13/06/2024 10:24:09

HV Battery (AWD) (3-Phase) (Remove and Install)

Correction code 16010221 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.

2024-06-13: Updated lift pad adapter PNs.
2023-11-21: Added new lift pad instructions.
2023-08-23: Updated EPB Service Mode reference.
2023-07-11: Reorganized steps to accommodate service while standing.
2023-07-06: Added step to perform a charge port voltage check.
2023-05-05: Added step to position battery table under vehicle.

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.
Open hood.

Note
Press "Open" button on the touchscreen to release the latch, Lift the lid manually.
Remove rear apron.

Note
12x clips, Only store rear apron visible face upwards .
Remove cabin intake upper duct assembly.

Note
4x clips, Heat pump vehicles have 3x clips.
Move LH front seat backward.
Remove LH IP end cap.

Note
3x clips.
Remove LH mid A-pillar assembly.

Note
1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove.
Remove clip for LH lower A-pillar trim.

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

Note
2x clips, 3 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet.
Remove screw and clips securing LH footwell cover.

Note
2x push clips, 1x screw, T20, 2.5 Nm.
Remove connectors from LH footwell cover and remove from vehicle.

Note
3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles have an additional OBDII connector that will have to be disconnected.
Remove LH front floor mat.
Remove LH console side panel carpet.

Note
12x clips, Use trim tool starting at rear edge to release upper clips, then pull bottom to release remaining clips.
Move RH front seat backward.
Remove RH IP end cap.

Note
3x clips.
Remove RH mid A-pillar assembly.

Note
1x clip, 1x tab, Release upper clip then pull mid A-pillar upward to remove from vehicle.
Remove clip for RH lower A-pillar trim.

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

Note
1x clip, 2 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet.
Remove clips securing RH footwell assembly.

Note
4x push clips.
Disconnect RH foot well assembly connectors and remove from vehicle.

Note
2x electrical connectors.
Remove RH front floor mat.
Remove RH console side panel carpet.

Note
12x clips, Use trim tool starting at rear edge to release upper clips, Pull bottom to release remaining clips.
Move RH front seat forward.
Move LH front seat forward.
Remove 2nd row floor mat from vehicle.
Remove 2nd row seat cushion and disconnect harness.

Note
2x tabs, 2x connectors, Press tab toward vertical backward of vehicle on each side to release front edge of seat cushion.
Fold the 40 seat in down position.

Note
Protect the seat cushion.
Remove RH side bolster.

Note
1x clip, 1 tab, Pull outward then slightly upward to remove.
Remove and discard bolster plastic bracket from RH side.

Note
2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal.
Fold the 40 seat into vertical position.
Remove the RH rear door sill trim panel.

Note
3x clips, 1x guide tab, Pull upward at the lower corner of sill trim to release clip from lower B-pillar, then remove the remaining clips by pulling away from the body.
Release clips securing the RH upper B-pillar assembly and move aside.

Note
4x clips, Pull the bottom of the upper B-pillar toward inside of the car, then pull the top of trim to release the remaining clips.
Remove the RH lower B-pillar assembly.

Note
1x push clip, 6x clips, Remove the front push clip from lower B-pillar, then pull the top of B-pillar to release top clips then work your way to bottom clips.
Fold the 60 seat in down position.

Note
Protect the seat cushion.
Remove LH side bolster.

Note
1x clip, 1 tab, Pull outward then slightly upward to remove.
Remove and discard bolster plastic bracket from LH side.

Note
2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal.
Fold the 60 seat into vertical position.

Note
Remove seat protection.
Remove the LH rear door sill trim panel.

Note
3x clips, 1x guide tab, Pull upward at the lower corner of sill trim to release clip from lower B-pillar, then remove the remaining clips by pulling away from the body.
Release clips securing the LH upper B-pillar assembly and move aside.

Note
4x clips, Pull the bottom of the upper B-pillar toward inside of the car, then pull the top to release the remaining clips.
Remove the LH lower B-pillar assembly.

Note
1x push clip, 6x clips, Remove the front push clip from lower B-pillar, then pull the top of B-pillar to release top clips then work your way to bottom clips.
Remove clips securing rear main cabin carpet to vehicle.

Note
4x push clips, Velcro strips, The number of clips on newer vehicles may vary.
Move LH front seat backward.
Remove clips securing LH front main carpet to vehicle.

Note
3x 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, Release seat harness from clip to allow the carpet to fold back more.
Remove LH front footwell HV battery bolts.

Note
2x bolts, EP20, 136 Nm.
Remove LH rear HV battery interior bolt.

Note
1x bolt, 16mm, 66 Nm, Lift up carpet for access.
Move RH front seat backward.
Remove clips securing RH front main cabin carpet to footwell area.

Note
3x push clips, Number of clips may vary on older vehicles.
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.
Remove RH rear HV battery interior bolt.

Note
1x bolt, 16mm, 66 Nm, Lift up carpet for access.
Place wheel chocks to keep vehicle from moving.
Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
Power off vehicle from center display.

Note
Via Controls > Safety & Security > Vehicle Power > Power Off, Confirm power off at warning dialogue box.
Disconnect 12V negative terminal.

Note
1x nut, 10mm, 6 Nm, Ensure the vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V.
Remove 12V cap from ancillary bay.

Note
1x cap.
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 all items from pockets and ensure not wearing metal items.
Inspect HV insulating gloves.

Note
Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, 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.
Perform a charge port voltage check. See Charge Port Voltage Check.
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, 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 the ancillary bay cover.

Note
Confirm no damage is present, Seal can be re-used.
Install bolts securing ancillary bay probe lid cover to ancillary bay cover.

Note
2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners.
Remove HV cap from ancillary bay.

Note
1x cap.
Remove edge support bracket.

Note
2x bolts, 10mm, 10 Nm, 1x clip.
Remove fastener securing busbar cover access door.

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

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

Note
4x guide tabs, Slightly wiggle aluminum connector housing back and forth to ease removal.
Disconnect 3PH chargeport inlet harness from HV header.

Note
1x connector, Release red locking tab and rotate lever arm to release.
Remove bolts securing LH inner ancillary bay rail to the ancillary bay cover.

Note
2x bolts, T40, 24 Nm.
Remove bolts securing RH inner ancillary bay rail to the ancillary bay cover.

Note
2x bolts, T40, 24 Nm.
Remove nut securing DCDC ground busbar to HV battery.

Note
1x nyloc nut, 13mm, 9 Nm, Discard nut after removal.
Remove bolt securing DCDC ground busbar to body.

Note
1x bolt, 13mm, 20 Nm.
Remove DCDC ground busbar.
Remove positive 12V output cover from PCS cable.

Note
1x cover.
Remove nut securing positive 12V output from PCS cable and move cable aside.

Note
1x nyloc nut, 13mm, 9 Nm, Discard nut after removal.
Close all four doors.

Note
Make sure all windows are lowered and rear doors are latched to prevent accidental closure when vehicle is powered down.
Push vehicle onto lift.

Note
Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed.
Install lift pad adapters.
- For EMEA only, install Adapter, Lift Pad, Model 3 (1453419-00-A
- For other regions, install Universal Lift Pad Adapters (1936724-00-A)
Warning
DO NOT use any other lift pad adapters.

Note
Outside of EMEA, Universal Lift Pad Adapters (1936724-00-A) replace Adapter, Lift Pad, Model 3 (1453419-00-A. Discard any other versions of lift pad adapters.

Note
In EMEA, the Universal Lift Pad Adapters are not yet available. Make sure to use the rubber Model Y lift pads on Model Y and the Model 3 lift pads on Model 3.

Instructions for Universal Lift Pad Adapters:
1. Depending on the lift type, install the correct thread adapter onto the lift adapter.
2. Make sure the thread stop washer is installed and tightened to the bottom of the lift adapter. If the thread stop washer is not installed, do not continue using the lift adapter.
3. Install the lift adapters onto the lift arms so that the black lift pad is toward the vehicle.
  Warning
  Make sure the adapter is install in the correct orientation.
4. Position the lift arms so that the lift adapters align with the datum hole on the vehicle.
5. Lift the lift arms to fully seat the lift pads into the vehicle.
6. Make sure all 4 adapters are fully seated into the vehicle.
Raise and support vehicle.
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 outer fasteners securing front aero shield.

Note
9x bolts, 10mm, 5 Nm.
Remove remaining nuts and remove front aero shield from vehicle.

Note
2x nuts, 15mm, 5 Nm.
Remove the clips securing the front LH and RH wheel liners to the front skid plate.

Note
2x push clips.
Remove bolts securing front skid plate.

Note
4x bolts, EP10, 13 Nm.
Remove skid plate from HV battery.
Release connector from bracket.

Note
1x connector.
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.
Remove bolt securing FDU HV harness to FDU.

Note
1x bolt, 10mm, 10 Nm.
Disconnect the FDU HV harness connector.

Note
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.
Remove the FDU HV harness connector from the FDU and move aside.

Note
1x connector.
Remove FDU ground strap bolt from HV battery and remove ground strap from vehicle.

Note
1x bolt, 10mm, 10 Nm.
Remove push clip securing LH front wheel liner to LH rocker panel.

Note
1x push clip.
Remove push clip securing RH front wheel liner to RH rocker panel.

Note
1x push clip.
Use bungee strap to pull back LH front wheel liner.

Note
Secure to subframe.
Use bungee strap to pull back RH front wheel liner.

Note
Secure to subframe.
Position coolant drain container underneath RH front of HV battery.
Release FDU Inverter Inlet hose RH side of vehicle and plug both hoses.

Note
1x hose clips, Plug both ends, Coolant loss greater than 1 L will require vacuum fill.
Disconnect rear PT supply hose at RH side of vehicle and plug both hoses.

Note
2x plugs, 1x spring clip, Coolant loss greater than 1 L will require vacuum fill.
Position coolant drain container underneath LH front of HV battery.
Disconnect HV battery return tube from HV battery hose.

Note
2x clips, 2x plugs, Located on LH front of HV battery, Install cap and plug to both ends, Coolant loss greater than 1 L will require vacuum fill.
Release HV battery front manifold hose from body.

Note
2x clips.
Disconnect HV battery front manifold hose and plug both hose ends.

Note
1x spring clip, 2x plugs, Coolant loss greater than 1 L will require vacuum fill.
Remove coolant drain container from underneath vehicle.
Remove mid aero shield.

Note
13x bolts, 10mm, 5 Nm.
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.
Release LH side hose clip from rear battery skid plate enclosure.

Note
2x clips, Clip quantity may vary on older vehicles.
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 RDU inverter inlet tube from LH rear of HV battery.

Note
1x spring clip, 2x plugs, Plug HV battery and hose, Coolant loss greater than 1 L will require vacuum fill.
Position coolant drain container underneath RH rear of vehicle.
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.
Remove coolant drain container from underneath 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 front bolts securing HV battery to vehicle.

Note
4x bolts, 13mm, 35 Nm, The number of fasteners on newer vehicles may vary.
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.

Install

Spin Flexitol adjustable elements down on the ancillary bay cover.

Note
4x nuts, Reverse thread.
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.
Install front bolts securing HV battery to vehicle hand tight.

Note
4x bolts, 13mm, 35 Nm, The number of fasteners on newer vehicles may vary, Reinstall fastener unless the body is patched or no hole exists, Patch the body if HV battery doesn't have these holes.
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.
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.
Open LH rear door.

Note
Use caution while working around this area not to damage any components.
Set LH rear HV battery interior bolt with cordless impact.

Note
1x bolt, 16mm, 66 Nm, Lift up carpet for access, Ensure smooth thread engagement and bolts are not cross threaded into pack, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
Close LH rear door.

Note
Do not latch.
Open LH front door.

Note
Use caution while working around this area not to damage any components.
Set LH front footwell HV battery bolts with cordless impact .

Note
2x bolts, EP20, 136 Nm, Ensure smooth thread engagement and bolts are not cross threaded into pack, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
Close LH front door.

Note
Do not latch.
Open RH rear door.

Note
Use caution while working around this area not to damage any components.
Set RH rear HV battery interior bolt with cordless impact.

Note
1x bolt, 16mm, 66 Nm, Lift up carpet for access, Ensure smooth thread engagement and bolts are not cross threaded into pack, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
Close RH rear door.

Note
Do not latch.
Open RH front door.

Note
Use caution while working around this area not to damage any components.
Set LH front footwell HV battery bolts with cordless impact .

Note
2x bolts, EP20, 136 Nm, Ensure smooth thread engagement and bolts are not cross threaded into pack, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
Close RH front door.

Note
Do not latch.
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 front bolts securing HV battery to vehicle.

Note
4x bolts, 13mm, 35 Nm, The number of fasteners on newer vehicles may vary, If joint is found loose, note the VIN, joint location, take pictures and escalate via toolbox session.
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.
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.
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 hand tight.

Note
2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts.
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.
Apply Loctite 222 onto mid aero shield bolts and install mid aero shield.

Note
13x bolts, 10mm, 5 Nm.
Position coolant drain container underneath LH front of HV battery.
Install HV battery front manifold hose clips to body.

Note
2x clips.
Remove plugs then connect male side to female side of HV battery front manifold hose.

Note
2x plugs, 1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Loss of coolant greater than 1L requires coolant vacuum fill.
Remove plugs then connect female side to male side of HV battery return hose.

Note
2x plugs, 1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Loss of coolant greater than 1L requires coolant vacuum fill.
Position coolant drain container underneath RH front of HV battery.
Remove plugs then connect PT supply tube.

Note
2x clips, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill.
Remove plugs then connect PT return tube.

Note
2x clips, 2x plugs, Perform push-pull-push test to make sure hose is fully seated, Loss of coolant greater than 1L requires coolant vacuum fill.
Remove coolant drain container from underneath vehicle.
Release RH front wheel liner from bungee strap.

Note
Remove strap from vehicle.
Release LH front wheel liner from bungee strap.

Note
Remove strap from vehicle.
Install push clip securing LH front wheel liner to LH front rocker panel.

Note
1x push clip.
Install clip securing RH front wheel liner to RH rocker panel.

Note
1x push clip.
Install FDU ground strap and bolt to HV battery.

Note
1x bolt, 10mm, 10 Nm.
Install FDU HV harness connector to FDU.

Note
1x connector, Ensure the connector is installed far enough on the FDU manifold so the manifold alignment tooth is making contact with the connector lever.
Secure FDU HV harness connection to FDU.

Note
1x locking connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and engage red locking tab, Do not damage connector or header.
Install bolt securing FDU HV harness to FDU.

Note
1x bolt, 10mm, 10 Nm.
Remove plastic bracket securing HV connectors to body.

Note
3x clips.
Connect A/C compressor HV harness connector.

Note
1x connector, 2 stage lock tab, Apply abrasion tape to harness if not present.
Connect PTC HV connector to HV cable then reinstall bracket.

Note
1x connector, 2 stage lock tab, Apply abrasion tape to harness if not present.
Install front skid plate onto HV battery.

Note
2x tabs, Slide tabs onto front of HV battery.
Install the bolts securing the front skid plate to the HV battery.

Note
4x bolts, E10, 13 Nm.
Install the clips securing the front LH and RH wheel liners to the front skid plate.

Note
2x push clips.
Position front aero shield to vehicle and install nuts.

Note
2x nuts, 15mm, 5 Nm.
Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield.

Note
9x bolts, 10mm, 5 Nm.
Lower vehicle fully and move rack arms away from vehicle.

Note
Remove M3 lift adapters from body and install body plugs.
Push vehicle away from lift.

Note
Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed, Chock wheels.
Open all four doors.
Install positive 12V output from PCS cable and torque nut.

Note
1x nyloc nut, 13mm, 9 Nm, Install new nut, Mark nut after torque, Make sure rubber boot is not pinched between cable terminal.
Install positive 12V output cover.

Note
1x cover.
Install DCDC ground busbar.
Install bolt securing DCDC ground busbar to body.

Note
1x bolt, 13mm, 20 Nm.
Install nut securing DCDC ground busbar to HV battery.

Note
1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut.
Install bolts securing RH inner ancillary bay rail to the ancillary bay cover.

Note
2x bolts, T40, 24 Nm.
Install bolts securing LH inner ancillary bay rail to the ancillary bay cover.

Note
2x bolts, T40, 24 Nm.
Connect 3PH chargeport inlet harness to HV header.

Note
1x connector, Rotate lever arm and secure locking tab.
Clean HV connector contact surface of residual Penetrox.

Note
Allow 1 minute dry time after wiping away Penetrox, New busbar comes with penetrox applied to HV connector.
Apply Penetrox onto HV connector joints.

Note
Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered.
Position chargeport busbar connector to HV header.

Note
4x guide tabs, Recommend assistance, 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 chargeport busbar connector to HV header.

Note
2x bolts, 10mm, 9 Nm.
Install edge support bracket.

Note
2x bolts, 10mm, 10 Nm, 1x clip.
Inspect HV insulating gloves.

Note
Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, 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.
Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head.

Note
2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.If the resistance is 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.
Remove HV insulating gloves.
Install fastener securing busbar cover access door.

Note
1x bolt, 10mm, 9 Nm.
Install HV cap to ancillary bay.

Note
1x cap.
Remove logic cap and connect the HVC logic connector.

Note
1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated.
Install 12V cap to ancillary bay.

Note
1x cap.
Connect 12V negative terminal.

Note
1x nut, 10mm, 6 Nm.
Press and hold park button to release EPB service mode.

Note
Remove wheel chocks if necessary.
Connect to vehicle using Toolbox 3.0.

Note
Vehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle.
Select ‘Actions/Autodiag’ and search for ‘Thermal’.
Select "Start Thermal Fluid Fill/Drain (Coolant only)", click Run and allow routine to complete.

Note
Select ‘X’ at top right of window to close once complete, Verify vehicle is in Series via Garage > Vitals > Thermal tab > Coolant loops, Thermal Fluid Fill/Drain routine has a 5 hour limit, After 5 hours routine must be performed again.
Remove HVAC plenum outer duct.

Note
2x clips.
Remove superbottle 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.
Place refill hose inside filled coolant container .

Note
Make sure hose end is fully submerged into coolant.
Install vacuum refill cap onto superbottle 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 installed.
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.
Slowly open the coolant refill valve to allow coolant to be drawn into the coolant refill hose, Close the valve when the hose is full of coolant.

Note
This purges trapped air from the hose.
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.
Once the gauge reads zero, close the coolant refill valve.
Once the gauge reads zero, close the refill valve.
Slowly open the refill valve to allow coolant to be drawn into the system.

Note
Make sure hose end of refill hose is fully submerged during entire process.
Once the gauge reads zero, close the 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 superbottle.

Note
Push down on black ring to release hose and pull hose up to remove.
Remove coolant overflow hose from coolant container.
Remove both coolant containers from inside underhood area.
Select ‘Actions/Autodiag’ tab and search for ‘Purge'.
Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE ’, click ‘Run’, and allow routine to complete.

Note
Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete.
Inspect coolant level and top off as necessary.

Note
Ensure that the fluid level is 5mm above the Max line.
Install superbottle cap.
Install HVAC plenum outer duct.

Note
2x clips, Align tab at bottom of duct before securing clips.
Select ‘TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCE’, click ‘Run’, and allow routine tocomplete.

Note
Select ‘X’ at top right of window to close once complete.
Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle.
Close RH rear door.
Close LH rear door.
Close LH front door.
Remove lift arms from below vehicle.

Note
Lower rack arms fully and remove them from under vehicle.
Open all four doors.
Torque LH rear HV battery interior bolt.

Note
1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access if necessary.
Move LH front seat backward.
Torque LH front footwell HV battery bolts.

Note
2x bolts, EP20, 136 Nm.
Fold the LH front main cabin carpet back to original position.

Note
Move front edge down and slide back section up to ease positioning, Install seat harness into clip.
Install clips securing LH front main cabin carpet to vehicle.

Note
3x push clips, Number of clips on newer vehicles may vary.
Move LH front seat forward.
Torque RH rear HV battery interior bolt.

Note
1x bolt, 16mm, 66 Nm, Lift up RH rear main carpet for access if necessary.
Move RH front seat backward.
Torque RH front footwell HV battery bolts.

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

Note
Move front edge down and slide back section up to ease positioning, Install seat harness into clips.
Install clips securing the RH front main cabin carpet to footwell area.

Note
3x push clips, Number of clips may vary on older vehicles.
Move RH front seat forward.
Install clips and secure Velcro holding rear main cabin carpet to vehicle.

Note
4x push clips, The number of clips on newer vehicles may vary.
Install the LH lower B-pillar assembly.

Note
1x push clip, 6x clips, Align the bottom guide tab to its slot then press the bottom clips, Work your way to top clips, Install the front push clip then make sure the seal correctly overlaps the trim.
Install the LH upper B-pillar assembly.

Note
4x clips, Lower the seat belt slider to align it with the B-pillar panel, Insert top portion of upper B-pillar under the headliner to align the clips, Press the bottom to fully seat upper B-pillar to lower B-pillar, Make sure the seal correctly overlaps the trim.
Install the LH rear door sill trim panel.

Note
3x clips, 1x guide tab, Align the guiding tab to slot, Then push downward to install the clips after aligning them, Make sure the seal sits overlapping the trim. Newer vehicles may not be equipped with metal bracket and a foam insert will be present the bottom of trim piece.
Fold the 60 seat in down position.

Note
Protect the seat cushion if necessary.
Install bolster plastic bracket to LH side bolster.

Note
2x tabs, Install new bolster bracket.
Install LH side bolster.

Note
1x clip, 1x tab, Align the bottom tab then push inward to install.
Fold the 60 seat into vertical position.

Note
Remove seat cushion protection.
Install the RH lower B-pillar assembly.

Note
1x push clip, 6x clips, Align the bottom guide tab to its slot then press the bottom clips, Work your way to top clips, Install the front push clip then make sure the seal correctly overlaps the trim.
Install the RH upper B-pillar assembly.

Note
4x clips, Lower the seat belt slider to align it with the B-pillar panel, Insert top portion of upper B-pillar under the headliner to align the clips, Press the bottom to fully seat upper B-pillar to lower B-pillar, Make sure the seal correctly overlaps the trim.
Install RH rear door sill trim panel.

Note
3x clips, 1x guide tab, Align the guiding tab to slot, then push downward to install the clips after aligning them, Make sure the seal sits overlapping the trim.
Fold the 40 seat in down position.

Note
Protect the seat cushion if necessary.
Install bolster plastic bracket to RH side bolster.

Note
2x tabs, Install new bolster bracket.
Install RH side bolster.

Note
1x clip, 1x tab, Align the bottom tab then push inward to install.
Fold the 40 seat into vertical position.

Note
Remove seat cushion protection.
Connect 2nd row seat cushion harness and install 2nd row seat cushion.

Note
2x connectors, 2x clips, Insert the seat belt buckles through the holes, Slide rear cushion inward then align front guide tabs to locking tabs, Make sure cushion is fully seated with push & pull test near clips.
Install 2nd row floor mat into vehicle.
Move RH front seat backward.
Install RH console side panel carpet.

Note
1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear.
Install RH front floor mat.
Connect RH footwell assembly connectors.

Note
2x connectors.
Install clips securing RH footwell assembly.

Note
4x push clips .
Install RH lower A-pillar trim.

Note
1x clip, 2 guide tabs, Align 2 front tabs then align slot with harness bracket and then push rear clip to secure to lower B-pillar.
Install clip for RH lower A-pillar trim.

Note
1x push clip.
Install RH mid A-pillar assembly.

Note
1x clip, 1x tab, Align bottom tab then push on top clip to fully seat mid A-pillar, Make sure seal seat on top of trim.
Install RH IP end cap.

Note
3x clips.
Move LH front seat backward.
Install LH console side panel carpet.

Note
1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear.
Install LH front floor mat.
Install connectors to LH footwell cover and position for installation, securing front tabs to driver air bag assembly.

Note
3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles have an additional OBDII connector.
Install screw and clips securing LH footwell cover.

Note
2x push clips, 1x screw, T20, 2.5 Nm.
Install LH lower A-pillar trim.

Note
2x clip, 3 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 LH lower A-pillar trim.

Note
1x push clip.
Install LH mid A-pillar assembly.

Note
1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Pull seal over trim.
Install LH IP end cap.

Note
3x clips.
Move LH front seat to original position.
Move RH front seat to original position.
Install cabin intake upper duct assembly.

Note
4x clips, Heat pump vehicles have 3x clips.
Install rear apron.

Note
12x clips .
Close hood.
Raise all windows.
Close all four doors.

Note
Unlatch rear doors before closing.
Install RH rocker panel lower cover into position.

Note
10x clips.
Install clips securing the RH rocker panel lower cover to wheel liners.

Note
4x push 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 LH rocker panel lower cover into position.

Note
10x clips.
Install clips securing the LH rocker panel lower cover to wheel liners.

Note
4x push 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.

Model 3 Service Manual

HV Battery (AWD) (3-Phase) (Remove and Install)

Remove

Install

Figure 1

Figure 2

Figure 3