14/12/2023 18:50:46

Hose - HV Battery Return (Remove and Replace)

Correction code 1830020082 FRT 0.96 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

Warning

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

Remove

Remove bolts securing LH rocker panel lower cover to body.

Note
4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary.
Remove clips securing the LH rocker panel lower cover to wheel liners.

Note
4x push clips.
Remove LH rocker panel lower cover.

Note
10x clips.
Remove bolts securing RH rocker panel lower cover to body.

Note
4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary.
Remove clips securing the RH rocker panel lower cover to wheel liners.

Note
4x push clips.
Remove RH rocker panel lower cover.

Note
10x clips.
Open all four doors.

Note
If vehicle is being powered down, Latch rear doors to prevent accidental closure.
Lower all four windows.
Move LH front seat backward.
Remove LH front floor mat.
Partially release LH front primary door seal.

Note
Release the lower section of LH front primary door seal.
Remove LH IP end cap.

Note
5x clips, 2x guide tabs.
Remove clip securing LH lower A-pillar assembly.

Note
1x push clip.
Remove LH lower A-pillar assembly.

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.
Release LH footwell cover.

Note
5x clips,1x guide tab.
Disconnect LH footwell cover connectors.

Note
2x connectors.
Remove LH console side panel carpet.

Note
11x clips, 2x positioning clips, 1x tab, Use trim tool starting at rear edge to release upper clips, If the clip is too tight, Use prytool to remove the clips, Then pull bottom to release remaining clips, Finally, release the tab and pull out the side panel backward, Replace the clips if it is damaged.
Remove LH front main cabin carpet clips.

Note
2x push clips, Number of clips on new vehicles may vary.
Fold the LH front main cabin carpet aside for access.

Note
Dead pedal and foam block are part of carpet,.
Remove LH front footwell HV battery bolts.

Note
2x bolts, EP20, 136 Nm.
Move LH front seat forward.
Move RH front seat backward.
Remove RH front floor mat.
Partially release RH front primary door seal.

Note
Release the lower section of RH front primary door seal.
Remove RH IP end cap.

Note
5x clips, 2x guide tabs.
Remove clip for RH lower A-pillar trim.

Note
1x push clip.
Remove RH lower A-pillar trim.

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.
Release RH footwell cover.

Note
2x magnets, 1x guide tab, 1x connector.
Remove connectors from RH footwell cover.

Note
1x puddle light connector, 1x Speaker connector.
Remove RH console side panel carpet.

Note
12x clips, 2x positioning clips, 1x datum, Use trim tool starting at rear edge to release upper clips, If the clip is too tight, Useprytool to remove the clips, Then pull bottom to release remaining clips, Finally, release the datum and pull out the side panel backward, Replace the clips if it is damaged.
Remove clips securing RH front main carpet to vehicle.

Note
1x clip, Number of clips on new vehicles may vary.
Fold RH front main cabin carpet aside for access.

Note
2x clips, Lift center piece and pull carpet back, Release seat harness from clips to allow carpet to fold back more.
Remove RH front footwell HV battery bolts.

Note
2x bolts, EP20, 136 Nm.
Move RH front seat forward.
Close RH front door.
Remove 2nd row floor mat from vehicle.
Release 2nd row seat cushion and disconnect harness.

Note
2x clips, 2x connectors, Press tabs backward then pull front edge up.
Pull back rear carpet to access rear interior battery bolts.

Note
2x push clips.
Remove LH rear HV battery interior bolt.

Note
1x bolt, 16mm, 66 Nm, Lift up carpet for access.
Close LH rear door latch manually.
Remove RH rear HV battery interior bolt.

Note
1x bolt, 16mm, 66 Nm, Lift up carpet for access.
Close RH rear door latch manually.
Raise and support vehicle.

Note
Remove body plugs and install M3 lift pad adapters to indicated locations .
Place vehicle in service mode plus.

Note
Using Vehicle Ops mobile app enter last six digits of VIN then select vehicle from list then swipe to the left and select "Enable Service Mode Plus"Vehicle Ops mobile app can be downloaded at: https://mobile.tesla.com/AppStore/Home/AppDetails?appId=6.
Unlock vehicle gateway.

Note
After vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information.
Run Thermal Fill Drain (Coolant Only) through the UI.

Note
Select Thermal > Coolant System > Coolant Fill/Drain, click Run, close once routine is completed, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours routine must be performed again.
Open hood.
Remove rear underhood apron.

Note
14x clips.
Power off vehicle from center display.

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

Note
2x connectors, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge.
Remove all items from pockets and ensure not wearing metal items.
Verify operation of multimeter.

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery.
Open LH rear door.
Inspect HV insulating gloves.

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
Put on HV insulating gloves and leather over gloves.

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

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

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

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

Note
2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners.
Remove fastener securing busbar cover access door.

Note
1x bolt, 10mm, 9 Nm.
Remove bolts securing charge port busbar kit to HV header.

Note
2x bolts, 10mm, 9 Nm.
Lift busbar kit connector to remove from HV header.

Note
4x guide tabs, Ease removal of aluminum connector housing by shifting rear end of busbar assembly upward.
Remove HV insulating gloves.
Open RH rear door.
Disconnect HVC logic connector and install logic cap.

Note
1x connector, 1x cap, Release locking tab then push the handle downward to release connector.
Remove bolt securing DCDC ground busbar to body.

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

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

Note
1x nut, 13mm, 15 Nm, Discard after removal.
Raise vehicle fully and lower lift onto locks.

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side, Verify doors are clear of surrounding objects.
Remove LH and RH clips securing rear aero shield to wheel house liner.

Note
2x clips.
Remove rear aero shield.

Note
11x bolts, 10mm, 5 Nm.
Remove outer fasteners securing front aero shield.

Note
7x bolts, 10mm, 5 Nm.
Remove remaining nuts and remove front aero shield from vehicle.

Note
2x nuts, 15mm, 5 Nm.
Remove push clips securing lower rear edge of LH front wheel liner to vehicle for access to coolant hose.

Note
3x push clips.
Remove bolt securing LH front wheel liner to skid plate.

Note
1x bolt, 10mm, 5 Nm.
Use bungee strap to pull back LH front wheel liner.

Note
Secure to subframe.
Position coolant drain container underneath LH front of HV battery.
Attach hose extension to coolant drain hose for extra length.
Connect battery flush fitting adapter to coolant cart drain hose.
Disconnect HV battery return hose at LH side of vehicle and connect battery flush fitting to male side.

Note
1x spring clip.
Attach battery drain fitting adapter to female side of HV battery return tube.

Note
1x spring clip, Make sure valve is set to closed, Perform push-pull test to verify adapter is fully engaged.
Attach battery drain fitting adapter to coolant cart pressure hose.
Open valve on battery drain fitting adapter.

Note
Turn valve knob to vertical position.
Slowly open valve on pressure regulator and allow coolant to drain out of HV battery return tube.

Note
Close valve on pressure regulator once no coolant is draining from HV battery return hose.
Close valve on pressure regulator once no coolant is draining from battery return hose.
Disconnect compressed air from coolant cart.
Remove battery drain fitting adapter from female side of HV battery return tube.

Note
1x spring clip, Set valve knob to closed position.
Remove battery flush fitting adapter from male side of HV battery return tube.

Note
1x spring clip, Plug hose once adapter has been removed.
Remove bolt securing RH front wheel liner to skid plate.

Note
1x bolt, 10mm, 5 Nm.
Remove push clips securing lower rear edge of RH front wheel liner to vehicle for access to coolant hose.

Note
3x push clips.
Use bungee strap to pull back RH front wheel liner.

Note
Secure to subframe.
Position coolant drain container underneath RH front of HV battery.
Disconnect powertrain supply hose from powertrain supply tube.

Note
1x spring clips, Plug hoses as required.
Disconnect powertrain return hose from powertrain return tube.

Note
1x spring clip, Plug hoses as required.
Disconnect HV battery manifold hose.

Note
1x spring clip, 2x plugs, Plug hoses as required.
Remove bolts securing front skid plate.

Note
4x bolts, EP10, 13 Nm.
Remove skid plate from HV battery.
Disconnect A/C compressor HV harness connector.

Note
1x connector, 1x Red locking tab, 2 stage push release, Unlock by pulling back red tab, Push orange lip and pull back ''stage 1'', Push green lip and pull back to disconnect.
Release LH side hose clip from rear battery skid plate enclosure.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Note
1x spring clip.
Disconnect RDU outlet hose from PT return tube and plug both hose ends.

Note
1x spring clip, 2x plugs, Lower hose located at RH rear of HV battery, Use shop towel to clean any residue coolant if necessary, Coolant loss greater than 1 L will require vacuum fill.
Support front portion of rear subframe.
Release clips securing coolant hoses to LH shear plate.

Note
2x fir tree clips.
Remove smaller fasteners securing LH shear plate.

Note
2x bolts, 13mm, 35 Nm.
Remove large bolt securing LH shear plate and subframe to body and remove shear plate.

Note
1x bolt, 21mm, 130 Nm, Discard after removal.
Hand tighten bolt securing LH side of subframe to body.

Note
1x bolt, 21mm, 130 Nm.
Release clips securing coolant hoses to RH shear plate.

Note
2x fir tree clips.
Remove smaller fasteners for RH shear plate.

Note
2x bolts, 13mm, 35 Nm.
Remove large bolt securing RH shear plate and subframe to body and remove shear plate.

Note
1x bolt, 21mm, 130 Nm, Discard at later step.
Hand tighten bolt securing RH side of subframe to body.

Note
1x bolt, 21mm, 130 Nm.
Remove support stand from under vehicle.
Remove nut securing RDU HV cable bracket to HV battery.

Note
1x nut, 10mm, 10 Nm, Number of fasteners may vary.
Disconnect RDU HV cable from HV battery.

Note
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged.
Place HV battery table into position and lower vehicle to support HV battery.

Note
Recommend assistance, Line up table so center 4 bolts are accessible through opening in table, Adjust final battery table position using adjustable caster jacks on table.
Remove central bolts securing HV battery center ski cover.

Note
4x bolts, EP14, 34 Nm.
Remove bolts securing LH front support bracket to vehicle.

Note
4x bolts, 16mm, 110 Nm.
Remove bolts securing RH front support bracket to vehicle.

Note
4x bolts, 16mm, 110 Nm.
Remove LH bolts securing HV battery to vehicle.

Note
8x bolts, 13mm, 35 Nm.
Remove RH bolts securing HV battery to vehicle.

Note
8x bolts, 13mm, 35 Nm.
Raise vehicle free of HV battery.

Note
Recommend assistance.
Remove battery from under vehicle.

Note
Recommend assistance.
Release clips securing HV battery return tube from rear of HV battery.

Note
2x clips.
Release HV battery return tube from LH side of HV battery and allow hose to fully drain.

Note
5x clips, Remove all coolant plugs from hose and allow coolant to fully drain.

Install

Install HV battery return tube onto LH side of HV battery.

Note
5x clips.
Remove plug and connect HV battery return tube to LH rear of HV battery.

Note
1x spring clip, 1x plug, Perform push-pull-push test to make sure hose is fully engaged.Loss of coolant greater than 1L requires coolant vacuum fill.
Install clips securing HV battery return tube onto rear of HV battery.

Note
2x clips.
Remove plug and connect HV battery return tube to RH rear of HV battery.

Note
1x spring clip, 1x plug, Perform push-pull-push test to make sure hose is fully engaged.Loss of coolant greater than 1L requires coolant vacuum fill.
Install HV battery alignment rods.

Note
2x rods, To body at front of vehicle, 2x rods, To battery near ancillary bay.
Position HV battery under vehicle.

Note
Recommend assistance.
Lower vehicle onto HV battery and align holes.

Note
Recommend assistance, Use alignment rods, Be sure coolant hoses do not get caught on alignment rods, Caution not to damage HV cable, Do not fully lower vehicle onto battery (this will help with installing battery bolts).
Set RH bolts securing HV battery to vehicle with cordless impact.

Note
8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
Set LH bolts securing HV battery to vehicle with cordless impact.

Note
8x bolts, 13mm, 35 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
Remove HV battery alignment rods.

Note
2x rods, To body at front of vehicle, 2x rods, To battery near ancillary bay.
Set bolts securing RH front support bracket to vehicle with cordless impact.

Note
4x bolts, 16mm, 110 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
Set bolts securing LH front support bracket to vehicle with cordless impact.

Note
4x bolts, 16mm, 110 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
Set central bolts securing HV battery center ski cover with cordless impact.

Note
4x bolts, EP14, 34 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
Install bolts securing HV battery to body at LH shear plate area hand tight.

Note
2x bolts, 13mm, 35 Nm, Torque at later step.
Install bolts securing HV battery to body at RH shear plate area hand tight.

Note
2x bolts, 13mm, 35 Nm, Torque at later step.
Connect RDU HV cable to HV battery.

Note
1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector, Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position.
Install nut securing RDU HV cable bracket to HV battery.

Note
1x nut, 10mm, 10 Nm, Number of fasteners may vary.
Remove hose plugs and connect RDU outlet hose to PT return tube.

Note
1x spring clip, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged, Use shop towel to clean any coolant residue if necessary, Loss of coolant greater than 1L requires coolant vacuum fill.
Remove plugs and connect RDU inverter inlet hose to LH rear of HV battery.

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully engaged.Loss of coolant greater than 1L requires coolant vacuum fill.
Position HV battery rear skid plate enclosure onto HV battery for installation.

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

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

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

Note
2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts.
Lower vehicle onto pack completely.

Note
Recommend assistance.
Torque RH bolts securing HV battery to vehicle.

Note
8x bolts, 13mm, 35 Nm.
Torque LH bolts securing HV battery to vehicle.

Note
8x bolts, 13mm, 35 Nm.
Torque bolts securing RH front support bracket to vehicle.

Note
4x bolts, 16mm, 110 Nm.
Torque bolts securing LH front support bracket to vehicle.

Note
4x bolts, 16mm, 110 Nm.
Torque central bolts securing HV battery center ski cover.

Note
4x bolts, EP14, 34 Nm.
Torque bolts securing HV battery rear skid plate enclosure to vehicle.

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

Note
1x nut, 10mm, 13 Nm.
Torque lower bolts securing rear battery enclosure skid plate.

Note
2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts.
Install RH side hose clips to HV battery rear skid plate enclosure .

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

Note
2x clips, Clip quantity may vary on older vehicles.
Raise vehicle and lower onto locks, then remove battery table from under vehicle.

Note
Recommend assistance, 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.
Support front portion of rear subframe.
Remove smaller fasteners for LH shear plate.

Note
2x bolt, 13mm, 35 Nm.
Remove smaller fasteners for RH shear plate.

Note
2x bolt, 13mm, 35 Nm.
Install LH front bolt and shear plate to rear subframe hand tight.

Note
1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step.
Install bolts securing LH shear plate to HV battery hand tight.

Note
2x bolts, 13mm, 35 Nm.
Install RH front bolt and shear plate to rear subframe hand tight.

Note
1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step.
Install bolts securing RH shear plate to HV battery hand tight.

Note
2x bolts, 13mm, 35 Nm.
Torque bolts securing shear plates to vehicle.

Note
4x bolts, 13mm, 35 Nm.
Torque bolt securing subframe and LH shear plate to body.

Note
1x front bolt, 21mm, 130 Nm, Mark bolt after torque.
Torque bolt securing subframe and RH shear plate to body.

Note
1x front bolt, 21mm, 130 Nm, Mark bolt after torque.
Remove support stand from under vehicle.
Install clips securing coolant hoses to RH shear plate.

Note
2x fir tree clips.
Install clips securing coolant hoses to LH shear plate.

Note
2x fir tree clips.
lnstall rear aero shield.

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

Note
2x clips.
Connect HV battery manifold hose.

Note
1x spring clip, Remove plugs.
Connect PT supply hose.

Note
1x spring clip, Remove plugs, Perform push-pull-push test to make sure hose is fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill.
Connect PT return hose.

Note
1x spring clip, Remove plugs, Perform push-pull test to verify hoses are fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill.
Install front skid plate.

Note
4x bolts, EP10, 13 Nm, 2x tabs, Position and move backward to installation.
Release RH front wheel liner from bungee strap.

Note
Remove strap from vehicle.
Install bolt securing RH front wheel liner to skid plate.

Note
1x bolt, 10mm, 5 Nm.
Connect HV battery return hose.

Note
1x spring clip.
Release LH front wheel liner from bungee strap.

Note
Remove strap from vehicle.
Install bolt securing LH front wheel liner to skid plate.

Note
1x bolt, 10mm, 5 Nm.
Connect A/C compressor HV harness connector.

Note
1x connector, Engage locking tab.
Position front aero shield onto vehicle.

Note
2x nuts, 15mm, 5 Nm, Hand-tighten the nuts to temporarily hold the panel in place.
Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield.

Note
7x bolts, 10mm, 5 Nm.
Lower vehicle fully.

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

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

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

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

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

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

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

Note
Make sure hose end of refill hose is fully submerged during entire process.
Once gauge reads zero, close refill valve.
Disconnect shop air supply from coolant refill tool.
Remove coolant refill hose from coolant container.
Remove coolant overflow hose from coolant container.
Remove vacuum refill hose from refill cap on coolant bottle.
Remove coolant refill tool from vehicle.
Remove both coolant containers from inside underhood area.
Position busbar kit connector and lower onto HV header.

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.
Install bolts securing charge port busbar kit to HV header.

Note
2x bolts, 10mm, 9 Nm.
Install fastener securing busbar cover access door.

Note
1x bolt, 10mm, 9 Nm.
Install DCDC ground busbar.

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

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

Note
1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut.
Connect DCDC positive cable to right body harness.

Note
1x connector,1x clip Connect the connector and push in the red locking tab.
Remove logic cap and connect HVC logic connector.

Note
1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated.
Connect First Responder Loop and LV battery.

Note
2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated.
Remove lift arms from below vehicle.

Note
Lower rack arms fully and remove them from under vehicle.
Move vehicle away from lift.

Note
Position to allow easy access to interior.
Select "Stop Thermal Fill Drain" through UI.

Note
Allow routine to complete, ensure routine is successful.
Inspect coolant level and top off as necessary.

Note
Ensure that fluid level is at Max line.
Select "Start Coolant Air Purge" using the UI.

Note
Wait until coolant pumps stop running (audible noise), Routine Passed will appear, but pumps will run for 10 minutes, If you start next another routine during this time, it will fail, Make sure vehicle is not in "Drive", Routine is still running despite the completed message, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, this indicates the pumps are air locked, perform a vacuum fill, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
Install RH rear HV battery interior bolt.

Note
1x bolt, 16mm, 66 Nm, Lift up carpet for access.
Install LH rear HV battery interior bolt.

Note
1x bolt, 16mm, 66 Nm, Lift up carpet for access.
Install rear carpet section.

Note
2x push clips, Tuck corners under lower C pillar trim.
Connect 2nd row seat harness and secure cushion.

Note
2x clips, 2x connectors, Insert buckles through holes, Slide rear inward then align front clips, Perform push-pull-push test.
Close LH rear door.

Note
Release latch before closing if manually latched.
Close RH rear door.

Note
Release latch before closing if manually latched.
Open LH front door.
Install LH front footwell HV battery bolts.

Note
2x bolts, EP20, 136 Nm.
Install LH front main cabin carpet to vehicle.

Note
2x push clips, Number of clips on new vehicles may vary.
Install LH console side panel carpet.

Note
11x clips, 2x positioning clips, 1x tab, Position side panel and align the front tab, Push the console panel from the front towards the rear.
Install connectors to LH footwell cover .

Note
1x connector, 1x OBDII connector, Ensure tabs engage on OBDII connector.
Install LH footwell cover.

Note
2x magnets,1x guide tab.
Install LH lower A-pillar assembly.

Note
4x clips, 2x guide tabs, Align the 2 front tabs then align the slot with harness bracket and then push rear clip to secure to lower B-pillar, Fully seat seal along trim.
Install clip securing LH lower A-pillar assembly.

Note
1x push clip.
Install LH IP end cap.

Note
5x clips, 2x guide tabs.
Install LH front primary seal.

Note
Verify seal is seated properly on all trim panels.
Install LH front floor mat.
Open RH front door.
Install RH front footwell HV battery bolts.

Note
2x bolts, EP20, 136 Nm.
Unfold RH front main cabin carpet back to original position.

Note
1x clip.
Install RH console side panel carpet.

Note
12x clips, 2x positioning clips, 1x datum, Position side panel and align the front datum, Push the console panel from the front towards the rear.
Install RH footwell cover .

Note
2x magnets, 1x guide tab, 1x connector.
Install RH lower A-pillar trim.

Note
4x clips, 2x guide tabs, Align the 2 front tabs then align the slot with harness bracket and then push rear clip to secure to lower B-pillar, Fully seat seal along trim.
Install clip for RH lower A-pillar trim.

Note
1x push clip.
Install RH IP end cap.

Note
5x clips, 2x guide tabs.
lnstall seat lower section of RH front primary seal.

Note
Verify seal is seated properly on all trim panels.
Install RH front floor mat.
Close RH front door.
Inspect coolant level and top off as necessary.

Note
Ensure that fluid level is at Max line.
Install coolant bottle cap.
Install frunk assembly to vehicle.

Note
4x clips, Replace any clips if broken or missing.
Install bolts securing frunk assembly.

Note
6x bolts, 10mm, 5 Nm.
Install frunk service panel.

Note
3x clips, Push towards rear of vehicle to secure.
Install access panel to frunk assembly.

Note
3x clips, 1x connector, Frunk safety switch, 3x guide tabs, Align 3x tabs then push forward to secure clips.
Install fresh air gutter assembly.

Note
3x clips.
Install rear underhood apron.

Note
14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips.
Close hood.
Install LH rocker panel lower cover into position.

Note
10x clips.
Install bolts securing LH rocker panel lower cover to body.

Note
4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary.
Install clips securing the LH rocker panel lower cover to wheel liners.

Note
4x push clips.
Install RH rocker panel lower cover into position.

Note
10x clips.
Install bolts securing RH rocker panel lower cover to body.

Note
4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary.
Install clips securing the RH rocker panel lower cover to wheel liners.

Note
4x push clips.
Exit Service Mode through UI.

Note
Exit Service Mode: Controls > Service Mode > Exit Service Mode, Press and hold to exit.
Raise all windows.
Close LH front door.

Hose - HV Battery Return (Remove and Replace)

Remove

Install

Figure 1

Figure 2

Figure 3