| Tesla

Raise and support vehicle

Nota

Ensure vehicle is not charging

Open all four doors

Lower all four windows

Move LH front seat forward

Move RH front seat forward

Release 2nd row seat cushion and disconnect harness

Nota

2x clips, 2x connectors, Press tabs backward then pull front edge up

Open hood

Remove rear underhood apron

Nota

14x clips

Place vehicle in service mode

Nota

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

Unlock vehicle gateway

Nota

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

Nota

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

Power off vehicle from center display

Nota

Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box

Disconnect LV battery and First Responder Loop

Nota

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

Verify operation of multimeter

Nota

Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery

Remove all items from pockets and ensure not wearing metal items

Inspect HV insulating gloves

Nota

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

Put on HV insulating gloves and leather over gloves

Nota

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

Nota

2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal

Remove ancillary bay probe lid cover from ancillary bay cover

Verify no high voltage

Nota

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

Inspect ancillary bay probe lid cover gasket then position onto ancillary bay cover

Nota

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

Nota

2x bolts, EP10 5-Lobe, 6 Nm, Install new fasteners

Fold 2nd row 60 seat back down

Nota

Pull release, Fold down, Protect seat cushion if necessary

Remove LH side bolster

Nota

1x locator clip, 3x guide tabs, Pull outward then slightly upward to remove

Remove bolster plastic bracket from LH side body

Nota

2x clips, If necessary, Depress clips from behind, this bracket may come out with bolster, Discard after removal

Move 2nd row 60 seat back into vertical position

Partially release LH front primary door seal

Nota

Release lower section of LH front primary door seal

Remove LH IP end cap

Nota

5x clips, 2x guide tabs

Remove clip securing LH lower A-pillar assembly

Nota

1x push clip

Remove LH lower A-pillar assembly

Nota

4x clips, 2x guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet

Remove LH lower B-pillar assembly

Nota

7x clips, 4x locator clips, Pull the trim panel outward in the direction of the arrow to release clip from lower B-pillar

Remove bolts securing sadface bracket to vehicle

Nota

2x bolts, 10mm, 10 Nm

Remove sadface bracket from vehicle

Nota

1x Positioning clip

Remove fastener securing busbar cover access door

Nota

1x bolt, 10mm, 9 Nm

Remove bolts securing charge port busbar kit to HV header

Nota

2x bolts, 10mm, 9 Nm. If 3PH vehicles are involved, please remove the AC charging interface

Remove AC chargeport inlet harness clip

Nota

1x clip

Lift busbar kit connector to remove from HV header

Nota

4x guide tabs, Ease removal of aluminum connector housing by shifting rear end of busbar assembly upward

Position chargeport busbar connector for access below

Nota

Rest on cross-member in front of penthouse

Remove HV insulating gloves

Disconnect HVC logic connector and install logic cap

Nota

1x connector, 1x cap, Release locking tab then push the handle downward to release connector

Remove bolts securing ancillary bay cover to HVC

Nota

3x bolts, E10, 5 Nm + 30 degrees

Remove bolts securing ancillary bay cover to HV battery

Nota

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

Inspect HV insulating gloves

Nota

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

Put on HV insulating gloves and leather over gloves

Nota

Make sure to wear Electrical Protective Gloves any time Hioki tester is used

Remove ancillary bay cover from HV battery

Inspect ancillary bay for any missing insulators

Nota

Install service insulator kit before continuing to next step, The number of bolts on newer vehicles may vary

Remove bolts securing pyro disconnect to ancillary bay

Nota

1x insulator, patch bolts, 13mm, 9 Nm, Discard after removal

Remove pyro disconnect from ancillary bay

Nota

1x connector from the bottom, Lift pyro disconnect straight up and out of the ancillary bay

Install pyro disconnect dummy

Use bungee to secure HVC in an upwards position

Nota

Wrap bungee around RH headrest

Raise vehicle fully and lower lift onto locks

Nota

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 rear aero shield clips

Nota

2x clips, One clip on LH side wheel liner, One clip on RH side wheel liner

Remove rear aero shield

Nota

11x bolts, 10mm, 5 Nm

Release LH side hose clip from rear battery skid plate enclosure

Nota

1x fir tree clip

Release RH side hose clips from rear battery skid plate enclosure

Nota

2x fir tree clips

Remove lower bolts securing HV battery rear skid plate enclosure

Nota

2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count

Remove upper nut securing HV battery rear skid plate enclosure

Nota

1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles

Remove upper bolts securing HV battery rear skid plate enclosure

Nota

4x bolts, 13mm, 35 Nm

Remove HV battery rear skid plate enclosure

Position coolant drain container underneath LH rear of HV battery

Remove fir tree clip securing coolant hose to rear subframe shear plate

Nota

1x fir tree clip

Disconnect RDU inverter inlet tube from LH rear of HV battery

Nota

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

Nota

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

Nota

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

Nota

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

Nota

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

Nota

Use caution as coolant may spill, Make sure to wear safety glasses

Open 2nd valve slowly

Nota

Use caution as coolant may spill, Make sure to wear safety glasses

Set timer for 1 minutes and select start

Nota

Once timer is complete, select Stop Reset

Close regulator valve

Set timer for 1 minutes and select start

Nota

Once timer is complete, select Stop Reset

Open regulator valve slowly

Set timer for 1 minutes and select start

Nota

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

Nota

1x spring clip

Attach coolant pressure tester with hose to PCS outlet hose coupling

Nota

1x spring clip, Make sure the locking tab is fully seated

Position coolant drain container underneath RH rear of vehicle

Attach coolant drain adapter with hose to PCS inlet hose coupling

Nota

1x spring clip, Make sure the locking tab is fully seated

Connect compressed air to coolant pressure tester

Open regulator valve then slowly adjust regulator to 50 psi

Nota

Use caution as coolant may spill, Make sure to wear safety glasses

Open 2nd valve slowly

Nota

Use caution as coolant may spill, Make sure to wear safety glasses

Set timer for 1 minutes and select start

Nota

Once timer is complete, select Stop Reset

Close regulator valve

Set timer for 1 minutes and select start

Nota

Once timer is complete, select Stop Reset

Open regulator valve slowly

Set timer for 1 minutes and select start

Nota

Once timer is complete, select Stop Reset

Close regulator valve

Disconnect compressed air from coolant pressure tester

Disconnect coolant hose extension from coolant drain hose

Disconnect coolant drain hose adapter from coolant hose extension

Remove coolant drain hose adapter from PCS inlet hose coupling

Nota

1x spring clip

Position coolant drain container underneath LH rear of HV battery

Remove pressure fitting adapter from coolant pressure tester

Remove coolant pressure tester from PCS outlet hose coupling

Nota

1x spring clip

Remove coolant drain container from underneath vehicle

Lower vehicle fully

Nota

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

Position absorbent sheets below and around PCS coolant inlet hose to avoid excess coolant dripping

Disconnect PCS coolant inlet hose from PCS

Nota

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

Disconnect PCS coolant outlet hose from PCS

Nota

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

Disconnect PCS to DC bus HV connector

Nota

1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Disconnect PCS logic connector from PCS

Nota

1x connector

Disconnect PCS LV connector from PCS

Nota

1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Disconnect PCS to AC harness connector

Nota

1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Remove bolts securing PCS to HV battery

Nota

5x bolts, 8mm, 18 Nm, Ensure only the 8mm fasteners are removed, Do not remove the T30 fasteners

Secure suction cups to PCS

Nota

Continue pressing plunger until red line is no longer visible

Lift PCS up and out of ancillary bay area and remove from vehicle

Nota

Slightly tilt rear of PCS upward then lift out to remove, Inspect any missing insulators under PCS, Install any missing insulators before continuing to next step, Visually inspect area for any coolant residue, Clean with shop towel if necessary

Install HV joint insulator for positive busbar module 2 to pyro disconnect

Nota

1x insulator

Install HV joint insulator for negative busbar module 3 to shunt

Nota

1x insulator

Install HV joint insulator for positive DC link to module 4

Nota

1x insulator

Remove HV joint insulator for negative busbar module 3 to shunt

Nota

1x insulator

Disconnect ancillary bay harness connectors from positive pack contactor

Nota

2x connectors

Remove ancillary bay harness clip from positive pack contactor

Nota

1x clip

Remove HV joint insulators from positive HV switch

Nota

2x insulators

Remove bolt securing positive pack contactor to positive busbar

Nota

1x patch bolt, 13mm, 9 Nm, Discard after removal

Remove nut securing positive pack contactor to module 4 rear terminal

Nota

1x patch nut, 13mm, 9 Nm, Discard after removal

Remove nuts securing positive pack contactor to ancillary bay

Nota

3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary

Remove positive pack contactor from ancillary bay

Nota

2x guide pins

Release positive LV output cover from PCS cable

Nota

1x cover

Remove bolt securing DCDC ground busbar to body

Nota

1x bolt, 12mm, 20 Nm

Remove nut securing DCDC ground busbar to HV battery

Nota

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

Nota

1x nut, 13mm, 9 Nm, Discard after removal

Remove bolts securing DCDC pass through to ancillary bay

Nota

2x bolts, E10 5-Lobe, 10 Nm

Remove DCDC pass through from ancillary bay

Nota

Electrical Protective Gloves

Remove HV joint insulator for positive DC link to module 4

Nota

1x insulator

Remove AC filter harness from FC contactor cover

Nota

1x connector, Release locking tab, 1x harness clip

Disconnect megaharness connector from DC input assembly

Nota

1x connector

Remove the bolts securing the busbar AC input assembly to ancillary bay

Nota

2x bolts, E10 5-Lobe, 10 Nm, Discard after removal

Release 3PH AC Filter Harness from 3PH 4P Header

Nota

2x tabs, Lift connector off HV battery for access

Remove the 3PH AC Filter harness from the vehicle

Nota

Harness must be removed through the ancillary bay, PCS connector does not fit through the header hole

Remove insulator for DC input assembly to both fast charge busbar inlet side

Nota

1x insulator

Remove bolt securing negative fast charge busbar inlet side and negative DC input assembly busbar

Nota

1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Discard after removal

Remove bolt securing positive fast charge busbar inlet side and positive DC input assembly busbar

Nota

1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Discard after removal

Remove bolts securing busbar DC input assembly to ancillary bay

Nota

4x bolts, E10 5-Lobe, 10 Nm, Discard after removal

Remove Busbar DC input assembly from ancillary bay

Disconnect ancillary bay harness connectors from negative pack contactor

Nota

2x connectors

Disconnect LV fast charge contactor connector

Nota

1x connector, Press tabs on both sides by hand and disconnect the connector upwards

Remove harness clips from FC contactor cover

Nota

1x clip

Remove harness clips from FC contactor cover

Nota

2x clips, Move the wiring harness around the FC cover aside

Remove ancillary bay left terminals cover

Nota

2x tabs, 1x datum

Remove bolt securing negative fast charge busbar DC link side

Nota

1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Discard after removal, 0300_007

Remove bolt securing positive fast charge busbar DC link side

Nota

1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Discard after removal, 0300_006

Remove bolts and nut securing FC assembly to ancillary bay

Nota

2x bolts, 10mm, 5.5 Nm

Remove the FC assembly from ancillary bay

Nota

2x guide pins

Remove the LH daisy chain pass through housing from ancillary bay

Nota

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

Disconnect HV controller connector X483 - BMB daisy B at HVC from HV Controller

Nota

1x connector

Disconnect HV controller connector X482 - BMB daisy A at HVC from HV Controller

Nota

1x connector

Disconnect HV controller connector X480 – Shunt at HVC from HV Controller

Nota

1x connector

Disconnect HV controller connector X481 – Negative contactor sense at HVC from HV Controller

Nota

1x connector

Disconnect HV controller connector X478 – Positive contactor sense at HVC from HV Controller

Nota

1x connector

Disconnect HV controller connector X484 – Pyro disconnect at HVC from HV Controller

Nota

1x connector

Disconnect HV controller connector X479 –Main HVC connector from HV Controller

Nota

1x connector

Remove megaharness clips from HV controller hinge tray

Nota

5x harness clips,1x tape, The harness tape needs to be carefully cut with insulating knife

Remove screws securing HVC tray assembly to ancillary bay

Nota

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

Remove the HVC and tray assembly from ancillary bay

Remove X423 connector from DC link busbar

Nota

1x connector, Release locking tab1x clip

Remove the pyro disconnect logic connector

Nota

1x connector, 1x clip

Disconnect shunt assembly connector

Nota

1x connector, Release locking tab

Release harness from shunt insulator

Nota

1x clip

Remove X422 connector from DC link busbar

Nota

1x connector, Release locking tab

Remove the X421 connector from the DC connection bus

Nota

1x connector, Release locking tab

Remove RH daisy chain pass through housing from ancillary bay

Nota

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

Remove nut securing DC link to module 4

Nota

1x patch nut, 13mm, 9 Nm, Discard after removal

Move positive DC link out to allow access to ancillary bay harness clips

Remove ancillary bay harness clips from positive DC link

Nota

3x clips

Remove positive DC link from ancillary bay

Nota

2x guide pins

Cut cable ties securing the megaharness to charger output to DC bus harness

Nota

2x cable ties

Remove the Ancillary bay harness assembly fixing clip from the DC link

Nota

5x clips

Remove the tab from the DC link shell

Nota

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.

Remove megaharness from ancillary bay

Nota

1x harness

Position megaharness to ancillary bay for installation

Nota

1x harness

Fix the Ancillary bay harness assembly to the DC link

Install new cable ties securing the megaharness to charger output to DC bus harness

Nota

2x cable tie, cut off any excess cable ties

Install the RH daisy chain pass through housing to ancillary bay

Nota

3x clips, 2x bottom clips

Position the positive DC link for installation

Nota

2x guide pins

Install ancillary bay harness clips to positive DC link

Nota

3x clips

Install nut securing joint DC link to module 4

Nota

1x patch nut, 13mm, 9 Nm, Install new patch bolt, Mark after torque

Perform resistance measurement on DC link to module 4 and busbar

Nota

1x HV joint, 60μΩ or less

Install HV joint insulator for positive DC link to module 4

Nota

1x insulator

Install the X423 connector onto the DC bus

Nota

1x connector1x clip

Install the pyro disconnect logic connector

Nota

1x connector, 1x clip

Install harness to shunt insulator

Nota

1x clip

Connect shunt assembly connector

Nota

1x connector

Install the X422 connector onto the DC bus

Nota

1x connector

Install the X421 connector onto the DC bus

Nota

1x connector

Install the LH daisy chain pass through housing to ancillary bay

Nota

3x clips, 2x bottom clips, 1x harness clip

Position FC assembly to ancillary bay for installation

Nota

2x guide pins

Install bolts securing FC assembly to ancillary bay

Nota

2x bolts, 10mm, 5.5 Nm, Mark after torque

Install and torque bolt securing positive fast charge busbar DC link side to first value, loosen 180 degrees, and then torque to final value

Nota

1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Install new patch bolt, Mark after torque

Install and torque bolt negative fast charge busbar DC link side to first value, loosen 180 degrees, and then torque to final value

Nota

1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Install new patch bolt, Mark after torque

Perform Hioki impedance test at the positive HV joint of the fast charge busbar DC link side

Nota

1x HV joint, 25μΩ or less

Perform Hioki impedance test at the negative HV joint of the fast charge busbar DC link side

Nota

1x HV joint, 55μΩ or less

Install ancillary bay left terminals cover

Nota

2x tabs, 1x datum

Install harness clips to FC contactor cover

Nota

2x clips

Install ancillary bay harness clip around negative pack contactor area

Nota

1x clip

Connect LV fast charge connector

Nota

1x connector

Connect ancillary bay harness connectors to negative pack contactor

Nota

2x connectors

Install Busbar DC input assembly to ancillary bay

Nota

Ensure seal is not damaged and seated properly

Install bolts securing Busbar DC input assembly to ancillary bay

Nota

4x bolts, E10 5-Lobe, 10 Nm, Install new bolts, Mark after torque

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

Nota

1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Install new patch bolt, Mark after torque

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

Nota

1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Install new patch bolt, Mark after torque

Perform Hioki resistance test at both HV joints of DC input assembly busbar

Nota

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

Install insulator for DC input assembly to both fast charge busbars inlet side

Nota

1x insulator

Route 3PH AC Filter Harness from the ancillary bay up through HV battery

Install 3PH AC Filter harness to the 3PH 4P Header

Nota

2x tabs, Inspect seal on 3PH header for any damage and replace as needed

Install the bolts securing the Busbar AC input assembly to ancillary bay

Nota

4x bolts, E10 5-Lobe, 10 Nm, Install new bolts, Mark after torque

Install AC filter harness to FC contactor cover

Nota

1x connector, Secure locking tab, 1x harness clip

Connect megaharness connector to DC input assembly

Nota

1x connector

Position DCDC pass through to ancillary bay for installation

Nota

Electrical Protective Gloves

Install bolts securing DCDC pass through to ancillary bay

Nota

2x bolts, E10 5-Lobe, 10 Nm, Mark the bolts after torque

Install positive LV output

Nota

1x nut, 13mm, 9 Nm, Make sure rubber boot is not pinched between cable terminal and pass through

Install positive LV output cover to PCS cable

Nota

1x cover

Install DCDC ground busbar

Nota

Slotted hole goes to body side

Install bolt securing DCDC ground busbar to body

Nota

1x bolt, 12mm, 20 Nm

Install nut securing DCDC ground busbar to HV battery

Nota

1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut

Position positive pack contactor to ancillary bay for installation

Nota

2x guide pins

Install nuts securing positive pack contactor to ancillary bay

Nota

3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs, The number of nuts on newer vehicles may vary

Install bolt securing positive pack contactor to positive busbar

Nota

1x patch bolt, 13mm. 9 Nm, Install new patch bolt, Mark after torque

Install nut securing positive pack contactor to HV battery tall terminal to module 4 rear terminal

Nota

1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque

Measure resistance from HV joint between HV battery positive contactor and the center of HV battery positive terminal

Nota

1x HV joint, 110μΩ or less

Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar

Nota

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.

Install HV joint insulators onto positive pack contactor

Nota

2x insulators

Install ancillary bay harness clip to positive pack contactor

Nota

1x clip

Connect ancillary bay harness connectors to positive pack contactor

Nota

2x connectors

Position HVC tray assembly in ancillary bay

Nota

4x locating pins, 3x wires routed through RH hinge

Secure HVC tray assembly to ancillary bay

Nota

2x screws, T25, 2 Nm

Connect HV controller connector X479 –Main HVC connector to HV Controller

Nota

1x connector

Connect HV controller connector X484 – Pyro disconnect at HVC to HV Controller

Nota

1x connector

Connect HV controller connector X478 – Positive contactor sense at HVC to HV Controller

Nota

1x connector

Connect HV controller connector X481 – Negative contactor sense at HVC to HV Controller

Nota

1x connector

Connect HV controller connector X480 – Shunt at HVC to HV Controller

Nota

1x connector

Connect HV controller connector X482 - BMB daisy A at HVC to HV Controller

Nota

1x connector

Connect HV controller connector X483 - BMB daisy B at HVC to HV Controller

Nota

1x connector

Install the megaharness clips to HV controller hinge tray

Nota

5x harness clips, 1x tape, Wrap harness tape around the hinge tray again

Install HV joint insulator for negative busbar module 3 to shunt

Nota

1x insulator

Position the PCS into ancillary bay

Nota

Ensure all busbar insulators beneath PCS are present, Slightly tilt rear of PCS upward and lower into position, Align datum into PCS holes, Inspect for any coolant residue inside ancillary bay and clean with absorbent sheets if necessary

Remove suction cups from PCS

Install bolts securing PCS to HV battery

Nota

5x bolts, 8mm, 18 Nm

Connect PCS to fast charge contactor HV harness connector

Nota

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

Connect PCS LV connector to PCS

Nota

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

Connect PCS logic connector to PCS

Nota

1x connector

Connect PCS to DC bus HV connector

Nota

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

Replace o-ring on PCS side inlet hose

Nota

1x o-ring, Apply light amount of Krytox 203

Connect PCS coolant inlet hose to PCS

Nota

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

Replace o-ring on PCS side outlet hose

Nota

1x o-ring, Apply light amount of Krytox 203

Connect PCS coolant outlet hose to PCS

Nota

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

Lay HVC in original position

Nota

Release bungee from back of headrest

Remove pyro disconnect dummy

Clean mating surfaces

Nota

Allow to 1 minute dry time,Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect

Set multimeter to "LoZ" (low impedance) mode

Measure voltage between busbar and shunt

Nota

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

Position pyro disconnect to ancillary bay for installation

Nota

1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way

Install bolts securing pyro disconnect to ancillary bay

Nota

2x patch bolts, 13mm, 9 Nm

Measure resistance from module 2 busbar to pyro disconnect

Nota

1x HV joint, 48μΩ or less, Perform zero adjust to Hioki meter prior to testing

Measure resistance from pyro disconnect to shunt

Nota

1x HV joint, 33μΩ or less, Perform zero adjust to Hioki meter prior to testing

Remove service insulator kit

Clean HV connector contact surface of residual Penetrox

Nota

Allow 1 minute dry time, New busbar comes with penetrox applied to HV connector

Clean busbar HV connector contact surface of residual Penetrox

Nota

Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar

Apply Penetrox onto HV connector joints

Nota

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

Position busbar kit connector and lower onto HV header

Nota

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 AC chargeport inlet harness clip

Nota

1x clip

Install bolts securing charge port busbar kit to HV header

Nota

2x bolts, 10mm, 9 Nm. If 3PH vehicles are involved, please install the AC charging interface

Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head

Nota

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

Install fastener securing busbar cover access door

Nota

1x bolt, 10mm, 9 Nm

Inspect ancillary bay walls for damage

Nota

Any dent or depression in the seal that causes it to not be flat will result in a leak, and cannot be reused, Any paint that comes off the ancillary bay wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled, It can still be reused

Inspect ancillary bay cover seal to confirm it has no visual damage

Nota

Image up close for clarity, Delaminated and torn seals cannot be reused

Position ancillary bay cover to HV battery for installation

Nota

Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.

Remove HV insulating gloves

Install bolts securing ancillary bay cover to HV battery

Nota

18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image

Install bolts securing ancillary bay cover to HVC

Nota

3x bolts, E10, 5 Nm + 30 degrees

Remove logic cap and connect HVC logic connector

Nota

1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated

Install sadface bracket into vehicle

Nota

1x Positioning clip

Install bolts securing sadface bracket to vehicle

Nota

2x bolts, 10mm, 10 Nm

Install LH lower B-pillar assembly

Nota

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

Install LH lower A-pillar assembly

Nota

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

Install clip securing LH lower A-pillar assembly

Nota

1x push clip

Install LH IP end cap

Nota

5x clips, 2x guide tabs

Install LH front primary seal

Nota

Verify seal is seated properly on all trim panels

Fold 2nd row 60 seat back down

Nota

Pull release, Fold down, Protect seat cushion if necessary

Install bolster plastic bracket to LH side bolster

Nota

2x tabs, Install new bolster bracket

Install LH side bolster

Nota

1x locator clip, 3x guide tabs, Align bottom and side tabs then push inward to install

Return 2nd row 60 seat back to vertical position

Connect 2nd row seat harness and secure cushion

Nota

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

Raise vehicle fully and lower lift onto locks

Nota

Set vehicle to comfortable working height, Make sure there's an audible click of locks on both sides before lowering, otherwise vehicle may tilt to side

Position coolant drain container underneath RH rear of vehicle

Install coolant pressure test plug adapter to PCS inlet hose coupling

Nota

1x spring clip, 1x plug, Remove plug from inlet hose coupling, Make sure the locking tab is fully seated

Position coolant drain container underneath LH rear of HV battery

Install coolant pressure tester to PCS outlet hose coupling

Nota

1x spring clip, 1x plug, Remove plug from outlet hose coupling, Make sure the locking tab is fully seated

Install pressure fitting adapter to coolant pressure tester

Connect compressed air to coolant pressure tester

Open regulator valve then slowly adjust regulator to 50 psi

Slowly open valve on pressure regulator and allow pressure to reach specification

Close the valve and let pressure settle

Nota

Wait 2 minutes for pressure to settle, Record the reading

Perform the coolant pressure leak test

Nota

Wait for another 4 minutes and record the reading. Max delta 0.35 psi. Check coolant hose to see if it is fully seated or not if pressure test fails

Remove pressure fitting adapter from coolant pressure tester

Remove coolant pressure tester from PCS outlet hose coupling

Nota

1x spring clip

Remove plug from HV battery and connect RDU inverter inlet tube

Nota

1x spring clip, 1x plug, Perform push-pull-push test to make sure hose is fully engaged

Position coolant drain container underneath RH rear of vehicle

Remove coolant pressure test plug adapter from PCS inlet hose coupling

Nota

1x spring clip

Connect rear PT supply hose to rear of HV battery and plug hose

Nota

1x spring clip, 1x plugs, Remove plugs, Perform push-pull-push test to make sure hose is fully seated. Vacuum fill required if > 1L lost during repair

Remove coolant drain container from underneath vehicle

Install fir tree clip securing coolant hose to rear subframe shear plate

Nota

1x fir tree clip

Position HV battery rear skid plate enclosure onto HV battery for installation

Nota

Recommend assistance if needed

Install upper bolts securing HV battery rear skid plate enclosure hand tight

Nota

4x bolts, 13mm, 35 Nm, Torque at later step

Install upper nut securing HV battery rear skid plate enclosure hand tight

Nota

1x nut, 10mm, 13 Nm, Torque at later step

Install lower bolts securing HV battery rear skid plate enclosure

Nota

2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts

Torque bolts securing HV battery rear skid plate enclosure to vehicle

Nota

4x bolts, 13mm, 35 Nm

Torque upper nut securing HV battery rear skid plate enclosure

Nota

1x nut, 10mm, 13 Nm

Install RH side hose clips to HV battery rear skid plate enclosure

Nota

2x fir tree clips

Install LH side hose clip to HV battery rear skid plate enclosure

Nota

1x clip

Install rear aero shield

Nota

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

Nota

2x clips

Lower vehicle fully

Nota

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

Nota

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

Nota

Perform push-pull-push test to verify hose is fully engaged

Position overflow hose into empty container

Place refill hose inside filled coolant container

Nota

Make sure hose end is fully submerged into coolant

Connect shop air supply to coolant refill tool

Nota

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

Nota

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

Nota

This purges trapped air from the hose

Monitor gauge for 30 seconds to verify a vacuum is maintained in cooling system

Reopen 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

Nota

Make sure hose end of refill hose is fully submerged during entire process

Once gauge reads zero, close refill valve

Disconnect shop air supply from coolant refill tool

Remove coolant refill hose from coolant container

Remove coolant overflow hose from coolant container

Remove vacuum refill hose from refill cap on coolant bottle

Remove coolant refill tool from vehicle

Remove both coolant containers from inside underhood area

Connect First Responder Loop and LV battery

Nota

2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated

Unlock vehicle gateway

Nota

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

Access Thermal System routines using UI

Nota

Select Service mode > Thermal

Select "Stop Thermal Fill Drain" through UI

Nota

Allow routine to complete, ensure routine is successful

Select "Coolant Purge Start" using UI

Nota

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