11/11/2024 07:13:57
Hose - Inverter Inlet - Front Drive Unit (Heat Pump) (Remove and Replace)
Correction code 18303312 3.30 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.
- 2023-08-29: Updated EPB Service Mode reference.
- 2023-03-10: Fixed errors.
Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
Remove
-
Remove bolts securing the LH rocker
panel lower cover to body
Note4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary
-
Remove clips securing the LH rocker
panel lower cover to wheel liners
Note4x push clips
-
Remove LH rocker panel lower
cover
Note10x clips
-
Remove bolts securing the RH rocker
panel lower cover to body
Note4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary
-
Remove clips securing the RH rocker
panel lower cover to wheel liners
Note4x push clips
-
Remove RH rocker panel lower
cover
Note10x clips
-
Open all four doors
NoteIf vehicle is being powered down, Latch rear doors to prevent accidental closure
-
Lower all four windows
-
Open hood
-
Remove rear apron
Note12x clips
-
Remove cabin intake upper duct
assembly
Note3x clips, Older vehicles may be equipped with 4x clips
-
Move LH front seat backward
-
Remove LH IP end cap
Note3x clips
-
Remove LH mid A-pillar assembly
Note1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove
-
Remove clip for LH lower A-pillar
trim
Note1x push clip
-
Remove LH lower A-pillar trim
Note1x clip, 2 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet
-
Remove screw and clips securing LH
footwell cover
Note2x push clips, 1x screw, T20, 2.5 Nm
-
Remove connectors from LH footwell
cover and remove from vehicle
Note3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles an additional ODII connector will have to be disconnected
-
Remove LH front floor mat
-
Remove LH console side panel
carpet
Note12x clips, Use trim tool starting at rear edge to release upper clips, then pull bottom to release remaining clips
-
Remove clips securing LH front main
carpet to vehicle
Note3x clips, Number of clips on new vehicles may vary
-
Fold the LH front main cabin carpet
aside for access
NoteDead pedal and foam block are part of carpet, Release seat harness from clip to allow the carpet to fold back more
-
Remove LH front footwell HV battery
bolts
Note2x bolts, EP20, 136 Nm
-
Move RH front seat backward
-
Remove RH IP end cap
Note3x clips
-
Remove RH mid A-pillar assembly
Note1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove
-
Remove clip for RH lower A-pillar
trim
Note1x push clip
-
Remove RH lower A-pillar trim
Note1x clip, 2 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet
-
Remove clips securing RH footwell
assembly
Note4x push clips
-
Disconnect RH foot well assembly
connectors and remove from vehicle
Note2x electrical connectors
-
Remove RH front floor mat
-
Remove RH console side panel
carpet
Note12x clips, Use trim tool starting at rear edge to release upper clips, Pull bottom to release remaining clips
-
Remove clips securing RH front main
cabin carpet to footwell area
Note3x push clips, Number of clips may vary on older vehicles
-
Fold the RH front main cabin carpet
aside for access
Note2x clips, Lift the center piece and pull the carpet back
-
Remove RH front footwell HV battery
bolts
Note2x bolts, EP20, 136 Nm
-
Move RH front seat forward
-
Move LH front seat forward
-
Remove 2nd row floor mat from
vehicle
-
Remove 2nd row seat cushion and
disconnect harness
Note2x tabs, 2x connectors, Both connectors are located on LH side of vehicle, Press tabs to the left and release front edge of seat cushion, Slide seat buckles out from access holes
-
Fold the 40 seat in down
position
NoteProtect the seat cushion
-
Remove RH side bolster
Note1x clip, 1 tab, Pull outward then slightly upward to remove
-
Remove and discard bolster plastic
bracket from RH side
Note2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal
-
Fold the 40 seat into vertical
position
-
Remove the RH rear door sill trim
panel
Note3x clips, 1x guide tab, Pull upward at the lower corner of sill trim to release clip from lower B-pillar, then remove the remaining clips by pulling away from the body
-
Fold the 60 seat in down
position
NoteProtect the seat cushion
-
Remove LH side bolster
Note1x clip, 1 tab, Pull outward then slightly upward to remove
-
Remove and discard bolster plastic
bracket from LH side
Note2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal
-
Fold the 60 seat into vertical
position
NoteRemove seat protection
-
Remove the LH rear door sill trim
panel
Note3x clips, 1x guide tab, Pull upward at the lower corner of sill trim to release clip from lower B-pillar, then remove the remaining clips by pulling away from the body
-
Remove clips securing rear main cabin
carpet to vehicle
Note2x push clips
-
Remove LH rear HV battery inner
bolt
Note1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access
-
Remove RH rear HV battery inner
bolt
Note1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access
-
Place wheel chocks to keep vehicle
from moving
- Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
-
Power off vehicle from center
display
NoteVia Controls > Safety & Security > Vehicle Power > Power Off
-
Disconnect 12V negative terminal
Note1x nut, 10mm, 6 Nm, Ensure the vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V
-
Disconnect first responder loop
Note1x connector, Release locking tab
-
Remove all items from pockets and
ensure not wearing metal items
-
Inspect HV insulating gloves
NoteCheck gloves for damage prior to each use
-
Put on HV insulating gloves and
leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
-
Remove bolts securing ancillary bay
probe lid cover to ancillary bay cover
Note2x bolts, E10 5-Lobe, 6 Nm, Discard after removal
-
Remove ancillary bay probe lid cover
from the ancillary bay cover
-
Verify no high voltage
NoteMake sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
-
Inspect ancillary bay probe lid cover
gasket then position onto the ancillary bay cover
NoteConfirm no visual damage present. Good to reuse seal.
-
Install bolts securing ancillary bay
probe lid cover to ancillary bay cover
Note2x bolts, E10 5-Lobe, 6 Nm, Install new rubber washer bolts
-
Remove HV cap from ancillary bay
Note1x cap
-
Remove edge support bracket
Note2x bolts, 10mm, 10 Nm, 1x clip
-
Remove fastener securing busbar cover
access door
Note1x bolt, 10mm, 9 Nm
-
Remove bolts securing chargeport
busbar to HV header
Note2x bolts, 10mm, 9 Nm
-
Lift chargeport busbar connector to
remove from HV header
Note4x guide tabs, Slightly wiggle aluminum connector housing back and forth to ease removal
-
Remove bolts securing LH inner
ancillary bay rail to the ancillary bay cover
Note2x bolts, T40, 24 Nm
-
Remove bolts securing RH inner
ancillary bay rail to the ancillary bay cover
Note2x bolts, T40, 24 Nm
-
Remove 12V cap from ancillary
bay
Note1x cap
-
Disconnect HVC logic connector and
install logic cap
Note1x connector, 1x cap, Release locking tab then push the handle downward to release connector
-
Remove nut securing DCDC ground busbar
to HV battery
Note1x nyloc nut, 13mm, 9 Nm, Discard nut after removal
-
Remove bolt securing DCDC ground
busbar to body
Note1x bolt, 12mm, 20 Nm
-
Remove DCDC ground busbar
-
Remove positive 12V output cover from
PCS cable
Note1x cover
-
Remove nut securing positive 12V
output from PCS cable and move cable aside
Note1x nyloc nut, 13mm, 15 Nm, Discard nut after removal
-
Close all four doors
NoteMake sure all doors are latched to prevent accidental closure when vehicle is powered down
-
Push vehicle onto lift
NoteRecommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed
-
Raise and support vehicle
NoteRemove body plugs and install M3 lift pad adapters to indicated locations
-
Raise vehicle fully and lower lift
onto locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side, Verify doors are clear of surrounding objects
-
Remove outer fasteners securing front
aero shield
Note9x bolts, 10mm, 5 Nm
-
Remove remaining nuts and remove front
aero shield from vehicle
Note2x nuts, 15mm, 5 Nm
-
Remove the clips securing the front LH
and RH wheel liners to the front skid plate
Note2x push clips
-
Remove bolts securing front skid
plate
Note4x bolts, E10, 13 Nm
-
Remove skid plate from HV
battery
-
Remove bolt securing FDU HV harness to
the FDU
Note1x bolt, 10mm, 10 Nm
-
Disconnect the FDU HV harness
connector
Note1x clip, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the FDU header are not damaged
-
Remove the FDU HV harness connector
from the FDU and move aside
Note1x connector
-
Remove bolt securing FDU ground strap
to HV battery
Note1x bolt, 10mm, 10 Nm
-
Remove FDU ground strap harness clip
from FDU
Note1x clip
-
Disconnect both AC compressor HV
harness connectors on HV battery
Note2x locking connectors, 2 stage locking connectors, Disengage the red locking tab by pulling it away from the connector, then depress the green tab to release
-
Remove push clip securing LH front
wheel liner to LH rocker panel
Note1x push clip
-
Remove push clip securing RH front
wheel liner to RH rocker panel
Note1x push clip
-
Use bungee strap to pull back LH front
wheel liner
NoteSecure to subframe
-
Use bungee strap to pull back RH front
wheel liner
NoteSecure to subframe
-
Position coolant drain container
underneath RH front of HV battery
-
Disconnect PT return tube from FDU
inverter inlet hose
Note2x clips, 2x plugs, Lower hose located on RH front of HV battery, Plug both hose ends
-
Disconnect PT supply tube and plug
both hose ends
Note2x clips, 2x plugs, Upper hose located on RH front of HV battery
-
Position coolant drain container
underneath LH front of HV battery
-
Disconnect HV battery return tube from
HV battery hose
Note2x clips, 2x plugs, Located on LH front of HV battery
-
Position coolant drain container below
HV battery front manifold hose
-
Release HV battery front manifold hose
from body
Note1x clip
-
Disconnect HV battery front manifold
hose and plug both hose ends
Note1x spring clip, 2x plugs
-
Remove coolant drain container from
underneath vehicle
-
Remove mid aero shield
Note13x bolts, 10mm, 5 Nm
-
Release clips securing coolant hoses
to LH shear plate
Note2x fir tree clips
-
Release LH side hose clip from rear
battery skid plate enclosure
Note2x clips, Clip quantity may vary on older vehicles
-
Release RH side hose clips from rear
battery skid plate enclosure
Note2x fir tree clips
-
Release clips securing coolant hoses
to RH shear plate
Note2x fir tree clips
-
Remove lower bolts securing HV battery
rear skid plate enclosure
Note2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count
-
Remove upper nut securing HV battery
rear skid plate enclosure
Note1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles
-
Remove upper bolts securing HV battery
rear skid plate enclosure
Note4x bolts, 13mm, 35 Nm
-
Remove HV battery rear skid plate
enclosure
-
Position coolant drain container
underneath LH rear of HV battery
-
Disconnect RDU inverter inlet tube
from LH rear of HV battery
Note1x spring clip, 2x plugs, Plug HV battery and hose
-
Position coolant drain container
underneath RH rear of HV battery
-
Disconnect RDU outlet hose from PT
return tube and plug both hose ends
Note1x spring clip, 2x plugs, Lower hose located at RH rear of HV battery, Use shop towel to clean any residue coolant if necessary
-
Disconnect PT supply tube from RH rear
of HV battery
Note1x spring clip, 1x plug, Plug HV battery side and allow coolant hose to fully drain
-
Remove coolant drain container from
underneath vehicle
-
Remove RDU HV cable bracket from HV
battery
Note1x nut, 10mm, 10 Nm, Number of fasteners may vary
-
Disconnect RDU HV cable from HV
battery
Note1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
-
Support front portion of rear
subframe
-
Remove smaller fasteners securing LH
shear plate
Note2x bolts, 13mm, 35 Nm
-
Remove smaller fasteners for RH shear
plate
Note2x bolts, 13mm, 35 Nm
-
Remove large bolt securing RH shear
plate and subframe to body and remove shear plate
Note1x bolt, 21mm, 128 Nm, Discard at later step
-
Hand tighten bolt securing RH side of
subframe to body
Note1x bolt, 21mm, 128 Nm
-
Remove large bolt securing LH shear
plate and subframe to body and remove shear plate
Note1x bolt, 21mm, 128 Nm, Discard at later step
-
Hand tighten bolt securing LH side of
subframe to body
Note1x bolt, 21mm, 128 Nm
-
Remove support stand from under
vehicle
-
Place HV battery table into position
and lower vehicle to support HV battery
NoteRecommend assistance, Line up table so center 4 bolts are accessible through opening in table, Adjust final battery table position using adjustable caster jacks on table
-
Remove central bolts securing HV
battery center ski cover
Note4x bolts, EP14, 34 Nm
-
Remove bolts securing RH front support
bracket to vehicle
Note4x bolts, 16mm, 110 Nm
-
Remove bolts securing LH front support
bracket to vehicle
Note4x bolts, 16mm, 110 Nm
-
Remove LH bolts securing HV battery to
vehicle
Note8x bolts, 13mm, 35 Nm
-
Remove RH bolts securing HV battery to
vehicle
Note8x bolts, 13mm, 35 Nm
-
Raise vehicle free of HV battery
NoteRecommend assistance
-
Remove ancillary bay perimeter seal
from HV battery pack
NoteDiscard anytime HV battery is removed from vehicle
-
Remove PT supply tube from RH side of
HV battery
Note5x clips, Upper hose location, Remove plugs from each end of hose and allow coolant to fully drain if discarding
Install
-
Install PT supply tube to RH side of
HV battery
Note5x clips, Upper hose location
-
Install ancillary bay perimeter seal
onto HV battery pack
NoteThis seal is a one time use item and should be replaced each time a HV battery pack is removed from vehicle or installed onto a new HV battery pack if not equipped
-
Install HV battery alignment
rods
Note2x rods, To body at front of vehicle, 2x rods, To battery near ancillary bay
-
Lower vehicle onto HV battery and
align holes
NoteRecommend assistance, Use alignment rods, Be sure coolant hoses do not get caught on alignment rods, Caution not to damage HV cable, Do not fully lower vehicle onto battery (this will help with installing battery bolts)
-
Loosely install RH bolts securing HV
battery to vehicle hand tight
Note8x bolts, 13mm, 35 Nm
-
Loosely install LH bolts securing HV
battery to vehicle hand tight
Note8x bolts, 13mm, 35 Nm
-
Remove HV battery front alignment
rods
Note2x rods
-
Install bolts securing RH front
support bracket to vehicle hand tight
Note4x bolts, 16mm, 110 Nm, Torque at later step
-
Install bolts securing LH front
support bracket to vehicle hand tight
Note4x bolts, 16mm, 110 Nm, Torque at later step
-
Install central bolts securing HV
battery center ski cover hand tight
Note4x bolts, EP14, 34 Nm, Torque at later step
-
Open LH rear door
NoteUse caution while working around this area not to damage any components
-
Remove HV battery alignment rod from
LH rear rear HV battery interior bolt location
Note1x rod
-
Install LH rear HV battery interior
bolt hand tight
Note1x bolt, 16mm, 66 Nm, Torque at later step, Lift up LH rear main carpet for access if necessary
-
Close LH rear door
NoteDo not latch
-
Open LH front door
NoteUse caution while working around this area not to damage any components
-
Install LH front footwell HV battery
bolts hand tight
Note2x bolts, EP20, 136 Nm, Torque at later step
-
Close LH front door
NoteDo not latch
-
Open RH rear door
NoteUse caution while working around this area not to damage any components
-
Remove HV battery alignment rod from
RH rear HV battery interior bolt location
Note1x rod
-
Install RH rear HV battery interior
bolt hand tight
Note1x bolt, 16mm, 66 Nm, Torque at later step, Lift up LH rear main carpet for access if necessary
-
Close RH rear door
NoteDo not latch
-
Open RH front door
NoteUse caution while working around this area not to damage any components
-
Install RH front footwell HV battery
bolts hand tight
Note2x bolts, EP20, 136 Nm, Torque at later step
-
Close RH front door
NoteDo not latch
-
Lower vehicle onto pack
completely
NoteRecommend assistance
-
Torque RH bolts securing HV battery to
vehicle
Note8x bolts, 13mm, 35 Nm
-
Torque LH bolts securing HV battery to
vehicle
Note8x bolts, 13mm, 35 Nm
-
Torque bolts securing RH front support
bracket to vehicle
Note4x bolts, 16mm, 110 Nm
-
Torque bolts securing LH front support
bracket to vehicle
Note4x bolts, 16mm, 110 Nm
-
Torque central bolts securing HV
battery center ski cover
Note4x bolts, EP14, 34 Nm
-
Raise vehicle and lower onto locks,
then remove battery table from under vehicle
NoteRecommend assistance, Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
-
Support front portion of rear
subframe
-
Remove bolt securing LH side of rear
subframe to body
Note1x bolt, 21mm, 130 Nm, Discard after removal
-
Install bolt and shear plate to LH
side of rear subframe hand tight
Note1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
-
Install bolts securing LH shear plate
to HV battery hand tight
Note2x bolts, 13mm, 35 Nm
-
Remove bolt securing RH side of rear
subframe to body
Note1x bolt, 21mm, 130 Nm, Discard after removal
-
Install RH front bolt and shear plate
to rear subframe hand tight
Note1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
-
Install bolts securing RH shear plate
to HV battery hand tight
Note2x bolts, 13mm, 35 Nm
-
Torque bolts securing shear plates to
vehicle
Note4x bolts, 13mm, 35 Nm
-
Torque bolt securing subframe and LH
shear plate to body
Note1x front bolt, 21mm, 130 Nm, Mark bolt after torque
-
Torque bolt securing subframe and RH
shear plate to body
Note1x front bolt, 21mm, 130 Nm, Mark bolt after torque
-
Remove support stand from under
vehicle
-
Connect RDU HV cable to HV
battery
Note1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector, Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position
-
Install RDU HV cable bracket to HV
battery
Note1x nut, 10mm, 10 Nm, Number of fasteners may vary
-
Position coolant drain container
underneath RH rear of HV battery
-
Install PT supply tube to RH rear of
HV battery
Note1x spring clip, 1x plug, Remove plug from HV battery side, Perform push-pull-push test to make sure hose is fully seated
-
Remove hose plugs and connect RDU
outlet hose to PT return tube
Note1x spring clip, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged, Use shop towel to clean any coolant residue if necessary
-
Position coolant drain container
underneath LH rear of HV battery
-
Remove plugs and connect RDU inverter
inlet hose to LH rear of HV battery
Note1x spring clip, Perform push-pull-push test to make sure hose is fully engaged
-
Remove coolant drain container from
underneath vehicle
-
Position HV battery rear skid plate
enclosure onto HV battery for installation
NoteRecommend assistance if needed
-
Install upper bolts securing HV
battery rear skid plate enclosure hand tight
Note4x bolts, 13mm, 35 Nm, Torque at later step
-
Install upper nut securing HV battery
rear skid plate enclosure hand tight
Note1x nut, 10mm, 13 Nm, Torque at later step
-
Install lower bolts securing HV
battery rear skid plate enclosure
Note2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
-
Torque bolts securing HV battery rear
skid plate enclosure to vehicle
Note4x bolts, 13mm, 35 Nm
-
Torque upper nut securing HV battery
rear skid plate enclosure
Note1x nut, 10mm, 13 Nm
-
Install clips securing coolant hoses
to RH shear plate
Note2x fir tree clips
-
Install RH side hose clips to HV
battery rear skid plate enclosure
Note2x fir tree clips
-
Install LH side hose clip to HV
battery rear skid plate enclosure
Note2x clips, Clip quantity may vary on older vehicles
-
Install clips securing coolant hoses
to LH shear plate
Note2x fir tree clips
-
Apply Loctite 222 onto mid aero shield
bolts and install mid aero shield
Note13x bolts, 10mm, 5 Nm
-
Position coolant drain container
underneath LH front of HV battery
-
Remove plugs then connect HV battery
return tube
Note2x clips, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged
-
Position coolant drain container below
HV battery front manifold hose
-
Remove plugs then connect HV battery
front manifold hose
Note1x spring clip, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged
-
Secure HV battery front manifold hose
to body
Note1x barrel clip
-
Position coolant drain container
underneath RH front of HV battery
-
Remove plug and connect PT supply
tube
Note2x clips, 1x plug, Perform push-pull test to verify hoses are fully engaged
-
Remove plugs then connect PT return
tube
Note2x clips, 2x plugs, Perform push-pull-push test to make sure hoses are fully engaged
-
Release RH front wheel liner from
bungee strap
NoteRemove strap from vehicle
-
Release LH front wheel liner from
bungee strap
NoteRemove strap from vehicle
-
Install push clip securing LH front
wheel liner to LH front rocker panel
Note1x push clip
-
Install clip securing RH front wheel
liner to RH rocker panel
Note1x push clip
-
Connect both AC compressor HV harness
connectors on HV battery
Note2x locking connectors, 2 stage locking connector, After the connector is seated and there is an audible click, Engage the second lock by pressing towards the connector
-
Install FDU ground strap and bolt to
HV battery
Note1x bolt, 10mm, 10 Nm
-
Install FDU ground strap harness clip
to FDU
Note1x clip
-
Install FDU HV harness connector to
FDU
Note1x connector, Ensure the connector is installed far enough on the FDU manifold so the manifold alignment tooth is making contact with the connector lever
-
Connect the FDU HV harness connector
and lock the release lever
Note1x clip, Apply slight pressure to the connector as the lever is rotated into position, Move the lever to the closed position slowly and ensure the lever teeth and manifold teeth are properly meshed, There should be a very small gap between the manifold and the connector when fully seated
-
Install bolt securing FDU HV harness
to FDU
Note1x bolt, 10mm, 10 Nm
-
Install front skid plate onto HV
battery
Note2x tabs, Slide tabs onto front of HV battery
-
Install the bolts securing the front
skid plate to the HV battery
Note4x bolts, E10, 13 Nm
-
Install the clips securing the front
LH and RH wheel liners to the front skid plate
Note2x push clips
-
Position the front aero shield to
vehicle and install nuts
Note2x nuts, 15mm, 5 Nm
-
Apply Loctite 222 onto front aero
shield bolts and install outer fasteners to front aero shield
Note9x bolts, 10mm, 5 Nm
-
Lower vehicle fully and move rack arms
away from vehicle
NoteRemove M3 lift adapters from body and install body plugs
-
Push vehicle away from lift
NoteRecommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed
-
Open all four doors
-
Install positive 12V output from PCS
cable and torque nut securing it
Note1x nut, 13mm, 9 Nm, Install new nut, Mark the nut after torque, Make sure rubber boot is not pinched between cable terminal and pass through
-
Install positive 12V output
cover
Note1x cover
-
Install DCDC ground busbar
-
Install bolt securing DCDC ground
busbar to body
Note1x bolt, 12mm, 20 Nm
-
Install nut securing DCDC ground
busbar to HV battery
Note1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut
-
Remove logic cap and connect the HVC
logic connector
Note1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
-
Install 12V cap to ancillary bay
Note1x cap
-
Install bolts securing RH inner
ancillary bay rail to the ancillary bay cover
Note2x bolts, T40, 24 Nm
-
Install bolts securing LH inner
ancillary bay rail to the ancillary bay cover
Note2x bolts, T40, 24 Nm
-
Clean busbar HV connector contact
surface of residual Penetrox
NoteAllow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
-
Clean HV connector contact surface of
residual Penetrox
NoteAllow 1 minute dry time after wiping away Penetrox, New busbar comes with penetrox applied to HV connector
-
Apply Penetrox onto HV connector
joints
NoteApply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
-
Position chargeport busbar connector
to HV header
Note4x guide tabs, Recommend assistance, Shift rear end of busbar assembly upward to help ease installation, If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary
-
Install bolts securing charge port
busbar HV header
Note2x bolts, 10mm, 9 Nm
-
Install edge support bracket
Note2x bolts, 10mm, 10 Nm, 1x clip
-
Inspect HV insulating gloves
NoteCheck gloves for damage prior to each use
-
Put on HV insulating gloves and
leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
-
Perform Hioki resistance test at each
HV joint from HV busbar lead to bolt head
Note2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the resistance is greater than 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again. If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), Hioki test passed, proceed to next step
-
Remove HV insulating gloves
-
Install fastener securing busbar cover
access door
Note1x bolt, 10mm, 9 Nm
-
Install HV cap to ancillary bay
Note1x cap
-
Torque LH rear HV battery interior
bolt
Note1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access if necessary
-
Torque RH rear HV battery interior
bolt
Note1x bolt, 16mm, 66 Nm, Lift up RH rear main carpet for access if necessary
-
Install clips and secure Velcro
holding rear main cabin carpet to vehicle
Note2x push clips
-
Install the LH rear door sill trim
panel
Note3x clips, 1x guide tab, Align the guiding tab to slot, Then push downward to install the clips after aligning them, Make sure the seal sits overlapping the trim. Newer vehicles may not be equipped with metal bracket and a foam insert will be present the bottom of trim piece
-
Install RH rear door sill trim
panel
Note3x clips, 1x guide tab, Align the guiding tab to slot, then push downward to install the clips after aligning them, Make sure the seal sits overlapping the trim
-
Remove coolant bottle cap
-
Place empty coolant container into
front storage area
-
Fill container with at least 15L of
coolant
-
Place filled coolant container into
front storage area
-
Install refill tool cap onto coolant
bottle assembly
-
Setup coolant refill tool
NoteVerify all valves on refill tool are in the closed position, See image for clarity
-
Install vacuum refill hose into refill
cap on coolant bottle
NotePerform push-pull-push test to verify hose is fully engaged
-
Place refill hose inside filled
coolant container
NoteMake sure hose end is fully submerged into coolant
-
Position overflow hose into empty
container
-
Connect shop air supply to coolant
refill tool
NoteIf not already done, Verify refill valve is set to off
-
Open air inlet valve to draw a vacuum,
Once gauge stabilizes, Fully close valve
NoteGauge stabilizes to approximately (-27 to -24 inHg or -70 to -60 cmHg). Vacuum should not drop after the valves are closed
-
Slowly open the refill valve to allow
coolant to be drawn into the system
NoteMake sure hose end of refill hose is fully submerged during entire process
-
Once the gauge reads zero, close the
refill valve
-
Disconnect shop air supply from
coolant refill tool
-
Remove coolant refill hose from
coolant container
-
Remove coolant overflow hose from
coolant container
-
Remove vacuum refill hose from refill
cap on coolant bottle
-
Remove refill tool cap from coolant
bottle assembly
-
Remove coolant refill tool from
vehicle
-
Remove both coolant containers from
inside underhood area
-
Connect first responder loop
Note1x connector, Engage locking tab, Connect FRL before connecting 12V to avoid damage to car computer
-
Connect 12V negative terminal
Note1x nut, 10mm, 6 Nm
-
Press and hold park button to release
EPB service mode
NoteRemove wheel chocks if necessary
-
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
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
- 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
NoteSelect ‘X’ at top right of window to close once complete -
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode:
- Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
- Thermal ➜ Coolant System ➜ Coolant Purge Start
- Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
- Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
- Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
- Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
- Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
- Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
NoteMake sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins. Coolant pump speeds can be monitored in Service Mode + (see Service Mode Plus), in the CAN Viewer submenu. Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete -
Inspect coolant level and top off as
necessary
NoteEnsure that the fluid level is at the Max line
- Install coolant bottle cap
-
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
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
NoteSelect ‘X’ at top right of window to close once complete. -
Install cabin intake upper duct
assembly
Note3x clips, Older vehicles may be equipped with 4x clips
-
Install rear apron
Note12x clips, If present untuck cut loop label and make sure it is still visible after apron is installed, Later builds may not have label
-
Close hood
-
Fold the 60 seat in down
position
NoteProtect the seat cushion if necessary
-
Install new bolster plastic bracket to
LH side bolster
Note2x tabs, Install new bolster bracket
-
Install LH side bolster
Note1x clip, 1x tab, Align the bottom tab then push inward to install
-
Fold the 60 seat into vertical
position
NoteRemove seat cushion protection
-
Fold the 40 seat in down
position
NoteProtect the seat cushion if necessary
-
Install new bolster plastic bracket to
RH side bolster
Note2x tabs, Install new bolster bracket
-
Install RH side bolster
Note1x clip, 1x tab, Align the bottom tab then push inward to install
-
Fold the 40 seat into vertical
position
NoteRemove seat cushion protection
-
Connect 2nd row seat cushion harness
and install 2nd row seat cushion
Note2x connectors, Both connectors are located on LH side of vehicle, Insert the seat belt buckles through the holes, Slide rear cushion inward then align front guide tabs to locking tabs, Make sure cushion is fully seated with push & pull test near clips
-
Install 2nd row floor mat into
vehicle
-
Move RH front seat backward
-
Torque RH front footwell HV battery
bolts
Note2x bolts, EP20, 136 Nm
-
Fold the RH front main cabin carpet
back to original position
NoteMove front edge down and slide back section up to ease positioning, Install seat harness into clips
-
Install clips securing the RH front
main cabin carpet to footwell area
Note4x push clips, Number of clips may vary on older vehicles
-
Install RH console side panel
carpet
Note1 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 RH lower A-pillar trim
Note1x clip, 2 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
-
Install clip for RH lower A-pillar
trim
Note1x push clip
-
Install RH mid A-pillar assembly
Note1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Make sure the seal seat on top of the trim
-
Install RH IP end cap
Note3x clips
-
Move LH front seat backward
-
Torque LH front footwell HV battery
bolts
Note2x bolts, EP20, 136 Nm
-
Fold the LH front main cabin carpet
back to original position
NoteMove front edge down and slide back section up to ease positioning, Install seat harness into clip
-
Install clips securing LH front main
cabin carpet to vehicle
Note3x push clips, Number of clips on newer vehicles may vary
-
Install LH console side panel
carpet
Note1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear
-
Install LH front floor mat
-
Install LH lower A-pillar trim
Note1x clip, 2 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
Note1x push clip
-
Install LH mid A-pillar assembly
Note1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Pull seal over trim
-
Install LH IP end cap
Note3x clips
-
Move RH front seat to original
position
-
Move LH front seat to original
position
-
Raise all the windows
-
Close all four doors
NoteUnlatch rear doors before closing
-
Install RH rocker panel lower cover
into position
Note10x clips
-
Install clips securing the RH rocker
panel lower cover to wheel liners
Note4x push clips
-
Install bolts securing RH rocker panel
lower cover to body
Note4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary
-
Install LH rocker panel lower cover
into position
Note10x clips
-
Install clips securing the LH rocker
panel lower cover to wheel liners
Note4x push clips
-
Install bolts securing LH rocker panel
lower cover to body
Note4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary