch bolt, Mark after torque
  185. Perform resistance measurement on DC link to module 4 and busbar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 60μΩ or less
  186. Install HV joint insulator for positive DC link to module 4
    Informational PurposesAn informational icon, calling your attention
    Note
    1x insulator
  187. Install the X423 connector onto the DC bus
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector1x clip
  188. Install the pyro disconnect logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x clip
  189. Install harness to shunt insulator
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  190. Connect shunt assembly connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  191. Install the X422 connector onto the DC bus
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  192. Install the X421 connector onto the DC bus
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  193. Install the LH daisy chain pass through housing to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 2x bottom clips, 1x harness clip
  194. Position FC assembly to ancillary bay for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    2x guide pins
  195. Install bolts securing FC assembly to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 5.5 Nm, Mark after torque
  196. Install and torque bolt securing positive fast charge busbar DC link side to first value, loosen 180 degrees, and then torque to final value
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
  197. Install and torque bolt negative fast charge busbar DC link side to first value, loosen 180 degrees, and then torque to final value
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
  198. Perform Hioki impedance test at the positive HV joint of the fast charge busbar DC link side
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 25μΩ or less
  199. Perform Hioki impedance test at the negative HV joint of the fast charge busbar DC link side
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 55μΩ or less
  200. Install ancillary bay left terminals cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, 1x datum
  201. Install harness clips to FC contactor cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  202. Install ancillary bay harness clip around negative pack contactor area
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  203. Connect LV fast charge connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  204. Connect ancillary bay harness connectors to negative pack contactor
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  205. Install Busbar DC input assembly to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure seal is not damaged and seated properly
  206. Install bolts securing Busbar DC input assembly to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, E10 5-Lobe, 10 Nm, Install new bolts, Mark after torque
  207. Install and torque bolt securing negative fast charge busbar inlet and negative DC input link to first value, loosen 180 degrees, and then torque to final value
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
  208. Install and torque bolt securing positive fast charge busbar inlet and positive DC input link to first value, loosen 180 degrees, and then torque to final value
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
  209. Perform Hioki resistance test at both HV joints of DC input assembly busbar
    Informational PurposesAn informational icon, calling your attention
    Note
    2x HV joints, 60μΩ or less, Test from negative fast charge busbar to negative DC input busbar and positive fast charge busbar to positive DC input busbar
  210. Install insulator for DC input assembly to both fast charge busbars inlet side
    Informational PurposesAn informational icon, calling your attention
    Note
    1x insulator
  211. Route 3PH AC Filter Harness from the ancillary bay up through HV battery
  212. Install 3PH AC Filter harness to the 3PH 4P Header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, Inspect seal on 3PH header for any damage and replace as needed
  213. Install the bolts securing the Busbar AC input assembly to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, E10 5-Lobe, 10 Nm, Install new bolts, Mark after torque
  214. Install AC filter harness to FC contactor cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Secure locking tab, 1x harness clip
  215. Connect megaharness connector to DC input assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  216. Position DCDC pass through to ancillary bay for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    Electrical Protective Gloves
  217. 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
  218. 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
  219. Install positive LV output cover to PCS cable
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  220. Install DCDC ground busbar
    Informational PurposesAn informational icon, calling your attention
    Note
    Slotted hole goes to body side
  221. Install bolt securing DCDC ground busbar to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 12mm, 20 Nm
  222. 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
  223. Position positive pack contactor to ancillary bay for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    2x guide pins
  224. Install nuts securing positive pack contactor to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    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
  225. Install bolt securing positive pack contactor to positive busbar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 13mm. 9 Nm, Install new patch bolt, Mark after torque
  226. 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
  227. 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, 110μΩ or less
  228. Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar
    Informational PurposesAn informational icon, calling your attention
    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), stop work and escalate a Toolbox session. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
  229. Install HV joint insulators onto positive pack contactor
    Informational PurposesAn informational icon, calling your attention
    Note
    2x insulators
  230. Install ancillary bay harness clip to positive pack contactor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  231. Connect ancillary bay harness connectors to positive pack contactor
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  232. Position HVC tray assembly in ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    4x locating pins, 3x wires routed through RH hinge
  233. Secure HVC tray assembly to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 2 Nm
  234. Connect HV controller connector X479 –Main HVC connector to HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  235. Connect HV controller connector X484 – Pyro disconnect at HVC to HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  236. Connect HV controller connector X478 – Positive contactor sense at HVC to HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  237. Connect HV controller connector X481 – Negative contactor sense at HVC to HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  238. Connect HV controller connector X480 – Shunt at HVC to HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  239. Connect HV controller connector X482 - BMB daisy A at HVC to HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  240. Connect HV controller connector X483 - BMB daisy B at HVC to HV Controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  241. Install the megaharness clips to HV controller hinge tray
    Informational PurposesAn informational icon, calling your attention
    Note
    5x harness clips, 1x tape, Wrap harness tape around the hinge tray again
  242. Install HV joint insulator for negative busbar module 3 to shunt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x insulator
  243. Position the PCS into ancillary bay
    Informational PurposesAn informational icon, calling your attention
    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
  244. Remove suction cups from PCS
  245. Install bolts securing PCS to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, 8mm, 18 Nm
  246. Connect PCS to fast charge contactor HV harness 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
  247. 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
  248. Connect PCS logic connector to PCS
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  249. 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
  250. 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
  251. 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
  252. 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
  253. 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
  254. Lay HVC in original position
    Informational PurposesAn informational icon, calling your attention
    Note
    Release bungee from back of headrest
  255. Remove pyro disconnect dummy
  256. Clean mating surfaces
    Informational PurposesAn informational icon, calling your attention
    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
  257. Set multimeter to "LoZ" (low impedance) mode
  258. 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
  259. 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
  260. Install bolts securing pyro disconnect to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, 13mm, 9 Nm
  261. Measure resistance from module 2 busbar to pyro disconnect
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 48μΩ or less, Perform zero adjust to Hioki meter prior to testing
  262. Measure resistance from pyro disconnect to shunt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 33μΩ or less, Perform zero adjust to Hioki meter prior to testing
  263. Remove service insulator kit
  264. Clean HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time, New busbar comes with penetrox applied to HV connector
  265. Clean busbar HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
  266. Apply Penetrox onto HV connector joints
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
  267. Position busbar kit connector and lower onto HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    4x guide tabs, Shift rear end of busbar assembly upward to help ease installation, If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary
  268. Install AC chargeport inlet harness clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  269. Install bolts securing charge port busbar kit to HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm. If 3PH vehicles are involved, please install the AC charging interface
  270. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Informational PurposesAn informational icon, calling your attention
    Note
    2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session. If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), Hioki test passed, proceed to next step
  271. Install fastener securing busbar cover access door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 9 Nm
  272. 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
  273. Inspect ancillary bay cover seal to confirm it has no visual damage
    Informational PurposesAn informational icon, calling your attention
    Note
    Image up close for clarity, Delaminated and torn seals cannot be reused
  274. Position ancillary bay cover to HV battery for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
  275. Remove HV insulating gloves
  276. 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
  277. Install bolts securing ancillary bay cover to HVC
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, E10, 5 Nm + 30 degrees
  278. 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
  279. Install sadface bracket into vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x Positioning clip
  280. Install bolts securing sadface bracket to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 10 Nm
  281. Install LH lower B-pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips, 4x locator clips, Align the locator clips to slot, Then push in the direction of the arrow to install the clips after aligning them, Make sure the seal sits overlapping the trim
  282. Install LH lower A-pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, 2x guide tabs, Align 2 front tabs then align slot with harness bracket and then push rear clip to secure to lower B-pillar, Fully seat seal along trim
  283. Install clip securing LH lower A-pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  284. Install LH IP end cap
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, 2x guide tabs
  285. Install LH front primary seal
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify seal is seated properly on all trim panels
  286. Fold 2nd row 60 seat back down
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull release, Fold down, Protect seat cushion if necessary
  287. Install bolster plastic bracket to LH side bolster
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, Install new bolster bracket
  288. Install LH side bolster
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locator clip, 3x guide tabs, Align bottom and side tabs then push inward to install
  289. Return 2nd row 60 seat back to vertical position
  290. 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
  291. 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
  292. Position coolant drain container underneath RH rear of vehicle
  293. 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
  294. Position coolant drain container underneath LH rear of HV battery
  295. 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
  296. Install pressure fitting adapter to coolant pressure tester
  297. Connect compressed air to coolant pressure tester
  298. Open regulator valve then slowly adjust regulator to 50 psi
  299. Slowly open valve on pressure regulator and allow pressure to reach specification
  300. 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
  301. 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
  302. Remove pressure fitting adapter from coolant pressure tester
  303. Remove coolant pressure tester from PCS outlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  304. 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
  305. Position coolant drain container underneath RH rear of vehicle
  306. Remove coolant pressure test plug adapter from PCS inlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  307. 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
  308. Remove coolant drain container from underneath vehicle
  309. Install fir tree clip securing coolant hose to rear subframe shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  310. Position HV battery rear skid plate enclosure onto HV battery for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance if needed
  311. 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
  312. 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
  313. 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
  314. Torque bolts securing HV battery rear skid plate enclosure to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  315. Torque upper nut securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm
  316. Install RH side hose clips to HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  317. Install LH side hose clip to HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  318. Install rear aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm, Apply Loctite 222 onto rear aero shield bolts
  319. Install LH and RH clips securing rear aero shield to wheel house liner
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  320. 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
  321. Remove coolant bottle cap
  322. Place empty coolant container into front storage area
  323. Fill container with at least 15L of coolant
  324. Place filled coolant container into front storage area
  325. Install refill tool cap onto coolant bottle assembly
  326. 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
  327. 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
  328. Position overflow hose into empty container
  329. Place refill hose inside filled coolant container
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end is fully submerged into coolant
  330. 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
  331. 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
  332. 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
  333. Monitor gauge for 30 seconds to verify a vacuum is maintained in cooling system
  334. Reopen air inlet valve for 3 minutes to continue evacuating cooling system, then close valve
  335. 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
  336. Once gauge reads zero, close refill valve
  337. Disconnect shop air supply from coolant refill tool
  338. Remove coolant refill hose from coolant container
  339. Remove coolant overflow hose from coolant container
  340. Remove vacuum refill hose from refill cap on coolant bottle
  341. Remove coolant refill tool from vehicle
  342. Remove both coolant containers from inside underhood area
  343. 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
  344. 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
  345. Access Thermal System routines using UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select Service mode > Thermal
  346. Select "Stop Thermal Fill Drain" through UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow routine to complete, ensure routine is successful
  347. Select "Coolant Purge Start" using 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, Speeds can be monitored in garage under PT Thermal tab, 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
  348. Exit Service Mode
    Informational PurposesAn informational icon, calling your attention
    Note
    Via UI > Service > Exit, Press and hold "Exit Service Mode" button
  349. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that fluid level is at Max line
  350. Install coolant bottle cap
  351. 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
  352. Close hood
  353. Move RH front seat to original position
  354. Move LH front seat to original position
  355. Raise all windows
  356. Close all four doors
  357. Remove lift arms from below vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove them from under vehicle