Code de correction 16010201 FRT 3.00 REMARQUE : À moins d’indications explicites contraires dans la procédure, le code de correction et le temps forfaitaire indiqués ci-dessus représentent tout le travail à être fait pour cette procédure, notamment les procédures connexes. N’appliquez pas plusieurs codes de correction à la fois, à moins qu’il vous soit explicitement indiqué de le faire. REMARQUE : Consultez Temps forfaitaires pour en apprendre plus à propos des temps forfaitaires et de leur création. NOTE : Consultez Protection individuelle pour vous assurer de porter l’équipement de protection individuelle adéquat lorsque vous effectuez la procédure ci-dessous. REMARQUE : Voir Précautions ergonomiques pour consulter les pratiques de travail sécuritaires et saines.

1. Remove bolts securing LH rocker panel lower cover to body
   Remarque

   4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary

   

2. Remove clips securing the LH rocker panel lower cover to wheel liners
   Remarque

   4x push clips

   

   

3. Remove LH rocker panel lower cover
   Remarque

   10x clips

   

   

4. Remove bolts securing RH rocker panel lower cover to body
   Remarque

   4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary

   

5. Remove clips securing the RH rocker panel lower cover to wheel liners
   Remarque

   4x push clips

   

   

6. Remove RH rocker panel lower cover
   Remarque

   10x clips

   

   

7. Open all four doors

   

8. Lower all four windows

   

9. Move LH front seat backward

   

10. Remove LH front floor mat

    

11. Partially release LH front primary door seal
    Remarque

    Release lower section of LH front primary door seal

    

12. Remove LH IP end cap
    Remarque

    5x clips, 2x guide tabs

    

    

13. Remove clip securing LH lower A-pillar assembly
    Remarque

    1x push clip

    

14. Remove LH lower A-pillar assembly
    Remarque

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

    

    

15. Release LH footwell cover
    Remarque

    5x clips,1x guide tab

    

    

16. Disconnect LH footwell cover connectors
    Remarque

    2x connectors

    

17. Remove LH console side panel carpet
    Remarque

    11x clips, 2x positioning clips, 1x tab, Use trim tool starting at rear edge to release upper clips, If clips is too tight, Use prytool to remove clips, Then pull bottom to release remaining clips, Finally, release tab and pull out side panel backward, Replace clips if it is damaged

    

    

    

    

    

    

18. Remove LH front main cabin carpet clips
    Remarque

    2x push clips, Number of clips on new vehicles may vary

    

19. Fold the LH front main cabin carpet aside for access
    Remarque

    Dead pedal and foam block are part of carpet,

    

20. Remove LH front footwell HV battery bolts
    Remarque

    2x bolts, EP20, 136 Nm

    

21. Move LH front seat forward

    

22. Move RH front seat backward

    

23. Remove RH front floor mat

    

24. Partially release RH front primary door seal
    Remarque

    Release lower section of RH front primary door seal

    

25. Remove RH IP end cap
    Remarque

    5x clips, 2x guide tabs

    

    

26. Remove clip for RH lower A-pillar trim
    Remarque

    1x push clip

    

27. Remove RH lower A-pillar trim
    Remarque

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

    

    

28. Release RH footwell cover
    Remarque

    5x clips, 1x guide tab

    

    

29. Remove connectors from RH footwell cover
    Remarque

    1x puddle light connector, 1x Speaker connector

    

    

30. Remove RH console side panel carpet
    Remarque

    12x clips, 2x positioning clips, 1x datum, Use trim tool starting at rear edge to release upper clips, If clips is too tight, Useprytool to remove clips, Then pull bottom to release remaining clips, Finally, release the datum and pull out side panel backward, Replace clips if it is damaged

    

    

    

    

    

    

31. Remove clips securing RH front main carpet to vehicle
    Remarque

    1x clip, Number of clips on new vehicles may vary

    

32. Fold RH front main cabin carpet aside for access
    Remarque

    2x clips, Lift center piece and pull carpet back, Release seat harness from clips to allow carpet to fold back more

    

    

    

33. Remove RH front footwell HV battery bolts
    Remarque

    2x bolts, EP20, 136 Nm

    

34. Move RH front seat forward

    

35. Close RH front door

    

36. Remove 2nd row floor mat from vehicle

    

37. Release 2nd row seat cushion and disconnect harness
    Remarque

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

    

    

    

    

    

38. Pull back rear carpet to access rear interior battery bolts
    Remarque

    2x push clips

    

39. Remove LH rear HV battery interior bolt
    Remarque

    1x bolt, 16mm, 66 Nm, Lift up carpet for access

    

40. Close LH rear door latch manually

    

41. Remove RH rear HV battery interior bolt
    Remarque

    1x bolt, 16mm, 66 Nm, Lift up carpet for access

    

42. Close RH rear door latch manually

    

43. Raise and support vehicle
    Remarque

    Remove body plugs and install M3 lift pad adapters to indicated locations

    

    

    

    

    

    

44. Place vehicle in service mode plus
    Remarque

    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

    

    

    

45. Unlock vehicle gateway
    Remarque

    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

    

    

    

    

46. Run Thermal Fill Drain (Coolant Only) through the UI
    Remarque

    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

    

    

    

    

47. Open hood

    

    

48. Remove rear underhood apron
    Remarque

    14x clips

    

    

49. Power off vehicle from center display
    Remarque

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

    

    

50. Disconnect LV battery and First Responder Loop
    Remarque

    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

    

    

    

    

    

    

51. Remove all items from pockets and ensure not wearing metal items

    

    

52. Verify operation of multimeter
    Remarque

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

    

53. Inspect HV insulating gloves
    Remarque

    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

    

54. Put on HV insulating gloves and leather over gloves
    Remarque

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

    

55. Remove bolts securing ancillary bay probe lid cover to ancillary bay cover
    Remarque

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

    

56. Remove ancillary bay probe lid cover from ancillary bay cover

    

    

57. Verify no high voltage
    Remarque

    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

    

    

    

58. Inspect ancillary bay probe lid cover gasket then position onto ancillary bay cover
    Remarque

    Confirm no visual damage present,Wipe ancillary bay with IPA to clean surface,Allow to 1 minute dry time

    

    

59. Install bolts securing ancillary bay probe lid cover to ancillary bay cover
    Remarque

    2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners

    

60. Remove fastener securing busbar cover access door
    Remarque

    1x bolt, 10mm, 9 Nm

    

61. Remove bolts securing charge port busbar kit to HV header
    Remarque

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

    

    

62. Lift busbar kit connector to remove from HV header
    Remarque

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

    

63. Remove HV insulating gloves

    

64. Disconnect HVC logic connector and install logic cap
    Remarque

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

    

    

    

65. Remove bolt securing DCDC ground busbar to body
    Remarque

    1x bolt, 12mm, 20 Nm

    

66. Remove nut securing DCDC ground busbar to HV battery
    Remarque

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

    

67. Remove DCDC ground busbar

    

68. Remove nut securing positive LV output from PCS cable and move cable aside
    Remarque

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

    

69. Raise vehicle fully and lower lift onto locks
    Remarque

    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

    

    

70. Remove rear aero shield clips
    Remarque

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

    

    

71. Remove rear aero shield
    Remarque

    11x bolts, 10mm, 5 Nm

    

    

72. Remove bolts securing front aero shield
    Remarque

    7x bolts, 10mm, 5 Nm

    

73. Remove front aero shield from studs
    Remarque

    2x nuts, 15mm, 5 Nm

    

    

74. Remove push clip securing lower edge of LH front wheel liner to vehicle for access to coolant hose
    Remarque

    1x push clip

    

75. Remove bolt securing LH front wheel liner to skid plate
    Remarque

    1x bolt, 10mm, 5 Nm

    

76. Use bungee strap to pull back LH front wheel liner
    Remarque

    Secure to subframe

    

    

    

77. Remove push clip securing lower edge of RH front wheel liner to vehicle for access to coolant hose
    Remarque

    1x push clip

    

78. Remove bolt securing RH front wheel liner to skid plate
    Remarque

    1x bolt, 10mm, 5 Nm

    

79. Use bungee strap to pull back RH front wheel liner
    Remarque

    Secure to subframe

    

    

80. Position coolant drain container underneath RH front of HV battery

    

81. Release FDU Inverter Inlet hose RH side of vehicle and plug both hoses
    Remarque

    1x hose clips, Plug both ends, Coolant loss greater than 1 L will require vacuum fill

    

    

82. Disconnect powertrain supply hose from powertrain supply tube
    Remarque

    1x spring clips, Plug hoses as required

    

    

83. Position coolant drain container underneath LH front of HV battery

    

84. Disconnect HV battery return tube from HV battery hose
    Remarque

    1x spring clip, 2x plugs, Located on LH front of HV battery, Install plug to both ends, Coolant loss greater than 1 L will require vacuum fill

    

    

85. Release HV battery front manifold hose from body
    Remarque

    1x clip

    

86. Disconnect HV battery manifold hose
    Remarque

    1x spring clip, 2x plugs, Plug hoses as required

    

    

87. Disconnect A/C compressor HV harness connector
    Remarque

    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

    

    

88. Remove bolt securing FDU HV harness to FDU
    Remarque

    1x bolt, 10mm, 10 Nm

    

89. Disconnect FDU HV harness connector
    Remarque

    1x clip, 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 FDU header are not damaged

    

    

90. Remove bolt securing FDU ground strap to FDU
    Remarque

    1x bolt, 10mm, 6 Nm

    

91. Release FDU ground strap harness clip from FDU
    Remarque

    1x clip

    

92. Release LH side hose clip from rear battery skid plate enclosure
    Remarque

    1x fir tree clip

    

93. Release RH side hose clips from rear battery skid plate enclosure
    Remarque

    2x fir tree clips

    

94. Remove lower bolts securing HV battery rear skid plate enclosure
    Remarque

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

    

95. Remove upper nut securing HV battery rear skid plate enclosure
    Remarque

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

    

96. Remove upper bolts securing HV battery rear skid plate enclosure
    Remarque

    4x bolts, 13mm, 35 Nm

    

97. Remove HV battery rear skid plate enclosure

    

98. Position coolant drain container underneath LH rear of HV battery

    

99. Disconnect LH coolant hose from rear of HV battery
    Remarque

    1x spring clip, 2x plugs, Plug both the coolant hose and passthrough

    

    

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

     1x fir tree clip

     

101. Disconnect RDU inverter inlet tube from LH rear of HV battery
     Remarque

     1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill

     

     

102. Position coolant drain container underneath RH rear of vehicle

     

103. Disconnect rear PT supply hose from rear of HV battery
     Remarque

     1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill

     

     

104. Position support stand to support front portion of rear subframe

     

105. Release clips securing coolant hoses to LH shear plate
     Remarque

     2x fir tree clips

     

106. Remove smaller fasteners securing LH shear plate
     Remarque

     2x bolts, 13mm, 35 Nm

     

107. Remove large bolt securing LH shear plate and subframe to body and remove shear plate
     Remarque

     1x bolt, 21mm, 130 Nm, Discard after removal

     

108. Hand tighten bolt securing LH side of subframe to body
     Remarque

     1x bolt, 21mm, 130 Nm

     

109. Release clips securing coolant hoses to RH shear plate
     Remarque

     2x fir tree clips

     

110. Remove smaller fasteners for RH shear plate
     Remarque

     2x bolts, 13mm, 35 Nm

     

111. Remove large bolt securing RH shear plate and subframe to body and remove shear plate
     Remarque

     1x bolt, 21mm, 130 Nm, Discard after removal

     

112. Remove smaller fasteners securing LH shear plate
     Remarque

     2x bolts, 13mm, 35 Nm

     

113. Hand tighten bolt securing RH side of subframe to body
     Remarque

     1x bolt, 21mm, 130 Nm

     

114. Remove support stand from under vehicle

     

115. Remove nut securing RDU HV cable bracket to HV battery
     Remarque

     1x nut, 10mm, 10 Nm, Number of fasteners may vary

     

116. Disconnect RDU HV cable from HV battery
     Remarque

     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

     

     

     

117. Place HV battery table into position and lower vehicle to support HV battery
     Remarque

     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

     

     

118. Remove central bolts securing HV battery center ski cover
     Remarque

     4x bolts, EP14, 34 Nm

     

119. Remove bolts securing LH front support bracket to vehicle
     Remarque

     4x bolts, 16mm, 110 Nm

     

120. Remove bolts securing RH front support bracket to vehicle
     Remarque

     4x bolts, 16mm, 110 Nm

     

121. Remove LH bolts securing HV battery to vehicle
     Remarque

     8x bolts, 13mm, 35 Nm

     

122. Remove RH bolts securing HV battery to vehicle
     Remarque

     8x bolts, 13mm, 35 Nm

     

123. Raise vehicle free of HV battery
     Remarque

     Recommend assistance

     

     

124. Remove battery from under vehicle
     Remarque

     Recommend assistance

     

125. Install penthouse engagement seal onto HV battery pack
     Remarque

     This seal is a one time use item and should be replaced each time a HV battery pack is removed from vehicle or installed onto a new HV battery pack if not equipped

     

126. Install HV battery alignment rods
     Remarque

     2x rods, To body at front of vehicle, 2x rods, To battery near penthouse

     

     

127. Position HV battery under vehicle
     Remarque

     Recommend assistance

     

128. Lower vehicle onto HV battery and align holes
     Remarque

     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)

     

     

     

     

129. Set RH bolts securing HV battery to vehicle with cordless impact
     Remarque

     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

     

130. Set LH bolts securing HV battery to vehicle with cordless impact
     Remarque

     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

     

131. Remove HV battery alignment rods
     Remarque

     2x rods, To body at front of vehicle, 2x rods, To battery near penthouse

     

     

132. Set bolts securing RH front support bracket to vehicle with cordless impact
     Remarque

     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

     

133. Set bolts securing LH front support bracket to vehicle with cordless impact
     Remarque

     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

     

134. Set central bolts securing HV battery center ski cover with cordless impact
     Remarque

     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

     

135. Install bolts securing HV battery to body at LH shear plate area hand tight
     Remarque

     2x bolts, 13mm, 35 Nm, Torque at later step

     

136. Install bolts securing HV battery to body at RH shear plate area hand tight
     Remarque

     2x bolts, 13mm, 35 Nm, Torque at later step

     

137. Connect RDU HV cable to HV battery
     Remarque

     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

     

     

     

     

     

138. Install nut securing RDU HV cable bracket to HV battery
     Remarque

     1x nut, 10mm, 10 Nm, Number of fasteners may vary

     

139. Remove hose plugs and connect RDU outlet hose to PT return tube
     Remarque

     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

     

     

140. Remove plugs and connect RDU inverter inlet hose to LH rear of HV battery
     Remarque

     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

     

141. Position HV battery rear skid plate enclosure onto HV battery for installation
     Remarque

     Recommend assistance if needed

     

     

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

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

     

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

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

     

144. Install lower bolts securing HV battery rear skid plate enclosure
     Remarque

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

     

145. Lower vehicle onto pack completely
     Remarque

     Recommend assistance

     

146. Torque RH bolts securing HV battery to vehicle
     Remarque

     8x bolts, 13mm, 35 Nm

     

147. Torque LH bolts securing HV battery to vehicle
     Remarque

     8x bolts, 13mm, 35 Nm

     

148. Torque bolts securing RH front support bracket to vehicle
     Remarque

     4x bolts, 16mm, 110 Nm

     

149. Torque bolts securing LH front support bracket to vehicle
     Remarque

     4x bolts, 16mm, 110 Nm

     

150. Torque central bolts securing HV battery center ski cover
     Remarque

     4x bolts, EP14, 34 Nm

     

151. Torque bolts securing HV battery rear skid plate enclosure to vehicle
     Remarque

     4x bolts, 13mm, 35 Nm

     

152. Torque upper nut securing HV battery rear skid plate enclosure
     Remarque

     1x nut, 10mm, 13 Nm

     

153. Torque lower bolts securing rear battery enclosure skid plate
     Remarque

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

     

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

     2x fir tree clips

     

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

     1x clip

     

156. Raise vehicle and lower onto locks, then remove battery table from under vehicle
     Remarque

     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

     

     

157. Support front portion of rear subframe

     

158. Remove smaller fasteners for LH shear plate
     Remarque

     2x bolt, 13mm, 35 Nm

     

159. Remove smaller fasteners for RH shear plate
     Remarque

     2x bolt, 13mm, 35 Nm

     

160. Install LH front bolt and shear plate to rear subframe hand tight
     Remarque

     1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step

     

161. Install bolts securing LH shear plate to HV battery hand tight
     Remarque

     2x bolts, 13mm, 35 Nm, Torque at a later step

     

162. Install RH front bolt and shear plate to rear subframe hand tight
     Remarque

     1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step

     

163. Install bolts securing RH shear plate to HV battery hand tight
     Remarque

     2x bolts, 13mm, 35 Nm, Torque at a later step

     

164. Torque bolts securing shear plates to vehicle
     Remarque

     4x bolts, 13mm, 35 Nm

     

     

165. Torque bolt securing subframe and LH shear plate to body
     Remarque

     1x front bolt, 21mm, 130 Nm, Mark bolt after torque

     

     

166. Torque bolt securing subframe and RH shear plate to body
     Remarque

     1x front bolt, 21mm, 130 Nm, Mark bolt after torque

     

167. Remove support stand from under vehicle

     

168. Install clips securing coolant hoses to RH shear plate
     Remarque

     2x fir tree clips

     

169. Install clips securing coolant hoses to LH shear plate
     Remarque

     2x fir tree clips

     

170. lnstall rear aero shield
     Remarque

     11x bolts, 10mm, 5 Nm, Apply Loctite 222 onto rear aero shield bolts

     

     

171. Install LH and RH clips securing rear aero shield to wheel house liner
     Remarque

     2x clips

     

     

172. Connect HV battery manifold hose
     Remarque

     1x spring clip, Remove plugs

     

     

173. Connect PT supply hose
     Remarque

     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

     

     

174. Connect PT return hose
     Remarque

     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

     

     

175. Release RH front wheel liner from bungee strap
     Remarque

     Remove strap from vehicle

     

176. Install bolt securing RH front wheel liner to skid plate
     Remarque

     1x bolt, 10mm, 5 Nm

     

177. Install push clip securing lower edge of RH front wheel liner to vehicle
     Remarque

     1x push clip

     

178. Connect HV battery return hose
     Remarque

     1x spring clip

     

179. Release LH front wheel liner from bungee strap
     Remarque

     Remove strap from vehicle

     

180. Install bolt securing LH front wheel liner to skid plate
     Remarque

     1x bolt, 10mm, 5 Nm

     

181. Install push clip securing lower edge of LH front wheel liner to vehicle
     Remarque

     1x push clip

     

182. Connect A/C compressor HV harness connector
     Remarque

     1x connector, Engage locking tab

     

     

183. Secure FDU ground strap harness clip to FDU
     Remarque

     1x clip

     

184. Install bolt securing FDU ground strap to FDU
     Remarque

     1x bolt, 10mm, 6 Nm

     

185. Install FDU HV harness connector to FDU
     Remarque

     1x connector, Install HV connector lever lock to FDU HV cable connector, Align connector to FDU then remove HV connector lever lock before fully latching 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

     

     

     

186. Position front aero shield onto vehicle
     Remarque

     2x nuts, 15mm, 5 Nm, Hand-tighten the nuts to temporarily hold the panel in place

     

     

187. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
     Remarque

     7x bolts, 10mm, 5 Nm

     

     

188. Lower vehicle fully
     Remarque

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

     

     

     

189. Remove coolant bottle cap

     

190. Place empty coolant container into front storage area

     

191. Fill container with at least 15L of coolant

     

192. Place filled coolant container into front storage area

     

193. Install refill tool cap onto coolant bottle assembly

     

194. Setup vacuum refill tool
     Remarque

     Verify all valves on refill tool are in the closed position, See image for clarity

     

     

195. Install vacuum refill hose into refill cap on coolant bottle
     Remarque

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

     

196. Position overflow hose into empty container

     

197. Place refill hose inside filled coolant container
     Remarque

     Make sure hose end is fully submerged into coolant

     

     

198. Connect shop air supply to coolant refill tool
     Remarque

     If not already done, Verify refill valve is set to off

     

199. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
     Remarque

     Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed

     

     

200. Slowly open coolant refill valve to allow coolant to be drawn into coolant refill hose, Close valve when hose is full of coolant
     Remarque

     This purges trapped air from the hose

     

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

     

202. Reopen air inlet valve for 3 minutes to continue evacuating cooling system, then close valve

     

     

203. Slowly open refill valve to allow coolant to be drawn into system
     Remarque

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

     

204. Once gauge reads zero, close refill valve

     

     

205. Disconnect shop air supply from coolant refill tool

     

206. Remove coolant refill hose from coolant container

     

207. Remove coolant overflow hose from coolant container

     

208. Remove vacuum refill hose from refill cap on coolant bottle

     

209. Remove coolant refill tool from vehicle

     

     

210. Remove both coolant containers from inside underhood area

     

211. Position busbar kit connector and lower onto HV header
     Remarque

     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

     

     

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

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

     

     

213. Install fastener securing busbar cover access door
     Remarque

     1x bolt, 10mm, 9 Nm

     

214. Install DCDC ground busbar
     Remarque

     Slotted hole goes to body side

     

215. Install bolt securing DCDC ground busbar to body
     Remarque

     1x bolt, 12mm, 20 Nm

     

216. Install nut securing DCDC ground busbar to HV battery
     Remarque

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

     

217. Connect DCDC positive cable to right body harness
     Remarque

     1x connector,1x clip Connect the connector and push in the red locking tab

     

218. Remove logic cap and connect HVC logic connector
     Remarque

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

     

     

219. Connect first responder loop and leave LV battery disconnected
     Remarque

     1x connector, Engage locking tab, Connect FRL but leave LV battery disconnected

     

     

220. Connecting low-voltage battery maintenancer-Charger
     Remarque

     Release positive terminal cover, Secure positive terminal to jump post, Secure negative terminal to bolt located between brake fluid reservoir and front trunk, Connect maintainer to power supply, To avoid damaging the vehicle DO NOT allow positive cable to make contact with other metal components, Never have a float charger and the LV battery simultaneously connected for any extended period of time

     

     

     

221. Remove lift arms from below vehicle
     Remarque

     Lower rack arms fully and remove them from under vehicle

     

222. Move vehicle away from lift
     Remarque

     Position to allow easy access to interior

     

223. Unlock vehicle gateway
     Remarque

     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

     

     

     

     

224. Select "Stop Thermal Fill Drain" through UI
     Remarque

     Allow routine to complete, ensure routine is successful

     

     

     

225. Inspect coolant level and top off as necessary
     Remarque

     Ensure that fluid level is at Max line

     

226. Select "Start Coolant Air Purge" using the UI
     Remarque

     Touch time only: 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

     

     

     

227. Install RH rear HV battery interior bolt
     Remarque

     1x bolt, 16mm, 66 Nm, Lift up carpet for access

     

228. Install LH rear HV battery interior bolt
     Remarque

     1x bolt, 16mm, 66 Nm, Lift up carpet for access

     

229. Install rear carpet section
     Remarque

     2x push clips, Tuck corners under lower C pillar trim

     

     

230. Connect 2nd row seat harness and secure cushion
     Remarque

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

     

     

     

231. Close LH rear door
     Remarque

     Release latch before closing if manually latched

     

232. Close RH rear door
     Remarque

     Release latch before closing if manually latched

     

233. Open LH front door

     

234. Install LH front footwell HV battery bolts
     Remarque

     2x bolts, EP20, 136 Nm

     

235. Install LH front main cabin carpet to vehicle
     Remarque

     2x push clips, Number of clips on new vehicles may vary

     

     

236. Install LH console side panel carpet
     Remarque

     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

     

     

     

     

237. Install connectors to LH footwell cover
     Remarque

     1x connector, 1x OBDII connector, Ensure tabs engage on OBDII connector

     

     

238. Install LH footwell cover
     Remarque

     2x magnets, 1x guide tab

     

     

239. Install LH lower A-pillar assembly
     Remarque

     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

     

     

     

240. Install clip securing LH lower A-pillar assembly
     Remarque

     1x push clip

     

241. Install LH IP end cap
     Remarque

     5x clips, 2x guide tabs

     

     

242. Install LH front primary seal
     Remarque

     Verify seal is seated properly on all trim panels

     

243. Install LH front floor mat

     

244. Open RH front door

     

245. Install RH front footwell HV battery bolts
     Remarque

     2x bolts, EP20, 136 Nm

     

246. Unfold RH front main cabin carpet back to original position
     Remarque

     1x clip

     

     

247. Install RH console side panel carpet
     Remarque

     12x clips, 2x positioning clips, 1x datum, Position side panel and align front datum, Push console panel from front towards rear

     

     

     

     

248. Install RH footwell cover
     Remarque

     2x magnets, 1x guide tab, 1x connector

     

     

249. Install RH lower A-pillar trim
     Remarque

     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

     

     

250. Install clip for RH lower A-pillar trim
     Remarque

     1x push clip

     

251. Install RH IP end cap
     Remarque

     5x clips, 2x guide tabs

     

     

252. lnstall seat lower section of RH front primary seal
     Remarque

     Verify seal is seated properly on all trim panels

     

253. Install RH front floor mat

     

254. Close RH front door

     

255. Inspect coolant level and top off as necessary
     Remarque

     Ensure that fluid level is at Max line

     

256. Install coolant bottle cap

     

257. Install frunk assembly
     Remarque

     8x clips, 3x locator pins, Ensure clips are aligned at thermal beam, Replace any clips if broken or missing

     

     

     

     

     

258. Install bolts securing frunk assembly
     Remarque

     4x bolts, 10mm, 5 Nm, Number of bolts may vary depending on build date

     

259. Install access panel to frunk assembly
     Remarque

     3x clips, 1x connector, Frunk safety switch, 3x guide tabs, Align 3x tabs then push forward to secure clips

     

     

260. Install fresh air gutter assembly
     Remarque

     3x clips

     

     

261. Install rear underhood apron
     Remarque

     14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips

     

     

262. Close hood

     

263. Install LH rocker panel lower cover into position
     Remarque

     10x clips

     

     

264. Install bolts securing LH rocker panel lower cover to body
     Remarque

     4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary

     

265. Install clips securing the LH rocker panel lower cover to wheel liners
     Remarque

     4x push clips

     

     

266. Install RH rocker panel lower cover into position
     Remarque

     10x clips

     

     

267. Install bolts securing RH rocker panel lower cover to body
     Remarque

     4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary

     

268. Install clips securing the RH rocker panel lower cover to wheel liners
     Remarque

     4x push clips

     

     

269. Exit Service Mode
     Remarque

     Via UI > Service > Exit, Press and hold "Exit Service Mode" button

     

270. Raise all windows

     

271. Close LH front door