Harness - HVAC Assembly (Remove and Replace)

This procedure requires refrigerant evacuation and recharge, please add specific evacuation and recharge correction code as needed

Note

18200102,18033302,18033305,18200122**Always use this Step ID**

Set up AC machine

Note

Touch time only, Connect to power, Turn power switch on

Open LH front door

Lower LH front window

Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODEvia Toolbox: (link)

Access Thermal System routines using UI

Note

Select Service mode > Thermal

Run ODIN routine PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-REFRIGERANTvia Toolbox: (link)

Raise and support vehicle

Open hood

Note

Press "Open" button on touchscreen to release latch, Lift lid manually

Remove rear apron

Note

12x clips, Only store rear apron visible face upwards

Remove cabin intake upper duct assembly

Note

3x clips, Some configurations may come with 4x clips

Remove closeout panel from frunk assembly

Note

4x clips, 1x connector, Frunk safety switch, 3x guide tabs, Grab closeout panel from bottom then pull it upward to release clips, Disconnect switch

Remove bolts securing frunk assembly

Note

7x bolts, 10mm, 5 Nm

Remove frunk assembly from vehicle

Note

12x clips, Replace any clips if broken or missing, Number of clips may vary on older vehicles

Remove RH wiper arm nut cover

Note

1x cover

Disconnect washer hose from RH wiper arm

Note

2x clips, 1x hose, Disconnect Y-tube fitting and release washer hose clips

Remove nut securing RH wiper arm to wiper module

Note

1x nut, 15mm, 25 Nm

Remove RH wiper arm and hose assembly from vehicle

Remove LH wiper arm nut cover

Note

1x cover

Disconnect washer hose from LH wiper arm

Note

2x clips, 1x hose, Disconnect Y-tube fitting and release washer hose clips

Remove nut securing LH wiper arm to wiper module

Note

1x nut, 15mm, 25 Nm

Remove LH wiper arm and hose assembly from vehicle

Flip LH shock tower cover

Note

1x push clip, Remove the clip and flip the cover following the arrow.

Flip RH shock tower cover

Note

1x push clip , Remove the clip and flip the cover following the arrow.

Release cowl screen from windshield and remove from vehicle

Note

2x push clips, 6x clips

Remove fresh air intake assembly

Note

2x studs, Lift cowl as needed

Remove bolts securing wiper module

Note

3x bolts, 10mm, 7 Nm

Disconnect wiper module harness

Note

1x connector, Do NOT place limbs within the linkage movement area as wiper arms will automatically transition to parking mode

Remove wiper module from vehicle

Release harness clip from LH side of washer tank inlet

Note

1x clip

Remove LH front wheel center cap

Note

1x cap

Loosen LH front wheel

Note

5x nuts, 21mm, 175 Nm

Raise vehicle partially 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

Remove LH front wheel

Note

5x nuts, 21mm, 175 Nm

Partially remove LH front wheel liner

Note

6x clips, 1x bolt, 10mm, 5 Nm, Newer vehicles may be equipped with 2x push clips securing lower portion of liner to body

Remove lower bolt securing washer tank to vehicle

Note

1x bolt, 10mm, 3 Nm

Partially install LH front wheel liner

Note

2x clips, Partially install LH front wheel liner, Wheel liner will be removed again later, Install 2 clips to secure LH front wheel liner

Install LH front wheel

Note

5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool, Torque at later step

Lower vehicle until tires are touching ground

Note

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

Remove upper bolt securing washer tank to vehicle

Note

1x bolt, 10mm, 3 Nm

Disconnect washer pump and level sensor connectors

Note

2x connectors

Remove washer tank from vehicle

Note

2x connectors，Keep washer tank upright to keep contents from spilling

Remove vehicle from lift

Note

Recommend assistance to push the vehicle backward, Note this vehicle can only be safely pushed for a very short distance and at very slow speed

Run ODIN routine PROC_EPB_X_SERVICE-MODE-STARTvia Toolbox: (link)

Push vehicle away from lift

Note

Recommend assistance, Place wheel chocks to keep vehicle from moving, Note this vehicle can only be safely pushed for a very short distance and at very slow speed

Open all four doors

Note

If vehicle is being powered down, Latch rear doors to prevent accidental closure

Lower all four windows

Remove caps from low side and high side A/C ports

Note

2x caps

Connect AC hoses to vehicle

Perform refrigerant system recovery

Note

Note or print the amount of refrigerant and oil recovered, If drained oil level increased more than 1.01 oz (30 mL) refer to drained oil loss chart https://toolbox.teslamotors.com/articles/353700

Move LH front seat forward

Remove console lower rear panel

Note

5x clips, Insert the plastic trim tool with a 90 degree bend at the bottom of the cover and pull straight out to release

Remove rear bolts securing center console to vehicle

Note

2x bolts, 10mm, 7 Nm

Move LH front seat backward

Remove LH front floor mat

Remove LH console side panel carpet

Note

10x clips, 1x tab, Use trim tool starting at rear edge to release upper clips, then pull bottom to release remaining clips, replace any damaged clips

Remove LH front exterior bolts from center console

Note

2x bolts, 10mm, 7 Nm

Move RH front seat forward

Remove RH rear exterior bolt from center console

Note

Delete step

Move RH front seat backward and seat back downward

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, replace any damaged clips

Remove RH front exterior bolts from center console

Note

2x bolts, 10mm, 7 Nm

Power off vehicle from center display

Note

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

Disconnect 12V negative terminal

Note

1x nut, 10mm, 6 Nm, Ensure vehicle is in park, Climate control system is off, and vehicle is not charging before disconnecting 12V

Disconnect first responder loop

Note

1x connector, Release locking tab

Remove AC hoses from vehicle

Release vacuum from AC lines

Note

2x Schrader valves, Carefully depress the schrader valves to release vacuum from AC lines

Disconnect harness from rear of center console

Note

1x connector

Disconnect USB harness at RH of center console

Note

1x connector

Remove center console from vehicle

Note

Recommend assistance, Tilt rear of console upward, pull assembly towards rear of vehicle, then tilt front of console upward and remove through passenger side

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 LH air wave bezel cap from main decor assembly

Note

2x clips, Newer vehicles are equipped with solid bezel.

Remove LH upper A-pillar trim

Note

3x clips, Pull inside of the upper portion of upper A-pillar, Remove 3x tether hooks by twisting and pulling away from housing, Then pull upper 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 outward to release front tabs from carpet

Release LH footwell cover

Note

2x push clips, 1x screw, T20, 2.5 Nm

Remove LH footwell cover

Note

3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles have an additional OBDII connector that will have to be disconnected

Release driver knee air bag from vehicle

Note

1x push clip, 2x screws, T20, 2 Nm, 4x patch bolts, T30, 8 Nm, Newer vehicles have 4x patch bolts, E10, Discard after removal, Support the knee air bag while lowering, The connector / harness length is very short

Remove driver knee air bag from vehicle

Note

1x connector, Release locking tabs, Then release squib from air bag, Support air bag while disconnecting, Connector release may vary

Remove LH footwell duct from HVAC module

Note

1x push clip

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 RH air wave bezel cap from main decor assembly

Note

2x clips, Newer vehicles are equipped with solid bezel.

Remove RH upper A-pillar trim

Note

3x clips, Pull inside of the upper portion of upper A-pillar, Remove 3x tether hooks by twisting and pulling away from housing, Then pull upper A-pillar upward to remove

Remove clip from 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 backward to release front tabs from carpet

Release RH footwell assembly from IP

Note

4x push clips

Remove RH footwell assembly

Note

2x connectors

Remove bolts securing passenger knee air bag onto vehicle

Note

4x patch bolts, T30, 8 Nm, Discard after removal, 2x screws, T20, 2 Nm, 1x push clip, Newer vehicles have 4x E10 patch bolts

Remove passenger knee air bag from vehicle

Note

1x connector, Release locking tab, Connector release may vary

Remove main decor assembly

Note

15x clips, Entire decor does not need to come off for glove box removal, If you lift RH side of decor then you will have access to 3x torx screws securing top of glove box, Replace securing clips as needed

Disconnect glove box USB cable from car computer

Note

1x connector, Depress latch on top of USB cable to release internal latches, Then release from car computer

Remove screws securing glove box assembly to IP carrier

Note

6x screws, T20, 2.3 Nm

Remove glove box from IP carrier

Note

3x clips

Disconnect glove box assembly connectors

Note

3x electrical connectors

Remove passenger footwell air duct

Note

1x push clip

Disconnect RH upper duct thermistor from RH IP air wave duct

Note

1x connector

Remove RH IP air wave duct

Note

2x push clips

Release driver air bag assembly away from steering wheel

Note

2x spring clips, 3x datums, Press the spring simultaneously from two access holes to release, Access holes located at 4 and 8 o’clock position, Do not insert tool too far as air bag connector could be damaged

Remove driver air bag assembly

Note

1x connector

Disconnect steering wheel

Note

1x connector

Release steering wheel from steering column

Note

1x patch bolt, 10mm hex, 80 Nm, Discard after removal, Counter hold the steering wheel when breaking bolt loose

Remove steering wheel from steering column

Note

Mark position of steering wheel

Release steering column upper shroud from lower shroud

Note

4x clips, Pull upward to release steering column upper shroud from lower shroud

Release lower shroud from steering column

Note

3x screws, T20, 1.5 Nm

Remove lower screw securing lower shroud to steering column

Note

1x screw, T20, 1.5 Nm

Remove lower shroud from steering column

Remove SCCM from steering column

Note

1x bolt, 5mm allen, 9 Nm

Disconnect SCCM assembly connector

Note

1x connector, Remove retaining clip on the connector, release connector, then remove the remaining broken clip from connector, Discard retaining clip after removal, Originally installed clip is black, Replacement clip is orange

Remove SCCM from steering column

Note

1x bolt, 5mm allen, 9 Nm

Release IP service panel from IP and disconnect temperature sensor connector

Note

4x clips, 4x tabs, 1x connector

Remove bolts securing center display to IP carrier

Note

Vehicle may be equipped with either: 2x patch bolts, T30, 12 Nm or 2x patch bolts, 10mm, 16 Nm, Discard after removal, Slide towards rear of vehicle to remove

Remove bolts securing housing neck to center display and slide away from display

Note

2x bolts, T30, 3 Nm, Number of fasteners on older vehicles may vary

Remove retaining clip from display connector

Note

1x clip

Disconnect harness connector from center display

Note

1x connector

Remove center display from vehicle

Remove center display neck housing from vehicle

Remove screws securing LH side of IP brow finisher

Note

4x screws, T20, 2.3 Nm, Fastener count may vary, Older production vehicles may have 5x screws

Remove screws securing RH side of IP brow finisher

Note

4x screws, T20, 2.3 Nm, Fastener count may vary, Older production vehicles may have 5x screws

Remove IP brow finisher from vehicle

Note

16x clips, Need to lift top pad up slightly to insert trim tool and release clips, Then slide IP brow finisher towards rear of vehicle

Pull RH side of RH air duct out and release from IP

Note

1x screw, T20, 2.3 Nm

Disconnect harness connector from RH air duct and remove duct

Note

1x connector

Pull LH side of LH air duct out and release from IP

Note

1x screw, T20, 2.3 Nm

Disconnect harness connector from LH air duct and remove duct

Note

1x connector

Release clips securing defroster grill

Note

8x clips, Replace any damaged clips

Pivot rear edge of defroster grill up and release tabs from IP

Note

6x tabs

Remove screws securing LH speaker to IP and remove speaker

Note

3x screws, T20, 2.3 Nm, 1x connector

Remove screws securing center speaker to IP and remove speaker

Note

1x connector, 3x screws, T20, 2.3 Nm

Remove screws securing center tweeter to IP and remove speaker

Note

1x connector, 2x screws, T20, 2.3 Nm, Discard tweeter and screws after removal

Remove screws securing RH speaker to IP and remove speaker

Note

3x screws, T20, 2.3 Nm, 1x connector

Disconnect connectors for passenger air bag assembly

Note

3x connectors, 2x connectors for regions other than North America, Connector release may vary

Remove bolts securing passenger air bag assembly to cross car beam

Note

4x patch bolts, T30, 8 Nm, Newer vehicles have 4x E10 patch bolts, Discard after removal

Remove screws securing IP carrier to cross car beam near passenger air bag

Note

2x screws, T20, 2.3 Nm

Remove screws securing IP carrier to cross car beam on lower LH side

Note

2x screws, T20, 2.3 Nm

Remove screw securing IP carrier to cross car beam on upper LH side

Note

1x screw, T20, 2.3 Nm

Remove screws securing IP carrier to cross car beam at lower center

Note

2x screws, T20, 2.3 Nm

Remove screws securing IP carrier to cross car beam at upper center

Note

2x screws, T20, 2.3 Nm

Remove screw securing IP carrier to cross car beam on upper RH side

Note

1x screw, T20, 2.3 Nm

Remove IP carrier from cross car beam

Note

Recommend assistance. Be cautious to clear the harness clipped at top center of HVAC assembly, This will also ease removal, Remove IP carrier through passenger front door

Remove screws securing driver air wave duct to cross car beam

Note

2x scews, T20, 2.3 Nm

Disconnect LH upper duct thermistor from drivers air wave duct

Note

1x connector

Remove driver air wave duct from HVAC assembly

Remove headliner harness clips on LH lower a-pillar

Note

2x clips

Disconnect headliner harness connector from LH lower a-pillar

Note

1x connector

Disconnect the dash connector from the left body controller

Note

1x connector, Release locking tab and gently pull down to release connector

Disconnect HVAC connector from left body controller

Note

1x connector

Disconnect IP harness connector from electronic steering column

Note

1x connector

Release IP harness clip located on blower motor assembly

Note

1x harness clip

Disconnect blower motor connector

Note

1x connector

Release clip securing center speaker harness to HVAC assembly

Note

1x clip

Disconnect connector from restraint control module

Note

1x connector, Disengage locking tab to release lever

Remove IP harness clips from body

Note

4x clips

Release IP harness clip next to RH duct thermistor

Note

1x harness clip

Release IP harness clip next to RH upper mode actuator

Note

1x harness clip

Release HVAC harness from IP harness holding mount on RH side of IP harness.

Note

3x harness holding mounts

Disconnect IP harness connectors from car computer

Note

2x connectors, Non EU vehicles have 3x connectors

Disconnect dash harness connector from right body controller

Note

1x connector

Release clip from RH side of cross car beam

Note

1x harness clip

Disconnect IP harness connectors from RH controller area

Note

3x connectors

Remove LH center display bracket

Note

2x bolts, T30, 12 Nm

Remove RH center display bracket

Note

2x bolts, T30, 12 Nm

Remove bleeder duct adapter from HVAC assembly

Note

4x clips

Remove nuts securing steering column to cross car beam and carefully lower steering column

Note

4x nuts, 13mm, 15 Nm

Remove bolts securing cross car beam to LH side of bulkhead

Note

2x bolts, 13mm, 25 Nm

Remove bolt securing LH cross car beam bracket to cross beam

Note

1x bolt, 13mm, 25 Nm

Remove nut securing LH cross car beam bracket to body

Note

1x nut, 13mm, 25 Nm

Remove LH cross car beam bracket from vehicle

Remove clips securing LH front main carpet to vehicle

Note

3x clips, Number of clips on new vehicles may vary

Remove bolt securing RH cross car beam bracket to cross beam

Note

1x bolt, 13mm, 25 Nm

Remove nut securing RH cross car beam bracket to body

Note

1x nut, 13mm, 25 Nm

Remove RH cross car beam bracket from vehicle

Remove clip securing RH front main carpet to cross car beam

Note

1 clip

Remove bolts securing cross car beam to HVAC assembly

Note

4x bolts, 10mm, 5.5 Nm

Remove bolt securing cross car beam to HVAC assembly

Note

1x bolt, 10mm, 5.5 Nm

Loosen bolt securing cross car beam to upper cowl

Note

1x bolt, 13mm, 25 Nm

Remove bolts securing LH cross car beam to body

Note

2x bolts, 15mm, 29 Nm

Remove the bolts securing the RH cross car beam to body

Note

2x bolts, 15mm, 29 Nm

Remove cross car beam from vehicle

Note

Recommend assistance, Use caution not to damage the interior

Lift LH front main carpet towards LH front seat

Disconnect HVAC harness connector from right body controller

Note

1x connector

Remove AC manifold to HVAC line from HVAC assembly

Note

2x bolts, 13mm, 22 Nm

Remove bolt securing HVAC assembly to RH side of bulkhead

Note

1x bolt, 10mm, 5.5 Nm, Recommend assistance to support HVAC assembly during removal

Remove main floor duct from HVAC assembly and set aside

Note

Use a bungee cord as needed to secure floor duct

Remove HVAC assembly from vehicle

Note

Recommend assistance, Rotate HVAC assembly counter clockwise and remove out of RH front door

Disconnect intake actuator connector

Note

1x connector

Disconnect upper mode actuator connector

Note

1x connector

Disconnect RH lower duct thermistor connector

Note

1x connector

Disconnect lower mode actuator connector

Note

1x connector

Disconnect RH bleed actuator connector

Note

1x connector

Disconnect LH bleed actuator connector

Note

1x connector

Disconnect LH evaporator thermistor connector

Note

1x connector

Disconnect LH lower duct thermistor connector

Note

1x connector

Remove bolts securing LH bleed actuator to HVAC assembly

Note

2x bolts, 6mm, 2.3 Nm

Remove bolts securing RH bleed actuator to HVAC assembly

Note

2x bolts, 6mm, 2.3 Nm

Release clips on RH side of HVAC assembly

Note

3x clips

Release HVAC harness from RH holding tabs

Note

3x holding tabs

Release HVAC harness from upper holding tabs

Note

2x holding tabs

Release HVAC harness from LH holding tabs and remove HVAC harness from HVAC assembly

Note

4x holding tabs

Position HVAC harness onto HVAC assembly and connect LH evaporator thermistor

Note

1x connector

Connect LH lower duct thermistor connector

Note

1x connector

Install HVAC harness into LH holding tabs

Note

4x holding tabs

Install HVAC harness into upper holding tabs

Note

2x holding tabs

Install clips on RH side of HVAC assembly

Note

3x clips

Install HVAC harness into RH holding tabs

Note

3x holding tabs

Connect lower mode actuator connector

Note

1x connector

Connect upper mode actuator connector

Note

1x connector

Connect intake actuator connector

Note

1x connector

Connect RH lower duct thermistor connector

Note

1x connector

Install bolts securing LH bleed actuator to HVAC assembly

Note

2x bolts, 6mm, 2.3 Nm

Install bolts securing RH bleed actuator to HVAC assembly

Note

2x bolts, 6mm, 2.3 Nm

Connect RH bleed actuator connector

Note

1x connector

Connect LH bleed actuator connector

Note

1x connector

Position HVAC assembly into vehicle for installation

Note

Recommend assistance, Install HVAC assembly through RH front door, Rotate HVAC assembly clockwise for installation

Install bolt securing HVAC assembly to RH side of bulkhead

Note

1x bolt, 10mm, 5.5 Nm

Install main floor duct to HVAC assembly

Replace seal washers on supermanifold to HVAC AC line assembly on HVAC side

Note

5x seal washers, Install new seal washers, Lube seal washers with ND-11 oil

Install supermanifold to HVAC AC line assembly to HVAC assembly

Note

2x bolts, 13 mm, 22 Nm

Reconnect AC hoses to vehicle

Perform system vacuum and refrigerant refill

Note

Select 20 mins of Vacuum, Recharge refrigerant to car's specs, select both HP and LP for charging, add oil quantity as needed, If drained oil level increased more than 1.01 oz (30 mL) refer to drained oil loss chart article 353700

Connect HVAC harness connector to right body controller

Note

1x connector

Install LH front main carpet into position for installation

Position cross car beam to vehicle for installation

Note

Recommend assistance, Use caution not to damage the interior

Loosely install bolts securing RH cross car beam to body

Note

2x bolts, 15mm, 29 Nm, Torque at later step

Loosely install bolts securing LH cross car beam to body

Note

2x bolts, 15mm, 29 Nm, Torque at later step

Loosely install bolt securing cross car beam to upper cowl

Note

1x bolt, 13mm, 25 Nm

Loosely install bolt securing cross car beam to HVAC assembly

Note

1x bolt, 10mm, 5.5 Nm, Torque at later step

Loosely install bolts securing cross car beam to HVAC assembly

Note

4x bolts, 10mm, 5.5 Nm, Torque at later step

Position RH cross car beam bracket to vehicle for installation

Loosely install nut securing RH cross car beam bracket to body

Note

1x nut, 13mm, 25 Nm, Torque at later step

Loosely install bolt securing RH cross car beam bracket to cross car beam

Note

1x bolt, 13mm, 25 Nm, Torque at later step

Position LH cross car beam bracket to vehicle for installation

Loosely Install nut securing LH cross car beam bracket to body

Note

1x nut, 13mm, 25 Nm, Torque at later step

Loosely install bolt securing cross car beam to LH cross car beam bracket

Note

1x bolt, 13mm, 25 Nm, Torque at later step

Install bolts securing cross car beam to LH side of bulkhead

Note

2x bolts, 13mm, 25 Nm

Torque bolt securing cross car beam to upper cowl

Note

1x bolts, 13mm, 25 Nm

Torque bolt securing cross car beam to HVAC assembly

Note

1x bolts, 10mm, 5.5 Nm

Torque bolts securing cross car beam to HVAC module

Note

4x bolts, 10mm, 5.5 Nm

Torque bolts securing the LH cross car beam to body

Note

2x bolts, 15mm, 29 Nm

Torque bolts securing RH cross car beam to body

Note

2x bolts, 15mm, 29 Nm

Torque the nut securing the RH cross car beam bracket to body

Note

1x nut, 13mm, 25 Nm

Torque bolt securing RH cross car beam bracket to cross car beam

Note

1x bolt, 13mm, 25 Nm

Install clip securing RH front main carpet to cross car beam

Note

1x clip

Torque nut securing LH cross car beam bracket to vehicle

Note

1x nut, 13mm, 25 Nm

Torque bolt securing LH cross car beam bracket to cross car beam

Note

1x bolt, 13mm, 25 Nm

Install clips securing LH front main cabin carpet to vehicle

Note

3x push clips, Number of clips on newer vehicles may vary

Position steering column for installation

Install nuts securing steering column to cross car beam

Note

4x nuts, 13mm, 15 Nm

Install bleeder duct adapter to HVAC

Note

4x clips

Install RH center display bracket

Note

2x bolts, T30, 12 Nm

Install LH center display bracket

Note

2x bolts, T30, 12 Nm

Install clip located on RH side of cross car beam

Connect IP harness connectors to RH controller area

Note

3x connector

Install dash harness connector to right body controller

Note

1x connector

Connect IP harness connectors to car computer

Note

2x connectors

Secure HVAC harness to IP harness

Note

3x harness holders

Install IP harness clip to HVAC assembly next to RH upper mode actuator

Note

1x clip

Install IP harness clip to HVAC assembly next to RH lower duct thermistor

Note

1x clip

Install IP harness clips to body

Note

4x harness clips

Connect IP harness connector to restrain control module

Note

1x connector, Engage locking tab

Install clip securing center speaker harness to HVAC assembly

Note

1x clip

Connect blower motor connector

Note

1x connector

Install blower motor harness clip to HVAC assembly

Note

1x clip

Connect IP harness connector to electronic steering column

Note

1x connector

Connect HVAC connector to left body controller

Note

1x connector

Connect dash connector to left body controller

Note

1x connector, Fully seat connector and pull release tab into locking position

Install headliner harness clips to lower a-pillar

Note

2x clips

Connect headliner harness connector

Note

1x connector

Install driver air wave duct into HVAC assembly

Connect LH upper duct thermistor to driver air wave duct

Note

1x connector

Install screws securing driver air wave duct to cross car beam

Note

2x screws, T20, 2.3 Nm

Install IP carrier onto cross car beam

Note

4x mounting tabs, Recommend assistance, Slide mounting tabs on IP carrier into brackets on vehicle, Be cautious to clear the harness clipped at top center of HVAC assembly, This will also ease installation

Install screw securing IP carrier to cross car beam on upper RH side

Note

1x screw, T20, 2.3 Nm

Install screws securing IP carrier to cross car beam at upper center

Note

2x screws, T20, 2.3 Nm

Install screws securing IP carrier to cross car beam at lower center

Note

2x screws, T20, 2.3 Nm

Install screw securing IP carrier to cross car beam on upper LH side

Note

1x screw, T20, 2.3 Nm

Install screws securing IP carrier to cross car beam on lower LH side

Note

2x screws, T20, 2.3 Nm

Install screws securing IP carrier to cross car beam near passenger air bag

Note

2x screws, T20, 2.3 Nm

Install bolts securing passenger air bag assembly to cross car beam

Note

4x patch bolts, E10, 8 Nm, Install new patch bolts

Install connectors for passenger air bag

Note

3x connectors, 2x connectors for regions other than North America

Install RH speaker to IP carrier

Note

1x connector, 3x screws, T20, 2.3 Nm

Install center tweeter to IP carrier

Note

1x connector, 2x screws, T20, 2.3 Nm

Install center speaker to IP

Note

3x screws, T20, 2.3 Nm, 1x connector

Install LH speaker to IP carrier

Note

3x screws, T20, 2.3 Nm, 1x connector

Position defroster grill and lower tabs into position on IP

Note

6x tabs

Secure clips securing defroster grill

Note

8x clips

Position LH air duct into IP and connect harness connector

Note

1x connector

Install LH air duct into IP

Note

1x screw, T20, 2.3 Nm

Position RH air duct into IP and connect harness connector

Note

1x connector

Install RH air duct into IP

Note

1x screw, T20, 2.3 Nm

Install IP brow finisher into vehicle

Note

16x clips, Need to lift top pad up slightly to slide IP brow finisher into position

Install screws securing RH side of IP brow finisher

Note

4x screws, T20, 2.3 Nm, Fastener count may vary, Older production vehicles may have 5x screws

Install screws securing LH side of IP brow finisher

Note

4x screws, T20, 2.3 Nm, Fastener count may vary, Older production vehicles may have 5x screws

Install RH IP air wave duct

Note

2x push clips

Connect RH upper duct thermistor to RH IP air wave duct

Note

1x connector

Install passenger footwell air duct

Note

1x push clip

Connect glove box assembly connectors

Note

3x connectors, New puddle lamp harness routing prevent blocking movement of pawls, Make sure harness is routed properly above passenger footwell air duct before connecting

Install glove box into IP carrier

Note

3x clips

Install screws securing glove box assembly to IP carrier

Note

6x screws, T20, 2.3 Nm

Connect glove box USB cable to car computer

Note

1x connector

Install passenger knee air bag onto vehicle

Note

1x connector, Use caution not to damage connector and harness, Support knee air bag while connecting connector

Install bolts securing passenger knee air bag to vehicle

Note

4x patch bolts, E10, 8 Nm, Install new patch bolts, 2x screws, T20, 2 Nm, 1x push clip, If vehicle equipped with T30 bolts update to E10

Install RH footwell assembly onto IP

Note

4x push clips

Position center display neck housing into vehicle

Position center display into vehicle

Connect center display

Note

1x connector

Install retaining clip to center display connector

Note

1x clip

Slide down neck housing and install bolts securing neck housing to center display

Note

2x bolts, T30, 3 Nm, Number of fasteners on older vehicles may vary

Install center display to IP carrier

Note

2x patch bolts, 10mm, 16 Nm, Install new 10mm patch bolts, Slide towards front of vehicle

Connect temperature sensor connector and install IP service panel into IP

Note

4x clips, 4x tabs, 1x connector

Install SCCM onto steering column

Note

1x bolt, 5mm allen, 9 Nm

Install SCCM onto steering column

Note

1x bolt, 5mm allen, 9 Nm

Connect SCCM assembly connector

Note

1x connector, Install new orange retaining clip to connector then install SCCM connector, Perform push-pull-push to make sure connector is seated properly

Position lower shroud onto steering column

Install lower screw securing lower shroud to steering column

Note

1x screw, T20, 1.5 Nm

Install lower shroud to steering column

Note

3x screws, T20, 1.5 Nm

Install upper shroud onto lower shroud

Note

4x clips

Position steering wheel to column

Note

Align the marking and keyed part of steering wheel and column

Secure steering wheel

Note

1x patch bolt, 10mm hex, 80 Nm, Install new patch bolt

Connect steering wheel

Note

1x connector

Position driver air bag assembly

Note

1x connector

Install driver air bag assembly to steering wheel

Note

3x datums, 2x spring clips, Inspect to make sure lower horn bracket is properly secured to steering wheel before installing driver air bag, make sure that the driver air bag harness doesn’t get caught between the driver air bag and the horn mechanism, verify air bag is fully engaged

Install main decor assembly

Note

15x clips, 1x center clip

Install LH footwell duct into HVAC module

Note

1x push clip

Position driver knee airbag

Note

1x connector, Use caution not to damage the connector/harness, Support the knee air bag while connecting the connector

Install driver knee air bag to vehicle

Note

4x patch bolts, E10, 8 Nm, Install new patch bolts, 2x screws, T20, 2 Nm, 1x push clip, If vehicle equipped with T30 bolts, update to E10

Position LH footwell cover

Note

3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles have an additional OBDII connector

Install LH footwell cover

Note

1x screw, T20, 2.5 Nm, 2x push clips

Install RH upper A-pillar trim

Note

3x clips, 1x tether, Slide bottom of trim along IP and speaker grill, attach tether to body side, Set clips starting at the bottom and work up, Pull seal over trim

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 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 air wave bezel cap to main decor assembly

Note

2x clips, Newer vehicles are equipped with solid bezel.

Install RH IP end cap

Note

3x clips

Install LH upper A-pillar trim

Note

3x clips, 1x tether, Slide bottom of trim along IP and speaker grill, attach tether to body side, Set clips starting at the bottom and work up, Pull seal over trim

Install LH lower A-pillar trim

Note

2x clips, 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 air wave bezel cap to main decor assembly

Note

2x clips, Newer vehicles are equipped with solid bezel.

Install LH IP end cap

Note

3x clips

Install center console into vehicle

Note

Recommend assistance, Tilt front of console downward, Slide assembly towards front of vehicle and tilt rear of console down into place

Connect USB harness at RH of center console

Note

1x connector

Connect harness from rear of center console

Note

1x connector

Install RH front exterior bolts to center console

Note

2x bolts, 10mm, 7 Nm

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

Install LH front exterior bolts to center console

Note

2x bolts, 10mm, 7 Nm

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

Connect first responder loop

Note

1x connector, Engage locking tab, Connect FRL before connecting 12V to avoid damage to car computer

Connect 12V negative terminal

Note

1x nut, 10mm, 6 Nm

Remove AC hoses from vehicle

Install caps onto A/C ports

Note

2x caps

Run ODIN routine PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia Toolbox: (link)via Service Mode:

Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain

via Service Mode Plus:

Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain

Run ODIN routine TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONINGvia Toolbox: (link)via Service Mode: Thermal ➜ Refrigerant System ➜ Run Heat Pump Commissioningvia Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Heatpump commissioning

Run ODIN routine TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:

Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test

Run ODIN routine TEST-SELF_VCRIGHT_X_HVAC-PERFORMANCEvia Toolbox: (link)via Service Mode:

Thermal ➜ Actions ➜ Test HVAC Performance
Thermal ➜ HVAC ➜ HVAC Performance Test
Thermal ➜ Actions ➜ Test HVAC Performance

Move RH front seat forward

Install rear exterior bolts to center console

Note

2x bolts, 10mm, 7 Nm

Move RH front seat to original position

Move LH front seat forward

Install LH rear exterior bolt to center console

Note

Delete step

Install console lower rear panel

Note

5x clips

Move LH front seat to original position

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

Press and hold park button to release EPB service mode

Note

Remove wheel chocks if necessary

Raise and support vehicle

Note

Ensure vehicle is not charging, Remove charging cable if it's plugged in

Install washer tank into position

Connect washer pump and level sensor connectors

Note

2x connectors

Install upper bolt securing washer tank to vehicle

Note

1x bolt, 10mm, 3 Nm

Secure harness clip onto LH side of washer tank inlet

Note

1x clip

Raise vehicle partially 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

Remove LH front wheel

Note

5x nuts, 21mm, 175 Nm

Partially release LH front wheel liner

Note

2x push clips

Install lower bolt securing washer tank to vehicle

Note

1x bolt, 10mm, 3 Nm

Install LH front wheel liner to vehicle

Note

6x clips, 1x bolt, 10mm, 5 Nm, Newer vehicles may be equipped with 2x push clips securing lower portion of liner to body

Install LH front wheel

Note

5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool

Lower vehicle until tires are touching ground

Note

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

Torque LH front wheel

Note

5x nuts, 21mm, 175 Nm

Install LH front wheel center cap

Note

1x cap, Verify emblem is aligned with valve stem

Install wiper module to vehicle

Connect wiper module connector

Note

1x connector, Do NOT place limbs within the linkage movement area as wiper arms will automatically transition to parking mode

Install bolts securing wiper module

Note

3x bolts, 10mm, 7 Nm

Install fresh air intake assembly

Note

2x studs, Lift cowl as needed

Install cowl screen assembly

Note

2x push clips, 6x clips

Install RH shock tower cover

Note

1x push clip, Flip back the shock tower cover then install clip.

Install LH shock tower cover

Note

1x push clip, Flip back the shock tower cover then install clip.

Install LH wiper arm and hose assembly onto vehicle

Note

Washer hose shall be routed over the arm pivot joint not under

Install nut securing LH wiper arm to wiper module

Note

1x nut, 15mm, 25 Nm, Make sure wiper tip is aligned between two indicators at windshield

Connect washer hose from LH wiper arm to Y-tube fitting and secure washer hose clips

Note

2x clips, 1x hose

Install LH wiper arm nut cover

Note

1x cover

Install RH wiper arm and hose assembly onto vehicle

Install nut securing RH wiper arm to wiper module

Note

1x nut, 15mm, 25 Nm, Make sure wiper tip is aligned between two indicators at corner of windshield

Connect washer hose from RH wiper arm

Note

2x clips, 1x hose, Connect to Y-tube fitting and secure washer hose clips

Install RH wiper arm nut cover

Note

1x cover

Install frunk assembly to vehicle

Note

12x clips, Make sure frunk assembly is fully seated onto clips, Number of clips may vary on older vehicles, Ensure A/C compressor HVIL harness is not pinched between frunk assembly and thermal beam, replace any damaged clips