19/12/2024 11:02:03

HV Battery (AWD) (Remove and Replace)

Correction codes 16010202 5.40 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.

  • 1936724-00-A - Universal Lift Pad Adapters
  • 1133787-00-A Key, Seat Belt Release, Model 3
  • 1020566-00-F ASY, Battery Table, Manual Lift
  • 1020566-99-A Top Plate, Battery Table, Manual Lift
  • 1129166-00-A Hoist, H-Frame EMEA
  • 1073363-00-A Gantry, Adjustable, Aluminum
  • 1134523-00-A Kit, Alignment Rods, Battery, Model 3
  • 1140311-00-A Lever Lock, HV Connector, Model 3
  • 1053600-00-B Drive Unit Pressure Test Fixture
  • 1130942-00-B Adapter, Coolant Reservoir Pressure Test
  • 1132185-00-B Kit, Coolant Leak Test Adapters, Model 3
  • 1133843-00-A Kit, Coolant Drain & Fill Adapters, M3
  • 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
  • GSN-TL-000564 Kit, Battery Coolant Drain and Fill
  • 1026636-00-A Pack Enclosure Leak Tester, HV Battery
  • 1140501-00-A Pack Kit, Enclosure, Leak Test, HV Battery, Complete
  • 1144879-00-A Kit, Encl Leak Test Adapters, HV Battery
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU
  • 2024-12-19: Added a step to verify the front HV battery coolant passthrough fittings on the new HV battery to determine if the updated front HV battery coolant manifold hose 1734606-00-D is needed.
  • 2024-12-18: Added step to determine if HV battery parameters are within safe limits before removing the pyro disconnect.
  • 2024-10-31: Updated HV battery discharge steps.
  • 2024-09-11: Added step to support the LV system.
  • 2024-06-13: Updated lift pad adapter PNs.
  • 2024-06-10: Added pyro disconnect removal steps.
  • 2023-11-21: Added new lift pad instructions.
  • 2023-11-13: Add note to further clarify fasten the HV battery pack to crate before shipping.
  • 2023-11-06: Updated UI steps.
  • 2023-10-25: Reorganized logic for PTC fuse check and installation.
  • 2023-07-11: Reorganized steps to accommodate service while standing.
  • 2023-05-22: Added conspicuous discharge warning table.
  • 2023-05-22: Added caution for correct positive DC cable connection.
  • 2023-03-16: Updated Discharge section and added steps to configure the HV battery.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
The video(s) included in this procedure are meant as an overview for supplemental purposes only. Follow all of the steps listed in the procedure to avoid damage to components and/or personal injury.

Discharge

WARNING: To conform with local laws, High Voltage Lithium Batteries must be discharged before packing for shipment. Additionally, HV batteries must be discharged before being put into storage. HV batteries to be shipped must have a State of Charge (SoC) of less than 30% or 50%, depending on the region. If the method of shipment is unknown or uncertain, or the battery is to be stored, it is recommended to discharge the HV battery to less than 30%.

WARNING: Do not ship or store an HV battery that has a loss of high voltage isolation. Verify HV battery isolation before packing for shipment or storage. Use the HV Battery Communication Tool, described in Toolbox article #41977 or Customer Document CD-21-16-003, to determine if the HV battery parameters are within safe limits for shipment or storage.
Informational PurposesAn informational icon, calling your attention
Note
If possible, perform the discharge procedure before HV battery removal. This method requires less time and user interaction than to use the Battery Discharge Tool after the battery has been removed. The Battery Discharge Tool can only be used by certified technicians..
Informational PurposesAn informational icon, calling your attention
Note
The steps of the discharge procedure are mostly touch time, and can be performed by the Service Advisors/Front of House team as well as Service Technicians..
  1. Enable Service Mode Plus. See Service Mode Plus.
  2. Identify the vehicle's current SOC Max: In the Service Mode Plus menu, touch High Voltage > HV Battery, and then touch the large HV battery diagram to display the HV Battery information window.
    • If the SOC Max is less than the SOC shipping threshold, skip to the Remove section in this procedure.
    • If the SOC Max is greater than the SOC shipping threshold, continue to the next step.
  3. Move the vehicle to a location where the battery can be safely discharged unattended.
  4. In the Service Mode Plus menu, touch High Voltage > HV Battery.
  5. In the Tools section, touch Start HV Discharge, and then in the window that opens, touch Run.
    Informational PurposesAn informational icon, calling your attention
    Note
    The discharge routine starts and will automatically stop when the SOC Max value for surface transport has been attained.
  6. After discharge is complete, move the vehicle to the service bay.

Remove

  1. Verify that the vehicle software version is at 2023.20 or later, and if not, update to the latest version. See Software Update.
  2. Remove the LH and RH lower rocker panel covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).
  3. Open all doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    Latch the rear doors to prevent accidental lockout.
  4. Lower all windows.
  5. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  6. Remove the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  7. Move the driver seat fully rearwards.
  8. Remove the LH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  9. Remove the LH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  10. Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  11. Remove the driver footwell cover. See Cover - Footwell - Driver (Remove and Replace).
  12. Remove the LH front floor mat.
  13. Remove the LH center console side panel carpet. See Side Panel - Center Console - LH (Remove and Replace).
  14. Move the front passenger seat fully rearwards.
  15. Remove the RH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  16. Remove the RH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  17. Remove the RH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  18. Remove the front passenger footwell cover. See Cover - Footwell - Passenger (LHD) (Remove and Replace).
  19. Remove the RH front floor mat.
  20. Remove the RH center console side panel carpet. See Side Panel - Center Console - LH (Remove and Replace).
  21. Move the driver and front passenger seats fully forward.
  22. Remove the 2nd row floor mat from the vehicle.
  23. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  24. Remove the clips (x4) and hook-and-loop strips that attach the rear carpet to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    The number of clips on newer vehicles might vary.
  25. Lift up the RH side of the rear carpet and insert a hand to feel if the 4th RH HV battery bolt is present. If the bolt is present, then remove the bolt.
  26. Lift up the LH side of the rear carpet and insert a hand to feel if the 4th LH HV battery bolt is present. If the bolt is present, then remove the bolt.
  27. Move the driver seat fully rearwards.
  28. Remove the clips (x3) that attach the LH front carpet to the vehicle.
  29. Fold the LH front carpet for access, and then release the seat harness from the clip to allow the carpet to fold back further.
    Informational PurposesAn informational icon, calling your attention
    Note
    The driver footrest is part of the LH front carpet.
  30. Remove the LH front inner HV battery bolts.
  31. Check to see if the 3rd LH inner HV battery bolt is present. If the bolt is present, remove the bolt.
  32. If the vehicle had the 3rd or the 4th LH inner HV battery bolts, move the driver seat to the center position and the seat back to the upright position. Otherwise, skip to the next step.
  33. Separate the LH side of the rear main carpet perforations to access the 4th LH inner HV battery bolt, if the bolt is present.
    Informational PurposesAn informational icon, calling your attention
    Note
    Might need to undo the hook-and-loop strips that are attach the front carpets to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Might need to move the driver seat forwards or rearwards if necessary to allow access for the bolt.
  34. Remove the 4th LH inner bolt that attaches the HV battery to the body.
  35. Remove the 5th LH rear inner bolt that attaches the HV battery to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift up the rear main carpet for access.
  36. Unfold the LH front carpet back to its original position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the front edge down, and then slide back the carpet to ease positioning.
  37. Move the front passenger seat fully rearwards.
  38. Remove the clips (x4) that attach the RH front carpet to the vehicle.
  39. Release the seat electrical harness from the clips to allow the RH front carpet to fold back more.
  40. Remove the RH front inner bolts (x2) that attach the HV battery to the body.
  41. Check if the 3rd RH bolt is present. Use a flashlight, if needed. Remove the bolt, if present. Otherwise, skip to the next step.
  42. Move the front passenger seat to the center position and the seatback to the upright position, if the 3rd RH and 4th RH inner HV battery bolts are present.
    Informational PurposesAn informational icon, calling your attention
    Note
    Might need to undo the hook-and-loop strips that are attach the front carpets to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Might need to move the driver seat forwards or rearwards if necessary to allow access for the bolt.
  43. Remove the 4th RH inner bolt that attaches the HV battery to the body, if equipped. Otherwise, skip to the next step.
  44. Remove the 5th RH rear inner bolt that attaches the HV battery to the body.
  45. 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 IconA warning icon, calling your attention to a possibly risky situation
    Warning
    DO NOT use any other lift pad adapters.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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 IconA warning icon, calling your attention to a possibly risky situation
      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.
  46. Connect a laptop with Toolbox 3 to the vehicle.
  47. Click Actions, type "thermal" in the search field, click the play button next to PROC_VCFRONT_X_THERMAL-FILL-DRAINvia Toolbox: (link), and then select Run.
    Informational PurposesAn informational icon, calling your attention
    Note
    The 5-way valve is set to Series position, and the coolant pumps are disabled.
  48. Remove the laptop from the vehicle, but do not close Toolbox.
  49. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  50. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  51. Remove the HV cap that covers the HV harness located on the LH side of the ancillary bay.
  52. Remove the bolts that attach the charge port to HV battery harness bracket at the ancillary bay, and then remove the bracket from the vehicle.
  53. If the HV battery DC input is configured with busbars, continue to the next step, otherwise skip to step 57.
  54. Remove the bolt that secures the charge port busbar connector access door.
  55. Remove the bolts (x2) that attach the charge port busbar connector to the DC input HV header, and then lift to remove the connector from the header.
  56. Skip to step 60.
  57. Slide the release to unlock the DC input connector handle of the charge port to HV battery harness from the secured position.
  58. Fully raise the handle on the DC input connector.
  59. Remove the DC input connector from the ancillary bay DC input header.
  60. If the charge port to HV battery harness has a 3-phase connector, continue to the next step, otherwise skip to step 64.
  61. Slide the release to unlock the 3-phase connector handle of the charge port to HV battery harness from the secured position.
  62. Fully raise the handle on the 3-phase connector.
  63. Remove the 3-phase connector from the ancillary bay 3-phase header.
  64. Release the clip that attaches the charge port to HV harness connector at the sill area.
  65. Remove the bolts that attach the LH and RH inner ancillary bay rails to the ancillary bay cover.
  66. Remove the DCDC ground busbar. See Busbar - DCDC Ground (Remove and Replace).
  67. Remove and discard the nut that attaches the positive 12V output cable to the DCDC passthrough, and then remove the cable from the passthrough.
    Informational PurposesAn informational icon, calling your attention
    Note
    Inspect the condition of the rubber boot at the end of the output cable, and replace the boot if it is melted or damaged.
  68. Remove the pyro disconnect from the ancillary bay prior to shipping the HV battery:
    1. Fully loosen and remove (if possible) the bolts that attach the ancillary bay cover to the HV battery.
      Informational PurposesAn informational icon, calling your attention
      Note
      Different ancillary bay cover revisions have 28, 18, or 16 bolts.
    2. Remove the logic connector cap from the high voltage controller connector.
    3. Use the HV Battery Communication Tool, described in Toolbox article #41977 or Customer Document CD-21-16-003, to determine if the HV battery parameters are within safe limits before proceeding.
    4. Remove the ancillary bay cover from the vehicle.
    5. Put on HV insulating gloves and leather over gloves.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      Continue to wear the gloves until instructed to remove them.
    6. Reinstall the logic connector cap onto the high voltage controller connector.
    7. Inspect whether HV insulators are present. If not present or partly present, use the Ancillary Bay Insulator kit and install the insulator caps onto the HV battery to cover live HV points. See Insulators - HV Battery (Install and Remove).
    8. Lower HV Controller back into place.
    9. Remove the pyrotechnic battery disconnect shunt insulator(s).
      Figure 1. 1st Generation
      Figure 2. 2nd Generation
    10. Remove and discard the bolts that attach the pyrotechnic battery disconnect to the HV battery, and then remove the pyrotechnic battery disconnect from the vehicle.
    11. Remove the logic connector cap from the high voltage controller connector.
    12. Remove all insulator kit covers from the HV battery. See Insulators - HV Battery (Install and Remove).
    13. Install the ancillary bay cover on the HV battery, and then hand-tighten the bolts.
      Informational PurposesAn informational icon, calling your attention
      Note
      Different ancillary bay cover revisions have 28, 18, or 16 bolts.
    14. Remove HV insulating gloves.
    15. Reinstall the logic connector cap onto the high voltage controller connector.
    16. Torque the ancillary bay cover bolts in the sequence shown, and mark each with an orange paint pen as they are torqued.
      8 Nm (5.9 lbs-ft)
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Use an External Torx E10 5-Lobe socket that is not magnetized. Sockets with magnets will not fully grip and can possibly strip the bolt head.
      Tip: Use of the following tool(s) is recommended:
      • External Torx E10 5-Lobe
      • 4 in extension
      • Ratchet/torque wrench
      Figure 3. 28-Bolt Ancillary Bay Cover Torque Sequence
      Figure 4. 18-Bolt Ancillary Bay Cover Torque Sequence
      Figure 5. 16-Bolt Ancillary Bay Cover Torque Sequence
  69. Partially close all doors.
  70. Raise the vehicle to a comfortable working height.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Verify that the vehicle is stable on the lift.
  71. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  72. Release the clips along the bottom edge of the LH and RH wheel arch liners.
  73. Install bungee straps to pull the LH and RH wheel arch liners away from the HV battery and expose the coolant hoses.
  74. Remove the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  75. Disconnect the electrical harness from the PTC heater HV connector, and then release the electrical harness from the bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    The PTC heater HV connector is only for vehicles without a heat pump. For vehicle with a heat pump, skip to the next step.
  76. Disconnect the electrical harness from the A/C HV connector, and then release the electrical harness from the bracket.
  77. Remove the bolt that attaches the front drive unit HV harness to the front drive unit.
  78. Slide the release to unlock the front drive unit HV connector handle of the front drive unit to HV battery harness from the secured position.
  79. Fully raise the handle on the front drive unit HV connector.
  80. Remove the front drive unit HV connector from the front drive unit HV header.
  81. Remove the bolt that attaches the ground strap to the front drive unit.
  82. Release the clip that attaches the front drive unit ground strap to the front drive unit.
  83. Remove the bolt that attaches the ground strap bolt to the HV battery, and then remove the ground strap from the vehicle.
  84. Perform a rear powertrain coolant drain. See Powertrain Coolant (Drain and Refill).
  85. Perform a platter enclosure coolant drain. See Platter Enclosure Coolant (Drain and Refill).
  86. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  87. Release the fir tree clips that attach the coolant hoses to the LH shear plate.
  88. Remove the smaller bolts that attach the LH shear plate to the body.
  89. Remove the larger bolt that attaches the LH shear plate and rear subframe to the body, and then remove the LH shear plate.
  90. Re-install the larger bolt, and hand-tighten the bolt to the rear subframe.
  91. Repeat steps 87 through 90 for the RH shear plate.
  92. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  93. Position the coolant drain under the rear LH side of the HV battery.
  94. Release the clip and disconnect the rear drive unit inverter inlet hose from the LH underside of the ancillary bay, and immediately plug the male and female fittings.
  95. Position the coolant drain under the rear RH side of the HV battery.
  96. Release the clip and disconnect the coolant outlet hose from the powertrain return hose, and immediately plug the male and female fittings.
  97. Remove the coolant drain from underneath the vehicle.
  98. Remove the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
  99. Slide the release to unlock the HV battery rear drive unit connector handle of the rear drive unit to HV battery harness from the secured position.
  100. Fully raise the handle on the HV battery rear drive unit connector.
  101. Remove the HV battery rear drive unit connector from the HV battery header.
  102. With an assistant, put the battery table in position, and then lower the vehicle to support the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Line up the battery table so that the center 4 bolts of the HV battery are accessible through the opening in the battery table.
  103. Remove the center bolts (x4) that attach the HV battery through the HV battery center rail ski cover.
  104. Remove the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
  105. Remove the front center bolt that attaches the HV battery to the vehicle.
  106. Remove the bolts (x4) that attach the front of the HV battery to the vehicle.
  107. Remove the bolts (x16) that attach the HV battery to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Record the positions of any installed washers, as they will be reinstalled to the same locations during the installation procedure.
  108. With an assistant, raise the vehicle and remove the HV battery from underneath the vehicle.
  109. Remove the HV battery cover gasket. See Seal - Perimeter - HV Battery (Remove and Replace).
  110. Turn the adjustable elements (x4) clockwise to remove them from the ancillary bay cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Keep the adjustable elements so that they can be installed onto the replacement HV battery.
  111. Release the clip and disconnect the LH outer HV battery supply hose fitting from the LH front of the HV battery platter enclosure.
  112. Release the clip and disconnect the LH inner HV battery supply hose fitting from the LH front of the HV battery platter enclosure.
  113. Release the clip and disconnect the RH inner HV battery supply hose fitting from the RH front of the HV battery platter enclosure.
  114. Release the clip and disconnect the RH outer HV battery supply hose fitting from the RH front of the HV battery platter enclosure, and remove the hose assembly from the HV battery.
  115. Release the clip and disconnect the RH inner HV battery return hose fitting from the RH rear of the HV battery platter enclosure.
  116. Release the clips that attach the RH inner HV battery return hose to the HV battery.
  117. Release the clip and disconnect the LH inner HV battery return hose fitting from the LH rear of the HV battery platter enclosure.
  118. Release the clips (x5) that attach the HV battery return hose to the LH side of the HV battery, and remove the hose from the HV battery.
  119. Release the clips (x5) that attach the powertrain return (lower) hose to the RH side of the HV battery, and remove the hose from the HV battery.
  120. Release the clip and disconnect the powertrain supply hose fitting from the RH rear underside of the ancillary bay.
  121. Release the clips (x5) that attach the powertrain supply (upper) hose to the RH side of the HV battery, and remove the hose from the HV battery.
  122. Use the gantry and H-frame hoist to lift the HV battery from the manual lift battery table.
  123. If the replacement HV battery has an HV battery center rail ski, go to step 133.
  124. Release the clips that attach the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then separate the bracket from the battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    The PTC heater HV connector is only for vehicles without a heat pump.
  125. Slide the release to unlock the HV battery front drive unit connector handle of the front drive unit to HV battery harness from the secured position.
  126. Fully raise the handle on the HV battery front drive unit connector.
  127. Remove the HV battery front drive unit connector from the HV battery header.
  128. Slide the release to unlock the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector handle of the PTC heater (non-heat pump) and A/C compressor to HV battery harness from the secured position.
  129. Fully raise the handle on the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector.
  130. Remove the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector from the HV battery header.
  131. Release the clips that attach the PTC heater (non-heat pump vehicles) and A/C compressor electrical harness cover to the rear of the HV battery.
  132. With an assistant, remove the end bolts that attach the center rail ski to the HV battery, and then remove the rail ski from the battery.
  133. Use the gantry and H-frame hoist to lower the HV battery into the shipping container.
    Informational PurposesAn informational icon, calling your attention
    Note
    Please make sure correctly fasten the HV battery pack to the crate before shipping.

Install

  1. Use the gantry and H-frame hoist to lift the new HV battery out of the shipping container.
  2. Transfer all of the HV header and coolant port caps from the front and rear of the new HV battery to the old HV battery for return shipment.
    Informational PurposesAn informational icon, calling your attention
    Note
    If it is not possible to fit the caps onto the old HV battery, include the caps in the shipping crate.
  3. For heat pump Model 3 vehicles, go to step 9.
  4. If the replacement HV battery does not have a center rail ski, go to step 8.
  5. Slide the release to unlock the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector handle of the PTC heater (non-heat pump) and A/C compressor to HV battery harness from the secured position.
  6. Fully raise the handle on the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector.
  7. Remove the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector from the HV battery header.
  8. Measure the resistance at the rear HV header for the HV battery PTC heater and A/C compressor harness connector between PTC B+ and PTC B- to verify whether a PTC heater fuse is installed inside the ancillary bay.
    • If the resistance measured is less than 50 kOhm, this indicates that a PTC heater fuse is already installed in the ancillary bay. Continue to the next step..
    • If the resistance measured is infinite, this indicates that no PTC heater fuse is installed inside the ancillary bay. Note that this fuse will need to be installed later in this procedure.
  9. If the replacement HV battery has an HV battery center rail ski, go to step 26.
  10. With an assistant, install the center rail ski to the HV battery.
  11. Install the bolts that attach the center rail ski to the HV battery.
    32 Nm (23.6 lbs-ft)
  12. Fasten the clips that attach the PTC heater (non-heat pump vehicles) and A/C compressor electrical harness cover to the rear of the HV battery.
  13. Fully raise the handle on the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector of the PTC heater and A/C compressor to HV battery harness.
  14. Use both hands to firmly connect the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector of the PTC heater (non-heat pump vehicles) and A/C compressor to HV battery harness to the HV battery header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  15. While pressing the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector onto the HV battery header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  16. Slide the release to lock the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector handle in the secured position.
  17. Verify that the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and PTC heater (non-heat pump vehicles) or A/C compressor problems later on.
  18. Fully raise the handle on the HV battery front drive unit connector of the front drive unit to HV battery harness.
  19. Install the HV connector special tool onto the HV battery front drive unit connector.
  20. Use both hands to firmly connect the HV battery front drive unit connector of the front drive unit to HV battery harness to the HV battery header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  21. Remove the HV connector special tool from the HV battery front drive unit connector.
  22. While pressing the HV battery front drive unit connector onto the HV battery header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  23. Slide the release to lock the HV battery front drive unit connector handle in the secured position.
  24. Verify that the HV battery front drive unit connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and front drive unit problems later on.
  25. Install the PTC heater (non-heat pump vehicles) and A/C compressor electrical harness bracket to the front of the HV battery, and then fasten the clips that attach the bracket to the HV battery.
  26. Use the gantry and H-frame hoist to set the HV battery onto the manual lift battery table.
  27. Inspect the top cover of the HV battery for the presence of NVH pads.
    • If the HV battery does not have NVH pads, install the NVH pads. See NVH Pads - HV Battery (Install).
      Informational PurposesAn informational icon, calling your attention
      Note
      Add correction code 16103101 to the Repair Order/Service Visit as a separate activity. The labor time to install the NVH pads is not included in this parent procedure.
    • If the HV battery already has NVH pads, continue to the next step.
  28. If it was noted that the PTC heater fuse was missing for a non-heat pump Model 3 (step 8), install the fuse now. See Fuse - Cabin Heater - HV Battery (Battery On Table) (Install).
    Informational PurposesAn informational icon, calling your attention
    Note
    Add correction code 16304026 to the Repair Order/Service Visit as a separate activity. The labor time to install the PTC fuse is not included in this parent procedure.
  29. Identify the DC input of the new HV battery.
    • If the new HV battery has the busbar type DC input, yet it is being installed into a vehicle with a charge port to HV battery harness and not busbars, retrofit the HV battery with a harness type DC input. See Busbar DC Input to Harness DC Input (Retrofit).
      Informational PurposesAn informational icon, calling your attention
      Note
      Add correction code 16302806 to the Repair Order/Service Visit as a separate activity. The labor time to retrofit to the harness type DC input is not included in this parent procedure.
    • If the new HV battery has the busbar type DC input, and is being installed into a vehicle with charge port to HV battery busbars, continue to the next step.
  30. Tighten the bolts (2x) on either side of the High Voltage Controller low voltage connector.
    12.5 Nm (9.2 lbs-ft)
  31. Install the powertrain supply hose to the upper clips on the RH side of the HV battery, and then fasten the clips (x5) to attach the hose to the HV battery.
  32. Connect the powertrain supply hose fitting to the RH rear underside of the ancillary bay, and then fasten the clip.
  33. Install the powertrain return hose to the lower clips on the RH side of the HV battery, and then fasten the clips (x5) to attach the hose to the HV battery.
  34. Verify if the new HV battery coolant passthrough fittings (x4) are male fittings or female fittings.
    1. If the HV battery coolant passthrough fittings (x4) are male fittings, no further action is required. Continue to the next step in this procedure.
      Figure 6. HV battery coolant passthrough fittings; Male
    2. If the HV battery coolant passthrough fittings (x4) are female fittings, perform the HV battery front manifold coolant hose retrofit procedure. See Service Development procedure.
    Figure 7. HV battery coolant passthrough fittings; Female
  35. Install the HV battery return hose to the clips on the LH side of the HV battery, and then fasten the clips (x5) to attach the hose to the HV battery.
  36. Connect the LH inner HV battery return hose fitting to the LH rear of the HV battery platter enclosure, and then fasten the clip.
  37. Fasten the clips that attach the RH inner HV battery return hose to the HV battery.
  38. Connect the RH inner HV battery return hose fitting to the RH rear of the HV battery platter enclosure, and then fasten the clip.
  39. Install the HV battery supply hose assembly to the HV battery, connect the RH outer HV battery supply hose fitting to the RH front of the HV battery platter enclosure, and then fasten the clip.
  40. Connect the RH inner HV battery supply hose fitting to the RH front of the HV battery platter enclosure, and then fasten the clip.
  41. Connect the LH inner HV battery supply hose fitting to the LH front of the HV battery platter enclosure, and then fasten the clip.
  42. Connect the LH outer HV battery supply hose fitting to the LH front of the HV battery platter enclosure, and then fasten the clip.
  43. Install and hand-tighten the adjustable elements (x4) on the ancillary bay cover counter-clockwise so that they are fully engaged.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Hand-tighten only.
  44. Install a new HV battery cover gasket. See Seal - Perimeter - HV Battery (Remove and Replace).
  45. Install the HV battery alignment rods; 2 at the front of the vehicle and 2 at the HV battery near the ancillary bay.
  46. With an assistant, position the HV battery underneath the vehicle.
  47. Lower the vehicle to the HV battery, and with an assistant, align the holes with the alignment rods.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not fully lower the vehicle onto the HV battery. The battery will still need to slightly move to install the bolts in the following steps.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the coolant hoses and HV harnesses are not caught on the alignment rods or sandwiched between the HV battery and the vehicle.
  48. Hand-tighten the LH and RH bolts (x16) that attach the HV battery to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the washers to the locations recorded earlier during removal.
  49. Hand-tighten the bolts (x4) that attach the front of the HV battery to the vehicle.
  50. Hand-tighten the front center bolt that attaches the HV battery to the vehicle.
  51. Remove the HV battery alignment rods.
  52. Hand-tighten the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
  53. Hand-tighten the bolts (x4) that attach the center portion of the HV battery through the HV battery center rail ski cover.
  54. Install and hand-tighten the smaller bolts that would attach the LH and RH shear plates to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not install the shear plates at this time.
    Figure 8. LH shown, RH similar
  55. Open the LH rear door.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage any components while working around this area.
  56. Hand-tighten the 5th LH rear inner bolt that attaches the HV battery to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift up the rear main carpet for access.
  57. Hand-tighten the 4th LH inner bolt that attaches the HV battery to the body.
  58. Partially close, but do not latch, the LH rear door.
  59. Open the LH front door.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage any components while working around this area.
  60. If the HV battery was retrofitted with a harness type DC input or is of the busbar type DC input, the 3rd LH inner bolt is no longer needed.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Under these conditions, do not install the 3rd LH inner HV battery bolt.
  61. Hand-tighten the LH front inner bolts (x2) that attach the HV battery to the body.
  62. Partially close, but do not latch, the LH front door.
  63. Open the RH rear door.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage any components while working around this area.
  64. Hand-tighten the 5th RH rear inner bolt that attaches the HV battery to the body.
  65. Hand-tighten the 4th RH inner bolt that attaches the HV battery to the body, if equipped.
  66. Partially close, but do not latch, the RH rear door.
  67. Open the RH front door.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage any components while working around this area.
  68. If the HV battery was retrofitted with a harness type DC input or is of the busbar type DC input, the 3rd RH inner bolt is no longer needed.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Under these conditions, do not install the 3rd RH inner HV battery bolt.
  69. Hand-tighten the RH front inner bolts (x2) that attach the HV battery to the body.
  70. Partially close, but do not latch, the RH front door.
  71. With an assistant, lower the vehicle onto the HV battery completely.
  72. Torque the LH and RH bolts (x16) that attach the HV battery to the vehicle.
    35 Nm (25.8 lbs-ft)
  73. Torque the bolts (x4) that attach the front of the HV battery to the vehicle.
    30 Nm (22.1 lbs-ft)
  74. Torque the front center bolt that attaches the HV battery to the vehicle.
    10 Nm (7.4 lbs-ft)
  75. Torque the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
    110 Nm (81.1 lbs-ft)
  76. Tighten the bolts (x4) that attach the center portion of the HV battery through the center ski cover.
    34 Nm (25.1 lbs-ft)
  77. With an assistant, raise the vehicle, and then remove the battery table from underneath the vehicle. Set the vehicle to a comfortable working height.
  78. Remove the smaller bolts (x2) and the larger bolt that are used to attach the LH shear plate to the vehicle.
  79. Install the LH shear plate, and then install the smaller bolts (x2) that attach the shear plate to the HV battery.
    35 Nm (25.8 lbs-ft)
  80. Install the larger bolt that attaches the shear plate to the vehicle, and then mark the bolt with a paint pen.
    130 Nm (95.9 lbs-ft)
  81. Fasten the fir tree clips that attach the coolant hoses to the LH shear plate.
  82. Repeat steps 78 through 81 for the RH shear plate.
  83. Fully raise the handle on the HV battery rear drive unit connector of the rear drive unit to HV battery harness.
  84. Install the HV connector special tool onto the HV battery rear drive unit connector.
  85. Use both hands to firmly connect the HV battery rear drive unit connector of the rear drive unit to HV battery harness to the HV battery header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  86. Remove the HV connector special tool from the HV battery rear drive unit connector.
  87. While pressing the HV battery rear drive unit connector onto the HV battery header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  88. Slide the release to lock the HV battery rear drive unit connector handle in the secured position.
  89. Verify that the HV battery rear drive unit connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and rear drive unit problems later on.
  90. Install the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
    10 Nm (7.4 lbs-ft)
  91. Position the coolant drain under the rear RH side of the HV battery.
  92. Remove the plugs from the coolant outlet hose and the powertrain return hose, immediately connect the male and female fittings, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  93. Position the coolant drain under the rear LH side of the HV battery.
  94. Remove the plugs from the rear drive unit inverter inlet hose and the LH underside of the ancillary bay, immediately connect the male and female fittings, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  95. Remove the coolant drain container from underneath the vehicle.
  96. Install the rear HV battery skid plate, but only hand-tighten the fasteners. See Skid Plate - HV Battery - Rear (Remove and Replace).
  97. Torque the fasteners that attach the rear skid plate to the vehicle. See Skid Plate - HV Battery - Rear (Remove and Replace).
  98. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  99. Position the coolant drain under the front LH side of the HV battery.
  100. Remove the plugs from the chiller to HV battery hose and the manifold at the LH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  101. Fasten the clips that attach the chiller to HV battery hose to the body.
  102. Remove the plugs from the HV battery return hose at the LH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  103. Position the coolant drain under the front RH side of the HV battery.
  104. Remove the plugs from the rear powertrain supply hose at the RH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  105. Remove the plugs from the powertrain return hose at the RH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  106. Remove the coolant drain from underneath the vehicle.
  107. Install the bolt that attaches the ground strap to the HV battery
    10 Nm (7.4 lbs-ft)
  108. Install the clip that attaches the front drive unit ground strap to the front drive unit.
  109. Install the bolt that attaches the ground strap to the front drive unit.
    6 Nm (4.4 lbs-ft)
  110. Fully raise the handle on the front drive unit HV connector of the front drive unit to HV battery harness.
  111. Install the HV connector special tool onto the front drive unit HV connector.
  112. Use both hands to firmly connect the front drive unit HV connector of the front drive unit to HV battery harness to the front drive unit HV header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  113. Remove the HV connector special tool from the front drive unit HV connector.
  114. While pressing the front drive unit HV connector onto the front drive unit HV header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  115. Slide the release to lock the front drive unit HV connector handle in the secured position.
  116. Verify that the front drive unit HV connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and front drive unit problems later on.
  117. Install the bolt that attaches the front drive unit HV harness to the front drive unit.
    10 Nm (7.4 lbs-ft)
  118. If not already present, apply abrasion tape to the harness towards the A/C HV connector, and then connect the A/C HV connector.
  119. If not already present, apply abrasion tape to the harness towards the PTC HV connector, connect the connector, and then install the harnesses to the bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    The PTC heater HV connector is only for vehicles without a heat pump. For vehicle with a heat pump, skip to the next step.
  120. Install the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  121. Remove the bungee straps from the LH and RH wheel arch liners.
  122. Fasten the clips along the bottom edge of the LH and RH wheel arch liners.
  123. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  124. Lower the vehicle fully, and chock a wheel.
  125. Remove the lift adapters from the body, and then install the body plugs.
  126. Remove the chock, and with an assistant, push the vehicle away from the lift to a stall, and then re-chock the wheel.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Push the vehicle for a very short distance and at less than 1 MPH.
  127. Open all doors.
  128. Connect the positive 12V output cable to the DCDC passthrough, install a new nut to attach the cable, and mark the nut with a green paint pen after torque.
    9 Nm (6.6 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the rubber boot is not trapped under the cable lug or pinched between the cable lug and nut.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure the positive output cable is positioned properly and in the right direction against the plastic anti-rotation edge on the DCDC passthrough.
  129. Replace the cover on the positive 12V output cable at the DCDC passthrough, and then press down to attach the cover.
  130. Install the DCDC ground busbar. See Busbar - DCDC Ground (Remove and Replace).
  131. Install the bolts that attach the LH and RH inner 2nd row rails to the ancillary bay cover.
    24 Nm (17.7 lbs-ft)
  132. If the HV battery DC input is configured with busbars, continue to the next step, otherwise skip to step 144.
  133. Use an alcohol wipe to clean the charge port busbar connector lead contact surfaces of residual Penetrox, and allow at least one minute to dry.
  134. Use an alcohol wipe to clean the DC input HV header terminal contact surfaces of residual Penetrox, and allow at least one minute to dry.
  135. Apply two small drops of Penetrox onto each DC input HV header terminal contact surface.
  136. Install the charge port busbar connector onto the DC input HV header, and then install the bolts (x2) that attach the connector to the header.
    9 Nm (6.6 lbs-ft)
  137. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances. See Resistance Meter (Zero Adjust).
  138. Put on the HV insulating gloves and leather over gloves.
  139. Use the Hioki resistance meter to measure the resistance between the charge port busbar connector lead and the DC input HV header bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
  140. Repeat step 139 for the other charge port busbar connector lead and DC input HV header bolt head.
  141. Remove the HV insulating gloves and leather over gloves.
  142. Install the bolt that secures the charge port busbar connector access door.
    9 Nm (6.6 lbs-ft)
  143. Skip to step 149.
  144. Fully raise the handle on the DC input connector of the charge port to HV battery harness.
  145. Use both hands to firmly connect the DC input connector of the charge port to HV battery harness to the ancillary bay DC input header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly.
  146. While pressing the DC input connector onto the DC input header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  147. Slide the release to lock the DC input connector handle in the secured position.
  148. Verify that the connector is fully seated, and compare both sides of the connector, that it is properly latched in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and charging problems later on.
  149. If the charge port to HV battery harness has a 3-phase connector, continue to the next step, otherwise skip to step 155.
  150. Fully raise the handle on the 3-phase connector of the charge port to HV battery harness.
  151. Use both hands to firmly connect the 3-phase connector of the charge port to HV battery harness to the ancillary bay 3-phase header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly.
  152. While pressing the 3-phase connector onto the 3-phase header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  153. Slide the release to lock the 3-phase connector handle in the secured position.
  154. Verify that the connector is fully seated, and compare both sides of the connector, that it is properly latched in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and charging problems later on.
  155. Install the clip that attaches the charge port to HV harness connector to the LH lower C-pillar.
  156. Install the harness clips, and then the bolts that attach the charge port to HV battery harness bracket at the ancillary bay.
    10 Nm (7.4 lbs-ft)
  157. Install the HV cap that covers the HV harness located on the LH side of the ancillary bay.
  158. Connect 12V power. See 12V/LV Power (Disconnect and Connect).
  159. Connect an LV maintainer to the vehicle, but do not disconnect the LV battery. See LV Maintainer (Connect and Disconnect).
    Informational PurposesAn informational icon, calling your attention
    Note
    On 12V lead acid batteries, connect the 12V maintainer to the lead acid battery terminals.
  160. Shift into Park to release the Electronic Parking Brake service mode, and then remove the wheel chock.
  161. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  162. Enable Service Mode Plus. See Service Mode Plus.
  163. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  164. On the vehicle touchscreen, touch Lightning Bolt icon > Procedures.
  165. Under High-Voltage-Battery, touch High Voltage Battery Replacement.
  166. Under After High Voltage Battery Replacement, touch CAN ECU Redeploy, and then in the window that opens, touch Run.
  167. Under After High Voltage Battery Replacement, touch High Voltage Battery Replacement Routine, and then in the window that opens, touch Run.
  168. Disable Service Mode Plus. See Service Mode Plus.
  169. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  170. Disconnect the 12V/LV battery maintainer.
  171. Tighten the 5th LH rear inner bolt that attaches the HV battery to the body.
    66 Nm (48.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift up the rear main carpet for access.
  172. Tighten the 4th LH inner bolt that attaches the HV battery to the body.
    66 Nm (48.7 lbs-ft)
  173. Unfold the carpet back to its original position.
  174. Move the driver seat fully rearwards.
  175. Only if the HV battery is the older type having an original harness type DC input, should you install and tighten the 3rd LH inner HV battery bolt.
    66 Nm (48.7 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not install a bolt if the HV battery has a retrofitted harness type DC input or a busbar type DC input.
  176. Tighten the LH front inner HV battery bolts (x2) that attach the HV battery to the body.
    136 Nm (100.3 lbs-ft)
  177. Unfold the LH front main carpet back to its original position; move the front edge down and slide back the section up to ease positioning. Install the seat electrical harness into the clip.
  178. Install the clips (x3) that attach the LH front carpet to the vehicle.
  179. Move the driver seat fully forwards.
  180. Tighten the 5th RH rear inner bolt that attaches the HV battery to the body.
    66 Nm (48.7 lbs-ft)
  181. Tighten the 4th RH inner bolt that attaches the HV battery to the body, if equipped.
    66 Nm (48.7 lbs-ft)
  182. Unfold the RH side of the rear carpet back to its original position.
  183. Move the front passenger seat fully rearward.
  184. Only if the HV battery is the older type having an original harness type DC input, should you install and tighten the 3rd RH inner HV battery bolt.
    66 Nm (48.7 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not install a bolt if the HV battery has a retrofitted harness type DC input or a busbar type DC input.
  185. Tighten the RH front inner bolts (x2) that attach the HV battery to the body.
    136 Nm (100.3 lbs-ft)
  186. Unfold the RH front main carpet back to its original position; move the front edge down and slide back the section up to ease positioning. Install the seat electrical harness into the clip.
  187. Install the clips (x4) that attach the RH front carpet to the vehicle.
  188. Move the front passenger seat fully forward.
  189. Install the clips (x4) and hook-and-loop strips that attach the rear carpet to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    The number of clips on newer vehicles might vary.
  190. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  191. Install the 2nd row floor mat inside the vehicle.
  192. Install the RH center console side panel carpet. See Side Panel - Center Console - LH (Remove and Replace).
  193. Install the RH front floor mat.
  194. Install the front passenger footwell cover. See Cover - Footwell - Passenger (LHD) (Remove and Replace).
  195. Install the RH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  196. Install the RH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  197. Install the RH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  198. Install the LH center console side panel carpet. See Side Panel - Center Console - LH (Remove and Replace).
  199. Install the LH front floor mat.
  200. Install the driver footwell cover. See Cover - Footwell - Driver (Remove and Replace).
  201. Install the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  202. Install the LH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  203. Install the LH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  204. Restore the driver and front passenger seats back to their original position.
  205. Install the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  206. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  207. Close the hood and all four doors.
  208. Install the LH and RH lower rocker panel covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).